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    KTI Hydraulics, Inc. / Support  / Installation Instructions: 12 VDC Dual Double-Acting

    Installation Instructions: 12 VDC Dual Double-Acting

    Installation Instructions: For 12 VDC, Hydraulic Power Units, Dual Double-Acting (Two Independent Power UP / Power DOWN Circuits)

    Download the or use the tabs below for the Installation Instructions.

    1. When stowing your three piece remote pendant, it is recommended that you store the remote switch box portion in your vehicle. This will help preserve the new condition of the remote control and prevent theft.
    2. Remove the four-button pendant from the power unit at the quick disconnect.
    3. Install 9/16-18 SAE ORB, SAE #6, hydraulic fittings into ports “A”, “B”, “A1 and “B1”. Torque fittings to 18 lb.-ft.
    4. Mount the Power Unit using two, 3/8-16 x 3/4 mounting bolts (Diagram A-2).
    5. Connect hydraulic hoses to two cylinders (applications may vary).a. Connect the “A” port (UP function) hose to the base of the up and down function cylinder.b. Connect the “B” port (DOWN function) hose to the rod end of the up and down function cylinder.c. Connect the “A1” port (OUT function) hose to the base of the out and in function cylinder. d. Connect the “B1” port (IN function) hose to the rod end of the out and in function cylinder.
    6. Remove the Filler/Breather Cap and fill the reservoir with hydraulic approximately 1 inch from the top(Please see fluid recommendations).
    7. Connect the battery Ground cable to the Ground terminal of the DC Motor (Diagram A-2 & A-4).
    8. Connect the Positive cable from the battery to the start solenoid (diagram A-5). Please see BatteryCable recommendation for proper cable length to use for your hydraulic power unit.
    9. Use a wrench to hold the bottom nut in place, to torque the upper nut (to 3 ft.-lbs.) to fasten the battery connections.
    10. Reconnect the four-button remote pendant at the quick disconnect.
    11. UP/DOWN cylinder: Extend the cylinder by pressing the UP button while running the power unit keep an eye on the fluid level in the reservoir.a. Insure that the fluid level doesn’t go lower than 1⁄2 full during the initial start-up.b. When the cylinder is fully extended, the reservoir should be about 1⁄2 full
    12. After the cylinder is fully extended, press the DOWN button to fully retract the cylinder.
    13. IN/OUT cylinder: Extend the cylinder by pressing the OUT button while running the power unit keep an eye on the fluid level in the reservoir.a. Insure that the fluid level doesn’t go lower than 1⁄2 full during the initial start-up.b. When the cylinder is fully extended, the reservoir should be about 1⁄2 full.
    14. After the cylinder is fully extended, press the IN button to fully retract the cylinder.

      a. Refer to the Bleed Cycle Procedure Instructions to purge air from the hydraulic system.

      1. If needed refill the reservoir to the “Full line” labeled on the side of the reservoir. Fluid level should be approximately 1 inch from the top of the reservoir.
      2. After both cylinders are primed and fully retracted, recheck the level of the oil in the reservoir.
    Diagram A-1
    Diagrams A-2 and A-3

    Do Not Mix Hydraulic Fluids.

    KTI recommends using a premium hydraulic oil to ensure optimum performance and system life. Select oil that has anti-wear properties, rust and oxidation inhibitors, foam inhibitors and good stability. Examples of premium grade hydraulic oils: Chevron Rando HDZ, Mobil DTE 10, DTE 20 series, AMSOIL, and Shell Tellus.

    Automotive Transmission Fluid (DEXTRON III) are acceptable under normal conditions.

    Aviation Oils such as Valvoline ROYCO series or Mobil Aero HF or HFA may be used in prolonged, extreme cold environments.

    Do Not Use Biodegradable Hydraulic Fluid with Buna seal, Biodegradable Hydraulic Fluid is compatible with Viton seals (optional).

    Ambient Temperature Range

    ISO Viscosity Gradew

    – 20°F to + 32°F (- 29°C to + 0°C)

    15

    + 14°F to + 120°F (- 10°C to + 49°C)

    22, 32, ATF (Dexron III)

    Battery Cables

    To minimize voltage drop, increase the gauge size of the battery cables as the length of the positive and ground cables increase. Low voltage will cause the motor to run higher amps causing damage to other electrical components.

    Cable Length

    Wire Gauge

    Nominal OD (in.)

    1 to 2 feet

    4 gauge

    0.43

    3 to 4 feet

    2 gauge

    0.49

    5 to 7 feet

    1 gauge

    0.56

    8 to 9 feet

    1/0 gauge

    0.61

    10 to 12 feet

    2/0 gauge

    0.66

    13 to 15 feet

    3/0 gauge

    0.72

    16 to 19 feet

    4/0 gauge

    0.78

    Hydraulic Schematic

    Diagram A-4

    Wiring Diagram

    Diagram A-5

    Bleed Cycle Instruction Sheet:

    1) Remove the breather cap with dip stick, so you may view the hydraulic fluid while operating the Hydraulic Power Unit.

    1. a)  Press the up button on the hand held remote pendant, to run the trailer bed up 1/3 of the way up. While running the bed up view the hydraulic fluid through the breather cap opening, you may see the fluid returning into the tank. If you see any air pockets or aera- tion of the fluid, please stop and allow the fluid to settle and continue to raise 1/3 of the way up.
    2. b)  Once you reach 1/3 of the way up, press the down button to return the trailer bed or deck to it fully seated position (down).

    *Please insure that the fluid level does not drop below the half full level of the reservoir while running the power unit.*

    2) Press the up button on the hand held remote pendant, to run the trailer bed up 2/3 of the way up.

    1. a)  While running the bed up view the hydraulic fluid through the breather cap opening, you may see the fluid returning into the tank. If you see any air pockets or aeration of the flu- id, please stop and allow the fluid to settle and continue to raise 2/3 of the way up.
    2. b)  Once you reach 2/3 of the way up, press the down button to return the trailer bed or deck to it fully seated position (down).

    *Please insure that the fluid level does not drop below the half full level of the reservoir while running the power unit.*

    3) Press the up button on the hand held remote pendant, to run the trailer bed up to the end of

    the stroke.

    1. a)  While running the bed up view the hydraulic fluid through the breather cap opening, you may see the fluid returning into the tank. If you see any air pockets or aeration of the flu- id, please stop and allow the fluid to settle, and then continue to raise the bed to the end of the stroke.
    2. b)  Once you reach the full up position, press the down button to return the trailer bed or deck to it fully seated position (down).

    *Please insure that the fluid level does not drop below the half full level of the reservoir while running the power unit.*

    You may have to repeat these 3 steps more than once to completely purge all of the air out of the system.

    If you have any questions, please feel free to contact us.

    Telephone: 1-949-752-8818
    Email: service@ktihydraulicsinc.com

    For more information about KTI’s Hydraulic Power Units, please contact one of our specialists by phone, (949) 752-8818 or send us a message.