K Tool International KTI-63500A User manual

OWNER’S MANUAL

700 LBS

PEDESTAL TRANSMISSION JACK

KTI-63500A

WARNING: Cancer and Reproductive Harm - www.P65Warnings.ca.gov

Capacity Minimum Lifting

Range

Maximum Lifting

Range

Saddle

Forward Tilt

Saddle

Backward Tilt Base L x W Ram Travel

700 lbs. 49-5/8 inch 68-3/4 inch 14° 72° 22-1/4 x 21-3/8 inch 19-1/8 inch

GENERAL SAFETY RULES

Jack use and care

Inspection

GENERAL SAFETY RULES

IMPORTANT SAFETY CONSIDERATIONS

WARNING: Read and understand all instructions. Failure to follow all instructions listed below may

result in serious injury.

WARNING: The warnings, cautions, and instructions discussed in this instruction manual cannot

cover all possible conditions or situations that could occur. It must be understood by the operator

that common sense and caution are factors that cannot be built into this product, but must be supplied by

the operator.

CAUTION: Do not allow persons to operate or assemble this jack until they have read this manual

and have developed a thorough understanding of how the jack works.

DO NOT OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL.

To maintain the service jack and user safety, the responsibility of the owner is to read and follow these

instructions.

• Inspect the service jack for proper operation and function.

• Keep instructions readily available for equipment operators.

• Make certain all equipment operators are properly trained; understand how to safely and correctly operate

the unit.

• Allow unit operation only with all parts in place and operating properly.

• Use only genuine replacement parts.

• Service and maintain the unit only with authorized or approved replacement parts; negligence will make the

jack unsafe for use and void the warranty.

• Carefully inspect the unit on a regular basis and perform all maintenance as required.

• Store these instructions in the handle of your jack.

• Keep all decals on the unit clean and visible.

• Inspect the jack carefully before each use. Ensure the jack is not damaged, excessively worn, or missing

parts.

• Do not use the jack unless it is properly lubricated.

• Using a jack that is not in good clean working condition or properly lubricated may cause serious injury.

• Inspect the work area before each use. Make sure it is free and clear of any potential hazards.

• Do not modify the Jack in any way. Unauthorized modication may impair the function and/or safety and

could affect the life of the equipment. There are specic applications for which the Jack was designed.

• Always check for damaged or worn out parts before using the jack. Broken parts will affect the jack

operation. Replace or repair damaged or worn parts immediately.

• Store the jack. When jack is not in use, store it in a secure place out of the reach of children. Inspect it for

good working condition prior to storage and before re-use.

• Not for use by children or people with reduced mental capacity.

• Do not use under the inuence of drugs or alcohol.

• Ensure children and other bystanders are kept at a safe distance when using product.

SAFETY MARKINGS

WARNING!

1. Study, understand, and follow all instructions before operating this device.

2. Do not exceed rated capacity.

3. Use only on hard, level surfaces, with less than 3 degrees of slope.

4. Lifting device only. Immediately after lifting, support the vehicle with appropriate means.

5. Do not move or dolly the vehicle while on the jack.

6. Lift only on areas of the vehicle as specied by the vehicle manufacturer.

7. No alterations shall be made to this product.

8. Only attachments and/or adapters supplied by the manufacturer shall be used.

9. Do not get under or allow anyone under the vehicle until it has been supported by jack stands.

10. Center load on saddle prior to lifting.

11. Use wheel chocks or other blocking device on opposing wheels before using jack.

12. Never use on a lawn mower or lawn tractor.

13. Do not use this jack for any use other than the manufacturer specied usage.

14. Do not rock the vehicle while working on or around equipment.

15. The following are not recommended for supporting on this equipment: Foundations, Homes, Mobile

Homes, Trailers, RV’s, Campers, nor Fifth Wheels, etc...

16. Failure to heed these markings may result in personal injury and/or property damage.

ASSEMBLY

BASE

1. Attach the four ball bearing caster wheels to the

4 respective legs of the jack bases making sure

to tighten the screw.

2. Attach the bases (14) to the support tube parts

(12) with screws (15), washers (5), spring

washers (6) and nuts (7).

CYLINDER

1. Attach the long ram jack (2) to the support tube

parts (12) with screws (8), washers (5), spring

washers (6) and nuts (7).

2. Attach the saddle to the jack with screw (11).

All numbers in parenthesis () refer to the index number from the parts breakdown.(page 9)

SADDLE

SYSTEM AIR PURGE PROCEDURE

IMPORTANT: BEFORE FIRST USE

Perform the following Air Purge Procedure to remove any air that may have been introduced into the hydraulic

system as a result of product shipment and handling. This step is to be completed without any weight on the

jack.

20 765

2. Pump handle (6) eight full strokes.1. Turn release valve (R25) counterclockwise one

full turn to the open position.

3. Turn release valve (R25) clockwise to the closed

position.

R25

4. Pump handle (6) until the ram reaches about half

height; continue to pump several times to remove

trapped air in the ram.

ASSEMBLY

1 2

1. Mount the four angle brackets (T4x4) to the saddle

using screws (T5x4), washers (T6x8), spring

washers (T7x4) and nuts (T8x4). Attach the hook

guide (13) to the saddle with washer (5), spring

washer (6) and nut (7) and assemble the chain

hook-to-hook guide (13) with two screws (4) and

washers (3). And then tighten screw (17) through

the chain to the saddle with washers (18), spring

washers (1) and nuts (2).

5. Carefully and slowly pinch oil ll plug (7) to

release trapped air.

6. Turn release valve (4) counterclockwise to the

open position one full turn and lower ram to the

lowest position.

7. Turn release valve (4) clockwise to the closed

position and check for proper pump action. It may

be necessary to perform the above step more

than once to assume air is completely evacuated.

1. Before using this product, read the owner's manual completely and familiarize yourself thoroughly with the

product and the hazards associated with its improper use.

2. Perform the air purge procedure. (See previous instructions for system purge procedure.)

3. Check and that the pump operates smoothly before putting into service.

4. Inspect before each use. Do not use if bent, broken or cracked components are noted.

BEFORE USE

All numbers in parenthesis () refer to the index

number (page 9) from the parts breakdown.

RAISING THE JACK

1. Before use, ensure the transmission weight and

size does not exceed the capacity of the jack.

2. Ensure the vehicle from which the gearbox is to

be removed is correctly positioned.

3. Check to ensure the handbrake is applied and

raised to allow the transmission jack to be

positioned correctly.

4. Ensure there are no other people around or

under the vehicle.

5. Ensure saddle is in its lowest position and use

handle to transport and centrally position jack

beneath vehicle transmission.

6. Close the release valve by turning it clockwise

until it is rmly closed.

7. Pump handle to lift until saddle contacts load.

Continue to pump the jack handle to lift the

vehicle to the desired height.

8. After lifting, support the load appropriately before

removing transmission.

OPERATION

oil ll

plug

Turn release

valve

LOWERING THE JACK

1. Support the load with appropriate means before

removing transmission. Check to make sure the

transmission is stable on the jack saddle and

load is fixed in place before attempting to lift

lower, or transport.

2. Grasp the handle firmly with both hands.

Securely hold on to the jack handle so your

hands do not slip and ensure the release valve

does not rapidly lower.

3. Carefully open the Release Valve by slowly

turning the handle counterclockwise. (Do not

allow bystanders around the jack or under the

load when lowering the jack.

4. Lower saddle to the lowest minimum height

before attempting to transport load.

TRANSPORTING THE LOAD

1. Ensure the jack saddle is fully lowered and

load is secure before attempting to lift, lower, or

transport transmission.

2. Transport the load over level and solid ground,

preferably concrete, and ensure the oor is swept

clean before transporting load.

3. Be diligent in continually monitoring the load in

transit. Keep all other people at a safe distance.

4. DO NOT use on asphalt, or any soft surface

as jack may sink or tip, causing damage to

transmission or personal or injury/harm may

result.

5. WARNING: If jack tips or leans STOP WHAT

YOUR ARE DOING. MOVE QUICKLY TO A

SAFE DISTANCE. DO NOT TRY TO HOLD OR

STEADY JACK to prevent personal injury and/or

property damage.

RE-INSTALLING A GEARBOX

1. Ensure the jack saddle is fully lowered and load

is secure before attempting to lift or transport

transmission.

2. Transport the load over level and solid ground,

preferably concrete, and ensure the oor is swept

clean before transporting load.

3. Be diligent in continually monitoring the load in

transit. Keep all other people at a safe distance.

4. DO NOT use on asphalt, or any soft surface

as jack may sink or tip, causing damage to

transmission or personal or injury/harm may

result.

5. If jack tips or leans STOP WHAT YOUR

ARE DOING. MOVE QUICKLY TO A SAFE

DISTANCE. DO NOT TRY TO HOLD OR

STEADY JACK.

6. Raise load to desired height.

7. WARNING: Use caution when re-installing.

Transmission load can shift causing personal

injury and/or property damage.

MAINTENANCE INSTRUCTIONS

If you use and maintain your equipment properly, it will give you many years of service. Follow the

maintenance instructions carefully to keep your equipment in good working condition. Never perform any

maintenance on the equipment while it is under a load.

Inspection

You should inspect the product for damaged, worn, broken or missing parts (e.g.: pins) and that all

components function before each use. Follow lubrication and storage instructions for optimum product

performance.

Binding

If the product binds while under a load, use equipment with equal or a larger load capacity to lower the load

safely to the ground. After unbinding; clean, lubricate and test that equipment is working properly. Rusty

components, dirt, or worn parts can be causes of binding. Clean and lubricate the equipment as indicated in

the lubrication section. Test the equipment by lifting without a load. If the binding continues contact Customer

Service.

Cleaning

If the moving parts of the equipment are obstructed, use cleaning solvent or another good degreaser to clean

the equipment. Remove any existing rust, with a penetrating lubricant.

Lubrication

This equipment will not operate safely without proper lubrication. Using the equipment without proper

lubrication will result in poor performance and damage to the equipment. Some parts in this equipment are not

self-lubricating. Inspect the equipment before use and lubricate when necessary. After cleaning, lubricate the

equipment using light penetrating oil, lubricating spray.

• Use a good lubricant on all moving parts.

• For light duty use lubrication once a month.

• For heavy and constant use lubrication recommended every week.

• NEVER USE SANDPAPER OR ABRASIVE MATERIAL ON THESE SURFACES!

Rust Prevention:

Check rams and pump plungers on the power unit assemblies daily for any signs of rust or corrosion.

Without a load, lift the equipment as high as it goes and look under and behind the lifting points. If signs of

rust are visible clean as needed.

Grease Fittings

Some models contain grease ttings that will regularly need to be greased and lubricated.

How the Jack Operates

With release valve closed, an upward stroke of the jack handle draws oil from the reservoir tank into the

plunger cavity. Hydraulic pressure holds the valve closed, which keeps the oil in the plunger cavity. A

downward stroke of the jack handle releases oil into the cylinder, which forces the ram out. This raises the

saddle. When the ram reaches maximum extension, oil is bypassed back into the reservoir to prevent an over

extended ram stroke and possible damage to the jack. Opening the release valve allows oil to ow back into

reservoir. This releases hydraulic pressure on the ram, which results in lowering the saddle.

Storing the Jack

1. Lower the Lifting ram.

2. Place the handle in the upright position.

3. Store in a dry location, recommended indoors.

Note: If the jack is stored outdoors, be sure to lubricate all parts before and after use to ensure the jack stays

in good working condition. Always store jack in the fully retracted postion when stored in outdoor or caustic

enviroments that can cause corrosion and/or rust.

PARTS BREAKDOWN

REF# PART # DESCRIPTION QTY

1KTP63500A-1 Caster assembly 4

2 Hex head bolt M10×90mm 3

3 Surporting tube assembly 1

4KTP63500A-4 Release valve assembly 1

5KTP63500A-5 Steel ball bearing Ø6mm 1

6KTP63500A-6 Handle 1

7KTP63500A-7 Oil plug 1

8KTP63500A-8 Chain 1

9 Washer M10 16

10 Spring washer M10 12

11 Nut M10 12

12 KTP63500A-12 Handwheel 2

13 KTP63500A-13 Spring pin Ø5x30mm 2

14 KTP63500A-14 Hook 1

15 KTP63500A-15 Hook pin 1

16 Washer M8 3

17 Nut M8 3

18 KTP63500A-18 Platform assembly 1

19 Hex bolt M10×30mm 8

20 KTP63500A-20 Sliding plate assembly 4

21 Hex bolt M8×30mm 1

22 Spring washer M8 1

23 Hex bolt M10×20mm 1

24 KTP63500A-24 Long ram jack 1

25 Handle socket 1

26 KTP63500A-26 Round wire snap ring Ø1.2x18mm 3

27 Connecting bar 1

28 KTP63500A-28 Pin Ø8x26mm 3

29 KTP63500A-29 Pump plunger assembly 1

30 KTP63500A-30 Surporting leg assembly 2

31 KTP63500A-31 Seal kit 1

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