K Tool International PRO Series Gebrauchsanweisung

This is the safety alert symbol. It is used to alert you to potential personal injury hazards.

Obey all safety messages that follow this symbol to avoid possible injury or death.

!ADVERTENCIA

• Leer, comprender, y seguir las instrucciónes antes

de utilizar el aparato.

• El manual de instrucciónes y la información de

seguridad deben estar comunicado en lengua del

operador antes del uso.

• No seguir estas indicaciónes puede causar daños

personales o materiales.

!WARNING

To avoid crushing and related injuries:

NEVER work on, under or around a

load supported only by a hydraulic

jack. ALWAYS use adequately rated

jack stands.

Model Number

KTI63503

Series A

KTI63504

Series A

Capacity

1000 Lbs

Operating Instructions

& Parts Manual

Transmission Jack

Printed in China

KTI63503-M2 10/09

K-Tool International

31111 Wixom Rd., Wixom, MI 48393

E-mail: [email protected] (248) 669-5000

Read this manual and follow all the Safety Rules and Operating Instructions before using this product.

U.S. Patent No. 5,341,723

KTI63503 Series A KTI63504 Series A

SAFETY and GENERAL INFORMATION

Save these instructions. For your safety, read, understand, and follow the information provided with and on this jack

before using. The owner and operator of this equipment shall have an understanding of this jack and safe operating

procedures before attempting to use. The owner and operator shall be aware that use and repair of this product

may require special skills and knowledge. Instructions and safety information shall be conveyed in the operator's

native language before use of this jack is authorized. If any doubt exists as to the safe and proper use of this jack,

remove from service immediately.

Inspect before each use. Do not use if broken, bent, cracked or damaged parts are noted. Any jack that appears

damaged in any way, or operates abnormally shall be removed from service immediately. If the jack has been or

suspected to have been subjected to a shock load (a load dropped suddenly, unexpectedly upon it), immediately

discontinue use until jack has been checked by a factory authorized service center (contact distributor or manufacturer

for list of authorized service centers). It is recommended that an annual inspection be done by qualied personnel.

Labels and Operator's Manuals are available from manufacturer.

PRODUCT DESCRIPTION

This Transmission Jack is designed to be used as an aid in the removal and installation of automotive and light truck

transmissions, transfer cases and transaxles. This telescopic style transmission jack is for use under an overhead

lift or in a garage pit. On air option model KTI63504 Series A, ensure that your air source can dedicate 7.8 CFM @

110-175 psi to each jack operated.

NEVER use for any purpose other than those uses outlined above!

SPECIFICATIONS

Model Capacity Min. Height Max. Height Saddle Base Extended Saddle

Area Jack Size

KTI63503

Series A

1000 Lbs 37-3/4" 78-1/8" 8-7/8" x 7-1/8" 21" x 21"

33-5/8" x 33-5/8"

KTI63504

Series A

PREPARATION

Assembly (refer to Figure 1)

Tools required: 1/4" allen key, 19mm wrench, 3/8" hex socket & torque wrench.

1. Three major parts should be included in the package:

(a) Hydraulic unit Assembly;

(b) Saddle Assembly;

2. Attach either one of the two base halves to the base of the hydraulic unit, then secure using allen head bolts and

washers provided. Apply the same procedure to the other base half. Use torque wrench to tighten to 30 lb.ft. Do

not overtighten.

3. Place the socket of the saddle assembly onto the ram piston. Tighten set screw on the socket.

Figure 1 - Model KTI63504 Series A Components

Before Use

Verify that the product and application are compatible, if in doubt call KTI Technical Service.

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

product, its components and recognize the hazards associated with its use.

3. Press the release valve pedal, ensure that saddle is fully lowered. Remove shipping screw and replace with

provided vent screw (shipping screw is located above the oil ller screw).

4. Remove the oil ller screw. Ensure oil level is just below the rim of oil ller hole. Reinstall the oil ller screw.

5. For air option model KTI63504 Series A, pour a teaspoon of good quality, air tool lubricant into the air supply inlet

of the lift control valve. Connect to air supply and operate for 3 seconds to evenly distribute lubricant.

Note: This unit is equipped with the popular 1/4” NPT air coupler. When installing a different air coupler of your

choice, ensure that thread tape or compound is used when servicing connections. To ensure dependable, trouble

free operation an inline air dryer and oiler is recommended.

6. Ensure that jack rolls freely. Raise and lower the unloaded jack throughout the lifting range before putting into

service to ensure the pump operates smoothly. Replace worn or damaged parts and assemblies with factory

authorized replacement parts only.

Saddle Plate

Saddle Socket

Tilt Adjustment Knobs

Position Handle

Hydraulic Unit

Lift Pedal Release Valve Pedal

Base Half

Caster

Oil Filler Screw

Shipping Screw

(replace w/ Vent Screw

before initial use)

Ratchet Bracket

*Air Motor

*Air Supply Inlet

*Air Pump Pedal

(*) For air option model KTI63504 Series A only

OPERATION

Follow the instruction for removal and installation of transmission, transfer case or transaxle according to the vehicle

manufacturer's service manual.

Raise saddle assembly:

Pump foot pedal or press air pump pedal (Model KTI63504 Series A) until saddle reaches desired position. Secure

load with provided chains.

Note: DO NOT OPERATE BY AIR AND BY HAND PUMPING AT THE SAME TIME.

Ensure center gravity of load is centered on the saddle and load is stable before moving jack. An off-center

transmission could cause the jack to tip or ip over .

Lower saddle:

Be sure all tools and personnel are clear before

lowering load. Slowly engage release valve pedal!

Maintain control of the rate of speed at which the load lowers at all times!

Slowly, gently apply downward pressure to the release valve pedal.

Never use this jack as a workstation!

To avoid crushing and related injuries:

•

Never work on, under or around a load supported only by hydraulic jack.

• Be alert and sober when using this product. Do not operate under the

inuence of drugs or alcohol.

!WARNING

•Read, understand, and follow all printed material provided with and on this product before use.

• Do not exceed rated capacity.

• Use only on hard, level surfaces.

•Adequately support the vehicle before starting repairs.

• If loaded jack must be moved, make certain that load is secured by appropriate means, is stable, is in

the lowest possible position, is moved over a smooth, hard level surface and that the lifting platform

is level.

• Use of this product is limited to removal, installation, and transportation of automotive and light

truck transmissions, transfer cases and transaxles.

• Use only adapters / accessories provided by the manufacturer of this transmission jack.

• Use only adapters / accessories whose rated capacity is greater than the rated capacity of this jack.

• Ensure the center of gravity is center loaded on the saddle.

• Never use this device as a work/repair station. Transfer the load immediately to a suitable work station.

• No alteration shall be made to this product.

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

TROUBLESHOOTING

MAINTENANCE

Important: Use only good grade hydraulic jack oil. Avoid mixing different types of uid and NEVER use brake uid,

turbine oil, transmission uid, motor oil or glycerin. Improper uid can cause premature failure of the jack and the

potential for sudden and immediate loss of load. Mobil DTE 13M or equivalent recommended.

Adding oil

1. With saddle fully lowered, set jack in its upright, level position. Remove oil ller screw.

2. Fill until oil is level with the oil ller screw hole, reinstal oil ller screw.

Changing oil

For best performance and longest life, replace the complete uid supply at least once per year.

1. With saddle fully lowered, remove oil ller screw.

2. Lay the jack on its side and drain the uid into a suitable container.

Note. Dispose of hydraulic uid in accordance with local regulations.

3. Set jack in its level position.

Fill until oil is level with the oil ller screw hole, reinstal oil ller screw.

Lubrication

1. A periodic coating of light lubricating oil to pivot points, axles and hinges will help to prevent rust and assure that

casters and pump assemblies move freely.

2. For air option model KTI63504 Series A: When used on a daily basis, air pump model should be internally lubricated

before each use. Use only good quality air tool lubricant. If no inline oiler is used, pour a teaspoon of air tool oil into

the inlet of the air supply inlet. Simply operate the jack using the air feature in order to fully distribute the oil.

Cleaning

Periodically check the pump piston and ram for signs of rust or corrosion. Clecan as needed and wipe with an oily

cloth.

Note: Never use sandpaper or abrasive material on these surfaces!

Storage

When not in use, store the jack with saddle fully lowered.

Symptom Possible Causes Corrective Action

Jack will not lift load • Release valve not tightly closed

• Load is too heavy

• Ensure release valve tightly closed

•Consider higher capacity jack

Jack will lift, but not maintain

pressure

•Release valve not tightly closed

•Hydraulic unit malfunction

•Ensure release valve tightly closed

•Discontinue use, contact KTI

technical service

Jack will not lower after unloading • Reservoir overlled

• Linkage binding

• Ensure load is removed, then drain

uid to proper level

• Clean and lubricate moving parts

Poor lift performance • Fluid level low

•Hydraulic unit malfunction

• Ensure proper uid level

•Discontinue use, contact KTI

technical service

Jack will not lift to full extension • Fluid level low • Ensure proper uid level

11 21

REPLACEMENT PARTS (refer to page 6 & 7)

Not all components of the jack are replacement items, but are illustrated as a convenient reference of location and

position in the assembly sequence. When ordering parts, give Model number, serial number and parts description.

To order parts contact KTI at (248)669-5000 or E-mail: [email protected].

KTI63504 Series A

Replacement Parts:

KTI63503 Series A

Replacement Parts:

Figure 2 - Replacement Parts Illustration for Models KTI63503 Series A & KTI63504 Series A

Replacement Parts List for Models KTI63503 Series A & KTI63504 Series A:

Item Part No. Description Qty.

1G360-20000-000 Base Half 2

2G360-90030-K04 Bolt Set (set of 4) 1

3G360-90030-K02 Caster, 3" Dia 2

4 G360-90030-K01 Caster w/ Brake 2

55105-08015-000 Socket Head Bolt 1

64200-03500-000 Tilt Screw Assembly 2

7 G390-41000-000 Nylon Strap Accessory 1

8 G360-40000-000 Saddle Assembly 1

9A070-90038-K02 Screw Assembly 1

10 G360-90009-K01 Vent Screw Assembly 1

11 G360-90030-K03 Handle Assembly 1

12 5104-10040-000 Bolt 1

13 5206-00010-000 Nylon Nut 1

14 G390-10005-000 Release Valve Pedal (2pc. for KTI63504 Series A) 1

15 5405-07027-000 Pin (2pc. for KTI63504 Series A) 1

16 5405-02018-000 Retaining Pin (2pc. for KTI63504 Series A) 1

17 G390-30000-000 Lift Pedal 1

18 5405-12070-000 Axle 1

19 5405-02028-000 Retaining Pin 1

20 G831-00002-000 Coupler, Male 1/4NPT (KTI63504 Series A only) 1

21 G360-10003-000 Air Hose (KTI63504 Series A only) 1

22 G360-10002-000 Spring (KTI63504 Series A only) 1

23 G360-16000-000 Hose Connector, Elbow (KTI63504 Series A only) 2

24 G360-17000-000 Air Motor (KTI63504 Series A only) 1

25 5308-00120-000 Copper Washer (KTI63504 Series A only) 1

26 5102-10016-000 Bolt (for KTI63503 Series A & KTI63504 Series A) 1

-G3601S-111 (KTI63503 Series A)

G3600S-130 (KTI63504 Series A) Repair Kit for Hydraulic Unit 1

K-Tool International

31111 Wixom Rd., Wixom, MI 48393

E-mail: [email protected]

(248) 669-5000

ONE YEAR LIMITED WARRANTY

For a period of one (1) year from date of purchase, KTI, will repair or replace, at its option, without

charge, any of its products which fails due to a defect in material or workmanship, or which fails to conform to any

implied warranty not excluded hereby.

Performance of any obligation under this warranty may be obtained by returning the warranted product,

freight prepaid, to K-Tool International 31111 Wixom Rd. Wixom, MI 48393, phone (248)669-5000.

Except where such limitations and exclusions are specically prohibited by applicable law. (1) the

CONSUMER'S SOLE AND EXCLUSIVE REMEDY SHALL BE THE REPAIR OR REPLACEMENT OF DEFEC-

TIVE PRODUCTS AS DESCRIBED ABOVE, and (2) KTI SHALL NOT BE LIABLE FOR ANY CONSEQUENTIAL

OR INCIDENTAL DAMAGE OR LOSS WHATSOEVER, and (3) THE DURATION OF ANY AND ALL EXPRESSED

AND IMPLIED WARRANTIES, INCLUDING WITHOUT LIMITATION, ANY WARRANTIES OF MERCHANTABIL-

ITY AND FITNESS FOR A PARTICULAR PURPOSE, IS LIMITED TO A PERIOD OF ONE (1) YEAR FROM DATE

OF PURCHASE.

Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may

not apply to you. Some states do not allow the exclusion or limitation of incidental or consequential damages, so

the above limitation or exclusion may not apply to you. This warranty gives you specic legal rights, and you may

also have other rights which vary from state to state.

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