K Tool International HD KTI63194A Manual de usuario

KTI63194A 1

22 TON CAPACITY AIR/HYDRAULIC TRUCK JACK

OWNERS MANUAL

KTI63194A

Complies with ASME PALD/2009 Safety Standard

SPECIFICATIONS

Capacity ............................................................22 Ton

Low Height...........................................................................9"

Ram Travel ...........................................................................4-3/4"

Ext. Screw Adj......................................................................4-1/4"

Max. Height with Adapter ..................................................18"

Overall Width......................................................................13"

Saddle Diameter .................................................................. 1-3/4"

Wheel Diameter ..........................................................................8"

Handle Length......................................................................48-2/5"

Shipping Weight..................................................................105.8 Lbs.

WARNING: Cancer and Reproductive Harm

- www.P65Warnings.ca.gov

KTI63194A 2

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.

IMPORTANT: READ THESE INSTRUCTIONS BEFORE OPERATING

BEFORE USING THIS DEVICE, READ THIS MANUAL COMPLETELY AND THOROUGHLY, UNDERSTAND ITS OPERATING

PROCEDURES, SAFETY WARNINGS AND MAINTENANCE REQUIREMENTS.

It is the responsibility of the owner to make sure all personnel read this manual prior to using the device. It is also the responsibility of

the device owner to keep this manual intact and in a convenient location for all to see and read.

shall be read to and discussed with the operator in the

chaser/owner or his designee, making sure that the operator comprehends its contents.

THE NATURE OF HAZARDOUS SITUATIONS

The use of portable automotive lifting devices is subject to certain hazards that cannot be prevented by mechanical means, but only

by the exercise of intelligence, care, and common sense. It is therefore essential to have owners and personnel involved in the use and

use. Examples of hazards are dropping, tipping or slipping of loads caused primarily by improperly securing loads, overloading, off-

centered loads, use on other than hard level surfaces, and using equipment for a purpose for which it was not designed.

METHODS TO AVOID HAZARDOUS SITUATIONS

CONSEQUENCES OF NOT AVOIDING HAZARDOUS SITUATIONS

Failure to read this manual completely and thoroughly, failure to understand its OPERATING INSTRUCTIONS, SAFETY WARNINGS,

MAINTENANCE INSTRUCTIONS and comply with them, and failure to comply with the METHODS TO AVOID HAZARDOUS

SITUATIONS could cause accidents resulting in serious or fatal personal injury and/or property damage.

WARNING: Indicates a hazardous situation

which, if not avoided, could result in death

or serious injury.

WARNING

WARNING INFORMATION

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

•Do not exceed the rated capacity stated.

•Use only on hard, level surfaces.

•This item is to be used as a lifting device only. Support the vehicle with appropriate means immedi-

ately after lifting.

•Do not move or dolly the vehicle while it is on the jack.

•No alterations shall be made to this product.

•Only attachments and/or adapters

supplied by the manufacturer shall be used.

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

operator’s native language by pu

KTI63194A3

SETUP

PLEASE REFER TO THE EXPLODED VIEW DRAWING IN THIS MANUAL IN ORDER TO IDENTIFY PARTS.

1. Feedtheblackhose(#64)andorangehose(#63)comingoutofthebottomofthehandleassembly(#76)throughthehandle-1(#52)whileat

thesametimelininguptheholeinthehandle-1(#52)withtheholeinthehandleconnector(#55).Securethemtogetherwiththescrew(#54).

2. Threadtwonuts(#53)allthewayonthebottomofthetierod(#50).Threadthebottomofthetierodallthewayinsidetheslottedpin

(#49).Nowtightenonenut(#53)downontopoftheslottedpin(#49)andtighten.Slipthespring(#51)downonthetierod(#50).Insertthe

tierod(#50)throughthebottomofthebracketthatisweldedtothehandle-1(#52)sothatthespringistrappedbetweenthebracketand

thenuts(#53)thataretightenedagainsttheslottedpin(#49).Compressthespringuntilthecrossholeinthetierod(#50)isvisibleonthe

othersideoftheweldedbracketandinstallther-pin(#71)throughthehole.

3. Threadanothernut(#53)allthewayonthetierod(#56).Holdthehandlelock(#58)downandawayfromthet-handle-2(#60)while

simultaneouslythreadingthetierod(#56)nutontothetierod(#50).

4. Raisethehandlelock(#58)upsotheslottedpin(#49)doesnotcomeincontactwithanyofthethreeholesinthehandleposition

seatassembly(#7).Removethescrew(#73)fromthehandlesocket(#11).Insertthehandle-1(#52)inthehandlesocket(#11)while

simultaneouslyinsertingtheslottedpin(#49)inthehandlesocket(#11)guideholes.Makesuretheholeinthelowerportionofthe

handle-1(#52)alignswiththethreadedholeinthehandlesocket(#11)andsecurethemtogetherwiththescrew(#73).Movethehandle

upanddownwhilesimultaneouslypullingthehandlelockdownsotheslottedpin(#49)willengagewithanyofthethreelockingholesin

thehandlepositionseatassembly(#7).Makesuretheslottedpinwillengageallthreeholes.Itmightbenecessarytoadjustthethreaded

connectionbetweentierods(#50and#56)inordertogetproperengagement.Afternaladjustment,tightenthenut(#53)tosecurethe

connection.

5. Therearetwoairhosesthatmustbermlyinsertedintothecouplers(#48).Theorangehose(#63)tsinthehigherlocatedcouplerwhile

theblackhose(#64)tsinthelowerlocatedcoupler.

6. Installtheairquickdisconnectofyourchoiceinthecrossvalve(#65).Putatleasttwowrapsofpipedopetapearoundthedisconnect

threads before installation to prevent air leaks.

7. Installthebracketassembly(#72)onthehandle-1tubeinthepositionasshownonthecoveroftheOwner’sManualandsecurethe

adaptorsinthebracketholesusingther-pins(#69).

8. Duetothevacuumreleasesystemdesignofthisjack,thejack’shydraulicsystemveryrarelybecomesairbound.Indicationofanair

bound system is a ram that does not rise smoothly. In some extreme case of an air bound system, air can be purged by following this

procedure:

PURGING AIR FROM THE HYDRAULIC SYSTEM

 a. Raisetheram(#32)tomaximumheightandthenloweritallthewaydownfollowingtheactivationdirectionsontopofthehandle.

 b. Repeatstep“a”severaltimesuntilallairispurgedfromthesystem.

OPERATING INSTRUCTIONS

This is the safety alert symbol used for the OPERATING INSTRUCTIONS section of this manual to alert you to potential

personal injury hazards. Obey all instructions to avoid possible injury or death.

IMPORTANT: Before attempting to raise any vehicle, check vehicle service manual for recommended lifting surfaces.

1. Becomefamiliarwiththeidenticationandfunctionoftheoperatingjackcomponents.

a. The ram

(#32)

is the shaft that comes out of the jack when you rotate the air lever to the right.

b. The ram

(#32)

is equipped with an extension screw which can be unscrewed to extend from the ram if there is not enough hydraulic

stroke to raise the load to the desired height. If additional height is required, extension adapters can be inserted in the hole on top of

the extension screw.

 c. Largerdiametersaddlescanbeinsertedintheextensionscrewwhenrequiringalargerdiametersaddlesurface.

2. Chockthevehicle'stiresthatwillnotbeliftedoffthegroundpriortoliftingthevehicleandifavailable,applytheemergencybrakeorany

other method of braking.

3. Positionthejackatthedesignatedliftpoint.Estimatetherequiredramtraveltoraisethevehicletothedesiredheight.Ifthedesired

vehicle height exceeds the entire ram travel, unscrew the extension screw to make up the difference and add an extension adapter if

necessary.

4. Lockthehandleinapositionthatwillnotinterferewiththevehiclewhenraisedorlowered.Keepthehandleinthatlockedpositionuntil

the work is completed and you are ready to remove the jack from use.

5. Withthejackintheloweredposition,pushthejackunderthevehicle.IMPORTANT:Usethevehiclemanufacturer'srecommendedlifting

procedures and lifting points before lifting loads.

6. Inmostcases100psiginputairpressure(donotexceed200psig)willliftthemaximumcapacityloadnottoexceed22tons.Rotatethe

air lever to the right until the top of the ram comes close to the designated lift point. Make sure the designated lift point is at, parallel

tothegroundandfreefromgrease,anykindoflubricant,anddebris.Proceedwithpumpingthejackinordertoliftthevehicletothe

desiredheight.Duringlifting,inspectthepositionofthejackinrelationtothegroundandtheraminrelationshiptotheloadtopreventany

unstable conditions from developing. If conditions look like they are becoming unstable, slowly lower the load and make appropriate setup

corrections after the load is fully lowered.

7.Whenthevehicleorloadisliftedtoitsdesiredheight,immediatelyplacesafetysupportstands(jackstands)intheirdesignated

locationsandadjustthestands'supportcolumnsupasclosetothedesignatedvehiclesupportpointsaspossible.Althoughjack

standsareindividuallyrated,theyaretobeusedinamatchedpairtosupportoneendofthevehicleonly.Standsarenottobeused

tosimultaneouslysupportbothendsoronesideofavehicle.Rotatetheairlevertothelefttolowerthevehicleontothesafetysupport

stands(jackstands).Makesurethevehicleissafelysupportedbythesafetysupportstands'(jackstands)saddlesandnotthelocating

lugsofthesaddles.Inspecttherelationshipofthesafetysupportstands(jackstands)withthegroundandthesafetysupportstand(jack

stand)columnsandsaddleswiththevehicletopreventanyunstableconditions.Ifconditionslookunstable,rotatetheairlevertotheright

toraisethevehicleoffthesafetysupportstands(jackstands).Maketheappropriatesetupchangesandslowlyandcarefullylowerthe

vehicle onto the safety support stand saddles.

8. Aftertheworkisdone,rotatetheairlevertotherightuntilthejackishighenoughtoremovethevehicleorloadfromthesafetysupport

stand saddles. Be sure load is stable. If it is not, lower load back onto safety support stands. Make appropriate setup corrections and

repeatthestepagain.Removethesafetysupportstandsfromunderthevehicle,beingverycarefulnottomovethevehicle.

9. Rotatetheairlevertothelefttolowerthevehicleorloaddowntotheground.

KTI63194A 4

PREVENTATIVE MAINTENANCE

This is the safety alert symbol used for the PREVENTATIVE MAINTENANCE section of this manual to alert you to

potential personal injury hazards. Obey all instructions to avoid possible injury or death.

IMPORTANT: The number one cause of jack failure in air/hydraulic jacks is dirt and moisture in the air motor and/or hydraulic system.

maintenance schedule. An in line oil lubricator will extend the life of air/hydraulic jacks. Inoperable jacks caused by poorly equipped or

maintained shop air systems are not eligible for warranty consideration. Contaminants can also enter the air/hydraulic system when

the shop air line is disconnected from the jack air line and the line is dropped on the Contaminants in the air couplers, once

reconnected, will be driven into the system.

1.Always store the jack in a well protected area where it will not be exposed to inclement weather, corrosive vapors, abrasive dust, or

any other harmful elements. The jack must be cleaned of

water, snow, sand, grit, oil, grease or other foreign matter before using

2.The jack must be lubricated periodically in order to prevent premature wearing of parts. A general purpose grease must be applied

to the threads on the extension screw. Do not lubricate any portion of the lift saddle and make sure the saddle is free from grease,

any kind of lubricant, or debris before using the jack. Jacks found to be defective due to worn parts resulting from inadequate or no

lubrication are not eligible for warranty consideration.

3.It

should not be necessary to or top off the reservoir with hydraulic unless there is an external leak. An external leak

requires immediate r

familiar with this equipment. Authorized Service Centers are recommended. IMPORTANT: In order to prevent seal damage and jack

failure, never use alcohol, hydraulic brake or transmission oil in the jack. Use hydraulic jack oil, Chevron Hydraulic Oil AW ISO

32 or its equivalent Unocal Unax AW 150.

4.Every jack owner is responsible for keeping the jack label clean and readable. Use a mild soap solution to wash external surfaces

of the jack but not any moving hydraulic components.

5.Inspect the jack before each use. Do not use the jack if any component is cracked, broken, bent, shows sign of damage or leaks

hydraulic Do not use the jack if it has loose or missing hardware or components, or is in any way. Take corrective

action before using the jack again.

6.Do not attempt to make any hydraulic repairs unless you are a hydraulic repair person that is familiar with this equipment.

TROUBLESHOOTING

PROBLEM: UNIT WILL NOT LIFT RATED LOAD.

ACTION: Purge air from hydraulic system by following procedure under SETUP.

PROBLEM: UNIT WILL NOT SUSTAIN RATED LOAD OR FEELS “SPONGY” UNDER RATED LOAD.

ACTION: Purge air from hydraulic system as above.

PROBLEM: UNIT WILL NOT LIFT TO FULL HEIGHT.

ACTION: Purge air from hydraulic system as above or check oil level in reservoir.

PROBLEM: UNIT STILL DOES NOT OPERATE.

ACTION: Contact your place of purchase for details on handling warranty.

KTI63194A 5

K-Tool International warrants that all jacks and service-related equipment will be free from defects in material and workmanship for a

period of 2 years following the original date of purchase. This warranty is extended to the original retail purchaser only. If any jack or

service-related item proves to be defective during this period, it will be replaced or repaired, at K-Tool International’s option, without

charge. This warranty does not apply to damage from accident, overload, misuse or abuse, nor does it apply to any equipment which

has been altered or used with special attachments other than those recommended.

WARRANTY

K-Tool international HD and XD service-related equipment 2 Year Limited Warranty.

Michigan

KTI63194A6

22 Ton CAPACITY AIR/HYDRAULIC TRUCK jACK

ExPLOdEd dRAWINg

KTI63194"

KTI63194A 7

*Available in KT63194AHRK - Hydraulic Repair Kit

Only numbers identied by Part No. are available separately.

22 TON CAPACITY AIR/HYDRAULIC TRUCK JACK

PARTS LIST

KTI63194A

REF. # PART # DESCRIPTION QTY. REF. # PART # DESCRIPTION QTY.

1 Bolt 8 41 Block 2

2 Bolt 2 42 Coupler 4

3 Bolt 4 43 Coupler 1

4 KTP63194A04 Nut 2 44 Short Orange Hose 1

5 KTP63194A05 Washer 2 45 Short Black Hose 1

6 KTP63194A06 Wheel 2 46 Orange Hose 1

7 Handle Position Seat Assy 1 47 Coupler 1

8 Base Plate 1 48 Coupler 2

9 Left Side Plate 1 49 Slotted Pin 1

10 Right Side Plate 1 50 Tie Rod 1

11 KTP63194A11 Handle Socket 1 51 * Spring 1

12 KTP63194A12 Cover Plate 1 52 Handle-1 1

13 Bolt 4 53 Nut 7

14 Pump Body Welded Components 1 54 Screw 2

15 Connecting Block Assembly 1 55 Handle Connector 1

16 Screw 2 56 Tie Rod 1

17 Copper Washer 2 57 Pin 1

18 * Spring 1 58 Handle Lock 1

19 * Steel Ball 3 59 Screw 2

20 Screw 4 60 Handle-2 1

21 * O-Ring 4 61 Screw 2

22 * Steel Ball 1 62 Handle Sleeve 2

23 * Copper Ring 1 63 Orange Hose 1

24 * Steel Ball 1 64 Black Hose 1

25 Regulating Ball Seat 1 65 KTP63194A65 Cross Valve & Air Lever 1

26 * Spring 1 66 KTP63194A66 Adaptor 1

27 Screw 1 67 KTP63194A67 Adaptor 1

28 Screw 1 68 KTP63194A68 Adaptor 1

29 Release Plate 1 69 KTP63194A69 R-Pin 3

30 Release Valve 1 70 U Bolt 2

31 KTP63194A31 Hydraulic Pump 1 71 R-Pin 1

32 KTP63194A32 Ram 1 72 Bracket Assembly 1

33 Nylon Washer 1 73 Screw 1

34 Washer 1 74 Steel Ball Block Slice 1

35 * O-Ring 1 75 O-Ring 1

36 Ring For Ram 1 76 KTP63194A76 Handle Assembly Complete 1

37 * O-Ring 1 77 KTP63194A77 Bracket Assembly and Hardware 1

38 * O-Ring 1 78 Air Lever 1

39 Circlip 1 Not Shown KTP63194ALK Product Label Kit 1

40 Oil Plug 1

KTP63194A14

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