K Tool International HD KTI63194A User manual

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
WARNING
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