K Tool International KTI-63505A User manual

KTI-63505A
1000 LB. TWO STAGE TELESCOPIC TRANSMISSION JACK
OWNER'S MANUAL
SPECIFICATIONS
KTI-63505A
Capacity ..........................................................................1000 Lbs.
Low Height................................................................................37"
High Height ............................................................................76-2/5"
Saddle Tilt Forward....................................................................10˚
Saddle Tilt Backward.................................................................27˚
Saddle Left Tilt...........................................................................29˚
Saddle Right Tilt.........................................................................45˚
Shipping Weight.............................................................158.9 Lbs.
www.P65Warnings.ca.gov
Cancer and Reproductive Harm-WARNING:
Complies with ASME PASE/2014 Safety Standard

KTI-63505A 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.
ead to and discussed with the operator in the
operator's native language by the purchaser/owner or his designee, making sure that the operator comprehends its contents.
THE NATURE OF HAZARDOUS SITUATIONS
The use of portable automotive lifting and support 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
Examples of hazards are dropping, tipping or slipping of loads caused primarily by improperly secured 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
•Read, study, understand and follow all instructions before operating this device.
•Inspect the jack before each use. Do not use jack if damaged, altered, in poor condition, or has loose or missing hardware
or components. Make corrections before using.
•Consult the vehicle manufacturer for the transmission’s center of balance.
•Secure the transmission to the jack’s saddle with the anchorage restraint system provided before raising or lowering the transmission.
•Center load on saddle. Be sure setup is stable before working on vehicle.
•Support the engine with a stand before unbolting the transmission from the engine.
•Wear eye protection that meets ANSI Z87.1 and OSHA standards (users and bystanders).
•Do not use jack beyond its rated capacity. Do not shock load.
•Use only on a hard level surface.
•Adequately support the vehicle before starting repairs.
•Use of this product is limited to the removal, installation and transportation in the lowered position, of transmissions, transfer cases
and transaxles.
•Do not use any adapters unless approved for this device.
•Always lower the jack slowly and carefully.
•Failure to heed these warnings may result in personal injury and/or property damage.
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

KTI 63505A 3
INSPECTION AND SETUP INSTRUCTIONS
Visual inspection should be made before each use of the transmission jack, checking for leaking hydraulic and damaged,
loose or missing parts. Each jack must be inspected by an authorized repair facility immediately if subjected to an abnormal
load or shock. Any jack which appears to be damaged in any way, is found to be badly worn, or operates abnormally MUST
BE REMOVED FROM SERVICE until necessary repairs are made by an authorized repair facility.
Refer to parts breakdown on page 6 and 7:
1. Before using jack for the time, some assembly is required. Place hydraulic unit in upright position and bolt legs (#R30) to base
(#R38) using bolts (#R34) and washers (#R32 and R33).
2. Assemble each caster to leg using washers (#R36) and nuts (#R35).
3. Attach (#2) to plate (#3) using bolts (#1), washers (#4), and wing nuts (#5).
AIR BLEEDING INSTRUCTIONS
IMPORTANT! If the transmission jack is not able to raise the load, or raises it very slowly, there may be air trapped in the hydraulic
system. Follow these instructions and refer to Diagram 1 and parts page 7:
1. Turn the air vent screw (#R23) counterclockwise until it stops.
2. With both rams in their lowered position, turn the release knob (#R50) clockwise until it stops.
3. Loosen but do not remove the M6 x 5 inner Allen socket screw (#R52) by turning it counterclockwise two revolutions.
4. Pump the foot pedal (#R44) 2 or 3 times until you see oil coming out of the M6 x 5 Allen socket screw hole.
5. After 3 foot pumps, hold the pedal (#R44) down while simultaneously turning the M6 x 5 Allen socket screw (#R52) clockwise
until tight.
6. Activate the pedal (#R44) to see if the jack can raise smoothly. If not, repeat steps #2 through #5 again.
If the transmission jack can raise a load but its rams are not traveling smoothly, there may be air trapped in the rams that need to be
bled as follows:
1. Turn the release valve knob (#R50) clockwise until it stops. Activate the foot pedal (#R44) until both rams are fully extended.
2. Turn the M8 x 10 BLEED SCREW (#R14) counterclockwise 1 to 1.5 revolutions, pump the foot pedal (#R44) 2 to 3 times until oil
comes out of the M8 x 10 BLEED SCREW hole.
3. Turn the M8 x 10 BLEED SCREW (#R14) clockwise until tight.
4. Turn the release valve knob (#R50) in a counterclockwise
direction to lower both rams all the way down. Turn
the release valve knob (#R50) clockwise until it
stops and pump the jack to maximum height.
Operate the jack up and down
once again to see if the rams
are responding properly. If better
but not complete, repeat steps
#1 through #4 again.
M6 x 5
SCREW
M8 x 10
BLEED
SCREW DIAGRAM 1
R50
R23
BLOCK
OF STEEL
R44

KTI-63505A4
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.
1. Liftthevehicletothedesiredworkheightandsupportthevehicleinaccordancewiththeliftmanufacturer'srecommended
support procedure and all the instructions and warnings in this manual.
2. Useanunderhoiststandratedgreaterthantheweightoftheenginetosupporttheenginebeforeunboltingthetransmission
from the engine or bolting the transmission to the engine.
3. Positionthetransmissionjackdirectlyunderthetransmission.Depressthelargefootpedalupanddowninordertoraisethe
saddle to a height very close to the center of balance point of the transmission oil pan but do not touch the transmission.
4. Adjustthengers(#2)onthesaddlesothatthebentupsectionofthengerswilltinthemountingangearoundtheperimeter
 ofthetransmissionoilpan.Slowlyandgentlypumpthejacksotheconnectionismadeandthensecurethetransmissiontothe
 jack'ssaddlewiththesafetychain(#28)provided.Sometimesitisnecessarytoturntheforeandaftknobsandsidetosidetilt
knobs so the saddle is in the proper alignment with the transmission pan before securing the load to the saddle.
5. Makesurethesafetychainisverytightwhensecuringthetransmissiontothesaddleandbeforeraisingorloweringthe
transmission.
6. Removethetransmissionfromtheengineaccordingtoinstructionsinthevehicleservicemanual.
7. Oncethetransmissionhasbeendisconnectedfromtheengine,veryslowlydepressthereleasepedaltomakesurethejack's
 saddleandtransmissiondonothanguponanyundercarcomponents,wiring,fuellines,etc.Continuetolowerthejackallthe
way down.
8. Wheninstallingatransmission,followtheaboveinstructionsbutintheapplicableorderandaccordingtothevehicle
manufacturer's installation procedure.
9. IMPORTANT!Thereleasefootpedal(#R42)isdesignedforordinaryloweringofload.Thereleaseknob(#R50)isusedforslow
 controlledloweringofload.Donotusebothreleasemechanisms(#R42and#R50)atthesametime.
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.
1. Regularlylubricateallmovingparts,payingcloseattentiontothetiltscrewsandrelatedlinkages.
2. Itshouldnotbenecessarytorefillortopoffthereservoirwithfluidunlessthereisanexternalleak.Anexternalleakrequires
immediate repair which must be preformed by qualified hydraulic repair personnel. In order to prevent seal damage, use hydraulic
jackoil,SAE30hydraulicoil,orShellOil22.
Theproperfluidlevelisapproximately1"belowtheleveloftheairventscrew(#R23)withbothramslowered.Overfillingwillcause
fluid to leak from the screw when the load is lowered.
TROUBLESHOOTING
PROBLEM: UNIT WILL NOT LIFT RATED LOAD.
ACTION: PurgeairfromhydraulicsystembyfollowingprocedureunderINSPECTIONAND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.
PROBLEM: UNIT STILL DOES NOT OPERATE.
ACTION: Contactyourplaceofpurchasefordetailsonhandlingwarranty.

KTI-63505A 5
WARRANTY
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.
K-Tool International HD and XD service-related equipment 2 Year Limited Warranty.
Michigan

KTI-63505A 6
1000 LB. TWO STAGE TELESCOPIC TRANSMISSION JACK
PARTS BREAKDOWN
KTI-63505A
R25
R24
R23
R15
R16
R17
R18
R19
R20
R21
R22
R6
R7
R8
R1
R2
R3
R4
R5
R9
R10
R11
R12
R13
R35
R36
R35
R36
R35
R36
R30
R20
R29
R38
R52
P23
R50
P27
R39
R43
R44
R45
R45
R46
R47
A
A
A
R49
R48
R31
R42
R40
R41
R32
R33
R32
R33
R34
R34
R17
R26
R27
R28
R14
P2
16
14
13
15
19 18
17
16
15
14
13
14
12
11
10
10
9
6
5
4
3
7
8
12
A
A
21
22
30
20
5
5
4
12
5
4
4
2
124
12
10
9
25
AA
26
27
28
27
29
2
1
2
11
2
10
23
R51
31
R31
R36
R35
R37
A
R30
R37

KTI-63505A 7
REF. # PART # DESCRIPTION QTY.
R1 Dust Cover 1
R2 O-Ring 1
R3 Secondary Cylinder Head 1
R4 O-Ring 1
R5 Secondary Cylinder Plunger 1
R6 Circlip 1
R7 Dust Cover 1
R8 O-Ring 1
R9 Primary Cylinder Head 1
R10 O-Ring 1
R11 Primary Cylinder Plunger 1
R12 Circlip 1
R13 Cap 1
R14 Bleed Screw (M8 x 10) 1
R15 O-Ring 1
R16 Cylinder Head Support 1
R17 Cylinder Bushing 2
R18 Cylinder 1
R19 Pin 1
R20 Clip 4
R21 Handle 1
R22 Handle Cover 1
R23 Air Vent Screw 1
R24 Seal Bushing 1
R25 Plug 1
R26 Ram 1
R27 Ram Bush 1
R28 Washer 2
R29 Pin 2
R30 Leg Assembly 2
R31 KTP63505AR31 Non-locking Casters 2
R32 Washer 4
R33 Spring Washer 4
R34 Hex Bolt 4
R35 Hex Nut 4
R36 Spring Washer 4
R37 KTP63505AR37 Locking Casters 1
R38 Pump Base 1
R39 Screw 1
R40 Spring Washer 1
R41 U-Shape Locking Pin 1
R42 Release Pedal 1
R43 Pin 1
R44 Pumping Pedal 1
R45 Circlip 2
R46 Pin 1
R47 Connecting Rod 1
R48 Hex Bolt 2
R49 Cover 2
R50 KTP63505AR50 Release Rod and Knob 1
R51 KTP63505AR51 Saddle Assembly Complete 1
R52 Inner Allen Socket Screw (M6 x 5) 1
P2 Ball 1
P23 O-Ring 1
P27 Ball 1
REF. # PART # DESCRIPTION QTY.
1 Bolt 4
2 KTP63505A02 Finger 4
3 Plate 1
4 Washer 4
5 Nut 4
6 Hook 1
7 Pin 1
8 Nut 1
9 Nut 2
10 Bearing 4
11 Pin 1
12 Circlip 4
13 Pin 2
14 Retaining Ring 4
15 Cotter Pin 2
16 KTP63505A16 Tilt Screw Assembly 2
17 Bolt 2
18 Liner 1
19 Bolt 1
20 Bracket 1
21 Bracket 1
22 Washer 2
23 Pin 1
24 Washer 1
25 Nut 1
26 Nut 1
27 Washer 2
28 KTP63505A28 Chain 1
29 Bolt 1
30 Nut 2
31 Hydraulic Unit 1
1000 LB. TWO STAGE TELESCOPIC TRANSMISSION JACK
PARTS BREAKDOWN
KTI-63505A
*Available in Seal Kit: KTP63505ASK
Label Kit: KTP63505ALK
Only reference numbers identified by part numbers
are available separately.