K Tool International KTI63155 User manual

KTI63155 7/17/14
5 Ton CAPACITY ServICe jACk
OWNERS MANUAL
SPECIFICATIONS
KTI63155
Capacity .................................................................................5 Ton
Low Height.................................................................................. 6"
Raised Height ............................................................................. 22"
Length ................................................................................. 55-1/2"
Chassis Width ........................................................................ 6-3/4"
Chassis Width with Swivel Caster Bracket ............................ 14-3/4"
Handle Length ..................................................................... 45-3 /4"
Saddle Diameter ................................................................... 5-3/4"
Shipping Weight................................................................ 232 Lbs.
Complies with ASME PALD/2009 Safety Standard

KTI63155 2 7/17/14
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. If the manual or product labels are lost
or not legible, contact K-Tool International for replacements. If the operator is not uent in English, the product and safety instructions
shall be read 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 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
operation of the equipment who are careful, competent, trained, and qualied in the safe operation of the equipment and its proper
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
 • Read,study,understandandfollowallinstructionsbeforeoperatingthisdevice.
 • Inspectthejackbeforeeachuse.Donotuseifdamaged,altered,modied,inpoorcondition,leakinghydraulicuidor
unstable due to loose or missing components. Make corrections before using.
 • Useonlyonahardlevelsurfacefreefromobstructionssothejackisfreetorepositionitselfduringliftingandlowering
operations.
 • Liftonlyonareasofthevehicleasspeciedbythevehiclemanufacturer.
 • UserandbystandersmustweareyeprotectionthatmeetsANSIZ87.1andOSHAstandards.
 • Donotusejackbeyonditsratedcapacity.Donotshockload.
 • This is a lifting device only. Immediately after lifting, support the vehicle with jack stands capable of sustaining the
load before working on the vehicle.
 • Centerloadonsaddle.Besuresetupisstablebeforeworkingonvehicle.
 • Donotmoveordollythevehiclewhileonthejack.
 • Donotuseanymaterialsthatmayserveasrisers,spacersorextendersbetweenthestockliftingsaddleandtheload.
 • Donotuseanyadaptorsthatreplacethestockliftingsaddleunlessapprovedorsuppliedbythejackmanufacturer.
 • Alwayslowerthejackslowlyandcarefully.
 • ThisproductmaycontainoneormorechemicalsknowntotheStateofCaliforniatocausecancerandbirthdefectsorother
reproductive harm. Wash hands thoroughly after handling.
 • Failuretoheedthesewarningsmayresultinseriousorfatal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

KTI63155 3 7/17/14
SETUP
PLEASE REFER TO THE EXPLODED VIEW DRAWING IN THIS MANUAL IN ORDER TO IDENTIFY PARTS.
1.Inordertoinstallthehandleassemblyitem#57inthehandlesocketitem#36,rstalignthemainhandletubewiththelargest
hole in the handle socket and the lock pin rod with the smaller hole in the handle socket.
2. Makesurethelockpinrodisinthedown/lockpositionbeforeinsertioninthehandlesocket.Oncethemainhandletube#41and
lockpinrod#45arealignedwiththeirrespectiveholesinthehandlesocket,pushthehandleassemblyinthehandlesocketsothe
endofthehandletubeengagesthereleaseexshaft#51inthebottomofthehandlesocket#36andthelockpinrodengagesone
ofthethree(3)lockingholesintheitem#1frame.
3.Nowrotatethe"T"handleportionofthehandleassemblysoitisperfectlyalignedwiththejackbeforetighteningtheitem#40bolt,
item#39washer,anditem#38nut.Tightenthebolt,washer,andnutsothehandlecannotrotate.Disengagethelockpinrod#45
bypullingupontheleverandengagingtheleverwiththeslotintopofthehandleassembly.Thehandleassembly#51shouldbe
free to pump up and down.
4.Inordertocheckforproperhandleassembly#57alignmentwiththehandlesocket,seeifthelockpinrod#45willengagewiththe
three(3)lockingholesintheframe.Also,turnthereleasevalveknob#43atthetopofthehandleassemblyleftandthenrightto
seeifthereleaseexshaft#51infrontandbelowthehandlesocketisrotatingsimultaneouslywiththeturningoftheknob#43.
5.BeforeUse:Airmaybecometrappedinthehydraulicsystem.
PURGING AIR FROM THE HYDRAULIC SYSTEM
 a. Rotatetheknobatthetopofthehandleassemblyinaclockwisedirectionuntiltight.
   Nowturnitinacounterclockwisedirectiontwofullturns.
 b. Activatethefootpumppedalitem#37about15times.
 c. Rotatetheknobatthetopofthehandleassemblyinaclockwisedirectionuntiltight.
 d. Activatethefootpumpuntiltheliftarmisraisedtomaximumheight.Youshouldexperienceafullpumpstrokewitheach
incremental pump of the pedal.
 e. Repeatsteps"a"through"d"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. Toraiseload:Turntheknobatthetopofthehandleassemblyinaclockwisedirectionuntiltight.Positionthejackundertheload.
Proceedtopumpthehandleorthefootpedalinordertoraisetheliftarmtotheload.Asthesaddleattheendoftheliftarmgets
closer to the load, reposition the jack so the saddle will contact the load rmly and the load is centered on the saddle. Make sure the
saddleiscorrectlypositioned.Rememberthatfootpedalpumpoperationisonlyusedtoquicklyraisethesaddletotheload.The
handlepumpoperationofthejackisusedtolifttheload.Raisetheloadtothedesiredworkheight.Placejackstandsofappropriate
capacity at the vehicle manufacturer's recommended support areas that provide stable support for the raised vehicle. DO NOT
CRAWL UNDER VEHICLE WHILE LIFTING VEHICLE OR INSTALLING JACK STANDS TO SUPPORT THE VEHICLE! Once jack
standsarepositioned,turntheknobatthetopofthehandleassemblyinacounterclockwisedirectionVERYSLOWLY.Lowertheload
to rest on the jack stands. Inspect the relationship between the jack stands and load to make sure the setup is stable and safe. If the
setupisnotstableorsafe,followtheprecedingstepsuntilcorrected.NOTE.Oncethehandpumpoperationhasceased,thehandle
assemblycanbelockedinanyofthethree(3)handlelockingpositions.Typically,thehandlelockingpositionsareusedformovingthe
jack around the shop, keeping the handle out of the way or preventing the handle from being pumped.
2. Tolowerload:Followtheproceduresmentionedin"Toraiseload"sectionoftheOPERATINGINSTRUCTIONSinordertoraise
the load off the jack stands. Once the load has cleared the jack stands, remove the stands from under the load and away from
the work area. Turn the knob at the top of the jack's handle assembly very slowly in a counterclockwise direction until the load is
completely lowered to the ground. Once the jack's lifting saddle has cleared the load, remove the jack from under the load.
DO NOT CRAWL UNDER VEHICLE WHILE LIFTING VEHICLE OR REMOVING THE JACK STANDS!
CAUTION: Keep hands and feet away from the hinge mechanism of the jack.
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. 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casterwheels,frontaxle,elevatorarm,handlebasepivotbolts,releasemechanismandallotherbearingsurfaces.Wornparts
resulting from inadequate or no lubrication are not eligible for warranty consideration. IMPORTANT: In order to prevent seal
damageandjackfailure,neverusealcohol,hydraulicbrakeuid,ortransmissionoilinthejack.Usehydraulicjackoil,alight
turbineoil,ChevronAWISO32orUnocalUnaxAW150.
3. Everyjackownerisresponsibleforkeepingthejacklabelscleanandreadable.Useamildsoapsolutiontowashexternalsurfaces
of the jack but not any moving hydraulic components.
4. Inspectthejackbeforeeachuse.Donotusethejackifanycomponentiscracked,broken,bent,showssignsofdamageorleaks
hydraulicuid.Donotusethejackifithaslooseormissinghardwareorcomponents,orismodiedinanyway.Takecorrective
action before using the jack again.

KTI63155 4 7/17/14
INSPECTION
Visualinspectionshouldbemadebeforeeachuseofthejack,checkingforleakinghydraulicfluidanddamaged,looseormissing
parts.Eachjackmustbeinspectedbyamanufacturer’s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amanufacturer’sauthorizedrepairfacility.Itisrecommendedthatanannualinspection
of the jack be made by a manufacturer’s authorized repair facility and that any defective parts, decals or warning labels be replaced
withmanufacturer’sspecifiedparts.Alistofauthorizedrepairfacilitiesisavailablefromthemanufacturer.
PROPER STORAGE
It is recommended that the jack be stored in a dry location with all wheels touching the ground on a relatively level surface.
TROUBLESHOOTING
Important:Servicejacksareself-containeddevicesusedforlifting,butnotsustaining,apartialvehicularload.Inaccordancewith
ASME-PALDLoadSustainingTest:“Aloadnotlessthantheratedcapacity…shallnotlowermorethan1/8"(3.18mm)intherstmin-
ute,noratotalof.1875"(4.76mm)in10minutes.”LoweringwithinthisrangeisconsiderednormaloperationandisNOTawarrantable
defect.
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: HANDLE TENDS TO RAISE UP WHILE THE UNIT IS UNDER RATED LOAD.
ACTION: Pumpthehandlerapidlyseveraltimestopushoilpastballvalvesinpowerunit.
PROBLEM: UNIT STILL DOES NOT OPERATE.
ACTION: Contactyourplaceofpurchasefordetailsonhandling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. This warranty does not cover repairs made by
anyonewhoisnotaK-ToolInternationalProfessionalLiftingEquipmentAuthorizedRepairCenter.
AllHD&XDjacksorservice-relatedequipmentwillbereplacedorrepairedatK-ToolInternational’soptionduringthe2yearwarranty
period.
Duringthe2yearwarrantyperiod,allallegeddefectiveproductsmustbeshipped,freightprepaid,alongwithproofofdate-of-purchase,
to your nearest K-Tool International Professional Lifting Equipment Authorized Warranty Center. Be certain to include your name,
address and phone number along with proof-of-purchase information, and a brief description of the alleged defect. The product will be
returned to the customer, freight prepaid.
ManyallegeddefectivesmaysimplybehandledbycallingyournearestServiceCenterforparts.Seepages16-18foralistingof
authorized warranty service centers.
In no event shall K-Tool International be liable for incidental or consequential damages. The liability on any claim for loss or damage
arisingoutofthesale,resaleoruseofajackorrelatedserviceequipment,shallinnoeventexceedthepurchaseprice.SOMESTATES
DONOTALLOWTHEEXCLUSIONORLIMITATIONOFINCIDENTALORCONSEQUENTIALDAMAGES,SOTHEABOVELIMITATION
MAYNOTAPPLYTOYOU.
THIS WARRANTY IS THE SOLE AND EXCLUSIVE WARRANTY PROVIDED IN CONNECTION WITH THE SALE OF K-TOOL
INTERNATIONALPROFESSIONALLIFTINGEQUIPMENT.ALL OTHERWARRANTIES,INCLUDINGANY IMPLIEDWARRANTIESOF
MERCHANTABILITYORFITNESSFORAPARTICULARPURPOSE,AREEXCLUDED.
THISWARRANTYGIVESYOUSPECIFICLEGALRIGHTSANDYOUMAYALSOHAVEOTHERRIGHTSWHICHVARYFROMSTATE
TOSTATE.
WARRANTY HANDLING PROCEDURES AND GUIDELINES FOR HD AND XD LIFTING EQUIPMENT

KTI63155 5 7/17/14
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KTI63155
8
6
1
39
10
4
2
2
5
9
15
4
11
5
713
12
14
25
30
29
27
26
28
40
23
24
36
38
37
54
54
49
48
43
35
33
31
45
47
48
46
42
50
56
52
51
41
44
55
53
3
16
17 18
19 20
21
21
22
34
13
14
29
32
3-1
5
57
HANDLE ASSEMBLY
KTP63155HA
58
POWER UNIT
KTP63155HY
1
2
2
4
5
6
789
10
11
12
13
14
15
16
22
58
21
20
19
18
17
12
24
23
25
27
26
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