K Tool International KTI-63421A User manual

KTI-63421A 1
1.5 TON FOLDABLE ENGINE CRANE WITH FAST RISE
OWNER'S MANUAL
SPECIFICATIONS
KTI-63421A
Boom Capacity.................................................................. .SBL0033
"5/3-06,"01/9-35,"01/3-74,"2/1-04..................................................htgnelelbatsujdAmooB
Base Dimensions - Open
Width Back.......................................................................34"
Width Front ......................................................................39"
Length...............................................................................65"
Power Unit .........................................................................8Ton Heavy Duty Fast Rise
Shipping Weight (shipped in 2 boxes) ..............................202.86 Lbs.
WARNING: Cancer and Reproductive Harm-
www.P65Warnings.ca.gov
Complies with ASME PASE/2014 Safety Standard

KTI-63421A 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.
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
the equipment and its proper use. 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 crane before each use. Do not use if damaged, altered, in poor condition, leaking hydraulic or unstable
due to loose or missing hardware or parts. Make corrections before using.
•Never get under a load being lifted or suspended.
•Wear eye protection that meets ANSI Z87.1 and OSHA standards (users and bystanders).
•Use only on a hard level surface.
•Do not raise the boom if the crane is equipped with a foldable or storable leg feature and the legs are in the upright position.
•Use only slings or chains with a rated capacity greater than the weight of the load being lifted.
•Do not exceed rated capacity.
•Do not lift or move a load that has a center of gravity extending beyond the front wheels.
•Do not allow load to swing or drop violently while raising, lowering or moving.
•Before moving, lower load to the lowest possible point.
•No alterations shall be made to this product, and do not use any unapproved attachments.
•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
shall be read to and discussed with the operator

KTI-63421A3
SETUP INSTRUCTIONS
   ThisisthesafetyalertsymbolusedfortheSETUPINSTRUCTIONSsectionofthismanualtoalertyoutopotentialpersonal
injury hazards. Obey all instructions to avoid possible injury or death.
Refertopartsbreakdownonpage6:
1. Securetherearcasterassemblies(#5)tothebaseframe(#1)withtheboltsandwashersprovidedandinaccordancewith
the assembly drawing.
2. Looselyassembletheuprightmast(#17)tothebaseframe(#1)inaccordancewiththeassemblydrawingandngertighten
 thebolts(#4),washers(#3)andnuts(#2).
3. Looselyassemblethemastbraces(#11)totheupright(#17)mastbyngertighteningthebolt(#18),washer(#15)and
 nut(#16).Looselyassembletheoppositeendsofthemastbraces(#11)tothebaseframe(#1)byngertighteningthe
 bolts(#4),washers(#3)andnuts(#2).
4. Tightenallthehardwarementionedinsteps2and3.
5. Installthelegextensions(#9Land#9R)inthebase(#1)wheretheholesinthelegslineupwiththeholesinthebaseas
 shownintheassemblydrawing.Securethelegstothebaseusingthedetentpins(#8)andR-clips(#7).
6. Accordingtotheassemblydrawing,securethehydraulicram(#14)inbetweenthemountingbracketsontheupright
 mast(#17)usingthebolt(#12),washer(#15)andnut(#16).Leantheramupagainstthemast.
7. Securetheboom(#26)inbetweenthemountingangeslocatedontopoftheuprightmast(#17)usingthebolt(#30),
 washer(#23)andnut(#24).
8. Lineuptheholeinthehydraulicram(#14)withtheholesinthegussetsoftheboom(#26)andsecuretheramtothe
 boomwiththebolt(#22),washer(#15)andnut(#16).Itmaybenecessarytoextendtheramtolineupalltheholes.
9. Pumpthejacksotheboom(#26)ishorizontaltotheground.Accordingtotheassemblydrawing,slidetheboomextension
 (#27)insidetheboom(#26)sotheholeintheboomalignswithanyofthefourholesintheboom(#26).Securetheboomand
 boomextensiontogetherusingthedetentpin(#25)andR-clip(#7).
10. Slideoneofthechainlinksofthehook(#29)andchainassemblythroughtheslotinthebottomoftheboomextension(#27).
 Feedthebolt(#28)throughtheholeononesideoftheextensionboom,thenthroughthechainlinkandnallythroughthe
 holeintheothersideoftheextensionboom.Securethebolt(#28)withwasher(#3)andnut(#2).
11. Securethepushbar(#19)onthebacksideoftheuprightmast(#17)usingthescrews(#21)andwashers(#20).
12. Installthepumphandle(#13)inthehydraulicrampumplinkage(#14)whenusingorintheuprightmastholder(#17)forstorage.
13. Sometimesairgetstrappedinthehydraulicsystemduringshipment.Anairboundhydraulicsystemfeelsspongywhenpumped
and may not allow the jack to pump full incremental strokes.
TO PURGE AIR FROM THE HYDRAULIC SYSTEM:
a. Open the release valve by turning the handle in a counterclockwise direction two full turns.
 b. Pumpthehandletenfullstrokes.
 c. Closethereleasevalvebyturningthehandleinaclockwisedirectionuntiltight.
 d. Pumpthejackuntiltheramisextendedtomaximumheight.
 e. Repeatsteps"a"through"d"untilallthe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.
1. Beforelifting,evaluatetheworktobedoneby:
 a. Determiningtheweightoftheloadtobeliftedandsecuretheboomextensionintheboomintheappropriateholeposition.
 b. Determinethecrane'sboomextensioninordertoensurethereisenoughboomlift/traveltoaccomplishthework.
IMPORTANT:THEWORKINGCAPACITYOFTHECRANEISDETERMINEDBYTHELOCATIONOFTHEEXTENSIONBOOM.
  THECAPACITYOFTHEEXTENSIONBOOMMUSTEXCEEDTHEWEIGHTTOBELIFTED.
  Securetheboomextensionintheboomwiththeappropriatehardwareprovided,makingsureitcannotcomelooseduringuse.
c. The crane's hook and chain assembly must be adjusted to the right length and secured to the end of the boom to prevent the
hook from binding with the boom when lifting.
2. Makesurethecrane'sfrontwheelsextendbeyondtheextensionboom'shookinordertoavoidloadtipping.Donotliftormovea
load with a center of gravity that extends beyond the sides of the crane and the crane's front wheels.
3. Usebalancers,levelers,slings,chainsoranycombinationthereof(whicharecapableofsustainingtheload)aroundtheloadbefore
using the crane's hook to lift the load. Make sure the complete setup is secure before lifting.

KTI-63421A4
4. Attachthecrane'shooktothebalancer,leveler,sling,chainoranycombinationthereof.Turnthereleasevalveonthecrane's
 hydraulicraminaclockwisedirectionuntiltight.Beforepumpingthecrane'sjackhandle,makesuretheengineorloadisfreefrom
all other restraints and connections that would hinder the raising of the load. Once the engine or load has cleared its location, make
sure there is no slope in the oor or any obstructions on the oor that could cause the crane to tip and lose the load.
5. Immediatelyuponremovaloftheenginefromtheenginecompartmentorloadfromitsposition,theengineorloadmustbeasclose
to the ground as possible when transporting. Lower the load to the proper transport height by slowly and carefully turning the
 hydraulicram'sreleasevalveinacounterclockwisedirection.Whenapproachingthetransportheight,startturningthecrane's
release valve in a clockwise direction until tight. This same procedure of lowering the load is also used for moving a load to its nal
or temporary resting place or location.
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craneinawellprotectedareawhereitwillnotbeexposedtoinclementweather,corrosivevapors,abrasive,
dust, or any other harmful elements. The crane must be cleaned of water, snow, sand, grit, oil, grease or other foreign matter before
using.
2. Lubricate the wheels, casters, and all pivot points on the crane according to an acceptable shop maintenance schedule.
Maintenance intervals are dependant on time and usage.
3. Everycraneownerisresponsibleforkeepingthecranelabelscleanandreadable.Useamildsoapsolutiontowashexternal
 surfacesofthecranebutnotanymovinghydrauliccomponents.ContactK-ToolInternationalforareplacementlabelifyourcrane's
label is not readable.
4. Inspectthecranebeforeeachuse.Donotusethecraneifanycomponentiscracked,brokenorbent.Donotusethecraneifit
has loose or missing hardware or components, or is modied in any way. Take corrective action before using the crane again.
5. Itshouldnotbenecessarytorellortopoffthecrane’sjackreservoirwithhydraulicuidunlessthereisanexternalleak.An
external leak requires immediate repair which must be performed in a dirt-free environment by qualied hydraulic repair personnel
 whoarefamiliarwiththisequipment.Authorizedservicecentersarerecommended.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.
TROUBLESHOOTING
PROBLEM: CRANE WILL NOT LIFT RATED LOAD.
POSSIBLE CAUSE: Releasevalvenottightlyclosed.
ACTION: Closereleasevalvermly.
POSSIBLE CAUSE: Overload condition.
ACTION: Usecranewithpropercapacity.
POSSIBLE CAUSE: Airtrappedinhydraulicsystem.
ACTION: Purgeairfromsystembyfollowingsteps"a"though"d"inthe"SETUPINSTRUCTIONS"sectionofthemanual.
POSSIBLE CAUSE: Hydraulicvalvesnotoperatingproperly.
ACTION: Contactyourdealer.
PROBLEM: CRANE WILL LIFT BUT LOWERS RATED LOAD SLOWLY.
POSSIBLE CAUSE: Releasevalvenottightlyclosed.
ACTION:Closereleasevalvermly.
POSSIBLE CAUSE: Hydraulicvalvenottightlyclosed.
ACTION: Contactyourdealer.
PROBLEM: CRANE WILL NOT LOWER AFTER RATED LOAD HAS BEEN REMOVED.
POSSIBLE CAUSE: Jack's reservoir has too much uid.
ACTION: Placejackinitsuprightposition.Retracttheram.Removethereservoirllplug.Allowoiltodrainoutofllpluguntiloillevel
isatbottomlevelofhole.Reinstallllplug.
PROBLEM: POOR LIFT PERFORMANCE OR WILL NOT LIFT MAXIMUM HEIGHT.
POSSIBLE CAUSE: Hydraulicuidlow.
ACTION: Placejackinitsuprightposition.Retracttheram.Removethereservoirllplug.Addonlyhighqualityhydraulicjackoil
upthebottomlevelofthehole.Reinstallllplug.Purgeairfromsystemaccordingtosteps"a"through"d"inthe"SETUP
INSTRUCTIONS"sectionofthismanual.
POSSIBLE CAUSE: Airtrappedinhydraulicsystem.
ACTION: Purgeairfromthesystem.Seesteps"a"through"d"inthe"SETUPINSTRUCTIONS"sectionofthismanual.

KTI-63421A 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-63421A 6
1.5 TON FOLDABLE ENGINE CRANE WITH FAST RISE
PARTS BREAKDOWN
KTI-63421A
REF. # PART # DESCRIPTION QTY.
1 Base Frame 1
2 Nut (M14) 5
3 Washer (14) 5
4 Bolt (M14 x 95) 4
ylbmessAretsaCraeR50A12436PTK5 2
leehWesaBtnorF"360A12436PTK6 2
7 R-Clip 5
8 Detent Pins 4
9L Left Leg Extension 1
9R Right Leg Extension 1
leehWgeLtnorF"401A12436PTK01 2
11 Mast Brace 2
12 Bolt (M16 x 90) 1
eldnaHpmuP31A12436PTK31 1
1)knatØmm58()31#.lcni(maRciluardyH41A12436PTK41
15 Washer (16) 3
REF. # PART # DESCRIPTION QTY.
16 Nut (M16) 3
17 Upright Mast 1
18 Bolt (M16 x 100) 1
19 Push Bar 1
20 Washer (8) 12
21 Screw (M8 x 12) 12
22 Bolt (M16 x 70) 1
23 Washer (8) 1
24 Nut (M18) 1
25 Detent Pin (16) 1
26 Boom 1
27 Boom Extension 1
28 Bolt (M14 x 70) 1
ylbmessAniahCdnakooH92A12436PTK92 1
30 Bolt (M18 x 100) 1
Available in KTP63421ARK.
1
5
2
3
4
4
2
3
23
7
8
7
8
9R
10
11
4
12
9L
13
14
15
16
17
18
23
24
19
30
16 15
20
21
21 20
22
15
16
25
726
27
28
29
2
3
6