KTI63517 7/16/14

1.5 TON TRUCK TRANSMISSION JACK

OWNERS MANUAL

KTI63517

SPECIFICATIONS

Capacity .......................................................................... 1-1/2 Ton Low Height ...........................................................................8-5/8" Raised Height .....................................................................36-5/8" Length ................................................................................43-1/2"

Chassis Width ...........................................................................26" Saddle Tilt Fore and Aft ................................................ 10 by 10 Saddle Tilt Side to Side ...................................................+10, 10 Shipping Weight .................................................................350 lbs.

Complies with ASME PALD/2009 Safety Standard

KTI63517 2 7/16/14

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 fluent 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 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 operation of the equipment who are careful, competent, trained, and qualified 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 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,andfollowallinstructionsbeforeoperatingthisdevice. Inspectthejackbeforeeachuse.Donotusejackifdamaged,altered,modified,inpoorcondition,orhaslooseormissing hardware or components. Make corrections before using. Consultthevehiclemanufacturerforthetransmissionscenterofbalance. Securethetransmissiontothejackssaddlewiththeanchoragerestraintsystemprovidedbeforeraisingorlowering the transmission. Centerloadonsaddle.Besuresetupisstablebeforeworkingonvehicle. Supporttheenginewithastandbeforeunboltingthetransmissionfromtheengine. WeareyeprotectionthatmeetsANSIZ87.1andOSHAstandards(usersandbystanders). Donotusejackbeyonditsratedcapacity.Donotshockload. Useonlyonahardlevelsurface. Adequatelysupportthevehiclebeforestartingrepairs. Useofthisproductislimitedtotheremoval,installationandtransportationintheloweredposition,oftransmissions,transfer cases and transaxles. DonotuseanyadaptersunlessapprovedorsuppliedbyK-ToolInternational. Alwayslowerthejackslowlyandcarefully. ThisproductmaycontainoneormorechemicalsknowntotheStateofCaliforniatocausecancerandbirthdefectsorother reproductive harm. Wash hands thoroughly after handling. Failuretoheedthesewarningsmayresultinpersonalinjuryand/orpropertydamage.

CONSEQUENCES OF NOT AVOIDING HAZARDOUS SITUATIONS

Failuretoreadthismanualcompletelyandthoroughly,failuretounderstanditsOPERATINGINSTRUCTIONS,SAFETYWARNINGS, MAINTENANCEINSTRUCTIONSandcomplywiththem,andfailuretocomplywiththeMETHODSTOAVOIDHAZARDOUS SITUATIONScouldcauseaccidentsresultinginseriousorfatalpersonalinjuryand/orpropertydamage.

WARNING:Indicatesahazardoussituationwhich, if not avoided, could result in death or serious injury.

WARNING

WARNING

WARNING

WARNING

WARNING INFORMATION

KTI63517 3 7/16/14

SETUP INSTRUCTIONS

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

1. Refertotheexplodedviewdrawingonpage5toidentifyjackcomponents.2. The#3-7and#3-13fingersmustbeinstalledinthe#3-8saddlewiththe#3-6bolts,#3-9washersand#3-10wingnutsas

shown in the exploded view drawing.3. The#3-4chainsmustbeattachedtothe#3-7fingersasshownintheexplodedviewdrawingandsecuredtothefingerswith

the#3-1bolts,#3-2washers,#3-3lockwashersand#3-5nutsprovided.4. Assemblethe#3-16chainhookstothe#3-15adaptorboltswiththe#3-14wingnutsasshowninthedrawing.5. Securethe#3-15adaptorboltstothetworemaining#3-13fingersusingthe#3-12washersand#3-11nuts.6. Airmaygettrappedinthehydraulicsystemduringfreightandhandling. PURGING AIR FROM THE HYDRAULIC SYSTEM: a. Rotatethereleaseknob#1-21atthetopofthebody#1-10inaclockwisedirectionuntiltight. Nowturnitinacounterclockwisedirectiontwofullturns. b. Activatethehandle#1-45about15times. c. Rotatethereleaseknob#1-21atthetopofthebody#1-10inaclockwisedirectionuntiltight. d. Activatethehandle#1-45untiltheliftarm#29israisedtomaximumheight.Youshouldexperienceafullpumpstrokewith

each incremental pump. e. Repeatsteps"a"through"d"untilallairispurgedfromthesystem.

OPERATING INSTRUCTIONS

ThisisthesafetyalertsymbolusedfortheOPERATINGINSTRUCTIONSsectionofthismanualtoalertyoutopotential personal injury hazards. Obey all instructions to avoid possible injury or death. 1. Liftthevehicletothedesiredworkheight,andsupportthevehicleinaccordancewiththeliftmanufacturer'srecommendedlifting

and support procedures.

2. Positionthetransmissionjackdirectlyunderthetransmission.Turntheknob#1-21allthewayinaclockwisedirectionuntilitstops.Pumpthehandle#1-45,andthesaddle#3-8willstarttorise.Raisethesaddletoaheightveryclosetothecenterofbalance point of the transmission, but do not touch the transmission.

3. Loosenthefourbolts#3-6thatsecurethefourfingers#3-7and#3-13tothesaddle#3-8.Thefingers#3-7and#3-13canbeadjustedinandouttohelppositionthetransmissiononthesaddle.Nowgentlyraisethesaddlesoitsupportsthetransmission.Adjustthefourfingersinpositionagainstthetransmission,andtightenthebolts#3-6thatsecurethefingerstothesaddle.Foreand aft saddle tilt adjustments and side to side adjustments are necessary to properly position the transmission on the saddle. Theseadjustmentscanbemadebyrotatingthetwoknobs#18.

4. Thechain#3-4shouldbepulledoverthecenterofbalanceportionofthetransmissionandsecuredonthechainhooks#3-16.Rotatethewingnuts#3-14totakeuptheslackinthechain#3-4andsecurethetransmissiontothesaddle#3-8.

5. Removethetransmissionfromtheengineaccordingtoinstructionsinthevehicleservicemanual.

6. Oncethetransmissionhasbeendisconnectedfromtheengine,veryslowlyturnthejack'sreleaseknob#1-21inacounterclockwisedirectiontomakesurethejack'ssaddle#3-8andtransmissiondonothanguponanyundervehiclecomponents,wiring,fuellines,etc.Continuetolowerthejackallthewaydown.

7. Remembertosecurethetransmissiontothesaddlebeforeinstalling,andfollowthevehiclemanufacturer'sinstallationinstructions.

PREVENTATIVE MAINTENANCE

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

1. Alwaysstorethejackinawellprotectedareawhereitwillnotbeexposedtoinclementweather,corrosivevapors,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. Thejackmustbelubricatedperiodicallyinordertopreventprematurewearingofparts.Ageneralpurposegreasemustbe applied to all zerk grease fittings, caster wheels, elevator arm, handle base pivot bolts, release mechanism and all other bearing surfaces.

KTI63517 4 7/16/14

3. Itshouldnotbenecessarytorefillortopoffthereservoirwithhydraulicfluidunlessthereisanexternalleak.Anexternalleak requires immediate repair which must be performed in a dirt-free environment by qualified hydraulic repair personnel who are familiar with this equipment.

IMPORTANT: In order to prevent seal damage and jack failure, never use alcohol, hydraulic brake fluid or transmission oil in the jack. Usehydraulicjackoil,alightturbineoil,ChevronAWISO32orUnocalUnaxAW150.

4. Everyjackownerisresponsibleforkeepingthejacklabelscleanandreadable.Useamildsoapsolutiontowashexternal surfacesofthejackbutnotanymovinghydrauliccomponents.ContactK-ToolInternationalforareplacementlabelifyourjack's label is unreadable.

5. Inspectthejackbeforeeachuse.Donotusethejackifanycomponentiscracked,broken,bent,showssignofdamageorleaks hydraulicfluid.Donotusethejackifithaslooseormissinghardwareorcomponents,orismodifiedinanyway.Takecorrective action before using the jack again.

6. Donotattempttomakeanyhydraulicrepairsunlessyouareaqualifiedhydraulicrepairpersonthatisfamiliarwiththis equipment.Repairsmustbeperformedbyanauthorizedservicecenter.

TROUBLESHOOTING

PROBLEM: UNIT WILL NOT LIFT RATED LOAD.ACTION: PurgeairfromhydraulicsystembyfollowingprocedureunderSETUPINSTRUCTIONS.

PROBLEM: UNIT WILL NOT SUSTAIN RATED LOAD OR FEELS "SPONGY" UNDER RATED LOAD.ACTION: Purgeairfromhydraulicsystemasabove.

PROBLEM: UNIT WILL NOT LIFT TO FULL H