K Tool International KTI63703 Manuals

KTI63703 rev. 11/10/16 4 TON PORTABLE RAM KIT OWNERS MANUAL SPECIFICATIONS KTI63703 Ram Capacity................................................. 4 Ton @ 7,250 psig Ram Minimum Height.......................................................... 10.51" Stroke..................................................................................... 4.72" Fluid Capacity................................................................... 10.5 oz. Complies with ASME PALD/2009 Safety Standard 2 KTI63703 rev. 11/10/16 WARNING WARNING 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 Hydraulic Power Kits is subject to certain hazards that cannot be prevented by mechanical means, but only by the exer- cise of intelligence, care, and common sense. The versatility of use is limited only by the imagination and ingenuity of its operator; therefore K-Tool International cannot be responsible for product damage or personal injury due to faulty operator judgement or improper use of the kit. It is essential to have personnel involved in the use and operation of the kit who are careful, competent, trained, and qualified in the safe operation of the kit and its proper use when working on vehicle frames and body parts. Examples of hazards are dropping or slipping of load, caused by improperly securing loads, overloading, off centered loads, and improper setups. Additional hazards may be caused by the rupture or bursting of the hydraulic hoses and related fittings due to abuse, misuse, improper setup and using the kit for a purpose for which it was not intended. METHODS TO AVOID HAZARDOUS SITUATIONS • Read, study, understand, and follow all instructions before operating this device. • The kit owner is responsible for the kit being used in accordance with OSHA, state, and local safety standards. • User and bystanders wear eye protection that meets ANSI Z87.1 and OSHA standards. • Do not exceed the rated capacity. Some kit attachments do not match the kit’s rated capacity. The kit’s rated capacity can also be reduced according to the number of kit attachments and extension tubes used and their assembly to the cylinder/ram. USE THE PRESSURE GAUGE (#11) INCLUDED IN THIS KIT TO MONITOR CORRECT LOAD CAPACITIES. Wedge Rams are rated at 1 ton capacity. Rubber Heads are rated at 1/2 ton capacity in the 4 ton kit and 1 ton capacity in the 10 ton kit. • Do not overextend the rams. • When using extension tubes, position the shortest tube farthest away from the cylinder. • Attachments and extension tubes must be aligned and fully engaged so the ram force is straight and avoids off-center load conditions. • Before operating, tighten all hose, gauge and manifold connections so they are secure and leak free. Do not over tighten or it may cause premature thread failure or split pressure fittings. Tighten all hose quick disconnect fittings by hand only. • Do not subject the hose to extreme heat or cold, sharp surfaces, abrasion, impact, kinking, twisting, curling, bending or any condition that restricts or affects fluid flow. • Make sure setup is stable and secure before performing any work. • Use this kit for the intended purpose of vehicle body/frame repair only. • Only components supplied with this kit shall be used with this kit. • No alterations or modifications shall be made to any of the kit components. • 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 personal injury, property damage, or both. 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 INFORMATION 3 KTI63703 rev. 11/10/16 PORTABLE HYDRAULIC POWER KIT 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. SETUP 1. Refer to the parts list and drawing in this manual to identify parts mentioned in this setup procedure. 2. Install the ram (part C.) at the end of the hose (part B.) and secure the quick disconnect fittings together by hand tightening the threaded sleeve (#S10) on the ram fitting (#S11) to the hose (part B.). 3. Insert the pump handle (#P41) in the pump linkage receiver (#P40) and rotate the handle (#P41) clockwise until tight. Before operating the pump, turn the reservoir vent screw (#P09) in a counterclockwise direction until it stops. 4. During shipping or handling air may have become trapped in the hydraulic system. If the pump (part A.) is not providing a full incremental pump stroke or the ram feels spongy, it will be necessary to purge the air out of the hydraulic system: a. Before operating the pump (part A.), turn the reservoir vent screw (#P09) in a counterclockwise direction until it stops. b. Place the pump (part A.) horizontally on a table. Position the hose (part B.) and ram (part C.) over the edge of the table, lower than the pump (part A.) with the ram piston (#R03) pointing down. c. Close the pump’s release valve (#P15) and pump the ram to its complete or its furthest extension. Open the pump’s release valve (#P15) to retract the ram (part C.) all the way. Conduct this procedure several times without a load. d. Repeat steps “b” and “c” 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. 1. Study the work to be done in order to determine the type ram and other attachments you will be using. Consult the enclosed chart titled “Applicable force for component set ups” in order to determine the maximum allowable force to be used in your specific setup. All rams have female hose disconnects attached to them, and the end of the hose has the male quick disconnect at- tached to it. Insert the end of the hose (part B.) all the way in to the ram’s female quick disconnect (#S11). Slide the female connec- tor’s threaded sleeve (#S10) on to the threads at the end of the hose (part B.) and hand tighten. Never use any tools to tighten this connection. 2. Consult this Owner’s Manual section titled APPLICABLE FORCE FOR COMPONENT SET UPS for typical attachment and extension tube setups and pay very close attention to the corresponding load ratings of certain attachment connections. The use of extension tubes, ram or plunger toes greatly reduces the hydraulic system’s capacity. When using extension tubes, put the shortest tubes on the ends of the setup. 3. The pump (part A.) may be operated in the horizontal or vertical position but the pump (part A.) must point down when used in the vertical position. 4. Make sure all hydraulic and attachment connections are fully engaged and tight so ram force is straight in order to avoid off-center load conditions. 5. During setup, make sure the hose routing avoids kinks, twists, curls or bends that will impede hydraulic fluid flow. Do not use the hose (part B.) as a means to carry the kit components. Do not subject the hose (part B.) to any hazards such as fire, extreme heat or cold, sharp surfaces, or heavy impact. IF A HOSE (PART B.) RUPTURES, BURSTS, OR NEEDS TO BE DISCONNECTED, IMMEDI- ATELY SHUT THE PUMP (PART A.) OFF AND OPEN THE RELEASE VALVE (#P15) TO RELEASE HYDRAULIC PRESSURE. NEVER GRASP A LEAKING PRESSURIZED HOSE, FITTING OR COMPONENT WITH YOUR HANDS OR SUFFER SERIOUS INJURY. 6. Always use the pressure gauge (#11) to make sure you are within the required force range when operating the system. 7. In order to pump the ram (part C.), it will be necessary to turn the release valve knob (#P15) in a clockwise direction until tight. Tighten by hand only. 8. Pumping the handle (#P41) up and down transfers the hydraulic fluid from the pump’s reservoir (#P04), through the hose (part B.), in to the cylinder and extends the ram with each incremental pump stroke. 9. To release the pressure and return the ram (part C.) back in to its cylinder (#R14) , turn the release valve knob (#P15) in a counter- clockwise direction very slowly. Turning the release valve knob (#P15) slowly will determine the speed in which the ram (part C.) will retract back into its cylinder (#R14). IMPORTANT: The pump includes an overload valve that will activate at the pump’s rated capacity only. If the setup requires a re- duced rating, the operator is responsible for using the gauge to determine when to stop pumping since the overload valve (#P22) is set to a higher rating. 10. Make sure the ram (part C.) is completely retracted inside its cylinder (#R14) before disconnecting the hose from the cylinder. 11. The the hose (part B.) and the ram (part C.) are repeatedly disconnected and exposed to shop or work place floors that are covered with dirt and debris. It is important to use the dust caps (#P18) provided to prevent contaminants from entering the air and hydraulic systems. 12. Based on continuous engagement and disengagement of the hose (part B.) from the cylinder (#R14), eventually it will become necessary to add hydraulic fluid to the pump’s reservoir (#P04). Completely retract the ram before adding hydraulic fluid. Do not overfill in order to avoid personal injury and hydraulic malfunction. Use only hydraulic jack oil, Chevron Hydraulic Oil AW ISO 32 or its equivalent Unocal Unax AW 150. Other fluids will cause damage to the hydraulic seals.

KTI63709 07/10/14 10 TON PORTABLE RAM KIT OWNERS MANUAL SPECIFICATIONS KTI63709 Ram Capacity ................................................. 10 Ton @ 7,250 psig Ram Minimum Height .......................................................... 12.68" Stroke ..................................................................................... 5.12" Fluid Capacity .................................................................... 17.5 oz. 2 KTI63709 07/10/14 WARNING WARNING 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 Hydraulic Power Kits is subject to certain hazards that cannot be prevented by mechanical means, but only by the exer- cise of intelligence, care, and common sense. The versatility of use is limited only by the imagination and ingenuity of its operator; therefore K-Tool International cannot be responsible for product damage or personal injury due to faulty operator judgement or improper use of the kit. It is essential to have personnel involved in the use and operation of the kit who are careful, competent, trained, and qualified in the safe operation of the kit and its proper use when working on vehicle frames and body parts. Examples of hazards are dropping or slipping of load, caused by improperly securing loads, overloading, off centered loads, and improper setups. Additional hazards may be caused by the rupture or bursting of the hydraulic hoses and related fittings due to abuse, misuse, improper setup and using the kit for a purpose for which it was not intended. METHODS TO AVOID HAZARDOUS SITUATIONS •� Read,�study,�understand,�and�follow�all�instructions�before�operating�this�device. •� The�kit�owner�is�responsible�for�the�kit�being�used�in�accordance�with�OSHA,�state,�and�local�safety�standards. •� User�and�bystanders�wear�eye�protection�that�meets�ANSI�Z87.1�and�OSHA�standards. •� Do�not�exceed�the�rated�capacity.�Some�kit�attachments�do�not�match�the�kit’s�rated�capacity.�The�kit’s�rated�capacity�can�also�be� reduced according to the number of kit attachments and extension tubes used and their assembly to the cylinder/ram. USE THE PRESSURE�GAUGE�(#11)�INCLUDED�IN�THIS�KIT�TO�MONITOR�CORRECT�LOAD�CAPACITIES. � Wedge�Rams�are�rated�at�1�ton�capacity. � Rubber�Heads�are�rated�at�1/2�ton�capacity�in�the�4�ton�kit�and�1�ton�capacity�in�the�10�ton�kit. •� Do�not�overextend�the�rams. •� When�using�extension�tubes,�position�the�shortest�tube�farthest�away�from�the�cylinder. •� Attachments�and�extension�tubes�must�be�aligned�and�fully�engaged�so�the�ram�force�is�straight�and�avoids�off-center�load�conditions. •� Before�operating,�tighten�all�hose,�gauge�and�manifold�connections�so�they�are�secure�and�leak�free.�Do�not�over�tighten�or�it�may�cause� premature thread failure or split pressure fittings. Tighten all hose quick disconnect fittings by hand only. •� Do�not�subject�the�hose�to�extreme�heat�or�cold,�sharp�surfaces,�abrasion,�impact,�kinking,�twisting,�curling,�bending�or�any�condition�that� restricts or affects fluid flow. •� Make�sure�setup�is�stable�and�secure�before�performing�any�work. •� Use�this�kit�for�the�intended�purpose�of�vehicle�body/frame�repair�only. •� Only�components�supplied�with�this�kit�shall�be�used�with�this�kit. •� No�alterations�or�modifications�shall�be�made�to�any�of�the�kit�components. •��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�personal�injury,�property�damage,�or�both.� 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 INFORMATION 3 KTI63709 07/10/14 OWNER'S MANUAL PORTABLE HYDRAULIC POWER KIT 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. SETUP 1. Refer to the parts list and drawing in this manual to identify parts mentioned in this setup procedure. 2. Install the ram (part C.) at the end of the hose (part B.) and secure the quick disconnect fittings together by hand tightening the threaded sleeve (#S10) on the ram fitting (#S11) to the hose (part B.). 3. Insert the pump handle (#P41) in the pump linkage receiver (#P40) and rotate the handle (#P41) clockwise until tight. Before operating the pump, turn the reservoir vent screw (#P09) in a counterclockwise direction until it stops. 4. During shipping or handling air may have become trapped in the hydraulic system. If the pump (part A.) is not providing a full incremental pump stroke or the ram feels spongy, it will be necessary to purge the air out of the hydraulic system: a. Before operating the pump (part A.), turn the reservoir vent screw (#P09) in a counterclockwise direction until it stops. b. Place the pump (part A.) horizontally on a table. Position the hose (part B.) and ram (part C.) over the edge of the table, lower than the pump (part A.) with the ram piston (#R03) pointing down. c. Close the pump’s release valve (#P15) and pump the ram to its complete or its furthest extension. Open the pump’s release valve (#P15) to retract the ram (part C.) all the way. Conduct this procedure several times without a load. d. Repeat steps “b” and “c” 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. 1. Study the work to be done in order to determine the type ram and other attachments you will be using. Consult the enclosed chart titled “Applicable force for component set ups” in order to determine the maximum allowable force to be used in your specific setup. All rams have female hose disconnects attached to them, and the end of the hose has the male quick disconnect at- tached to it. Insert the end of the hose (part B.) all the way in to the ram’s female quick disconnect (#S11). Slide the female connec- tor’s threaded sleeve (#S10) on to the threads at the end of the hose (part B.) and hand tighten. Never use any tools to tighten this connection. 2. Consult this Owner’s Manual section titled APPLICABLE FORCE FOR COMPONENT SET UPS for typical attachment and extension tube setups and pay very close attention to the corresponding load ratings of certain attachment connections. The use of extension tubes, ram or plunger toes greatly reduces the hydraulic system’s capacity. When using extension tubes, put the shortest tubes on the ends of the setup. 3. The pump (part A.) may be operated in the horizontal or vertical position but the pump (part A.) must point down when used in the vertical position. 4. Make sure all hydraulic and attachment connections are fully engaged and tight so ram force is straight in order to avoid off-center load conditions. 5. During setup, make sure the hose routing avoids kinks, twists, curls or bends that will impede hydraulic fluid flow. Do not use the hose (part B.) as a means to carry the kit components. Do not subject the hose (part B.) to any hazards such as fire, extreme heat or cold, sharp surfaces, or heavy impact. IF A HOSE (PART B.) RUPTURES, BURSTS, OR NEEDS TO BE DISCONNECTED, IMMEDI- ATELY SHUT THE PUMP (PART A.) OFF AND OPEN THE RELEASE VALVE (#P15) TO RELEASE HYDRAULIC PRESSURE. NEVER GRASP A LEAKING PRESSURIZED HOSE, FITTING OR COMPONENT WITH YOUR HANDS OR SUFFER SERIOUS INJURY. 6. Always use the pressure gauge (#11) to make sure you are within the required force range when operating the system. 7. In order to pump the ram (part C.), it will be necessary to turn the release valve knob (#P15) in a clockwise direction until tight. Tighten by hand only. 8. Pumping the handle (#P41) up and down transfers the hydraulic fluid from the pump’s reservoir (#P04), through the hose (part B.), in to the cylinder and extends the ram with each incremental pump stroke. 9. To release the pressure and return the ram (part C.) back in to its cylinder (#R14) , turn the release valve knob (#P15) in a counter- clockwise direction very slowly. Turning the release valve knob (#P15) slowly will determine the speed in which the ram (part C.) will retract back into its cylinder (#R14). IMPORTANT: The pump includes an overload valve that will activate at the pump’s rated capacity only. If the setup requires a re- duced rating, the operator is responsible for using the gauge to determine when to stop pumping since the overload valve (#P22) is set to a higher rating. 10. Make sure the ram (part C.) is completely retracted inside its cylinder (#R14) before disconnecting the hose from the cylinder. 11. The the hose (part B.) and the ram (part C.) are repeatedly disconnected and exposed to shop or work place floors that are covered with dirt and debris. It is important to use the dust caps (#P18) provided to prevent contaminants from entering the air and hydraulic systems. 12. Based on continuous engagement and disengagement of the hose (part B.) from the cylinder (#R14), eventually it will become necessary to add hydraulic fluid to the pump’s reservoir (#P04). Completely retract the ram before adding hydraulic fluid. Do not overfill in order to avoid personal injury and hydraulic malfunction. Use only hydraulic jack oil, Chevron�Hydraulic�Oil�AW�ISO�32�or�its� equivalent�Unocal�Unax�AW�150. Other fluids will cause damage to the hydraulic seals. 4 KTI63709 07/10/14 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 kit in a well protected area where it will not be exposed to inclement weather, corrosive vapors, abrasive dust, or any other harmful elements. The kit must be cleaned of water, snow, sand, grit, oil, grease or other foreign matter before using. 2. Based on continuous engagement and disengagement of the hose from the cylinder, eventually it will become necessary to add hydrau- lic fluid to the pump’s reservoir. Completely retract the ram before adding hydraulic fluid. Do not overfill in order to avoid personal injury and hydraulic malfunction. Use only hydraulic jack oil, Chevron�Hydraulic�Oil�AW�ISO�32�or�its�equivalent�Unocal�Unax�AW�150. Other fluids will cause damage to the hydraulic seals. IMPORTANT: In order to prevent seal damage and kit failure, never use alcohol, hydraulic brake fluid or transmission oil in the pump. 3. Every kit owner is responsible for keeping the kit labels clean and readable. Use a mild soap solution to wash external surfaces of the kit components but not any moving hydraulic components. 4. Do not attempt to make any hydraulic repairs unless you are a qualified hydraulic repair person that is familiar with this equipment. Repairs must be performed by an authorized service center. 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 by following procedure under SETUP. PROBLEM: UNIT WILL NOT LIFT TO FULL HEIGHT ACTION: Purge air from hydraulic system by following procedure under SETUP. PROBLEM: UNIT STILL DOES NOT OPERATE ACTION: Contact K-Tool International authorized hydraulic service center. OWNER'S MANUAL Spreader Capacity 100% of Ram Capacity 100% of Ram Capacity 50% of Ram Capacity 25% of Ram Capacity 50% of Ram Capacity 50% of Ram Capacity 25% of Ram Capacity 6% of Ram Capacity APPLICABLE FORCE FOR COMPONENT SET UPS