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.
