OTC Tools 5110 Operating Instructions Manual

© Bosch Automotive Service Solutions Inc. Form No. 102753 Parts List & Operating Instructions for: 5110 1 of 4 Air / Hydraulic Floor Service Jack Max. Capacity: 10 Tons Application: Designed to lift a wide range of motor vehicles. This service jack is equipped with a manual foot and handle pump, along with an air-over hydraulic pump. Rated Capacity: 20,000 lbs. Air Supply: 90–175 psi Weight: 410 lbs. 55 in. 73/8 in. dia. 265/8 in. raised height 63/4 in. lowered height 5 in. dia. 93/4 in. 4 in. dia. 551/4 in. 201/8 in. 33/8 in. 171/8 in. 655 Eisenhower Drive Owatonna, MN 55060 USA Phone: (507) 455-7000 Tech. Serv.: (800) 533-6127 Fax: (800) 955-8329 Order Entry: (800) 533-6127 Fax: (800) 283-8665 International Sales: (507) 455-7223 Fax: (507) 455-7063 Website: www.otctools.com TOP VIEW SIDE VIEW Shaded area reflects current revision.

Form No. 102753, sheet 1 of 4, back 23 29 30, 8 31 32 33 35 36 37 38 39, 40 26, 27 27, 28 41 A A 24 26, 27 25 28 25 24 View A-A 42 SIDE VIEW 1, 2, 3 4 5 6, 7 8 9 10 11, 7 12 13 14 15 16 17 18 19 20 21, 22 3 1 41 TOP VIEW 43 44

© Bosch Automotive Service Solutions Inc. 1 5110-01 4 External Retaining Ring (11/2 in. dia.) 2 5110-02 2 Flat Washer (11/2 x 14 ga.) 3 5110-03 4 Flanged Bearing (1.5 x 1.625 x 1.5) 4 5110-04 2 Roll Pin (5/16 in. dia.; 2 in. lg.) 5 5110-05 2 Leveling Link 6 5110-06 8 Hex Nut (5/8-11 UNC) 7 5110-07 10 Lockwasher (5/8 in. dia.) 8 5110-08 4 External Retaining Ring (1 in. dia.) 9 5110-09 1 Roll Pin (3/16 in. dia. x 2 in. lg.) 10 5110-10 4 Pan Hd. Screw (10-32 UNC x 1/2 in. lg.) 11 5110-11 2 Cap Screw (5/8-11 UNC x 11/2 in. lg.) 12 5110-12 2 Swivel Caster (4 in. dia.; steel wheel) 13 5110-13 1 Frame Weldment (RH) 14 5110-14 2 Wheel and Grease Fitting Subassembly 15 5110-15 1 Front Axle 16 5110-16 1 Lift Pad Retainer 17 5110-17 4 Threaded Shaft (3/4 in. dia.) 18 5110-18 1 Top Cover 19 5110-19 1 Frame Rail Weldment (LH) 20 5110-20 2 Special Nut 21 5110-21 2 Hex Nut (3/4-10 UNC) 22 5110-22 2 Split Lockwasher (3/4 in. external tooth) 23 5110-23 1 Handle Subassembly 24 5110-24 1 Pump Pivot Link Weldment 25 5110-25 2 Pump Link 26 5110-26 1 Rear Pin Pump Link 27 5110-27 4 Heavy Duty External Retaining Ring (7/16 in. dia.) 28 5110-28 1 Front Pin Pump Link 29 5110-29 1 Lift Pad 30 5110-30 1 Lift Pad Pivot Shaft 31 5110-31 1 Spring (115/32 in. dia. x 12.5 in. lg.) 32 5110-32 1 Lift Pad Bracket Weldment 33 5110-33 1 Front Pin Leveling Link 35 5110-35 1 Power Unit 36 5110-36 1 Flex Shaft 37 5110-37 2 Spring (15/16 in. O.D.) 38 5110-38 1 Roll Pin (3/16 in. dia. x 3/4 in. lg.) 39 5110-39 1 Cap Screw (3/4-10 UNC x 9.5 in. lg.; grade 8) 40 5110-40 1 Hex Nut (3/4-10 UNC) 41 5110-41 2 Grease Fitting (3/16 in. drive) 42 5110-42 1 Foot Pump Pivot Weldment 43 525394 1 Air Motor Assembly 44 531439 1 Air Hose with Fittings 223119 1 Optional — Seal Repair Kit to Service Pump/Ram 518087 1 Optional — Seal Repair Kit (Use on jacks with a serial no. of 78-003914 and higher. Use also on power units purchased in November, 2002, and later.) Parts List & Operating Instructions Form No. 102753 Description Item No. Part No. No. Req'd 2 of 4

Form No. 102753, sheet 2 of 4, back 518087 Seal Repair Kit Hydraulic Unit 525394 Air Motor Assembly 1 3 4 5 2 6 7 5 1 3 4 5 2 3 1 Seal, 5/8 in. O.D. x 3/8 in. I.D. x 1/4 in. Type B 2 Back-up Ring, 15/16 in. x 3/4 in. x .040 in. Thick 3 Back-up Ring, 33/4 in. x 3/8 in. x .055 in. Thick 4 Seal, 21/2 in. I.D. x 31/4 in. O.D. x 3/8 in. 5 O-ring, 5 in. I.D. x 51/4 in. O.D. x 1/8 in. CS 6 Quad Seal, 2 in. I.D. x 23/8 in. O.D. x 3/16 in. CS 7 O-ring, 7/16 in. I.D. x 5/16 in. O.D. x 1/16 in. CS Item No. Description 1 Seal, Shuttle Valve 2 O-ring, 2 1/4 in. x 1/16 in. x 21/8 in. 3 Quad Ring, 3 in. O.D. x 25/8 in. x 3/16 in. 4 Seal, 11/4 in. O.D. x 1 in. I.D. x 1/8 in. W 5 Seal, .277 in. I.D. x .528 in. O.D. x .188 in. Type B 6 Spring (This spring may be ordered separately under No. 525198.) Item No. Description 6

© Bosch Automotive Service Solutions Inc. Safety Precautions Caution: To prevent personal injury and damage to equipment, • Study, understand, and follow all instructions, including ASME PALD Part 10 for service jacks. • If the operator cannot read these instructions, operating instructions and safety precautions must be read and discussed in the operator’s native language. • Before using the service jack to lift a vehicle, refer to the vehicle service manual to determine recommended lifting surfaces on the vehicle chassis. • Wear eye protection that meets ANSI Z87.1 and OSHA standards. • Inspect the jack before each use; do not use the jack if it’s damaged, altered, or in poor condition. Take corrective action if any of the following conditions are found: cracked or damaged housing; excessive wear, bending, or other damage; leaking hydraulic fluid; scored or damaged piston rod; loose hardware; modified or altered equipment. • A load must never exceed the rated lifting capacity of the jack. • Only use the jack on a hard, level surface. • Use the jack for lifting purposes only. Stay clear of a lifted load. Place support stands under the axles before working on the vehicle. • Center the load on the jack saddle. Off-center loads can damage seals and cause jack failure. Lift only dead weight. • Do not use blocks or other extenders between the saddle and the load being lifted. • Do not modify the jack or use adapters unless approved or supplied by OTC. Do not adjust the safety valve. • Lower the jack slowly and carefully while watching the position of the jack saddle. • Use only approved hydraulic fluid (Mobil DTE #11 or equivalent). The use of alcohol, hydraulic brake fluid, or automatic transmission fluid (ATF) could damage seals and result in jack failure. This guide cannot cover every situation, so always do the job with safety first. Operating Instructions 1. Connect the shop air supply to the jack. (90–175 psi of clean, dry air is required for the capacity of this jack.) 2. Position the jack under the vehicle using the manufacturer’s recommended lifting points on the chassis. 3. Close the release valve by turning the knob clockwise (CW) as far as it will go. 4. Press the air valve lever to raise the jack saddle until it touches the vehicle. 5. Check the placement of the jack; the load must be centered on the jack saddle. CAUTION: Avoid wheel obstructions such as gravel, tools, or uneven expansion joints. The jack must be free to roll forward 11 inches during lifting, and backward 11 inches during lowering. The load could become unstable, or even fall off the saddle, if the rolling movement of the jack is impaired. 6. Finish lifting the vehicle. 7. Place approved support stands under the vehicle at points that will provide stable support. Before making repairs on the vehicle, lower it onto the support stands by SLOWLY and carefully turning the release knob counterclockwise (CCW). 3 of 4 Parts List & Operating Instructions Form No. 102753

well lubricated to prevent foreign matter from entering the system. If the jack has been exposed to rain, snow, sand, or grit, it must be cleaned before it is used. 1. Store the jack in a well-protected area where it will not be exposed to corrosive vapors, abrasive dust, or any other harmful elements. 2. Lubricate rotating and sliding parts at least once per month. 3. Lubricate the air inlet on the jack using 1/2 oz. clean lubricating oil; lack of oil may cause pump malfunction. 4.�Grease�the�jack�once�a�month�using�a�good�bearing�grease.�(There�are�grease�fittings�located�on�the�pivot� tube of the lift arm, the block on the rod end of the cylinder, and on all four wheels of the jack.) 5. Keep warning labels and instructional decals clean and readable. Use a mild soap solution to wash the external surfaces of the jack. 6. Replace the oil in the reservoir at least once per year. 7. Inspect the jack before each use. Take corrective action if any of the following problems are found: a. Cracked or damaged housing d. Scored or damaged piston rod b. Excessive wear, bending, or other damage e. Loose hardware � c.�Leaking�hydraulic�fluid� f.� Modified�or�altered�equipment Adding Hydraulic Fluid 1. Remove the jack from service, and place it on a level surface. 2. Lower the lift arm completely. 3. Disassemble the top cover by removing the four pan head screws. 4.�Clean�around�the�surface�of�the�oil�fill�plug;�this�will�help�prevent�contamination�of�the�hydraulic�oil�system. 5.�Remove�the�oil�fill�plug,�and�check�the�hydraulic�oil�level.�The�fluid�should�be�visible�and�just�covering�the� hydraulic�cylinder.�If�the�fluid�level�is�low,�add�a�high-grade�hydraulic�fluid�equivalent�to�Mobil�DTE�#11�until� the oil level just covers the cylinder. 6.�Install�the�oil�fill�plug.�Clean�up�any�spilled�oil,�and�secure�the�top�cover�back�onto�the�frame.� 7. Test the jack for normal operation. If the lift pad doesn’t rise to the correct height, repeat Steps 2–6, adding two more ounces of oil. If this doesn’t solve the problem, call the OTC Technical Services Dept. Parts List & Operating Instructions Form No. 102753, sheet 3 of 4, back

© Bosch Automotive Service Solutions Inc. Troubleshooting Guide Repair�procedures�must�be�performed�in�a�dirt-free�environment�by�qualified�personnel�who�are�familiar�with� this equipment. CAUTION: All inspection, maintenance, and repair procedures must be performed when the jack is free of a load (not in use). Trouble Cause Solution Failure to lift a load Failure to hold a load Air motor won’t run, or runs erratically Reservoir leaks 1. Low oil level 2. Air line leaks. 3. Inadequate air pressure. 4. Release knob open. 5. Jack is overloaded. 1. Release knob not closed. 1. Leak in air line. 2. Air piston is sticking. 3. Inadequate air pressure. 1.�Loose�oil�fill�plug. 2.�Reservoir�is�overfilled. 1. Refer to the section Adding Hydraulic Fluid. 2. Locate leak, tighten connections, and/or replace hose. 3. Set air pressure at 90–175 psi. 4. Close release knob. 5. Use equipment that has the correct capacity for the job. 1. Turn release knob clockwise to tighten securely. 1. Locate leak, tighten connections, and/or replace hose. 2. Add small amount of oil to jack’s air inlet to lube air motor. 3. Set air pressure at 90–175 psi. 1.�Tighten�oil�fill�plug. 2. Drain some oil from reservoir. 4 of 4 Parts List & Operating Instructions Form No. 102753