OTC Tools 1537 Operating Instructions Manual

Parts List & Operating Instructions for: 1537 Form No. 525073 Racing Jack Max. Capacity: 3,000 lbs. (1,361 kg) 1 of 3 SPX Corporation 655 Eisenhower Drive Owatonna, MN 55060-0995 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 1 16 Screw (M10 x 25 mm) 2 2 Flat Washer (16 mm) 3 2 Link Rod Axis 4 1 E-Ring (8 mm) 5 4 Linkage Washer (8 mm) 6 2 Flat Washer (8 mm) 7 2 Locknut (M18) 8 4 C-Ring (19 mm) 9 2 Caster 10 2 Rear Wheel Saddle 11 1 Holder Axis 12 2 Hex Nut (M16) 13 2 Locknut (M12) 14 4 Screw (M8 x 25 mm) 15 1 Rubber Saddle Pad 16 2 Screw Bushing 17 1 Handle Base 18 2 Handle Base Axis 19 1 Handle Base Screw 20 1 Lower Handle 21 1 Joint Connector 22 1 Hex Bolt (M6 x 18 mm) 23 1 Upper Handle 24 1 Power Unit Assembly 25 1 Raise Arms Axis 26 2 Pull Rod Axis 27 2 Pull Rod 28 4 Bolt (M8 x 25) 29 1 Front Wheel 30 2 Frame 31 2 Handle Bar 32 4 C-ring (16 mm) 33 2 Link Rod 34 2 Link Rod Washer 35 1 Saddle Base Axis (lg.) 36 1 Spring 37 1 Saddle Base Axis 38 1 Lift Arm 39 1 Saddle Base 40 1 Nylon Washer 41 1 Saddle 42 1 Bolt (M6 x 18 mm) 43 1 Bolt (M6 x 40 mm) 44 2 Hex Nut (M6) 45 2 Nylon Wheel 46 2 Flat Washer (14 mm) 47 2 C-ring 48 2 Socket Nut 49 1 Front Wheel Axis 50 14 Linkage Washer (10 mm) 51 2 Flat Washer (19 mm) 52 2 Linkage Washer (18 mm) 53 1 Spring Pin (3 mm x 14) 54 1 Shaft 55 2 Roller Item No. Qty. Description Shaded areas reflect the last revisions made to this form. R 21 20 30 24 44 42 43 36 53 19 17 26 23 22 38 25 8 8 27 3 16 5 14 48 54 51 52 18 1 7 50 1 55 35 34 33 32 29 28 6 5 14 13 10 50 9 15 11 41 40 39 37 32 49 30 31 12 2 46 45 47 Replacement parts for Item 24 on sheet 2. © 2004 SPX Corporation

16 2 Screw Bushing Handle Stop Kit No. 525131 Item No. Qty. Description 1 3 Screw (M10 x 25 mm) 9 1 Caster 10 1 Rear Wheel Saddle 13 1 Locknut (M12) 50 3 Linkage Washer (10 mm) Caster Kit No. 525132 Item No. Qty. Description 2 2 Flat Washer (16 mm) 12 2 Hex Nut (M16) 29 1 Front Wheel 45 2 Nylon Wheel 46 2 Flat Washer (14 mm) 47 2 C-ring 49 1 Front Wheel Axis Front Roller No. 525133 Item No. Qty. Description 20 1 Lower Handle 21 1 Joint Connector 22 1 Hex Bolt (M6 x 18 mm) 23 1 Upper Handle Handle Kit No. 525134 Item No. Qty. Description 19 1 Handle Base Screw 53 1 Spring Pin Handle Retaining Bolt Kit No. 525135 Item No. Qty. Description 1 8 Screw (M10 x 25 mm) 24 1 Power Unit Assembly 50 8 Linkage Washer (10 mm) Power Unit Kit No. 525136 Item No. Qty. Description 15 1 Rubber Saddle Pad Saddle Pad Kit No. 525137 Item No. Qty. Description 11 1 Holder Axis 15 1 Rubber Saddle Pad 40 1 Nylon Washer 41 1 Saddle Saddle Kit No. 525138 Item No. Qty. Description 36 1 Spring 42 1 Bolt (M6 x 18 mm) 44 1 Hex Nut (M6) Return Spring Kit No. 525140 Item No. Qty. Description 8 2 C-Ring (19 mm) 37 1 Pin (see hydraulic unit parts list) 38 1 Block (see hydraulic unit parts list) 43 1 Bolt (M6 x 40 mm) Load Block Kit No. 525141 Item No. Qty. Description 28 2 Bolt (M8 x 25 mm) 31 1 Handle Bar Side Handle Kit No. 525142 Item No. Qty. Description 8 2 C-Ring (19 mm) 26 1 Pull Rod Axis 27 1 Pull Rod Load Block Arms Kit No. 525143 Item No. Qty. Description 3 2 Link Rod Axis 5 2 Linkage Washer (8 mm) 6 2 Flat Washer (8 mm) 32 2 C-ring (16 mm) 33 2 Link Rod 34 2 Link Rod Washer 35 1 Saddle Base Axis (lg.) Leveling Arms Kit No. 525144 Item No. Qty. Description 7 2 Locknut (M18) 25 1 Raise Arms Axis Main Pivot Pin Kit No. 525146 Item No. Qty. Description 37 1 Saddle Base Axis 39 1 Saddle Base Saddle Base Kit No. 525147 Item No. Qty. Description 4 2 E-ring (8 mm) 17 1 Handle Base 18 2 Handle Base Axis 48 2 Socket Nut 51 2 Washer (19 mm) 52 2 Washer (18 mm) 54 1 Shaft 55 2 Roller Handle Pivot / Pump Roller Kit No. 525139 Parts List & Operating Instructions Form No. 525073, Sheet 1 of 3, Back

Hydraulic Unit Parts List 1 1 Valve Body 2 1 Washer 3 1 Cap Screw 4 2 Steel Ball 5 2 Solid Ball 6 2 Taper Compression Spring 7 2 High Pressure Screw 8 2 Thimble 9 2 Adjustable Compression Spring 10 2 Low Pressure Spring 11 2 Adjustable Pressure Screw 12 2 Washer 13 2 Valve Release Screw 14 2 Pump Washer 15 2 Pump Core 16 2 Y-ring 17 2 Pump Cylinder 18 2 Pump Core Compression Spring 19 2 Retaining Ring 20 2 Retaining Ring for Axle 21 1 Steel Ball 22 1 O-ring 23 1 Release Valve Rod Assembly 24 2 End Cover 25 2 Seal for End Cover 26 2 Filtrate Net 27 2 Oil Stem 28 1 Cylinder Washer 29 1 Oil Tank 30 1 Retaining Ring for Axle 31 2 O-ring 32 1 Split Retaining Ring 33 1 Piston 34 2 O-ring 35 1 Piston Rod 36 1 Outer Covering 37 1 Elastic Split Pin 38 1 Joint Adapter Item No. Qty. Description Item No. Qty. Description Parts List & Operating Instructions Form No. 525073 2 of 3 2 3 4 5 9 10 16 18 6 12 13 14 24 27 28 29 25 30 32 33 34 35 31 37 17 19 8 11 15 22 21 20 23 16 18 14 17 19 15 20 7 4 5 6 8 7 26 36 38 9 10 12 13 11 24 27 25 26 31 34 1

Item No. Qty. Description 2 1 Washer 12 2 Washer 14 2 Pump Washer 16 2 Y-ring 22 1 O-ring 25 2 Seal for End Cover 26 2 Filtrate Net 28 1 Cylinder Washer 30 1 Retaining Ring 31 2 O-ring 32 1 Split Retaining Ring 34 2 O-ring Seal Kit No. 525148 Item No. Qty. Description 21 1 Steel Ball 22 1 O-ring 23 1 Rod Assembly U-joint / Release Valve Kit No. 525149 Item No. Qty. Description 14 1 Pump Washer 15 1 Pump Core 16 1 Y-ring 17 1 Pump Cylinder 18 1 Compression Spring 19 1 Retaining Ring 20 1 Retaining Ring Pump Station Kit No. 525150 Item No. Qty. Description 18 1 Compression Spring 19 1 Retaining Ring 20 1 Retaining Ring Pump Station Spring Kit No. 525151 Item No. Qty. Description 24 1 End Cover 25 1 Seal for End Cover 26 1 Filtrate Net 27 1 Oil Stem Oil Cover Kit No. 525152 Item No. Qty. Description 2 1 Washer 3 1 Cap Screw Seal Bolt Kit No. 525154 Item No. Qty. Description 2 1 Washer 3 1 Cap Screw 4 2 Steel Ball 5 2 Solid Ball 6 2 Compression Spring 7 2 High Pressure Screw 8 2 Thimble 9 2 Adj. Comp. Spring 10 2 Low Pressure Spring 11 2 Adj. Pressure Screw 12 2 Washer 13 2 Valve Release Screw Pump Hardware Kit No. 525153 Item No. Qty. Description 28 1 Cylinder Washer 29 1 Oil Tank 36 1 Outer Covering Reservoir Kit No. 525155 Item No. Qty. Description 30 1 Retaining Ring 31 2 O-ring 32 1 Split Retaining Ring 33 1 Piston 34 2 O-ring 35 1 Piston Rod Ram Kit No. 525156 Parts List & Operating Instructions Form No. 525073, Sheet 2 of 3, Back Refer to any operating instructions included with the product for detailed information about operation, testing, disassembly, reassembly, and preventive maintenance. Items found in this parts list have been carefully tested and selected by OTC. Therefore: Use only genuine OTC replacement parts. Additional questions may be directed to our Technical Service Dept.

Setup Assemble the Handle 1. Loosen the thumb screw on the back of the handle socket. 2. Grease the socket opening. Insert the handle. 3. Hand tighten the thumb screw. Bleed Air from the Service Jack Air can accumulate within a hydraulic system during shipment or after prolonged use. This entrapped air causes the jack to respond slowly or feel “spongy.” To remove the air: 1. Open the release valve by turning the handle all the way counterclockwise. 2. Pump the jack handle six full strokes. 3. Close the release valve by turning the handle all the way clockwise. 4. Pump the jack handle until the lift arm is fully extended. 5. Lower the lift arm by turning the handle counterclockwise. If the jack does not immediately respond, repeat Steps 2–4. WARNING: To prevent personal injury and/or damage to equipment, • Study, understand, and follow instructions and safety precautions, 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 for 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. • Use the jack for lifting purposes only; use approved safety stands to support the axles before working on the vehicle. • Never exceed the rated lifting capacity of the jack. • Use the jack on a hard, level surface. The jack must be free to roll without obstruction while lifting or lowering the vehicle. The wheels of the vehicle must be in the straight-ahead position, with the hand brake released. • Center the load on the jack saddle. Off-center loads can damage seals and cause jack failure. • Lift only dead weight. Do not move the jack while it is supporting a vehicle. • Stay clear of lifted loads. Use approved safety stands to support the axles before making repairs. Do not use blocks or other extenders between the saddle and the load being lifted. • 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 (Chevron AW Hydraulic Oil MV or equivalent). The use of alcohol, hydraulic brake fluid, or transmission oil could damage seals and result in jack failure. • Do not modify the jack, or use adapters, unless approved or supplied by OTC. This guide cannot cover every situation, so always do the job with safety first. Safety Precautions Operating Instructions 1. Close the release valve by turning the handle completely counterclockwise. 2. Position the jack under the vehicle using the manufacturer’s recommended lifting points on the chassis. The jack must be free to roll without any obstructions while lifting or lowering the vehicle. The wheels of the vehicle must be in the straight-ahead position, with the emergency brake released. 3. Pump the jack handle until the saddle touches the vehicle. Check the placement of the jack; the load must be centered on the jack saddle. IMPORTANT: Avoid wheel obstructions such as gravel, tools, or uneven expansion joints. 4. Finish lifting the vehicle by pumping the handle. Do not attempt to raise the jack beyond its travel stops. 5. Place approved support stands under the vehicle at points that will provide stable support. Before working on the vehicle, SLOWLY lower the vehicle onto the support stands by turning the handle counterclockwise. Parts List & Operating Instructions Form No. 525073 3 of 3

To prevent personal injury, inspection, maintenance, and repair procedures must be performed when the jack is free of a load (not in use). Jack does not lift 1. Release valve is open. 1. Close release valve. 2. Low/no oil in reservoir. 2. Fill with oil and bleed system. 3. Air-locked system. 3. Bleed system. 4. Load is above capacity of jack. 4. Use correct equipment. 5. Delivery valve and/or bypass 5. Clean to remove dirt or foreign matter. Replace oil. valve not working correctly. 6. Packing worn out or defective. 6. Replace hydraulic unit. Jack lifts only partially 1. Too much or not enough oil. 1. Check oil level. Jack advances slowly 1. Pump not working correctly. 1. Replace hydraulic unit. 2. Leaking seals. 2. Install seal kit No. 525148. Jack lifts load, 1. Cylinder packing is leaking. 1. Replace hydraulic unit. but doesn't hold 2. Valve not working correctly (suction, 2. Inspect valves. Clean and repair seat surfaces. delivery, release, or bypass). 3. Air-locked system. 3. Bleed system. Jack leaks oil 1. Worn or damaged seals. 1. Replace hydraulic unit. Jack will not retract 1. Release valve is closed. 1. Open or clean release valve. Jack retracts slowly 1. Cylinder damaged internally. 1. Send jack to OTC authorized service center for repair. Refer to OTC Form No. 104060. 2. Link section is binding. 2. Lubricate or replace link section. a. cracked or damaged housing e. malfunctioning swivel heads or adjusting screws b. excessive wear, bending, or other damage f. loose hardware c. leaking hydraulic fluid g. modified or altered equipment d. scored or damaged piston rod IMPORTANT: Dirt is the greatest single cause of failure in hydraulic units. Keep the service jack clean and 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. Regularly (at least once per month) lubricate the moving parts in the wheels, arm, and handle. 3. Replace the oil in the reservoir at least once per year. To check the oil level, place the service jack on level ground and lower the lift arm completely. Remove the Phillips hd. oil screw. The oil level should be at the bottom of the filler plug hole. If necessary, add approved anti-wear hydraulic jack oil, and install the filler plug again. IMPORTANT: The use of alcohol, hydraulic brake fluid, detergent motor oil, or transmission oil could damage the seals and result in jack failure. 4. Inspect the jack before each use. Take corrective action if any of the following problems are found: Preventive Maintenance Trouble Cause Solution Parts List & Operating Instructions Form No. 525073, Sheet 3 of 3, Back