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Parts List & Operating Instructions
IMPORTANT: The greatest single cause of failure in hydraulic units is dirt. 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 lubricate the moving parts in the wheels, arm, handle, and pump roller pin.
3. Replace the automatic transmission fluid (ATF) in the reservoir at least once per year. To check the ATF level, lower
the lift arm completely. Remove the rubber filler plug. The ATF level should be at the bottom of the filler plug hole. If
necessary, add ATF, and install the filler plug. IMPORTANT: The use of alcohol or hydraulic brake fluid 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:
a. cracked, damaged housing
b. excessive wear, bending, other damage
5. Keep warning labels and instructional decals clean and readable. Use a mild soap solution to wash external surfaces
of the jack.
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
Jack does not lift
Jack lifts only partially
Jack advances slowly
Jack lifts load, but doesn't hold
Jack leaks ATF
Jack will not retract
Jack retracts slowly
Form No. 107372, Back of Sheet 2 of 2
Preventive Maintenance
c. leaking hydraulic fluid
d. scored, damaged piston rod
Troubleshooting Guide
Cause
1. Release valve is open.
2. Low/no ATF in reservoir.
3. Air-locked system.
4. Load is above capacity of jack.
5. Delivery valve and/or bypass valve not
working correctly.
6. Packing worn out or defective.
1. Too much or not enough ATF.
1. Pump not working correctly.
2. Leaking seals.
1. Cylinder packing is leaking.
2. Valve not working correctly (suction,
delivery, release, or bypass).
3. Air-locked system.
1. Worn or damaged seals.
1. Release valve is closed.
1. Cylinder damaged internally.
2. Return spring(s) is damaged.
3. Link section is binding.
e. loose hardware
f. modified equipment
Solution
1. Close the release valve by turning the
handle all the way clockwise (CW).
2. Fill with automatic transmission fluid and
bleed system.
3. Bleed system. (See "Bleeding Air from
the system" on back of page 1.)
4. Use correct equipment.
5. Clean to remove dirt or foreign matter.
Replace ATF.
6. Replace packing.
1. Check ATF level.
1. Rework pump.
2. Replace seals. (Seal kit No. 519675 is
available from OTC.)
1. Replace packing.
2. Inspect valves. Replace if necessary.
3. Bleed system.
1. Replace seals.
1. Open the release valve by turning the
handle all the way counterclockwise
(CCW). May be necessary to clean
release valve.
1. Send jack to OTC-authorized service
center. (Refer to OTC Form No. 104031.)
2. Replace return spring(s).
3. Lubricate link sections.
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