Parts List & Operating Instructions Form No. 540669, Sheet 2 of 2, Back
Preventive Maintenance
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. Replacethehydraulicuidinthereservoiratleastonceperyear.Tocheckthehydraulicuidlevel,lowerthelifting
armcompletely.Removetherubberllerplugfromthepowerunit.Thehydraulicuidlevelshouldbeatthebottom
ofthellerplughole.Ifnecessary,addhydraulicuid,andinstallthellerplug. IMPORTANT: The use of alcohol or
hydraulicbrakeuidcoulddamagethesealsandresultinjackfailure.
4. Inspect the jack before each use. Take corrective action if any of the following problems are found:
a.cracked,damagedhousing c.leakinghydraulicuid e.loosehardware
b.excessivewear,bending,otherdamage d.scored,damagedpistonrod f.modiedequipment
5. Keep warning labels and instructional decals clean and readable. Use a mild soap solution to wash external surfaces
of the jack.
Troubleshooting Guide
Repairproceduresmustbeperformedinadirt-freeenvironmentbyqualiedpersonnelwhoarefamiliarwiththisequipment.
CAUTION: To prevent personal injury, all inspection, maintenance, and repair procedures must be performed
when the jack is free of a load (not in use).
Trouble Cause Solution
Jack does not lift
Jack lifts only partially
Jack advances slowly
Jack lifts load,
but doesn't hold
Jackleakshydraulicuid
Jack will not retract
Jack retracts slowly
1. Release valve is open.
2.Low/nohydraulicuidinreservoir.
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. Verify the release valve is closed by position of the
handle. Release valve may need cleaning.
2.Fillwithapprovedhydraulicuidandbleedsystem.
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
hydraulicuid.
6. Replace packing.
1.Toomuchornotenoughhydraulicuid. 1.Checkhydraulicuidlevel.
1. Pump not working correctly.
2. Leaking seals.
1. Rework pump.
2. Replace seals. (OTC Seal Kit No. 541510)
1. Cylinder packing is leaking.
2. Valve not working correctly (suction,
delivery, release, or bypass).
3. Air-locked system.
1. Replace packing.
2. Inspect valves. Replace if necessary.
3. Bleed system.
1. Worn or damaged seals. 1. Replace seals.
1. Release valve is closed. 1. Open the release valve by pulling on and turning
the handle clockwise (CW). May be necessary to
clean release valve.
1. Cylinder damaged internally.
2. Return spring(s) is damaged.
3. Link section is binding.
1. Send jack to OTC-authorized service center.
(Refer to OTC Form No. 104031.)
2. Replace return spring(s).
3. Lubricate link sections.
