OTC Tools 1537 User manual

Sheet No.
Issue Date: Rev. D, March 24, 2008
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: [phone]
Tech. Serv.: [phone]
Fax: [phone]
Order Entry: [phone]
Fax: [phone]
International Sales: [phone]
Fax: [phone]
116 Screw (M10 x 25 mm)
22Flat Washer (16 mm)
32Link Rod Axis
41E-Ring (8 mm)
54Linkage Washer (8 mm)
62Flat Washer (8 mm)
72Locknut (M18)
84C-Ring (19 mm)
92Caster
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 8827
3
16
5
14
48 54
51
52
18
1
750 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
2
12
45
46
47
Replacement
parts
for Item 24
on sheet 2.
© 2004 SPX Corporation

Replacement Kits
Item
No. Qty. Description
14 2 Screw (M8 x 25 mm)
16 2 Screw Bushing
Handle Stop Kit No. 525131
Item
No. Qty. Description
13Screw (M10 x 25 mm)
91Caster
10 1 Rear Wheel Saddle
13 1 Locknut (M12)
50 3 Linkage Washer (10 mm)
Caster Kit No. 525132
Item
No. Qty. Description
22Flat 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
18Screw (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
82C-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
82C-Ring (19 mm)
26 1 Pull Rod Axis
27 1 Pull Rod
Load Block Arms Kit No. 525143
Item
No. Qty. Description
32Link Rod Axis
52
Linkage Washer (8 mm)
62Flat 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
72Locknut (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
42E-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

Sheet No.
Issue Date: Rev. D, March 24, 2008
Hydraulic Unit Parts List
11Valve Body
21Washer
31Cap Screw
42Steel Ball
52Solid Ball
62Taper Compression Spring
72High Pressure Screw
82Thimble
92Adjustable 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
59
10
16
18
612
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

Hydraulic Unit Replacement Kits
Item
No. Qty. Description
21Washer
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
21Washer
31Cap Screw
Seal Bolt Kit No. 525154
Item
No. Qty. Description
21Washer
31Cap Screw
42Steel Ball
52Solid Ball
62Compression Spring
72High Pressure Screw
82Thimble
92Adj. 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.

Sheet No.
Issue Date: Rev. D, March 24, 2008
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.
•Beforeusingtheservicejacktoliftavehicle,refertothevehicleservicemanualforrecommended
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. Positionthe jack underthe vehicle using the manufacturer’s recommended lifting points on the chassis. Thejack must befree
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
stablesupport.Beforeworkingonthevehicle,SLOWLYlowerthevehicleonto
the support stands by turning the handle counterclockwise.
Parts List & Operating Instructions Form No. 525073
3 of 3

Troubleshooting Guide
Repairproceduresmustbeperformedinadirt-freeenvironmentbyqualifiedpersonnelwhoarefamiliarwiththisequipment.CAUTION:
Topreventpersonalinjury, inspection,maintenance,andrepair proceduresmustbeperformed whenthejackis freeofaload
(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. Storethejackinawell-protectedareawhereitwillnotbeexposedtocorrosivevapors,abrasivedust,oranyotherharmfulelements.
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