OTC Tools 1511B User manual

Sheet No.
Issue Date: August 16, 2012, Rev. A
© 2012
1 of 3
1
2
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9
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16
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19
14
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5
21
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25
24
C
B
A
D
Y
EFGH
60
61
64 63
62
27
28
29
28
30
31
32
33 34 35
36
37
QL
37 M
N
O
56
57
59
58
R
S
P
47
48
49
50
51
Q
L
95
94
93
92
91
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86
85
84
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81
79
80
79
107
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W
99
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96
108
26
43
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38 44
45
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44
I
J
K
L
109
66
69
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77
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71
72
72
65
73
T
74
75
78
V
U
76
X
Form No. 565786
Parts List &
Operating Instructions
for: 1511B
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]
Air-Assist Service Jack
Max. Capacity: 10 Tons

Parts List & Operating Instructions Form No. 565786, Sheet 1 of 3, Back
Replacement Kit List
Item
No. Qty. Description
520778 Wheel Kit
2 1 Front wheel
3 1 Washer
4 1 Snap ring
 5 1 Greasetting
520796 Grease Fitting
 5 1 Greasetting
565776 Leveling Arm Kit
6 2 Rod link
7 2 Bolt
9 2 Lockwasher
10 2 Nut
Y 2 Ring
520780 Saddle
8 1 Saddle
520782 Lift Arm Spring Kit
11 1 Spring
12 2 Bolt
14 2 Snap ring
15 1 Shaft
565773 Caster Kit
16 1 Rear wheel
17 2 Nut
A 12 Steel ball
B 19 Steel ball
C 1 Ball support
D 1 Washer
520790 Handle Pivot Kit
18 2 Snap ring
19 1 Shaft
60 1 Handle socket
565777 Plunger/Connect Bar Kit
20 1 Washer
21 1 Pin
22 1 Connecting bar
24 2 Snap ring
25 1 Shaft
56 2 O-ring
57 2 Washer
58 1 Pin
59 1 Cyl. pump plunger
520793 Handle Return Spring
23 1 Spring
520788 Inspection Plate
26 1 Cover board
565775 Hydraulic Unit Kit
27 1 Snap ring
28 2 Washer
29 1 O-ring
30 1 Piston rod
31 1 Piston ring
32 1 Sealing washer
33 1 O-ring
34 1 O-ring retainer
35 1 Snap ring
36 1 Oil cylinder assy
 37 2 Oilllerplug
38 1 Steel ball
39 1 Ball seat
40 1 Spring
41 1 Screw
42 1 Sealing washer
43 1 Bolt
44 1 Steel ball
45 1 Copper washer
46 1 Bolt
47 1 Steel ball
48 1 O-ring
49 1 O-ring
50 1 Release valve rod
51 1 Pin
56 2 O-ring
57 2 Washer
58 1 Pin
59 1 Cyl. pump plunger
I 1 Steel ball
J 1 Spring
K 1 Copper washer
L 1 Bolt
M 1 Bolt
N 1 Washer
O 1 Washer
P 1 Oil box assy
Q 2 Nut
R 1 Hose
S 1 Spring
565778 Pump Hardware Kit
27 1 Snap ring
35 1 Snap ring
38 1 Steel ball
39 1 Ball seat
40 1 Spring
41 1 Screw
42 1 Sealing washer
43 1 Bolt
44 2 Steel ball
45 1 Copper washer
46 1 Bolt
I 1 Steel ball
J 1 Spring
K 1 Copper washer
L 1 Bolt
565779 Hydraulic Seal Kit
27 1 Snap ring
28 2 Washer
29 1 O-ring
31 1 Piston ring
32 1 Sealing washer
33 1 O-ring
34 1 O-ring retainer
35 1 Snap ring
 37 2 Oilllerplug
42 1 Sealing washer
45 1 Copper washer
48 1 O-ring
49 1 O-ring
56 2 O-ring
57 2 Washer
K 1 Copper washer
531864 Release Valve Kit
47 1 Steel ball
48 1 O-ring
49 1 O-ring
50 1 Release valve rod
51 1 Pin
520791 Foot Pedal
61 1 Pedal
520792 Handle Retaining Kit
62 1 Nut
63 1 Washer
64 1 Bolt
524984 Handle Kit
65 1 Handle
66 2 Grip
67 1 Knob
68 1 Pin
69 1 Control rod
70 1 Spring
71 2 Washer
72 2 Screw
73 1 Rod joint
74 1 Spring
75 1 U-joint assy
76 1 Convery rod
77 1 Washer
78 1 Pin
T 1 Pin
U 1 Pin
V 1 Washer
Item
No. Qty. Description
Item
No. Qty. Description

Sheet No.
Issue Date: August 16, 2012, Rev. A
© 2012
2 of 3
Parts List & Operating Instructions Form No. 565786
Replacement Kit List
Item
No. Qty. Description
Item
No. Qty. Description
Item
No. Qty. Description
565772 Air Motor Kit
79 2 Copper washer
80 1 Oil valve assy
81 1 Nylon gasket
82 1 Pump cylinder
83 1 Oil seal
84 1 Washer
85 1 Copper washer
86 1 Nut
87 8 Bolt
88 1 Front cover
89 4 Steel ball
90 1 Air pump housing
91 1 Nut
92 1 Spring
93 1 Washer
94 1 Cyl. pump plunger
95 1 Piston body "A"
96 2 O-ring
97 1 Air release rod
98 2 O-ring
99 1 Piston body "B"
100 1 Bolt
101 1 Air seal
102 2 O-ring
103 1 O-ring
104 1 Rear cover
105 1 Snap ring
106 2 O-ring
107 1 Bolt
108 1 Air valve assy
W 3 O-ring
X 2 Ring
565800 Air Motor Seal Kit
79 2 Copper washer
80 1 Oil valve assy
81 1 Nylon gasket
83 1 Oil seal
84 1 Washer
85 1 Copper washer
96 2 O-ring
98 2 O-ring
102 2 O-ring
103 1 O-ring
106 2 O-ring
X 2 Ring
566225 Air Motor Hardware Kit
82 1 Pump cylinder
86 1 Nut
87 8 Bolt
88 1 Front cover
91 1 Nut
92 1 Spring
97 1 Air release rod
99 1 Piston body "B"
100 3 Bolt
104 1 Rear cover
W 3 O-ring
565771 Air Hose/Air Valve Kit
105 1 Snap ring
106 2 O-ring
107 1 Bolt
108 1 Air valve assy
X 2 Ring
Safety Precautions
WARNING: To prevent personal injury or equipment damage,
• Study, understand, and follow all instructions before operating this device.
• Wear eye protection that meets OSHA and ANSI Z87.1 standards.
• No alterations shall be made to this product.
• Before using the service jack to lift a vehicle, refer to the vehicle service manual for
recommended lifting surfaces on the vehicle chassis.
• Inspect the jack before each use. Do not use the jack if it is 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 any
obstructions while lifting or lowering the vehicle. The wheels of the vehicle must be
in the straight-ahead position, and the hand brake must be 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 adjust the safety valve.
• Lower the jack slowly and carefully while watching the position of the jack saddle.
• Useonlyapprovedhydraulicuid(ChevronAWHydraulicOil
MVorequivalent).Theuseofalcohol,hydraulicbrakeuid,or
transmission oil could damage seals and result in jack failure.
• This guide cannot cover every situation. Always work with
safetyrst.

Setup
Assemble the Handle
1. Loosen the bolt (Item 64) on the handle socket (60). NOTE: Item numbers refer to the parts list on page 1.
2. Insert the handle.
3. Tighten the bolt.
Air Bleed
Air can accumulate within a hydraulic system during shipment or after prolonged use. This trapped air causes
the jack to respond slowly or feel "spongy." To remove the air, follow the instructions for both the manual pump
and the air pump:
Manual Pump
1. Openthe releasevalvebyturningthereleaseknobcounterclockwise.
2. Pump the jack handle six full strokes.
3. Close the release valve by turning the release knob clockwise.
4. If the jack does not immediately respond to pumping the handle,
repeat Steps 1–3.
Air Pump
1. Place the jack on a level surface.
2. Openthe releasevalvebyturningthereleaseknobcounterclockwise.
3. Run the air pump for 20 seconds, then close the release valve by
turning the release knob clockwise.
4. Pump the jack pedal (Item 61) until the jack reaches its maximum
height.
5. Depress the air valve while turning the release knob two full turns
counterclockwise. Continue to depress the air valve until the lift arm fully lowers. Turn the knob clockwise
until it stops. Pump normally.
6. If the jack does not immediately respond to the air pump, repeat steps 1–5, or follow the priming instructions.
Priming the Air Pump
If air cannot be bled using the air pump air bleed procedure, the air pump has lost its prime. To prime the pump:
1. Remove the cover board (Item 26).
2. Loosen the bolt (Item 46; also see Figure 1) one-half turn.
3. Close the release valve by turning the release knob clockwise.
4. Run the air pump while repeatedly tightening and loosening the
bolt. (A small amount of oil may seep from underneath the bolt
during this process.)
5. When the piston begins to rise, tighten the bolt.
6. Verify the jack will rise to its full height; add oil to the reservoir
if necessary.
Operating Instructions
Control rod in Position A: Allows you to pump the jack using the
handle.
Control rod in Position B: Locks the handle in place in three
different positions.
Parts List & Operating Instructions Form No. 565786, Sheet 2 of 3, Back
Control Rod
Release Knob
Figure 2
Position A Position B
Release
Knob
Figure 1
Bolt

Sheet No.
Issue Date: August 16, 2012, Rev. A
© 2012
3 of 3
Parts List & Operating Instructions Form No. 565786
1. Connect the shop air supply to the jack. (Shop air should be clean, dry, and regulated at 85–142 psi.)
2. Turn the release knob completely counterclockwise, and place the control rod in Position A.
3. 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.
4. Turn the release knob on the jack completely clockwise. Operate the air valve, pump the jack handle, or
pump the foot pedal until the saddle touches the vehicle. Check the placement of the saddle lugs. Finish
lifting the vehicle.
5. Place approved safety stands under the vehicle at points that will provide stable support. Before working on
the vehicle, SLOWLY lower the vehicle onto the safety stands by turning the release knob counterclockwise.
Preventive Maintenance
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. Refer to Figure 3, and regularly (at least once per month)
lubricate the moving parts shown.
3. Add grease to upper arm grease nipple (shown) every
three months.
4. If necessary, add approved anti-wear hydraulic jack oil.
IMPORTANT: The use of alcohol, hydraulic brake uid,
detergent motor oil, or transmission oil could damage the
seals and result in jack failure.
5. Inspect the jack before each use. Take corrective action if
any of the following problems are found:
• cracked or damaged housing
• excessive wear, bending, or other damage
• leakinghydraulicuid
• scored or damaged piston rod
• malfunctioning swivel heads or adjusting screws
• loose hardware
• modiedoralteredequipment
Grease Nipple
Figure 3

Troubleshooting Guide
Repairproceduresmustbeperformedinadirt-freeenvironmentbyqualiedpersonnelwhoarefamiliarwith
thisequipment.
Trouble Cause Solution
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.
6. Packing worn out or defective. 6. Install seal kit.
7. Leak in air line. 7. Locate leak; tighten connections or replace
hose.
8.Inadequateairpressure. 8. Set air pressure to 85–142 psi.
Jack lifts only
partially.
1. Not enough oil. 1. Add oil.
Jack advances
slowly.
1. Pump not working correctly. 1. Install seal kit, or replace power unit.
2. Leaking seals. 2. Install seal kit.
Jack lifts load, but
does not hold.
1. Cylinder packing is leaking. 1. Install seal kit.
2. Valve not working correctly
(suction, delivery, release, or
bypass).
2. Inspect valves. Clean and repair seat
surfaces.
3. Air-locked system. 3. Bleed system.
Jack leaks oil. 1. Worn or damaged seals. 1. Install seal kit.
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.
2. Link section is binding. 2. Lubricate link section.
Air motor will
not run or runs
erratically.
1. Leak in air line. 1. Locate leak, tighten connections, or replace
hose.
2.Inadequateairpressure. 2. Set air pressure to 85–142 psi.
3. Air piston is sticking. 3. Lube air motor by adding a small amount of
oil to jack’s air inlet.
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.
Parts List & Operating Instructions Form No. 565786, Sheet 3 of 3, Back