OTC 1546 User manual

Parts List & Operating Instructions for: 1546
Form No. 577597
655 Eisenhower Drive
Owatonna, MN 55060 USA
Phone: [phone]
Tech. Serv.: [phone]
Fax: [phone]
Order Entry: [phone]
Fax: [phone]
International Sales: [phone]
Fax: [phone]
Racing Jack
Max. Capacity: 6,000 lbs. (2,722 kg)
Sheet No. 1 of 4
Issue Date: Rev. C, October 26, 2017
WARNING: To prevent personal injury and/or damage to equipment,
• Read, understand, and follow instructions and safety precautions, including ASME PASE, 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 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.
• 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 rst.
Safety Precautions
© Bosch Automotive Service Solutions Inc.

Parts List & Operating Instructions Form No. 577597, Sheet 1 of 4, Back
Jack Parts List
4
32
13
14
16
18
17
3
15
21
31
9
8
5
6
12
11
7
5
6
4
3
25
22
30
25
26
27
10
23
24
5
6
25 27
27
25
33
39
36
37
40
32
29
21
18
17
51
45
43
2
1
46
49
47
48
45
44
43
50
47
62
61
57
21
22
23
24
55
57
26
58
5
59
15
3
16
5
12
9
10
6
11
52
53
54
60
63
35
38
25
29
21
19
19
19
5
6
6

Parts List & Operating Instructions Form No. 577597
Sheet No. 2 of 4
Issue Date: Rev. C, October 26, 2017
Replacement Kits
Item
No. Qty. Description
60 1 Lower Handle
61 1 Handle Sleeve
62 1 Upper Handle
63 1 Handle Lock Clip
No. 577805 Handle Kit
Item
No. Qty. Description
36 1 Saddle
37 1 Saddle Screw
38 1 Rubber Pad
No. 577808 Saddle Kit
Item
No. Qty. Description
7 8 Lock Washer
8 8 Bolt
46 1 Cotter Pin
50 1 Hydraulic Unit
No. 577809 Hydraulic Unit
Item
No. Qty. Description
No. 577807 Casters Kit
1 2 Rear Caster
3 2 Lock Nut M12
3 2 Lock Nut M12
16 2 Washer
17 2 Front Wheel
18 2 Spacer
30 1 Axle
Item
No. Qty. Description
No. 577806 Wheels Kit
2 2 Caster Mount
4 2 Washer
5 6 Lock Washer
6 6 Button Head Cap Screw
9 2 Button Head Cap Screw
10 2 Lock Washer
11 2 Nut
12 2 Washer
13 2 Lock Washer
14 2 Button Head Cap Screw
19 6 Button Head Cap Screw
22 2 Load Leveling Arm
23 2 Load Level Arm Bolt
25 10 Flat Socket Cap Screw
26 2 Spacer
27 6 Flat Socket Cap Screw
29 2 Button Head Cap Screw
31 1 Axle Cover
32 2 Retaining Ring
33 1 Pin
35 4 Button Head Cap Screw
39 1 Spacer Tube
40 1 Spacer
43 2 Lift Arm Nut
44 1 Load Block
45 2 Retaining Ring
46 1 Cotter Pin
47 2 Load Arm
57 2 Spacer
58 1 Main Lift Pin
59 1 Spacer Tube
Item
No. Qty. Description
No. 577812 Hardware Kit
Item
No. Qty. Description
15 1 Side Carrying Grip
21 2 Bolt
No. 577811 Side Handle
Item
No. Qty. Description
4 2 Washer
5 2 Lock Washer
6 2 Bolt
24 2 Handle Yoke Stud
51 1 Roller Pin
52 1 Roller
53 1 Retaining Ring
54 1 Handle Retaining Bolt
55 1 Handle Yoke
No. 577810 Handle Pivot
Item
No. Qty. Description
No. 577813 Handle Retaining Bolt
54 1 Handle Retaining Bolt
Item
No. Qty. Description
No. 577814 Return Spring
48 2 Return Spring Bolt
49 2 Return Spring
Get parts at OTCparts.com
This document contains product parts lists and information regarding
operation and maintenance. Items listed in the parts list have been carefully
tested and selected by OTC. Therefore, use only OTC replacement parts.
Product questions may be directed to the OTC Technical Service Department
at [phone].

Parts List & Operating Instructions Form No. 577597, Sheet 2 of 4, Back
Hydraulic Unit Parts List
1
2
3
4
5
11
6
7
8
9
10
12
13
14
15
16
17
18
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41

Parts List & Operating Instructions Form No. 577597
Item
No. Qty. Description
1 1 Reservoir Bottom Seal Ring
3 1 Reservoir Top Seal Ring
4 1 O-ring 29.5X3.55
10 1 O-ring 31X4.6
12 1 Cylinder Bottom Seal Ring
18 2 Circlip 15X10.6X1.25
21 1 Piston Housing Copper
Seal Ring
24 1 O-ring 6.8X1.8
26 1 Piston Housing Copper
Seal Ring
28 2 O-ring 17X2.65
29 2 Circlip 22X17.6X1.25
36 2 Seal Member 15X9.5X2
No. 577815 Seal Kit
Item
No. Qty. Description
13 1 Piston Return Spring
14 1 Dust Cover
15 1 Return Spring Holder
16 1 Circlip 15
17 1 Piston
18 2 Circlip 15X10.6X1.25
19 2 O-ring 10X2.65
20 1 Piston Housing
21 1 Piston Housing Copper
Seal Ring
22 5 Steel Ball 5
26 1 Piston Housing Copper
Seal Ring
27 1 Piston Housing
28 2 O-ring 17X2.65
29 2 Circlip 22X17.6X1.25
30 1 Piston
31 1 Circlip 22
32 1 Return Spring Holder
33 1 Dust Cover
34 1 Piston Return Spring
No. 577817 Pump Piston Kit
Item
No. Qty. Description
23 1 Steel Ball 6
24 1 O-ring 6.8X1.8
25 1 U-Joint
No. 577816 Release Screw Kit
Item
No. Qty. Description
35 2 Relief Valve Cover Screw
36 2 Circlip 15X9.5X2
37 1 Relief Valve Set Screw
38 1 Relief Valve Spring
39 1 Spring Retainer
40 2 Steel Ball 4
41 1 Screw M6X8
No. 577820 Hardware Kit
Item
No. Qty. Description
1 1 Reservoir Bottom Seal Ring
2 1 Reservoir
3 1 Reservoir Top Seal Ring
4 1 O-ring 29.5X3.55
5 1 Top Nut
No. 577818 Reservoir Kit
Item
No. Qty. Description
1 1 Reservoir Bottom Seal Ring
3 1 Reservoir Top Seal Ring
4 1 O-ring 29.5X3.55
6 1 Piston Rod
7 1 Circlip 30
8 1 Piston Rod Base
9 1 Piston Rod Retainer
10 1 O-ring 31X4.6
11 1 Cylinder
12 1 Cylinder Bottom Seal Ring
No. 577819 Cylinder Kit
Hydraulic Unit Replacement Kits
Sheet No. 3 of 4
Issue Date: Rev. C, October 26, 2017
Get parts at OTCparts.com
This document contains product parts lists and information regarding
operation and maintenance. Items listed in the parts list have been carefully
tested and selected by OTC. Therefore, use only OTC replacement parts.
Product questions may be directed to the OTC Technical Service Department
at [phone].

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.
Operating Instructions
1. Close the release valve by turning the handle completely clockwise.
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 obstruction 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.
CAUTION: To prevent personal injury, 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.
Preventive Maintenance
CAUTION: Dirt is the greatest single cause of failure in hydraulic units. Keep
the 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 jack on level ground and lower the lift arm completely. Remove the oil screw. The
oil level should be at the bottom of the ller plug hole. If necessary, add approved
anti-wear hydraulic jack oil, and install the ller plug again. CAUTION: The use of
alcohol, hydraulic brake uid, 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:
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; or modied or altered equipment.
Parts List & Operating Instructions Form No. 577597, Sheet 3 of 4, Back

Parts List & Operating Instructions Form No. 577597
Sheet No. 4 of 4
Issue Date: Rev. C, October 26, 2017
Troubleshooting Guide
Repair procedures must be performed in a dirt-free environment by qualied personnel who are familiar with this equipment.
CAUTION: To prevent personal injury, 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
Jack leaks oil
Jack will not retract
Jack retracts slowly
1. Release valve is open.
2. Low/no oil 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 oil.
1. Pump not working correctly.
2. Leaking seals.
1. Cylinder packing is leaking
2. Valve not working correct (suction, delivery, release, or bypass).
3. Air-locked system.
1. Worn or damaged seals.
1. Release valve is closed.
1. Cylinder damaged internally.
2. Link section is binding.
1. Close release valve.
2. Fill with oil and bleed system.
3. Bleed system.
4. Use correct equipment.
5. Clean to remove dirt or foreign matter. Replace oil.
6. Replace seals (Kit No. 577815) or hydraulic unit (Kit No. 577809).
1. Check oil level.
1. Replace seals (Kit No. 577815) or hydraulic unit (Kit No. 577809).
2. Replace seals (Kit No. 577815) or hydraulic unit (Kit No. 577809).
1. Replace seals (Kit No. 577815) or hydraulic unit (Kit No. 577809).
2. Inspect valves. Clean and repair seat surfaces.
3. Bleed system.
1. Replace seals (Kit No. 577815) or hydraulic unit (Kit No. 577809).
1. Open or clean release valve.
1. Send jack to OTC authorized service center for repair;
refer to OTC Form No. 104060.
2. Lubricate or replace link section.