OTC HDJ5 Operating instructions

(en-US)
SERVICE JACK INSTRUCTIONS

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About OTC
OTC was founded in
1925 in Owatonna,
Minnesota as the
Owatonna Tool Company.
What started as a small specialty tool
manufacturer has grown into a global provider of
specialty tools to nearly every technician, mechanic, independent
repair shop, automotive dealership and tractor manufacturer.
OTC continues to operate its design, engineering, manufacturing
and distribution facility in Owatonna, Minnesota. The current
plant opened in the late 1950s, employing hundreds of tool
specialists who forge, heat treat, coat and assemble the OTC
tools you trust.
Since its founding, OTC has always stood for quality and
ingenuity, creating reliable solutions that make repairing vehicles
and equipment easier.
The OTC tool you purchased today has been crafted to exacting
specifications to provide you with the tool you need, when you
need it, for life. All OTC tools are covered by a lifetime warranty,
ensuring years of worry-free use. OTC tools are key to getting
the job done.
Thank you for supporting OTC. Your purchase drives the
research, innovation, engineering and development of new tools
and equipment.
Looking for more OTC tools? Visit www.otctools.com and
subscribe to our e-newsletter for new tools, promotions and
OTC news.

SERVICE JACK INSTRUCTIONS
• Study, understand, and follow all instructions before
operating this device.
• Wear ANSI Z87.1 and OSHA approved eye protection.
• Do not exceed rated capacity.
• Use only on a hard, level surface.
• Do not use blocks or extenders between the saddle
and the load being lifted. This could reduce the jack’s
stability and cause vehicle to fall.
• Support vehicle with appropriate means immediately
after lifting.
• Do not move or dolly the vehicle while it is on the jack.
• Lift only on areas of the vehicle as specified by the
vehicle manufacturer.
• No alterations shall be made to this product.
• Failure to heed these markings may result in personal
injury/property damage.
Safety Information
Shop Equipment Recommendations
As with any tool or piece of equipment, it is highly recommended
to follow all applicable safety guidelines pertaining to its
use. Appropriate Personal Protective Equipment as outlined
by OSHA and ANSI standards, include (but are not limited
to) safety glasses or face shields, protective gloves, hearing
protection and reinforced (or safety toe) footwear. While using
tools and equipment, ensure that you are clear of any moving
parts or potential pinch points. To ensure the continued safe
operation of tools and equipment, always follow manufacturer’s
recommended cleaning and lubrication schedules to prevent
foreign material build up.
The warnings and instructions discussed
in this manual cannot cover every situation,
Always work with a focus on safety.
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Wheels
• Ensure wheels are properly fastened to wheel
mounts and that they roll and/or swivel.
Handle
• Must be securely seated in yoke.
• Bumper pad is on the lower half of handle.
• Handle must be easy to rotate to the right (raise) and
to the left (lower).
Saddle
• Saddle pad is securely placed on saddle.
• Saddle is free to rotate 360°.
Function
• Without a load on jack, operate handle as follows:
a. Rotate to the right.
b. Pump to lift.
c. Rotate to the left to lower.
General
• Inspect paint for chipping, runs, misses or overspray.
• Inspect weldments for breaks or spatter.
Inspection/Set-Up Instructions
Upon delivery, inspect carton for unnecessary damage. Where
appropriate, address carton damage with carrier (See Figure 1).
Remove jack from carton and attach handle. Inspect jack for the
following:
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If your inspection reveals any issue with the jack’s appearance
or performance, please contact the
OTC Technical Service Hotline at 800-533-6127
to report an issue and file a warranty claim.
If possible, retain the original carton for return shipping.
A replacement will be sent and a call tag will be issued
to pick up the jack in question.

Handle
Saddle Pad
Lift Arm
Wheels
Yoke
Bumper
Pad
SERVICE JACK INSTRUCTIONS
Figure 1
Inspection List Components
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1. Before every use – INSPECT the jack for performance issues.
Do not use the jack if any quality issue is discovered.
2. When jack is fully retracted, check hydraulic oil level and fill to
¼” below the fill plug hole (See Maintaining Your OTC Service
Jack). Do not overfill.
3. Ensure the work area is free from debris and obstructions that
may inhibit the performance of the jack.
4. Position the jack saddle on a factory specified lift point for the
vehicle.
5. Apply parking brake and chock wheels before lifting vehicle.
6. If using air feature on jack, connect air line to air hydraulic pump
on jack and rotate release knob clockwise to activate air pump
to elevate and center saddle to lift point (See Figure 2). If using
hydraulic feature on jack, rotate handle clockwise until it
contacts the stop—Do NOT over torque this rotation. Pump
handle to elevate and center saddle to lift point.
7. Continue to pump handle until desired height is achieved.
8. Keep clear of load while lifting and lowering the vehicle.
9. Immediately position approved support stands for holding
vehicle in elevated position.
10. Slowly rotate handle counterclockwise or release air pressure to
allow vehicle to gently settle onto properly positioned support
stands.
11. When service is completed, rotate handle clockwise and pump
or activate air pump to lift vehicle o of support stands.
12. Remove support stands from under vehicle.
13. Slowly rotate handle counterclockwise or turn release knob
until vehicle begins to descend.
14. Allow vehicle to descend to floor and remove service jack.
15. Store service jack in a fully retracted position until next use.
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Operating Your OTC Service Jack

Position A Position B
Release Knob
Control Rod
Control Rod
SERVICE JACK INSTRUCTIONS
Figure 2
Bleeding 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 air do the following:
1. Open the release valve by turning the handle all the way
counterclockwise.
2. For Hydraulic Units - Pump the handle six full strokes.
For Air Assist Hydraulic Units - Activate air pump six times.
3. Close the release valve by turning the handle all the way clockwise.
4. For Hydraulic Units - Pump the handle until the lift arm is fully
extended. For Air Assist Hydraulic Units - Activate air pump until lift
arm is fully extended.
5. Lower lift arm by turning the handle all the way counterclockwise.
If the jack does not immediately lower, repeat steps 2–4.
Replacement Parts
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Air/Hydraulic Jack
(special features)
Control Rod in Position A:
Allows you to hydraulically
pump the jack using the
handle.
Control Rod in Position B:
Locks the handle in place in
three dierent positions.
To ensure the safety features of your service jack are not
compromised, OTC oers a limited selection of replacement parts.
Replacement part information for your model can be found by
visiting www.otctools.com.
Contact our tech service team at 800-533-6127 for assistance.

Maintaining Your OTC Service Jack
1. Checking Hydraulic Fluid
When jack is fully retracted, check hydraulic fluid level and
fill to ¼” below the fill plug hole (See Figure 3).
Fill Plug
1/4" Below Fill Hole
Note: On certain service jack
models, a steel cover plate may
need to be removed before
gaining access to fill plug.
Figure 3
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SERVICE JACK INSTRUCTIONS
2. Locating Grease Zerks
Grease zerks are located at various locations. Lubricate
periodically with a medium weight lithium-based grease to
ensure smooth and trouble-free operation (See Figure 4).
Possible Grease
Zerk Locations
Figure 4
Depending on the
jack, grease zerks are
located in many various
locations. Grease all
visible zerks.
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3. Lubricate Various Pivot Points
Use a general lubricating oil for other moving components
(See Figure 5).
4. Keep Jack Clean
Periodically wipe jack down keeping all moving parts
visible throughout operation. Ensure all labels and decals
are readable.
When jack is fully extended,
apply oil on the face side of
all metal pivot plates.
Regularly lubricate
yoke pivot points.
Figure 5
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