SPX 1503 User manual

Sheet No.
Issue Date: Rev. C, 6-4-2003
© SPX Corporation
Form No. 106461
1 of 2
Parts List and
Operating Instructions
for: 1503
1504
Service Jack
No. 1503 Max. Capacity: 2-1/2 Tons
No. 1504 Max. Capacity: 3 Tons
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]
2
3
1
4
Replacement Items for 1503 & 1504
Item Part
No. No. Description
1504887 Saddle
2504884 Caster
3504885 Wheel (for 1503)
511501 Wheel (for 1504)
4504886 Handle
5504883 Hydraulic Unit (for 1503)
511507 Hydraulic Unit (for 1504)
Not shown 512223 Handle Return Spring
6512224 Handle Retaining Bolt
5
6

Safety Precautions
Caution: To prevent personal injury and damage to equipment,
•Read, understand, and follow all instructions, including ASME PALD Part 10 for
service jacks. If the operator cannot read English, operating instructions and safety
precautions must be read and discussed in the operator’s native language.
Si el operador no puede leer el inglés, las instrucciones de operación y las
precauciones de seguridad deberán leerse y comentarse en el idioma nativo del
operador.
Si l’utilisateur ne peut lire l’anglais, les instructions et les consignes de sécurité
doivent lui être expliquées dans sa langue maternelle.
•Before using the service jack to lift a vehicle, refer to the vehicle service manual to
determine 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. Take corrective action if any of the following conditions are found:
cracked or damaged housing; excessive wear, bending, or other damage; leaking
hydraulic fluid; scored or damaged piston rod; loose hardware; modified or altered
equipment.
•A load must 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 released.
•Use the jack for lifting purposes only. Stay clear of a lifted load. Place support stands under the axles
before working on the vehicle.
•Center the load on the jack saddle. Off-center loads can damage seals and cause jack failure. Lift only
dead weight.
•Do not use blocks or other extenders between the saddle and the load being lifted.
•Do not modify the jack or use adapters unless approved or supplied by OTC.
•Lower the jack slowly and carefully while watching the position of the jack saddle.
•Use only approved hydraulic fluid (Chevron AW Hydraulic Oil or equivalent). The use of alcohol,
hydraulic brake fluid, or transmission oil could damage seals and result in jack failure.
This guide cannot cover every situation, so always do the job with safety first.
Parts List & Operating Instructions Form No. 106461, sheet 1 of 2, back
Setup
Assembling the Handle
1. Loosen the thumb screw on the back of the handle socket.
2. Grease the socket opening. Insert the handle.
3. Torque the thumb screw again to 150–200 in. lbs.
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 the air:
1. Open the release valve by turning the handle all the way counterclockwise (CCW).

Sheet No.
Issue Date: Rev. C, 6-4-2003
© SPX Corporation
Operating Instructions
Setup
1. Loosen the thumb screw on the front of the handle socket.
2. Grease the socket opening. Insert the handle.
3. Torque the thumb screw to 150–200 in. lbs.
Operation
1. Close the release valve by turning the handle clockwise (CW) as far as it will go.
2. Position the jack under the vehicle. IMPORTANT: Use the manufacturer’s recommended lifting points
on the chassis.
3. Pump the jack handle to raise the saddle to the contact point.
4. 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.
5. Finish lifting the vehicle by pumping the handle. Do not attempt to raise the jack beyond its travel stops.
6. Place approved support stands under the vehicle at points that will provide stable support. Before making
repairs on the vehicle, lower it onto the support stands by SLOWLY and CAREFULLY turning the handle
counterclockwise (CCW).
Parts List & Operating Instructions Form No. 106461
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, and handle.
3. Replace the oil in the reservoir at least once per year. To check the oil level, lower the lift arm completely. Remove the
rubber filler plug. 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. IMPORTANT: The use of alcohol, hydraulic brake fluid, 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:
a. cracked, damaged housing c. leaking hydraulic fluid e. loose hardware
b. excessive wear, bending, other damage d. scored, damaged piston rod f. modified equipment
5. Keep warning labels and instructional decals clean and readable. Use a mild soap solution to wash external surfaces
of the jack.
2 of 2
These instructions are written to help you, the user, more effectively use and maintain your OTC jacks. Some of the
information applying to construction, installation, operation, inspection, and maintenance of hydraulic jacks was selected from
ANSI B30.1. It is strongly recommended that the user read ANSI B30.1. The document may be ordered from the American
Society of Mechanical Engineers, United Engineering Center, 345 East 47th, New York, New York 10017.
2. Pump the handle six full strokes.
3. Close the release valve by turning the handle all the way clockwise (CW).
4. Pump the handle until the lift arm is fully extended.
5. Lower the lift arm by turning the handle all the way counterclockwise (CCW). If the jack does not
immediately respond, repeat steps 2–4.

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. 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 hydraulic unit.
1. Too much or not enough oil.
1. Check oil level.
1. Pump not working correctly.
2. Leaking seals.
1. Replace hydraulic unit.
2. Replace hydraulic unit.
1. Cylinder packing is leaking.
2. Valve not working correctly (suction,
delivery, release, or bypass).
3. Air-locked system.
1. Replace hydraulic unit.
2. Inspect valves. Clean and repair seat
surfaces.
3. Bleed system.
1. Worn or damaged seals.
1. Replace hydraulic unit.
1. Release valve is closed.
1. Open release valve all the way
counterclockwise (CCW). May be
necessary to clean release valve.
1. Cylinder damaged internally.
2. Link section is binding.
1. Send jack to OTC-authorized service
center. (Refer to OTC Form No. 104031.)
2. Lubricate or replace link section.
Parts List & Operating Instructions Form No. 106461, sheet 2 of 2, back
Troubleshooting Guide
Repair procedures must be performed in a dirt-free environment by qualified personnel who are familiar with this
equipment. CAUTION: All inspection, maintenance, and repair procedures must be performed when the jack is free
of a load (not in use).
Trouble Cause Solution