Preventive Maintenance; Troubleshooting Guide - OTC 1788B Lista De Partes E Instrucciones De Funcionamiento

Parts List & Operating Instructions
Pump Prime Instructions
The air/hydraulic pump may lose its prime during shipment or after long
periods without use. To prime the pump, follow these steps:
1. Remove the upper cover.
2. Loosen the hex socket bolt one-half turn. See Figure 2.
3. Close the release valve.
4. Operate the air pump while repeatedly tightening and loosening the bolt.
5. When the piston begins to rise, tighten the bolt. Verify the piston can rise
to the maximum height position.
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. When the jack is not in use, keep the piston and pump rods fully retracted. Store the jack on its base and in a well
protected area where it will not be exposed to corrosive vapors, abrasive dust, or any other harmful elements.
2. Maintain the oil level. If it's necessary to add oil, remove the filler plug, and fill the reservoir with Chevron AW Hydraulic
Oil MV or equivalent.
3. Visually inspect the jack before each use. Take corrective action if any of the following problems are found:
a. Cracked or damaged housing
b. Excessive wear, bending, or other damage
c. Leaking hydraulic fluid
d. Scored or damaged piston rod
Repairs must be performed in a dirt-free environment by qualified personnel who are familiar with this equipment.
Trouble
Erratic Action
Ram does not advance
Ram only extends partially
Ram advances slowly
Ram advances but doesn't
hold pressure
Jack leaks oil
Ram will not retract, or
retracts slowly
© Bosch Automotive Service Solutions LLC
Operating Instructions

Preventive Maintenance

Troubleshooting Guide

Cause
1. Air in system
2. Viscosity of oil too high
3. Ram sticking or binding
4. Internal leakage in ram
1. Release valve is open
2. Low/no oil in reservoir
3. Air locked system
4. Load is above capacity of system
5. Pump lost its prime
1. Low oil level in reservoir
2. Piston rod is binding
1. Low air pressure
2. Pump not working correctly
3. Leaking seals
1. Release valve is open
2. Ram seals are leaking
3. Pump check valve not working
4. Overload valve leaking / not adjusted 4. Replace / adjust overload valve.
1. Worn or damaged seals
1. Release valve is closed
2. Reservoir too full
3. Ram damaged internally
Hex Socket
e. Incorrectly functioning swivel heads or adj. screw
f. Loose hardware
g. Modified or altered equipment
1. With jack sitting on its base and ram retracted,
bleed air by opening release valve. Pump 10 seconds.
2. Change to a lower viscosity oil.
3. Look for dirt, gummy deposits, leaks, misalignment,
worn parts, or defective packings.
4. Replace worn packings. Look for excessive
contamination or wear.
1. Close release valve located on top of "T" handle.
2. Fill with oil & bleed system.
3. With jack sitting on its base and ram retracted,
open release valve, run pump for 10 seconds.
4. Use correct equipment.
5. Follow "Pump Prime Instructions."
1. Fill reservoir with oil; bleed system.
2. Look for dirt, gummy deposits, leaks, misalignment,
worn parts, or defective packings.
1. Adjust air pressure to 90–145 psi.
2. Rework pump.
3. Replace seals.
1. Close release valve located on top of T" handle.
2. Replace seals.
3. Clean / replace check valve.
1. Replace seals.
1. Open release valve.
2. Drain oil to correct level.
3. Take jack to authorized service center for repair.
Issue Date: Rev. B August 14, 2014
Form No. 573424
Release
Valve
Bolt
Figure 2
Solution
Sheet No. of 3
3