SPX 1507A, 1511A Operating Instructions Manual

Page 1

SPX Corporation 655 Eisenhower Drive

Form No. 524678

Owatonna, MN 55060-0995 USA Phone: (507) 455-7000 Tech. Serv.: (800) 533-6127 Fax: (800) 955-8329 Order Entry: (800) 533-6127 Fax: (800) 283-8665 International Sales: (507) 455-7223

Parts List & Operating Instructions for: 1507A

1511A

Fax: (507) 455-7063

Air-Assist Service Jack

Max. Capacity: 5 and 10 Tons

88 87

86 85 84 83 82

79 80

107

106

105

104

103

102

101

100

108

43 42

40 39

46 45 44

109

Sheet No.

1 of 3

Issue Date: Rev. G, May 30, 2007

Page 2

Parts List & Operating Instructions Form No. 524678, Sheet 1 of 3, Back

Parts List

Item

No. Qty. Description

11Frame 22Front Wheel 32Washer 44Snap Ring 53Grease Fitting 62Rod Link 72Bolt 81Saddle

92Lockwasher 10 2 Nut 11 1 Spring 12 4 Bolt 13 1 Bolt 14 4 Snap Ring 15 2 Shaft 16 2 Rear Wheel 17 4 Nut 18 2 Snap Ring 19 1 Shaft 20 1 Washer 21 1 Pin 22 1 Connecting Bar 23 1 Spring 24 2 Snap Ring 25 1 Shaft 26 1 Cover Board 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 Assembly 37 1 Oil Filler Plug

Item

No. Qty. Description

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 52 2 Copper Washer 53 1 Oil Valve Assembly 54 1 Nylon Gasket 55 1 Cylinder Pump 56 2 O-ring 57 2 Washer 58 1 Pin 59 1 Cylinder Pump Plunger 60 1 Handle Socket 61 1 Pedal 62 1 Nut 63 1 Washer 64 1 Bolt 65 1 Handle 66 2 Sleeve 67 1 Knob 68 1 Pin 69 1 Control Rod 70 1 Spring 71 3 Washer 72 3 Screw 73 1 Rod Joint

Item

No. Qty. Description

74 1 Spring 75 1 Universal Joint Assy. 76 1 Convey Rod 77 1 Washer 78 2 Pin 79 2 Copper Washer 80 1 Oil Valve Assembly 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 Cylinder Pump Plunger 95 1 Piston Body “A” 96 1 O-ring 97 1 Air Release Rod 98 2 O-ring

99 1 Piston Body “B” 100 3 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 109 1 Handle Assembly

Shaded areas reflect the latest

revisions made to this form.

Page 3

Parts List & Operating Instructions Form No. 524678

Replacement Kits

Kit numbers followed by an asterisk (j) are used on 1507A units only.

Kit numbers followed by a triangle (

) are used on 1511A units only.

Item

No. Qty. Description

Air Hose / Air Valve Kit No. 524986

105 1 Snap Ring 106 2 O-ring 107 1 Bolt 108 1 Air Valve

Air Motor Kit No. 531865

79 2 Copper Washer 80 1 Oil Valve Assembly 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 Cylinder Pump Plunger 95 1 Piston Body “A” 96 1 O-ring 97 1 Air Release Rod 98 2 O-ring

99 1 Piston Body “B” 100 3 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

Caster Kit No. 520775j or 520776

16 1 Rear Wheel

17 2 Nut

Foot Pedal Kit No. 520791

61 1 Pedal

Grease Fitting Kit No. 520796

51Grease Fitting

Handle Kit No. 524984

109 1 Handle Assembly

Handle Pivot Kit No. 520790

18 2 Snap Ring

19 1 Shaft

60 1 Handle Socket

Handle Retaining Bolt Kit No. 520792

62 1 Nut

63 1 Washer

64 1 Bolt

Item

No. Qty. Description

Handle Return Spring Kit No. 520793

23 1 Spring

Hydraulic and Air Motor Seal Kit No. 531857

or 531858

28 2 Washer 29 1 O-ring 32 1 Sealing Washer 33 1 O-ring 34 1 O-ring Retainer 37 1 Oil Filler Plug 42 1 Sealing Washer 45 1 Copper Washer 48 1 O-ring 49 1 O-ring 52 2 Copper Washer 54 1 Nylon Gasket 56 2 O-ring 57 2 Washer 79 2 Copper Washer 80 1 Oil Valve Assembly 81 1 Nylon Gasket 83 1 Oil Seal 84 1 Washer 85 1 Copper Washer 96 1 O-ring

98 2 O-ring 101 1 Air Seal 102 2 O-ring 103 1 O-ring 106 2 O-ring

Hydraulic Unit No. 531859j or 531860

13 1 Bolt

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 Assembly

37 1 Oil Filler 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

52 2 Copper Washer

53 1 Oil Valve Assembly

Item

No. Qty. Description

54 1 Nylon Gasket 55 1 Cylinder Pump 56 2 O-ring 57 2 Washer 58 1 Pin 59 1 Cylinder Pump Plunger 79 1 Copper Washer

Inspection Plate Kit No. 520787j or 520788

26 1 Cover Board

Leveling Linkage Arm Kit No. 520785

or 520786

42Snap Ring 62Rod Link 72Bolt 92Lockwasher

10 2 Nut

Lift Arm Return Spring Kit No. 520781j or 520782

11 1 Spring 12 2 Bolt 14 2 Snap Ring 15 1 Shaft

Pump Plunger / Connect Bar Kit No. 531862j or 531863

20 1 Washer 21 1 Pin 22 1 Connecting Bar 24 2 Snap Ring 25 1 Shaft 52 2 Copper Washer 53 1 Oil Valve Assembly 54 1 Nylon Gasket 55 1 Cylinder Pump 56 2 O-ring 57 2 Washer 58 1 Pin 59 1 Cylinder Pump Plunger

Release Valve Kit No. 531864

47 1 Steel Ball 48 1 O-ring 49 1 O-ring 50 1 Release Valve Rod 51 1 Pin

Saddle Kit No. 520779j or 520780

81Saddle

Wheel Kit No. 520777j or 520778

21Front Wheel 31Washer 41Snap Ring 51Grease Fitting

Sheet No.

2 of 3

Issue Date: Rev. G, May 30, 2007

Page 4

Parts List & Operating Instructions Form No. 524678, Sheet 2 of 3, Back

Safety Precautions

WARNING: To prevent personal injury and/or damage to equipment,

Study, understand, and follow all instructions and safety precautions. If the operator cannot read

•

these instructions, the safety precautions and instructions 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 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 axle 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 fluid (Chevron AW Hydraulic Oil MV 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.

Setup

Assemble the Handle

1. Loosen the bolt (Item 64) on the handle socket (60).

2. Insert the handle.

3. Tighten the bolt.

NOTE: Item numbers refer to the parts list on page 1.

Air Bleed Instructions

Air can accumulate within a hydraulic system during shipment or after prolonged use. This entrapped air causes the jack to respond slowly or to feel “spongy.” To remove the air, follow the instructions for both the manual pump and the air pump:

Bleed Air — Manual Pump

1. Open the release valve by turning the release knob counterclockwise.

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.

Bleed Air — Air Pump

1. Place the jack on a level surface.

2. Open the release valve by turning the release knob counterclockwise.

3. Run the air pump for 20 seconds, then close the release valve by turning the release knob clockwise.

4. Pump the jack pedal until the jack reaches its maximum height.

5. Open the release valve by turning the release knob counterclockwise, lower the jack to its minimum height.

6. If the jack does not immediately respond to the air pump, repeat steps 1– 5, or follow the priming instructions on the next page.

Release Knob

Position A

Control Rod

Position B

Figure 1

Page 5

Parts List & Operating Instructions Form No. 524678 Air Bleed 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 2) 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.

continued . . .

Release

Knob

Bolt

Figure 2

Operating Instructions

(Refer to Figure 1)

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.

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 the illustration, 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 fluid, 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:

a. cracked or damaged housing e. malfunctioning swivel heads or adjusting screws b. excessive wear, bending, or other damage f. loose hardware c. leaking hydraulic fluid g. modified or altered equipment d. scored or damaged piston rod

Grease Nipple

Sheet No. Issue Date: Rev. G, May 30, 2007

3 of 3

Page 6

Parts List & Operating Instructions Form No. 524678, Sheet 3 of 3, Back

Troubleshooting Guide

Repair procedures must be performed in a dirt-free environment by qualified personnel who are familiar with this equipment.

Trouble

Jack does not lift 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.

7. Leak in air line.

8. Inadequate air pressure.

Jack lifts only partially 1. Not enough oil. Jack advances slowly 1. Pump not working correctly.

2. Leaking seals.

Jack lifts load, 1. Cylinder packing is leaking. but doesn't hold 2. Valve not working correctly (suction,

delivery, release, or bypass).

3. Air-locked system.

Jack leaks oil 1. Worn or damaged seals. Jack will not retract 1. Release valve is closed. Jack retracts slowly 1. Cylinder damaged internally.

2. Link section is binding.

Air motor won’t run 1. Leak in air line. or runs erratically 2. Inadequate air pressure.

3. Air piston is sticking.

Cause

Solution

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. Install seal kit.

7. Locate leak; tighten connections or replace hose.

8. Set air pressure to 85–142 psi.

1. Add oil.

1. Install seal kit, or replace power unit.

2. Install seal kit.

1. Install seal kit.

2. Inspect valves. Clean and repair seat surfaces.

3. Bleed system.

1. Install seal kit.

1. Open or clean release valve.

1. Send jack to OTC authorized service center for repair.

2. Lubricate link section.

1. Locate leak, tighten connections, or replace hose.

2. Set air pressure to 85–142 psi.

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.

Additional questions can be directed to our Technical Service Dept.