Sheet No. of 3
Issue Date: Rev. B August 14, 2014
© Bosch Automotive Service Solutions LLC
Operating Instructions
Hex Socket
Bolt
Release
Valve
Figure 2
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. 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
e. Incorrectly functioning swivel heads or adj. screw
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
3
Parts List & Operating Instructions
Form No. 573424
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.
Trouble
Cause
Solution
Erratic Action
1. Air in system
1. With jack sitting on its base and ram retracted,
bleed air by opening release valve. Pump 10 seconds.
2. Viscosity of oil too high
2. Change to a lower viscosity oil.
3. Ram sticking or binding
3. Look for dirt, gummy deposits, leaks, misalignment,
worn parts, or defective packings.
4. Internal leakage in ram
4. Replace worn packings. Look for excessive
contamination or wear.
Ram does not advance
1. Release valve is open
1. Close release valve located on top of “T” handle.
2. Low/no oil in reservoir
2. Fill with oil & bleed system.
3. Air locked system
3. With jack sitting on its base and ram retracted,
open release valve, run pump for 10 seconds.
4. Load is above capacity of system
4. Use correct equipment.
5. Pump lost its prime
5. Follow “Pump Prime Instructions.”
Ram only extends partially
1. Low oil level in reservoir
1. Fill reservoir with oil; bleed system.
2. Piston rod is binding
2. Look for dirt, gummy deposits, leaks, misalignment,
worn parts, or defective packings.
Ram advances slowly
1. Low air pressure
1. Adjust air pressure to 90–145 psi.
2. Pump not working correctly
2. Rework pump.
3. Leaking seals
3. Replace seals.
Ram advances but doesn’t
1. Release valve is open
1. Close release valve located on top of T” handle.
hold pressure
2. Ram seals are leaking
2. Replace seals.
3. Pump check valve not working
3. Clean / replace check valve.
4. Overload valve leaking / not adjusted 4. Replace / adjust overload valve.
Jack leaks oil
1. Worn or damaged seals
1. Replace seals.
Ram will not retract, or
1. Release valve is closed
1. Open release valve.
retracts slowly
2. Reservoir too full
2. Drain oil to correct level.
3. Ram damaged internally
3. Take jack to authorized service center for repair.
Troubleshooting Guide
Repairs must be performed in a dirt-free environment by qualified personnel who are familiar with this equipment.
