OTC Tools 61821 - Manual (Page 6)

Operating Instructions, Form No. 102841, Back sheet 3 of 3
TROUBLE-SHOOTING
WARNING: To help prevent personal injury, always release pump pressure and disconnect hoses(s)
from pump before making repairs.
Refer to the appropriate pump parts list during trouble-shooting. Repairs must be performed in a dirt-free
environment by qualified personnel familiar with this equipment.
Pump handle can be pushed down
(slowly) without raising the load 1. Inlet checks are not seating
2. Damaged piston assembly or
piston seals leaking
1.* Check for dirt and/or reseat
valve seats
2.* Replace piston assembly and/or
piston seals
Pump handle operates with a
spongy action 1. Air trapped in system
2. Too much fluid in reservoir
1. Position cylinder lower than
pump. Extend and return
cylinder several times. Follow
bleeding instructions.
2. Check fluid level per instructions
Pump handle effort drops
significantly after some pressure
has been obtained 1. This is normal operation on most
two-stage hand pumps
Pump does not reach full pressure 1. Low fluid level in reservoir
2. System components leaking
3. Directional control valve leaks or
not adjusted properly
4. Improperly adjusted relief valve
5. Fluid leaking past inlet or outlet
checks or high pressure piston
seal damaged
1. Check fluid level per instructions
2. Repair or replace as necessary
3.* Reseat, repair, or replace
directional control assembly and
correctly adjust
4.* Readjust
5.* Reseat or repair inlet or outlet
checks or replace high pressure
piston seal
PROBLEM CAUSE SOLUTION
Pump not delivering fluid 1. Low fluid level in reservoir
2. Intake filter is dirty
3. Seats worn and not seating
properly
1. Check fluid level per instructions
2. Remove reservoir and clean
3.* Repair seats or replace pump
body
Pump losing pressure 1. System components leaking
2. Directional control valve leaks or
not adjusted properly
3. Fluid leaking past outlet check
seat(s)
1. Repair or replace as necessary
2.* Reseat, repair, or replace
directional control assembly and
correctly adjust
3.* Check for dirt. Reseat pump
body and/or replace poppet(s) or
ball(s)
Handle rises after each stroke 1. Fluid leaking past outlet check
seat(s) 1.* Check for dirt. Reseat pump
body and/or replace poppet(s)
or ball(s)
*OTC recommends these hand pump repairs be performed by an Authorized Hydraulic Service Center.