OTC 2510A Bedienungsanleitung

Sheet No.

Issue Date: Rev. C September 19, 2011

Form No. 538016

Parts List &

Operating Instructions

for: 2510A

Air / Hydraulic Pump

Maximum Capacity: 690 bar (10,000 psi)

655 EISENHOWER DRIVE

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

FAX: (507) 455-7063

Original Instructions

Description: The 2510A air/hydraulic pump is designed to have a maximum capacity of 690 bar (10,000 psi).

It has a 2-stage release mechanism, internal relief valve, and 1606 CC (98 cu. in.) of useable oil. It pumps,

holds, or releases a load with pedal control.

1 of 4

Explanation of Safety Signal Words

The safety signal word designates the degree or level of hazard seriousness.

DANGER: Indicates an imminently hazardous situation which, if not avoided, will result in death or

serious injury.

WARNING: Indicates a potentially hazardous situation which, if not avoided, could result in death or

serious injury.

CAUTION: Indicates a potentially hazardous situation which, if not avoided, may result in minor or

moderate injury.

CAUTION: Used without the safety alert symbol indicates a potentially hazardous situation which, if not

avoided, may result in property damage.

Parts List & Operating Instructions Form No. 538016, Sheet 1 of 4, Back

Safety Precautions

WARNING : To prevent personal injury and equipment damage,

• Read, understand, and follow all safety precautions and operating instructions included

with this pump. If the operator cannot read these instructions, operating instructions and

safety precautions must be read and discussed in the operator's native language. Only

qualied operators should install, operate, adjust, maintain, clean, repair, or transport

this equipment.

• Wear eye protection that meets ANSI Z87.1 and OSHA standards.

• Before operating the pump, tighten hose connections using the correct tools. Do not

overtighten; connections should be secure and leak free. Overtightening connections

may cause premature thread failure, or high pressure ttings to split at pressures lower

that their rated capacities.

• Should a hydraulic hose ever rupture, burst, or need to be disconnected, IMMEDIATELY

SHUT OFF THE PUMP AND RELEASE ALL PRESSURE. Never attempt to grasp a leaking,

pressurized hose with your hands. The force of escaping hydraulic uid could cause

serious injury.

• Do not subject the hose to potential hazard, such as re, sharp surfaces, extreme heat or cold, or

heavy impact. Do not allow the hose to be altered, kinked, twisted, curled, crushed, cut, or bent

so tightly that the uid ow within the hose is blocked or reduced. Periodically inspect the hose

for wear, because any of these conditions can damage the hose and result in personal injury.

• Do not use the hose to move attached equipment. Stress can damage the hose and cause personal

injury.

• Hose material and coupler seals must be compatible with the hydraulic uid used. Hoses must not

come in contact with corrosive materials, such as creosote-impregnated objects and some paints.

Consult the manufacturer before painting a hose. Hose deterioration due to corrosive materials

can result in personal injury. Never paint couplers.

• Inspect the pump for wear, damage, and correct function before each use. Repair or replace parts

as necessary. Replace worn or damaged safety decals.

• Modication of this pump requires written OTC authorization; contact OTC Technical Services.

• When assembling a system, use components having the same pressure rating as the pump. Do

not exceed the hydraulic pressure rating noted on the pump data plate, or tamper with the internal

high pressure relief valve. Creating pressure beyond the rating can result in personal injury.

• Before replenishing the uid level, completely retract the system to prevent overlling the pump

reservoir. An overll can cause personal injury due to excess reservoir pressure created when the

cylinders are retracted.

• Shut off and disconnect the air supply when the pump is not in use, or before breaking any

connections in the system.

Sheet No.

Issue Date: Rev. C September 19, 2011

Parts List & Operating Instructions Form No. 538016

2 of 4

Operating Instructions

Hydraulic Connections

1. It is necessary to vent the pump before using it. Loosen the oil ll knob by turning it counterclockwise.

(The oil ll knob was installed and tightened to prevent the oil from leaking during shipment.)

2. Clean all the areas around the uid ports of the pump and cylinder.

3. Inspect all threads and ttings for signs of wear or damage, and replace as needed.

4. Clean all hose ends, couplers, and union ends.

5. Remove the thread protector from the hydraulic uid outlet. Connect the hose assembly to the hydraulic

uid outlet, and couple the hose to the cylinder.

Important: Seal external pipe connections with high-grade thread sealant.

Air Connections

1. Remove the thread protector from the air inlet of the pump. Install a threaded tting that is compatible with

your air supply tting.

2. Connect shop air (with an air line lter installed) to the tting, and regulate air supply pressure to between

6 bar (90 psi) and 9 bar (140 psi).

Priming the Pump

1. Press the RELEASE end of the pedal while holding down the air intake valve with a athead screwdriver.

(The air intake valve is located directly under the pedal in the area marked PUMP.)

2. Allow the pump to cycle for approximately 15 seconds.

3. Remove the screwdriver, and press the PUMP end of the pedal. If the cylinder extends and pressure builds,

the pump has been successfully primed. If the pump does not respond, repeat steps 1–3, jogging the air

intake valve while holding the pedal in the RELEASE position.

Operation

1. To extend the cylinder, press the end of the pedal marked PUMP.

2. To hold the cylinder in position, release the pedal.

3. To retract the cylinder, press the end of the pedal marked RELEASE.

Parts List & Operating Instructions Form No. 538016, Sheet 2 of 4, Back

CAUTION: To prevent personal injury,

• Only qualied personnel shall perform inspections and repairs to this air/hydraulic pump.

• Use only those repair parts called out in the parts list in this document. Items found in the parts

list have been carefully tested and selected by OTC.

Bleeding Air from the System

During the rst moments of operation or after prolonged use, air may accumulate within the hydraulic system,

causing the cylinder to respond slowly or in an unstable manner. To remove the air,

1. Position the cylinder at a lower level than the pump. (This allows air to be released through the pump

reservoir.)

2. Run the system through several cycles of extending and retracting the cylinder, free of any load.

Lubrication

If the pump is operated on a continuous duty cycle for extended periods, the manufacturer recommends

installing an automatic air line oiler in the air inlet line, as close to the pumping unit as possible. Set the unit

to feed approximately one drop of oil (SAE No. 10) per minute into the system.

Inspecting the Hydraulic Fluid Level

Check the hydraulic uid level after every 10 hours of use. The uid level should be 19 mm (3/4 inch) from the

ller / vent cap when the cylinder is retracted. Add OTC-approved hydraulic uid—215 SSU@ 38°C (100°F),

if necessary.

1. Retract the cylinder, and disconnect the air supply.

2. Clean the area around the ller/vent plug. Remove the ller/vent plug.

3. Insert a clean funnel with a lter. Add OTC-approved hydraulic uid—215 SSU@ 38°C (100°F)—to a level

19 mm (3/4 inch) from the ller/vent plug.

4. Replace the ller/vent plug.

Draining and Flushing the Reservoir

Drain the reservoir after every 300 hours of use. Dispose of the uid according to local, state, and federal

laws.

1. Release pressure and disconnect the pump from other hydraulic system components (hose, cylinder, etc.).

Clean the pump exterior of dirt and oil.

2. Remove the bolts that hold the pump assembly to the reservoir. Remove the pump assembly, being careful

not to damage the gasket, lter, or safety valve.

3. Drain the reservoir of all uid, and rell half-full using clean hydraulic uid. Rinse the lter clean.

4. Place the pump assembly back onto the reservoir, and secure it using two of the bolts, assembled in

opposite corners of the housing.

5. Press the RELEASE end of the pedal while holding down the air intake valve with a athead screwdriver.

(The air intake valve is located directly under the pedal marked PUMP.) Allow the pump to cycle for

approximately 15 seconds.

6. Drain and clean the reservoir, and ll it with new OTC hydraulic uid to a level of 19 mm (3/4 inch) from

the ller / vent cap when the cylinder is retracted.

Preventive Maintenance

Sheet No.

Issue Date: Rev. C September 19, 2011

Parts List & Operating Instructions Form No. 538016

Troubleshooting Guide

The greatest single cause of failure in hydraulic pumps is dirt. Keep the pump and attached equipment clean

to prevent foreign matter from entering the system. Seal unused couplers with thread protectors. Keep hose

connections free of dirt and oil.

Pump reciprocates, but no

uid delivery. (Cylinder does

not extend.)

Low uid delivery. (The

cylinder extends slowly.)

Pump will not build to

maximum pressure, and

there's no visible leakage.

Pump builds pressure, but will

not hold pressure.

Pump continues to run

slowly even after the desired

pressure has been reached.

There is excess oil spray from

the mufer.

Problem Cause Solution

1. Low uid level.

2. Pump is not primed.

Fluid intake lter contaminated.

4. Overload conditions.

1. Air supply not adequate.

2. Contamination on air side of

pump.

3. Contamination on hydraulic

side of pump.

4. Air in hydraulic system.

1. Air supply not adequate to

obtain maximum pressure.

2. Pressure regulator not set

correctly.

1. Leak in hydraulic system.

1. Output pressure equal to, or

higher than, relief valve setting.

1. Air lubricator is set too rich, if

so equipped.

1. Add hydraulic uid to within 19

mm (3/4 inch) of ller / vent hole.

2. Press RELEASE end of pedal

while holding down air intake

valve. Allow pump to cycle for

approx. 15 seconds.

3. Remove pump assembly from

reservoir, and clean intake lter.

4. Use equipment with sufcient

capacity for the job.

1. Verify air input supply is

5–10

CFM @ 7 bar (100 psi) minimum.

2. Clean air inlet screen on air

side of pump.

3. Remove pump assembly from

reservoir, and clean intake lter.

4. Position cylinder at a lower

level than the pump. Run

system through several cycles

of extending and retracting the

cylinder.

1. Verify air input supply is

5–10

CFM @ 7 bar (100 psi) min.

2. Verify air is regulated at 7 bar

(100 psi) at the pump.

1. Check all hydraulic

connections for leakage, and ret

or repair as needed.

1. Normal operation.

1. Regulate air lubricator to one

drop per minute.

3 of 4

Draining and Flushing the Reservoir continued–

7. Position the pump assembly (with gasket) on the reservoir, and install the bolts. Torque the bolts to 2.8–3.4

N•m (25–30 inch pounds).

8. Drain and clean the other hydraulic components (hoses, cylinders, etc.) before reconnecting them to the

pump. This should prevent contaminated uid from entering the pump again.

65 64

66 62

68 61

44 41

43 39

33 10

Parts List

Parts List & Operating Instructions Form No. 538016, Sheet 3 of 4, Back

Sheet No.

Issue Date: Rev. C September 19, 2011

Parts List & Operating Instructions Form No. 538016

Item

No. Qty. Description Item

No. Qty. Description

Part numbers marked with an asterisk (j) are included in Seal Kit No. 538592.

Part numbers marked with a check mark (4) are included in Pedal Kit No. 538593.

1 1 Oil Reservoir

2 1 Oil Filter

3 1 Oil Filter

4 1 Valve Block

5 1 Screw

6 1 Spring

7 1 Ball Seat

8 1 Steel Ball

9 1 Safety Valve

10 8 Bolt

11 1 Copper Washer

12 1 Pump Cylinder

j13 1 Y-seal

j14 1 Nylon Gasket

15 1 Copper Washer

16 1 Nut

17 1 Spring

j18 1 O-ring

19 1 Air Pump Housing

20 1 Washer

21 1 Pump Plunger

22 1 Air Piston Base

j23 1 O-ring

24 1 Air Shuttle Valve

j25 2 O-ring

26 1 Piston

27 3 Bolt

j28 1 Shuttle Valve Seal

j29 2 O-ring

j30 1 O-ring

31 1 Rear Cover

j32 1 O-ring

j33 1 O-ring

34 1 Bolt

35 1 Fixing Base

j36 2 O-ring

j37 1 O-ring

j38 1 O-ring

39 1 Spring

40 1 Ball Seat

41 1 Steel Ball

j42 1 O-ring

j43 1 Nylon Gasket

Parts List continued

4 of 4

44 1 Release Valve

45 1 Ball Seat

46 1 Spring

j47 1 O-ring

48 1 Release Rod

j49 4 O-ring

50 1 Steel Ball

51 1 Spring

52 1 Steel Ball

53 1 Spring

j54 1 O-ring

j55 1 Nylon Gasket

56 1 Coupler

j57 1 Nylon Gasket

j58 1 O-ring

j59 1 Seal

60 1 Cover

61 6 Screw

j62 2 O-ring

63 1 Oil Filter Plug

64 1 Oil Filter Plug

65 1 Screw

66 1 Oil Filter

j67 1 O-ring

j68 1 O-ring

69 1 Mufer

70 1 Fixing Base

71 4 Bolt

72 1 Spring

473 2 Snap Ring

474 1 Shaft

475 1 Foot Pedal

j76 1 O-ring

77 1 Screw

78 1 Air Valve

79 1 Spring

j80 1 Seal

81 2 Bolt

82 1 Air Valve Rod

j83 1 O-ring

j84 1 O-ring

85 1 Coupler

86 6 Copper Washer

EC Declaration of Conformity

I hereby declare that the equipment named here has been designed to

comply with the relevant sections of the above referenced specications

and is in accordance with the requirements of the Directive(s).

Signed by:

Name: Mike Schoenoff

Position: Manager, Mechanical Engineering

Location: Owatonna, Minnesota

Date:

The technical documentation for the machinery is available from

Name: SPX Service Solutions Germany GmbH

Address: Am Dörrenhof 1

85131 Pollenfeld / Preith, Germany

represented by Gary Palmer, Geschäftsführer

We SPX Service Solutions

of 655 Eisenhower Drive

Owatonna, Minnesota 55060-995 USA

in accordance with the following Directive(s):

2006/42/EC The Machinery Directive

hereby declare that:

Equipment Air / Hydraulic Pump

Model Number 2510A

is in conformity with the applicable requirements of the following

documents:

Ref. No. Title Edition / Date

N/A N/A N/A

English

Español

Français

Deutsch

Declaración de conformidad con EC

Declaro por la presente que el equipamiento nombrado aquí ha

sido diseñado para cumplir con las secciones relevantes de las

especicaciones anteriormente indicadas y está de acuerdo con

los requisitos de la(s) Directiva(s).

Firmado por:

Nombre: Mike Schoenoff

Puesto: Director, Ingeniero mecánico

Ubicación: Owatonna, Minnesota

Fecha:

La documentación técnica de la maquinaria se encuentra

disponible en

Nombre: SPX Service Solutions Germany GmbH

Dirección: Am Dörrenhof 1

85131 Pollenfeld / Preith, Alemania

representado por Gary Palmer, Geschäftsführer

Nosotros SPX Service Solutions

de 655 Eisenhower Drive

Owatonna, Minnesota 55060-995 EE.UU.

de acuerdo con la(s) siguiente(s) Directiva(s):

2006/42/EC La directiva de la maquinaria

por la presente declara que:

Equipo Bomba de aire / hidráulica

Número de modelo 2510A

está en conformidad con los requerimientos aplicables de los

siguientes documentos:

N°. de ref. Título Edición / Fecha

N/A N/A N/A

Déclaration de conformité européenne

Je déclare par la présente que l’équipement, désigné ici

présent, a été conçu conformément aux articles appropriés des

spécications susmentionnées et respecte les exigences de la

ou des Directives.

Signé par :

Nom : Mike Schoenoff

Fonction : Responsable du génie mécanique

Lieu : Owatonna, Minnesota

Date :

La documentation technique de la machinerie est disponible

auprès de

Nom : SPX Service Solutions Germany GmbH

Adresse : Am Dörrenhof 1

85131 Pollenfeld/Preith, Allemagne

représenté par Gary Palmer, Geschäftsführer

Nous, SPX Service Solutions

résidant au 655 Eisenhower Drive

Owatonna, Minnesota 55060-995, États-Unis

en vertu de la ou des directives suivantes :

2006/42/EC Directive « Machines »

déclarons par la présente que :

L’équipement Pompe oléopneumatique

Numéro de modèle 2510A

est conforme aux exigences applicables des documents

suivants :

Nº de réf. Titre Édition/Date

S/O S/O S/O

EG-Konformitätserklärung

Ich erkläre hiermit, dass das oben genannte Gerät so entwickelt

wurde, dass es den relevanten Abschnitten der oben angegebenen

Spezikationen entspricht und die Anforderungen der Richtlinie(n)

erfüllt.

Unterschrift:

Name: Mike Schoenoff

Stellung: Manager, Mechanical Engineering

Standort: Owatonna, Minnesota

Datum:

Die technischen Unterlagen für dieses Gerät sind erhältlich bei

Name: SPX Service Solutions Germany GmbH

Anschrift: Am Dörrenhof 1

85131 Pollenfeld/Preith, Deutschland

vertreten durch Gary Palmer, Geschäftsführer

Wir, SPX Service Solutions

in 655 Eisenhower Drive

Owatonna, Minnesota 55060-995 USA

erklären in Übereinstimmung mit der/den folgende/n Richtlinie(n):

2006/42/EG Maschinenrichtlinie

dass:

Gerät Luft-/Hydraulikpumpe

Modellnummer 2510A

die Anforderungen der folgenden Dokumente erfüllt:

Ref.-Nr. Titel Auage/Datum

n. z. n. z. n. z.

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