OTC 2510A User manual

Sheet No.
Issue Date: Rev. C September 19, 2011
© SPX
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: [phone]
TECH. SERV.: [phone]
FAX: [phone]
ORDER ENTRY: [phone]
FAX: [phone]
INTERNATIONAL SALES: [phone]
FAX: [phone]
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
© SPX
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
© SPX
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.
3. 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.

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

Sheet No.
Issue Date: Rev. C September 19, 2011
© SPX
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.