Sunex Tools 4910B - User Manual

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Overview

Function Description
Important Technical Specifications
Usage Features
Maintenance Features
Warranty Information

This document describes the SUNEX® TOOLS MODEL 4910B CAPACITY: 10 TON PORTABLE RAM KIT, a hydraulic power kit designed for vehicle body and frame repair.

Function Description

The Sunex 4910B Portable Ram Kit is a versatile hydraulic tool used to apply force for pushing, spreading, and straightening operations in vehicle body and frame repair. It consists of a hydraulic pump, a ram (or spreader), a hose, and various attachments and extension tubes. The pump generates hydraulic pressure, which is transmitted through the hose to the ram, causing it to extend and apply force. The kit includes a force gauge to monitor the applied load, ensuring operations stay within safe capacity limits. A release valve allows for controlled retraction of the ram.

Important Technical Specifications

Model: 4910B
Capacity: 10 Ton @ 7,250 psi
Ram Minimum Height: 322mm / 12.68"
Stroke: 130mm / 5.12"
Fluid Capacity: 22 oz.
Compliance: Complies with ASME PASE-2019 Safety Standard.
Components: The kit includes a pump with an integrated hose, a 10-ton ram, a spreader, a case, various extension tubes (4.33", 10.43", 14.37", 20.47"), a ram toe, a plunger toe, a wedge head, a V-base, a male connector, a serrated saddle, a rubber head, a flat base, and a pressure gauge.
Rated Capacities of Attachments:
- Spreader Capacity: 100% of Ram Capacity
- Plunger Toe Capacity: 100% of Ram Capacity (50% when used with plunger toe extension)
- Ram Capacity: 100%
- Rubber Head Capacity: 100% of Ram Capacity
- Extension Tubes: Reduce overall system capacity; shortest tubes should be placed farthest from the cylinder.
- Spreader Rams: Rated at 1/2 ton capacity.
- Rubber Heads: Rated at 1/2 ton capacity in 4-ton kits and 1 ton capacity in 10-ton kits.

Usage Features

Setup:
- Before operation, the force gauge (P39) must be installed by threading it into the gauge fitting (P41) and connecting it with the receiver (P42).
- Air purging of the hydraulic system is performed by opening the release valve (P29) and pumping the handle several times.
- The ram (02) or spreader (03) is connected to the hose (P30) using quick disconnect fittings, hand-tightening the threaded sleeve (R15) on the ram female coupler (R16) to the male coupler (P31) on the hose.
Operation:
- The pump (1) can be operated horizontally or vertically, but must point downwards when used vertically.
- All hydraulic and attachment connections must be fully engaged and tight to ensure straight ram force and prevent off-center loads.
- The hose (P30) should be routed to avoid kinks, twists, curls, or bends, and protected from extreme heat, cold, sharp surfaces, abrasion, impact, and kinking. It should not be used to carry kit components.
- To extend the ram, the release valve knob (P29) is turned clockwise until tight, then the handle (P34) is pumped.
- To retract the ram and release pressure, the release valve knob (P29) is turned counterclockwise slowly.
- The force gauge (14) must always be used to monitor the load and ensure it stays within the required force range.
- An overload valve is integrated into the pump, activating at the pump's rated capacity. For setups requiring reduced ratings, the operator must rely on the gauge to stop pumping.
- The ram must be fully retracted before disconnecting the hose from the cylinder.
- Dust caps (P32) should be used to prevent contaminants from entering the hydraulic system when disconnecting components.
Safety Warnings:
- Always read and understand the manual thoroughly before operation.
- Wear eye protection (ANSI Z 87.1 and OSHA standards).
- Never exceed the rated capacity of the kit or its lowest-rated component.
- Do not overextend rams.
- Ensure attachments and extension tubes are aligned and fully engaged.
- Tighten all hose, gauge, and manifold connections securely by hand; do not overtighten.
- In case of hose rupture or burst, immediately shut off the pump and open the release valve. Never grasp a leaking pressurized hose or fitting.
- Use the kit only for its intended purpose of vehicle body/frame repair.
- Only use components supplied with the kit; no alterations or modifications.

Maintenance Features

Storage: Store the kit in a well-protected area, away from inclement weather, corrosive vapors, abrasive dust, and other harmful elements.
Cleaning: The kit must be cleaned of water, snow, sand, grit, oil, grease, or other foreign matter before use. External surfaces of kit components can be cleaned with a mild soap solution, but avoid moving hydraulic components.
Hydraulic Fluid:
- Hydraulic fluid may need to be added to the pump's reservoir (P6) due to continuous engagement and disengagement of the hose from the cylinder.
- Always fully retract the ram before adding hydraulic fluid.
- Do not overfill.
- Use only hydraulic jack oil, Chevron Hydraulic Oil AW ISO 32, or equivalent Unocal Unax AW 150. Other fluids will damage hydraulic seals.
- Important: Never use alcohol, hydraulic brake fluid, or transmission oil in the pump to prevent seal damage and kit failure.
Labels: The kit owner is responsible for keeping all kit labels clean and readable.
Repairs: Do not attempt hydraulic repairs unless you are a qualified hydraulic repair person. Repairs must be performed by an authorized service center.
Troubleshooting (Ram will not lift rated load):
- Turn the reservoir fill screw (P7) counterclockwise two full revolutions, wait 10 seconds, then turn it clockwise until tight and pump.
- If the problem persists, check the pump reservoir's fluid level. The proper amount is 22 ounces. Use only hydraulic jack oil.
- For other problems, contact a Sunex hydraulic service center.

Warranty Information

Warranty Period: ONE-YEAR warranty.
Coverage: Sunex Tools will repair or replace, at its option, any part or unit defective in material or workmanship.
Exclusions: Does not cover damage from alteration, abuse, misuse, or repairs/replacements made by unauthorized personnel. Sunex Tools is not liable for incidental or consequential damages.
Service: Return equipment or parts to an authorized service center, transportation prepaid, with name, address, proof of purchase, and description of the defect.
Parts Availability: Repair kits and replacement parts are available for many Sunex Tools products, regardless of warranty status.