Sunex HD 5740AH Owner'S Manual Download Page 1

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ASSEMBLY INSTRUCTIONS

CONTINUED

Stand unit upright

Slide bed above holes and

hold in place

Secure pins underneath bed, one at a time

WARNING

Pins must be COMPLETELY through BOTH SIDES of frame.

Let bed rest on inserted pins

Place 3rd and 4th pin on each side

Secure pins completely through bed and frame.

WARNING

ALL FOUR (4) pins must be COMPLETELY through BOTH SIDES
of frame in order to operate press.

Cross-section of press

Front view

Use bolts, washers and nuts to attach
Z Bar to both sides of the press.

Note:

Check all bolts for tightness.

If press rocks, or is not level, loosen press
feet slightly to compensate and retighten.

WARNING

Bed must be at the BOTTOM of the frame
before proceeding to the next step.

ASSEMBLY INSTRUCTIONS

CONTINUED

Front view

Slide bed down to bottom of frame

Note:

When sliding bed to frame

bottom, DO NOT use bed handles.

PUMP INSTRUCTIONS

WARNING

DO NOT attempt to operate pump unless the BREATHER VALVE IS OPEN.
Valve is closed prior to shipping to prevent the loss of hydraulic fluid.

CAUTION

HAND TIGHTEN VALVE ONLY.
Excess pressure could
damage the valve assembly.

CAUTION

DO NOT TURN RELEASE VALVE
MORE THAN ONE FULL TURN
or equipment may be disabled.

WARNING

This symbol alerts you to the possibility of serious injury or death if instructions are not followed.

Failure to heed these warnings may result in loss of load, damage to the press and/or failure resulting in property damage, personal or fatal injury.
This operating manual contains important details concerning the safe operation of this tool.
The user must read and understand these details before any use of the tool.

This manual must be retained for future reference.

2.  CLOSE the valve located on the
  FRONT of the pump assembly by
  turning CLOCKWISE. Connect
  using a 3/8" line. Do not exceed
  air pressure of 90-120 psig.

3. Squeeze air hose trigger until ram

comes into contact with item to be pressed.

4.  Once ram is in contact with the item to be pressed,
  insert pump handle into high pressure cradle. Using
  the high pressure pump moves the ram less with
  each stroke and requires less effort to apply pressure.

5.  To relieve pressure and retract
  ram, turn valve located on FRONT
  of pump assembly ONE FULL
  TURN COUNTERCLOCKWISE.

Air Hose Trigger

High Pressure Cradle

PUMP AND RAM ASSEMBLY INSTRUCTIONS

Note:

There are two sets of holes for bolts.

Use centermost holes on the side.

Note:

Hose from pump’s outer side must

run BEHIND the frame. Hose with nozzle will
be used later.

This end up

Top of press frame, looking down

This end up

Note:

Allow ram to rest on press

bed while installing pump.

Note:

Handle ram carefully to avoid damage to gauge or gauge face.

Do not disconnect hoses prior to assembly.

Note:

Position press feet on each side of the press.

Attach one bolt, washer and nut on each side.
Bolts should be attached

OFFSET

from one another.

Front view

Stand frame upside down

Slide bed onto frame

Slide bed down to bottom of frame

ASSEMBLY INSTRUCTIONS

Inside of frame

WARNING

Be aware of jagged edges
on frame. Not all welds are smooth.
Press bed can pinch or crush fingers.
Wear safety gloves.

Note:

In the upright position,

inner bracing should form an
inverted "v" with the narrower
space facing the top of the press.

Note:

Air motor

must be operating
at the same time.

PROCEDURE FOR BLEEDING AIR

1.  Turn valve handle on FRONT of
  pump CLOCKWISE until closed.
  DO NOT OVERTIGHTEN.

3. Move press bed into highest position
and lock bed into place with all four pins.

Air Hose Trigger

WARNING

Do not allow the ram to
extend more than 5.5".

4. Place press plates DIRECTLY
under ram, on press bed.

7.  Squeeze trigger on air hose.
  Air will enter motor and extend
  the ram. Pump ram against press
  plates until gauge reads "5 Tons".

8.  Insert pump handle into HIGH
  PRESSURE CRADLE for more precise
  control. Pump ram against press
  plates until gauge reads "10 Tons".

High Pressure Cradle

US TONS

WARNING

DO NOT attempt to operate pump unless the BREATHER VALVE IS OPEN.
Valve is closed prior to shipping to prevent the loss of hydraulic fluid.

CAUTION

Bed must be in UP position, or
you will over extend ram.

PARTS LIST

Press Frame - 1

Press Bed - 1

Press Feet - 2

Z Bar - 1

1/2"-13 x 1-1/2"
Hex Head Bolts - 10

1/2" Nuts - 10

Washers - 10

1-1/4" x 14" Press Pins - 4

Air Motor
Pump and Ram - 1

Pump Extension Handle - 1

1" x 3" x 14"
Press Plates - 2

Accessory only -

Not needed for assembly

Pushing Adapter - 1

Accessory only -

Not needed for assembly

Bearing Shield - 1

Accessory only -

Not needed for assembly

ESTIMATED ASSEMBLY TIME: 30 MINUTES

Examine box contents, then proceed with the following instructions.

TOOLS NEEDED

3/4" and 9/16" sockets and wrenches

ACCESSORIES

WARNING

Leg ends and press feet are sharp
and potentially dangerous. Wear
safety gloves and safety goggles.

Top view of pump

REPLACEMENT PARTS LIST

Air/Hydraulic Shop Press

Only items identified by part number are available separately.

1.  BEFORE OPERATING PUMP, open
  petcock valve (breather) located
  on TOP of pump assembly by
  turning COUNTERCLOCKWISE.

5. Put cradle in the
DOWN position. Use an
adapter on your air
hose and allow air to
flow through the
opening in the petcock
valve into the pump.

6.  Air that has flowed into the pump
  causes the cradle to move up and
  the ram to move down. If this happens,
  proceed to step 7. If not, check all
  hoses and connections and repeat
  the procedure.

9.  Turn valve handle on pump
COUNTERCLOCKWISE
  a maximum of one (1)
  turn to open valve.
  Ram will retract as
  pressure is released.

2.  Turn petcock valve
  (breather) on TOP of pump
  COUNTERCLOCKWISE to open.

SAFETY INFORMATION

This symbol alerts you to the possibility

of serious injury or death if instructions

are not followed.

This symbol alerts you to the possibility

of damage to or destruction of equipment

if instructions are not followed.

Failure to heed these warnings may result in loss

of load, damage to the press and/or failure resulting

in property damage, personal or fatal injury. This

operating manual contains important details concern-

ing the safe operation of this tool. The user must read and understand these details

before any use of the tool. This manual must be retained for future reference.

• Read, study, understand and follow all instructions before operating this press.

• Always wear safety goggles, (users and bystanders).

• Parts being pressed may splinter, shatter, or be ejected from the press at a dangerous

rate of speed. Because there are a variety of press applications, it is the responsibility

of the press owner to provide adequate guards, eye protection and protective clothing

to the press operator.

• Visual inspection of the press should be made before use, checking for signs of cracked

welds, bent bed pins, loose or missing bolts, leaks, or any other structural damage.

Corrections must be made before using the press.

• Do not go near leaks. High pressure hydraulic ﬂuid can puncture skin and cause serious

injury, gangrene, or death. If injured, seek emergency medical help as immediate

surgery is required to remove the ﬂuid.

• Prior to use make sure the press is securely anchored to a concrete ﬂoor.

• Keep hands, arms, feet, and legs out of work area. Accidental slippage can result in

personal injury.

• Always use an accurate force gauge to measure pressing force.

• Do not exceed the rated capacity or tamper with the pressure/force settings. When

attachments and adapters are used the rated capacity of the system shall be no greater

than the rated capacity of the lowest rated component or combination of components

that make up the system.

• Avoid off-center loads. Offset loads can damage ram and may cause load to eject at a

dangerous rate of speed. Do not use any spacer or extender between the press ram

plunger and the item being pressed. If there is not enough ram stroke, adjust the height

of the movable bolster.

• Remove all loads from movable bolster before attempting to adjust bolster height.

Beware of possible falling bolster.

• Press only on loads supported by movable bolster and press plates included. Do not

support loads on ﬂoor or press frame legs.

• When using any accessories such as press plates or arbor plates, be certain they are

centered on the movable bolster and in full contact with both sides of the bolster.

• Before applying load, be certain all movable bolster supporting pins are fully engaged.

Verify lift cables (if equipped) are slack before pressing on the bolster.

• Always use a bearing shield when pressing bearings.

• Use caution when positioning work to be pressed to ensure the item to be pressed

cannot be ejected at a dangerous rate of speed.

• Release hydraulic pressure before loosening any ﬁttings.

• Maintain proper hydraulic ﬂuid levels.

• Do not make any alterations or modiﬁcations to the press.

• This product may contain one or more chemicals known to the State of California to

cause cancer and birth defects or other reproductive harm.

Wash hands thoroughly

after handling.

• Failure to heed and understand these markings may result in serious or fatal personal

injury and/or property damage.

OWNER/USER RESPONSIBILITY

The owner and/or user must have an understanding of the manufacturer's

operating instructions and warnings before using this press. Personnel involved

in the use and operation of equipment shall be careful, competent, trained,

and qualiﬁed in the safe operation of the equipment and its proper use when

servicing motor vehicles and their components. Warning information should

be emphasized and understood.

If the operator is not ﬂuent in English, the manufacturer's instructions and

warnings shall be read to and discussed with the operator in the operator's

native language by the purchaser/owner, making sure that the operator

comprehends its contents.

Owner and/or user must study and maintain for future reference the

manufacturer’s instructions. Owner and/or user is responsible for keeping all

warning labels and instruction manuals legible and intact. Replacement labels

and literature are available from the manufacturers.

INSPECTION

Visual inspection of the shop press should be made before each use of the

press, checking for damaged, loose or missing parts. Each press must be

inspected by a manufacturer’s repair facility immediately, if subjected to an

abnormal load or shock. Any press which appears to be damaged in any way,

is found to be badly worn, or operates abnormally must be removed from

service until necessary repairs are made by a manufacturers's authorized repair

facility. It is recommended that an annual inspection of the press be made by

a manufacturer’s authorized repair facility and that any defective parts, decals

or warning labels be replaced with manufacturer’s speciﬁed parts. A list of

authorized repair facilities is available from the manufacturer.

SAFETY INSTRUCTIONS

• CHECK YOUR LOCAL, STATE AND FEDERAL REGULATIONS

REGARDING THE SAFE USE OF THIS EQUIPMENT.

• Your safety is top priority. Please handle equipment with care.

• Fully retract unit and remove all items from the press bed frame.

• Support the press bed, and remove the pins.

• Raise or lower bed to desired height and reinstall press pins. Be certain

pins are fully engaged in the parallel ﬂanges of the upright columns.

• Position press on a ﬂat, level, hard surface, preferably concrete.

Make sure all nuts and bolts are tight.

• Clear the area of bystanders, especially small children, before using.

• Set the press bed to the required height. The press is most effective

when the work piece is located 1 inch below the ram’s retracted position.

The compression stroke can include the entire 5 inch working range.

• The press is designed to exert a force on anything which is positioned

beneath its ram. The work piece can pop out from under the ram at a

high rate of speed and injure someone.

• Pressing Bearings: It is essential that you use the bearing shield when

pressing bearings on or off.

LIMITED WARRANTY:

SUNEX INTERNATIONAL, INC. WARRANTS TO ITS CUSTOMERS THAT THE
COMPANY’S SUNEX TOOLS

BRANDED PRODUCTS ARE FREE FROM

DEFECTS IN WORKMANSHIP AND MATERIALS.
Sunex International, Inc. will repair or replace its Sunex Tools

branded products

which fail to give satisfactory service due to defective workmanship or materials,
based upon the terms and conditions of the following described warranty plans
attributed to that speciﬁc product. This product carries a ONE-YEAR warranty.
During this warranty period, Sunex Tools

will repair or replace at our option any

part or unit which proves to be defective in material or workmanship.

Other important warranty information....

This warranty does not cover damage to equipment or tools arising from
alteration, abuse, misuse, damage and does not cover any repairs or replace-
ment made by anyone other than Sunex Tools

or its authorized warranty

service centers. The foregoing obligation is Sunex Tools

’ sole liability under

this or any implied warranty and under no circumstances shall we be liable for
any incidental or consequential damages.

Note: Some states do not allow the

exclusion or limitation of incidental or consequential damages, so the above
limitation or exclusion may not apply to you.

Return equipment or parts to Sunex Tools

, transportation prepaid. Be certain to

include your name and address, evidence of the purchase date, and description
of the suspected defect.
If you have any questions about warranty service, please write to Sunex Tools

This warranty gives you speciﬁc legal rights and you may also have other rights
which vary from state to state. Repair kits and replacement parts are available
for many of Sunex Tools

products regardless of whether or not the product is

still covered by a warranty plan.

SHIPPING ADDRESS:

MAILING ADDRESS:

Sunex Tools

315 Hawkins Rd.

P.O. Box 4215

Travelers Rest, South Carolina 29690

Greenville, South Carolina 29608

WARNING

CAUTION

THIS OPERATING MANUAL CONTAINS IMPORTANT SAFETY INFORMATION. READ CAREFULLY AND UNDERSTAND ALL
INFORMATION BEFORE OPERATING THIS TOOL. SAVE THIS MANUAL FOR FUTURE USE.

5740AH - 40 Ton Air/Hydraulic Shop Press

5750AH - 50 Ton Air/Hydraulic Shop Press

Sunex Part No. Total Height

Inside Width

Press Feet Length Bed Width

Ram Stroke

Pin Diameter

PB Winch Sliding Head Press Plates Included

5740AH

74" 35" 29.75" 8.25" 6" 1.25" Y Y Y(2)

5750AH

74" 35" 29.75" 8.25" 6" 1.25" Y Y Y(2)

PRESS SPECIFICATIONS

OWNER'S MANUAL

CONTENTS:

Page 1 Specifications

2 Safety Information and Warranty Information
3 Parts List

4-6 Assembly Instructions

7
8
9

Pump and Ram Assembly Instructions
Procedure for Bleeding Air
Pump Instructions

10-11 Winch Kit Parts List and Winch Installation Instructions

12 Replacement Parts List

5740AH, 5750AH

rev. 12/05/14

5740AH - 40 Ton Air/Hydraulic Shop Press

5750AH - 50 Ton Air/Hydraulic Shop Press

5740AH - 40 Ton Air/Hydraulic Shop Press

5750AH - 50 Ton Air/Hydraulic Shop Press

5740AH - 40 Ton Air/Hydraulic Shop Press

5750AH - 50 Ton Air/Hydraulic Shop Press

5740AH - 40 Ton Air/Hydraulic Shop Press

5750AH - 50 Ton Air/Hydraulic Shop Press

5740AH - 40 Ton Air/Hydraulic Shop Press

5750AH - 50 Ton Air/Hydraulic Shop Press

5740AH - 40 Ton Air/Hydraulic Shop Press

5750AH - 50 Ton Air/Hydraulic Shop Press

5740AH - 40 Ton Air/Hydraulic Shop Press

5750AH - 50 Ton Air/Hydraulic Shop Press

5740AH - 40 Ton Air/Hydraulic Shop Press

5750AH - 50 Ton Air/Hydraulic Shop Press

5740AH - 40 Ton Air/Hydraulic Shop Press

5750AH - 50 Ton Air/Hydraulic Shop Press

5740AH - 40 Ton Air/Hydraulic Shop Press

5750AH - 50 Ton Air/Hydraulic Shop Press

5740AH - 40 Ton Air/Hydraulic Shop Press

5750AH - 50 Ton Air/Hydraulic Shop Press

5740AH, 5750AH 2

rev.

12/05/14

5740AH, 5750AH 3

rev.

12/05/14

5740AH, 5750AH 4

rev.

12/05/14

5740AH, 5750AH 5

rev.

12/05/14

5740AH, 5750AH 6

rev.

12/05/14

5740AH, 5750AH 7

rev.

12/05/14

5740AH, 5750AH 8

rev.

12/05/14

5740AH, 5750AH 9

rev.

12/05/14

5740AH, 5750AH 10

rev.

12/05/14

5740AH, 5750AH 11

rev.

12/05/14

5740AH, 5750AH 12

rev.

12/05/14

PUMP AND RAM EXPLODED PARTS DIAGRAM

8.886"

9.113"

ITEM NO. DESCRIPTION

QTY.

Base Weldment

Plug

* Polypak Seal (Parker)

1/2-13 x 2 Hex HD C-S GR 2 Zinc

Piston

* O-Ring (Parker)

Rod

Retaining Ring Int. 3.5 NOM

Piston Guide

Retractor Plate

Spring

Fitting Gauge 1.75

Gauge

90˚ Elbow 1/4 NPTF to -6 JIC

Hose Hydraulic 41 1/2 LG 7/16-20 JICF 1

RAM

PUMP

ITEM NO. DESCRIPTION

QTY.

Tank

Tie Rod

1" Piston Body

1/2" Piston Body

1" Piston

1/2" Piston

1/4" MNPT Pressure Plug

Pump Body

Pump Lid

Pump Bracket

Valve Assembly

Pivot Pin

* 5/16" Steel Ball

Brass Drain Cock

Cradle Assembly

Hydraulic Hose 41-1/2" L 7/16-20 JICF 1

7/16-14 Fin Hex Nut Zinc

* O-Ring

* 3-1/2" Seal

* 3-5/16" Seal

* 3-3/16" Seal

SHCS 7/16 14 x 1/2"

SHCS 7/16 14 x 3/4"

* Light Spring

* Heavy Spring

7/16" Split Lock Washer

Pump Filter

Pump Fitting 1/4" MNPT 7/16" JICF

7/8" Grip

Handle for Pump

* O-Ring

# 23 (Pump)

QTY: 1

# 21 (Pump)

QTY: 2

# 19 (Pump)

QTY: 1

# 22 (Pump)

QTY: 1

See Replacement Parts List for parts available separately.
Parts with (*) are only available in Seal Kit, part number RSCBP1217.

# 3 (Ram)

(

Poly Pak - Note: Only the upper

seal normally needs replacement)

QTY: 1

# 33 (Pump)

(

O-Ring for # 11

Valve Assembly

on Pump)

QTY: 1

# 6 (Ram)

QTY: 1

# 20 (Pump)

QTY: 1

# 13 (Pump)

QTY: 5

26 24

# 26 (Pump)

QTY: 2

# 27 (Pump)

QTY: 2

Individual parts pictured are components of the Seal Kit, RSCBP1217.

Air Motor not shown

5740AH - 40 Ton Air/Hydraulic Shop Press

5750AH - 50 Ton Air/Hydraulic Shop Press

5740AH, 5750AH 13

rev.

12/05/14

ITEM NO. SUNEX PART NO.

DESCRIPTION

QTY.

RS345009

2" Pushing Adaptor (Spring)

Press Bed

Press Frame

Ram Frame

RSCBP1225

Press Pin

RS310012

Pushing Adapter

RSBS1

Bearing Shield

RSCBP1205

Press Plate

RSCBP1211

Press Feet

RSCBP1212

Z Bar

RSCBP1209

Pump Handle

RS40AOPAM

Pump (with air motor)

RSCBP1202

Ram (includes gauge) (5740AH)

RSCBP1202GG

Ram (includes gauge) (5750AH)

RSCBP1206

Gauge (5740AH)

RSCBP1206G

Liquid Filled Gauge (5750AH)

ITEM NO.

SUNEX PART NO.

DESCRIPTION

QTY.

RSCBP1204

Hose & Fitting

RSCBP1217

Seal Kit for Pump and Ram (not shown)

RS40MPPHK

Press Hardware Kit

1 set

1/2"-13 x 1-1/2" Hex Head Bolt

1/2" Nut

Washer

RSAAMO2

Air Motor (shown with pump)

19 RS4050WCH Winch

not shown RSWHK

Winch Hardware Kit

1 set

Cable Clamp

1/2"-13 x 1-1/2" Hex Head Bolt

1/2" Nut

Washer

Winch

Short Cable (includes eye bolt)

Long Cable

not shown RS5740AHLK

Product Label Kit

not shown RS5750AHLK

Product Label Kit

Dark Gray- Long Cable

Light Gray- Short Cable

1. Move press bed into LOWEST position
so it is resting on top of pins 1 and 2.

Right side of press

3.  Thread the BARE end of the LONGER
  of the two steel cables up and through
  the pump bracket.

Right side of press,

under pump assembly

2. Install pre-attached eye bolt on LONGER
cable to press bed handle located

under

pump assembly

. DO NOT FULLY TIGHTEN.

  Center with side of press bed and make
  sure there is enough room to lower or raise
  both nuts on eye bolt for precise alignment.

WARNING

DO NOT FULLY TIGHTEN.

WINCH KIT PARTS LIST

Winch - 1

Long Cable - 1

Short Cable- 1

Cable Clamp - 1

1/2"-13 x 1-1/2"

Hex Head Bolts - 2

1/2" Nuts - 2

Washers - 2

WINCH INSTALLATION INSTRUCTIONS

4.  Run the long cable up and OVER
  BOTH ROLLER BRACKETS and feed
  into winch.

Be sure to thread 12 inches

(1 foot) of extra cable through winch.

5.  Once winch cable has been threaded, pull excess
  cable back through winch as shown in diagram
  above. The cable should be locked tightly around
  itself with no excess cable left hanging. Operate
  winch enough to remove slack from longer cable.

WARNING

Mount winch to frame
AFTER threading cable.

6.  Mount winch to frame using the
  provided washers, 1/2" nuts and
  1/2"-13 x 1-1/2" bolts.

Left side of press, under winch

8. Install pre-attached eye bolt on SHORTER cable to press bed
handle located under winch

after feeding it around in step 7

7. Feed the short cable by running it up and OVER first roller, then UNDER second roller. Loop the short cable back toward the winch and securely attach to the longer cable
using the cable clamp. Remove slack from short cable before securing to long cable. Clamp should be NO LESS THAN ONE INCH (1") from roller.

9. Turn eye hooks to adjust and level press bed. Once bed is level,
  firmly tighten eye hook mounting hardware. The steel cable
  will stretch with use. It may be necessary to repeat this leveling
  procedure in the future.

10. Test the winch kit by raising and lowering the press bed from

its lowest to highest position. Repeat and adjust until bed is

level and moves freely throughout its entire range of motion.

Cut excess cable when all adjustments are complete.

LONG CABLE top view of press

Top view of press with bed in lowest position

This end feeds into winch.

SHIPPING ADDRESS:

Sunex Tools
315 Hawkins Rd.
Travelers Rest, South Carolina 29690

MAILING ADDRESS:

Sunex Tools
P.O. Box 4215
Greenville, South Carolina 29608

Note: