Sunex Tools 6603 User manual

6603 1
Visual inspection should be made before each use of the jack, checking for leaking hydraulic fl uid and dam-
aged, loose or missing parts. Each jack must be inspected by a manufacturer’s repair facility immediately,
if subjected
to an abnormal load or shock. Any jack 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 manu-
facturer’s authorized repair facility. It is recommended
that an annual inspection of the jack be made by a
manufacturer’s authorized repair facility and that any
defective parts, decals or warning labels be replaced
with manufacturer’s specifi ed parts.
A list of authorized repair facilities is available from
the manufacturer.
6603 1 Rev. 10/19/05
Description
Model 6603 service jack is a self-contained device designed for lifting, but not sustaining, a partial vehicular
load. It consists of a frame with wheels and swivel casters supporting a mechanism that actuates a pivoting
lift arm equipped with a saddle. It is designed for use by professional auto mechanics.
Air may become trapped in the hydraulic system during transit. To purge air:
1. Open release valve by turning handle counterclockwise.
2. Pump handle rapidly 4 full strokes. This will expel air that may have entered oil passages during transit.
3. Close release valve by rotating handle clockwise and pump handle.
4. If lift arm raises to full height, jack is ready for use. If not, repeat this procedure or follow the
troubleshooting instructions provided.
Before Use
Inspection
6603
3 TON CAPACITY
SERVICE JACK
SERVICE JACK SERVICE JACK
THIS IS A LIFTING DEVICE ONLY. DO NOT MOVE OR
DOLLY THE VEHICLE WHILE ON THE JACK. IMMEDIATELY
AFTER LIFTING SUPPORT THE VEHICLE WITH AP PRO PRI ATE
MEANS.
DO NOT OVERLOAD. OVERLOADING CAN CAUSE DAM AGE
TO OR FAILURE OF THE JACK.
LIFT ONLY ON AREAS OF THE VE HI CLE AS SPEC I FIED BY THE
VEHICLE MAN U FAC TUR ER.
CENTER LOAD ON SADDLE PRI OR TO LIFT ING. OFF-CENTER
LOADS MAY CAUSE DAM AGE TO JACK, LOSS OF LOAD,
PROPERTY DAMAGE, PERSONAL OR FATAL INJURY.
THIS JACK IS DESIGNED FOR USE ONLY ON HARD LEVEL SUR-
FAC ES CAPABLE OF SUS TAIN ING THE LOAD. USE ON OTHER
THAN HARD LEVEL SUR FAC ES CAN RE SULT IN JACK IN STA BIL-
I TY AND POSSIBLE LOSS OF LOAD.
NO ALTERATIONS TO THE JACK SHALL BE MADE.
READ, STUDY AND UN DER STAND THE OP ER AT ING MAN U AL
PACKED WITH THIS JACK BEFORE OP ER AT ING.
FAILURE TO HEED THESE WARNINGS MAY RE SULT IN LOSS
OF LOAD, DAMAGE TO JACK, AND/OR FAIL URE RE SULT ING
IN PROP ER TY DAMAGE, PERSONAL OR FATAL INJURY.
WARNING
▲
!
▲
WARNING
FOR YOUR SAFETY
AND TO PREVENT INJURY:
Use Service Jack for
Lifting Purposes ONLY.
Always Support Vehicle with
Support Stands
!
Model 1003
3 TON
CAPACITY
RATCHETING
JACK STAND
▲ WARNING
!
ENSURE BOTH STANDS ARE SET AT SAME HEIGHT & HOLDING DOGS ARE FULLY ENGAGED.
USE STANDS IN PAIRS, ON HARD, LEVEL SURFACES CAPABLE OF SUSTAINING THE LOAD.
LOAD & STANDS SHALL BE STABLE. USE ON OTHER THAN HARD, LEVEL SURFACES MAY
RESULT IN POSSIBLE LOSS OF LOAD.
READ, STUDY & UNDERSTAND THE INSTRUCTION MANUAL PACKED WITH THIS STAND
BEFORE USING STAND.
FAILURE TO HEED THESE WARNINGS MAY RESULT IN LOSS OF LOAD, DAMAGE TO STAND,
AND/OR FAILURE RESULTING IN PROPERTY DAMAGE, PERSONAL OR FATAL INJURY.
DO NOT OVERLOAD STAND. OVERLOADING CAN CAUSE DAMAGE TO, OR FAILURE OF,
THE STAND.
INSPECT EACH STAND TO BE SURE IT IS IN GOOD CONDITION.
NO ALTERATIONS TO THE STAND SHALL BE MADE.
PLACE LOAD IN THE CENTER OF THE SADDLE ONLY.
USE SUPPORT POINTS SPECIFIED BY VEHICLE MANUFACTURER.
DO NOT CRAWL UNDER VEHICLE WHEN PLACING OR REMOVING STANDS.
Model 1003
3 TON
CAPACITY
RATCHETING
JACK STAND
▲ WARNING
!
ENSURE BOTH STANDS ARE SET AT SAME HEIGHT & HOLDING DOGS ARE FULLY ENGAGED.
USE STANDS IN PAIRS, ON HARD, LEVEL SURFACES CAPABLE OF SUSTAINING THE LOAD.
LOAD & STANDS SHALL BE STABLE. USE ON OTHER THAN HARD, LEVEL SURFACES MAY
RESULT IN POSSIBLE LOSS OF LOAD.
READ, STUDY & UNDERSTAND THE INSTRUCTION MANUAL PACKED WITH THIS STAND
BEFORE USING STAND.
FAILURE TO HEED THESE WARNINGS MAY RESULT IN LOSS OF LOAD, DAMAGE TO STAND,
AND/OR FAILURE RESULTING IN PROPERTY DAMAGE, PERSONAL OR FATAL INJURY.
DO NOT OVERLOAD STAND. OVERLOADING CAN CAUSE DAMAGE TO, OR FAILURE OF,
THE STAND.
INSPECT EACH STAND TO BE SURE IT IS IN GOOD CONDITION.
NO ALTERATIONS TO THE STAND SHALL BE MADE.
PLACE LOAD IN THE CENTER OF THE SADDLE ONLY.
USE SUPPORT POINTS SPECIFIED BY VEHICLE MANUFACTURER.
DO NOT CRAWL UNDER VEHICLE WHEN PLACING OR REMOVING STANDS.
6603_OpMan_101905.indd 1 10/31/05 2:43:42 PM

6603 2
Owner/User
Responsibility
The owner and/or user must have an understanding of the manufacturer’s operating instructions and warn-
ings before using this jack. Personnel involved in the use and operation of equipment shall be careful,
competent, trained, and qualifi ed 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 fl uent in English, the manufacturer’s instructions and warning 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 manufacturers’ 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 manufacturer.
Lubrication
All moving joints require lubrication often. Remove handle and grease the lower end of handle where it
rotates in the handle socket. Grease release valve gears. Using a grease gun, grease the lift arm pivot shaft
grease fi tting until grease appears at the end of the shaft. Grease all lift arm linkages, front wheels and rear
casters.
Maintenance
IMPORTANT: When adding or replacing hydraulic fl uid, always use a quality hydraulic fl uid. DO NOT use
brake fl uid, alcohol, glycerine, detergent motor oil, or dirty oil as improper fl uid can cause serious internal
damage to jack.
To add hydraulic fl uid
:
With saddle fully lowered and jack on level ground, remove fi ller plug (see Fig.1).
The hydraulic fl uid should just cover the surface of the internal cylinder visible through the hole.
If low, add hydraulic fl uid as needed.
NO NOT
overfi ll.
Replace fi ller plug.
Maintenance and Inspection: The owner and/or user must maintain and inspect the jack in accordance with
the manufacturer’s instructions.
Operating
Instructions
IMPORTANT
:
Before attempting to raise a vehicle, check vehicle service manual for reommended lifting surfaces.
1. To raise load: Close release valve tightly (by turning handle clockwise).
DO NOT OVERTIGHTEN.
Position jack under load so that saddle will contact load fi rmly and load is centered so it cannot slip.
Operate jack handle until saddle approaches the load. Once again check to see that saddle is correctly
positioned. Raise load to desired height. Place jack stands of appropriate capacity under the vehicle.
Place jack stands at vehicle manufacturers recommended lift areas that provide stable support for the
raised vehicle.
2. To lower load: Open release valve
VERY SLOWLY
(by turning handle counterclockwise). When release
VERY SLOWLY (by turning handle counterclockwise). When release VERY SLOWLY
valve is opened, saddle and load will be lowered. Lower the vehicle slowly so as not to shock
load the jack stands. Once repairs are completed, raise vehicle enough to remove jack stands. Lower
vehicle very slowly.
CAUTION
: Keep hands or feet away from the hinge mechanism of the jack.
3 TON CAPACITY
SERVICE JACK
DO NOT CRAWL UNDER VEHICLE WHILE LIFTING VEHICLE OR PLACING OR REMOVING
JACK STANDS
JACK STANDS
6603_OpMan_101905.indd 2 10/31/05 2:43:44 PM

6603 3
SPECIFICATIONS
Capacity
..........................
Capacity ..........................Capacity
3 Tons
Low Height
........................
Low Height ........................Low Height
5.68"
High Height
..........................
High Height ..........................High Height
20"
Saddle Diameter
..............
5.125"
Handle Length
......................
40"
Base Length
..........................
26"
Chassis Width
......................
14"
Wheel Width
....................
2.25"
Shipping Weight
...............
Shipping Weight ...............Shipping Weight
95lbs.
Part No.
RS661209
RS661238
RS660307
RS6612SK
RS661212
RS661202
RS661231
RS661225
RS661208
RS661210
RS6612FP
Description
2-1/4" Width Front Wheel
Handle Assembly
Power Unit Assembly
Seal Kit for Power Unit
Saddle
Rear Caster Assembly
Gear (Set of 2)
Torsion Spring
Handle Locking Bolt
Handle Yoke
Filler Plug
Item No.
1
2
3
4
5
6
7
8
9
10
6603
3 Ton Service Jack
WARNIN
G
THIS IS A LIFTING DEVICE ONLY. DO NOT MOVE
OR
DOLLY THE VEHICLE WHILE ON THE JACK. IMMEDI
ATELY
AFTER LIFTING SUPPORT THE VEHICLE WITH
APPROPRIATE MEANS.
DO NOT OVERLOAD. OVERLOADING CAN CAUS E
DAMAGE TO OR FAILURE OF THE JACK.
LIFT ONLY ON AREAS OF THE VEHICLE AS SPECIFIED BY
THE VEHICLE MANUFACTURER.
CENTER LOAD ON SADDLE PRIOR TO LIFTING. OFF-
CENTER LOADS MAY CAUSE DAMAGE TO JACK, LOSS OF
LOAD, PROPERT Y DAMAGE, PERSONAL OR FATAL
INJURY.
THIS JACK IS DESIGNED FOR USE ONLY ON HARD LEVEL
SURFACES CAPABLE OF SUSTAINING THE LOAD. USE ON
OTHER THAN HARD LEVEL SURFACES CAN RESULT IN
JACK INSTABILITY AND POSSIBLE LOSS OF LOA D.
NO ALTERATIO NS TO THE JACK SHALL BE MADE.
READ, STUDY AND UNDERSTAND TH E O PERATING
MANUAL PACKED WITH THIS JACK BEFORE OPERATING.
FAILURE TO HEED THESE WARNINGS MAY RESULT IN
LOSS OF LOAD, DA MAGE TO JACK, AND/OR FAILURE
RESULTING IN PROPERTY DAMAGE, PERSONAL OR FATAL
INJU
RY.
MADE IN CHINA
M
O
D
E
L
#
2-1/4 TON
C
A
P
A
C
I
T
Y
6612UPS
D
ES
C
R
I
PT
IO
N
SERVICE
JACK
M
ADE
IN
C
HINA
™
5
3
6
2
4
1
7
8
Figure1
9
10
Also Available:
RS6612105B Short bolt for
handle yoke
RS6612106B Long bolt for
handle yoke
RS661206-1 E-Clips for
front wheels
6603_OpMan_101905.indd 3 10/31/05 2:43:53 PM

6603 4
PROPER STORAGE
It is recommended that this jack be stored in a dry location with all wheels touching the ground on a relatively level surface.
TROUBLESHOOTING
Important: Service jacks are self-contained devices used for lifting, but not sustaining, a partial vehicular load. In accordance with
ASME-PALD standard, section 10-4.1.2 Load Sustaining Test: “A load not less than the rated capacity…shall not lower more than 1/8”
(3.18mm) in the first minute, nor a total of .1875” (4.76mm) in 10 minutes.” Leak down within this range is considered normal opera-
tion and is NOT a warrantable defect.
PROBLEM
Jack will not lift load or
leaks down excessively
Jack will not hold load
or handle rises
Jack will not lift to
its full height
Jack will not lower
completely
Jack will not lift smoothly
Jack will not lift smoothly
or jack feels spongy
Jack will not lift smoothly
or jack feels spongy
Jack will not lift smoothly
The release valve is not closed. Turn the valve clockwise tightly. If this does not
work, remove handle, lubricate handle receptacle and handle end, then retry.
The release valve is not closed. Turn the valve clockwise tightly. If this does not
work, remove handle, lubricate handle receptacle and handle end, then retry.
The release valve is not closed. Turn the valve clockwise tightly. If this does not
Low on hydraulic fluid. Refill the jack to the correct level of
hydraulic fluid, using an approved hydraulic fluid or jack oil.
Low on hydraulic fluid. Refill the jack to the correct level of
hydraulic fluid, using an approved hydraulic fluid or jack oil.
Low on hydraulic fluid. Refill the jack to the correct level of
Pump seals or back-up ring may be defective. Clean hydraulic fluid passages,
replace seals and refill hydraulic fluid. (Must be serviced by qualified service
Pump seals or back-up ring may be defective. Clean hydraulic fluid passages,
replace seals and refill hydraulic fluid. (Must be serviced by qualified service
Pump seals or back-up ring may be defective. Clean hydraulic fluid passages,
center)
The hydraulic system has trapped air. Open the release valve, pump handle
rapidly (4) full strokes to purge air, close release valve.
The hydraulic system has trapped air. Open the release valve, pump handle
rapidly (4) full strokes to purge air, close release valve.
The hydraulic system has trapped air. Open the release valve, pump handle
Return spring is broken or linkages are binding. Replace spring if broken. Grease
pivot shaft and all lift arm linkages.
Return spring is broken or linkages are binding. Replace spring if broken. Grease
pivot shaft and all lift arm linkages.
Return spring is broken or linkages are binding. Replace spring if broken. Grease
Discharge ball is not sealing hydraulic system and oil may be dirty. Manually flush
hydraulic system. Open the release valve, as required, to raise and lower the lift
Discharge ball is not sealing hydraulic system and oil may be dirty. Manually flush
hydraulic system. Open the release valve, as required, to raise and lower the lift
Discharge ball is not sealing hydraulic system and oil may be dirty. Manually flush
arm. Manually raise and lower lift arm.
hydraulic system. Open the release valve, as required, to raise and lower the lift
arm. Manually raise and lower lift arm.
hydraulic system. Open the release valve, as required, to raise and lower the lift
SOLUTION
6603_OpMan_101905.indd 4 10/31/05 2:44:02 PM
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