Sunex Tools 6616 User manual

SPECIFICATIONS
OWNER'S MANUAL
MODEL 6616
CAPACITY: 3/4 TON
ATV/MOTORCYCLE LIFT
CONTENTS:
Page 1 Specifications
2 Warning Information
3 Setup and Operating Instructions
4 Maintenance, Troubleshooting and Warranty Information
5 Exploded View Drawing and Parts List
Capacity...........................................3/4 Ton (1500 Lbs.)
Low Height...................................................................4"
Raised Height ............................................................19"
Length.....................................................................38.8"
Chassis Width.........................................................18.5"
Lift Rails (2 each).............................3" wide x 17" Long
Shipping Weight ............................................... 94.6 lbs.

WARNINg INFORMATION
This is the safety alert symbol. It is used to alert you
to potential personal injury hazards. Obey all safety
messages that follow this symbol to avoid possible
injury or death.
IMPORTANT: READ THESE INSTRUCTIONS BEFORE OPERATING
BEFORE USING THIS DEVICE, READ THIS MANUAL COMPLETELY AND THOROUGHLY, UNDERSTAND ITS OPERATING
PROCEDURES, SAFETY WARNINGS AND MAINTENANCE REQUIREMENTS.
It is the responsibility of the owner to make sure all personnel read this manual prior to using the device. It is also the responsiblity of
the device owner to keep this manual intact and in a convenient location for all to see and read. If the manual or product labels are lost
or not legible, contact Sunex for replacements. If the operator is not fluent in English, the product and safety instructions shall be read
to and discussed with the operator in the operator's native language by the purchaser/owner or his designee, making sure that the
operator comprehends its contents.
THE NATURE OF HAZARDOUS SITUATIONS
The use of portable automotive lifting devices is subject to certain hazards that cannot be prevented by mechanical means, but only
by the exercise of intelligence, care, and common sense. It is therefore essential to have owners and personnel involved in the use and
operation of the equipment who are careful, competent, trained, and qualified in the safe operation of the equipment and its proper
use. Examples of hazards are dropping, tipping or slipping of loads caused primarily by improperly securing loads, overloading, off-
centered loads, use on other than hard level surfaces, and using equipment for a purpose for which it was not designed.
METHODS TO AVOID HAZARDOUS SITUATIONS
• Read,study,understandandfollowallinstructionsbeforeoperatingthisdevice.
• Useofthisproductislimitedtolifting,lowering,transporting/storingonlyintheloweredposition,ATV'sandmotorcycles
with exposed frame undercarriages.
• Liftonlyonareasofthevehicleasspeciedbythevehiclemanufacturer.
• Keepoperator'sandbystander'shead,handsandfeetawayfromliftarmswhenraisingandlowering.
• Neverworkon,aroundorunderaloadthatisnotsecuredandstable.
• Donotusejackbeyonditsratedcapacity.
• Useonlyonahardlevelsurface.
• Centerloadonliftplatforms.
• Secureloadwithappropriaterestraintdevice.
• Immediatelyafterliftingaload,ensureliftmechanicalloadholdingmeansareengaged.
• Noalterationsshallbemadetothisproduct.
• Onlyattachments,restraints,oradapterssuppliedbySunexToolsshallbeused.
• Failuretoheedthesewarningsmayresultinseriousorfatalpersonalinjuryand/orpropertydamage.
CONSEQUENCES OF NOT AVOIDING HAZARDOUS SITUATIONS
Failure to read this manual completely and thoroughly, understand its OPERATING INSTRUCTIONS, SAFETY WARNINGS,
MAINTENANCE INSTRUCTIONS and not comply with them, and neglecting the METHODS TO AVOID HAZARDOUS SITUATIONS could
cause accidents resulting in serious or fatal personal injury and/or property damage.
WARNING: Indicates a hazardous situation
which, if not avoided, could result in death
or serious injury.
WARNING
WARNING
WARNING
WARNING

SETUP
PLEASE REFER TO THE EXPLODED VIEW DRAWING IN THIS MANUAL IN ORDER TO IDENTIFY PARTS.
1. Line up the two mounting holes in the base of the hydraulic jack (#11) with two holes in the lift's jack base pad. The hydraulic jack's release pedal
should be facing towards the lift's rear caster wheel assemblies. Secure the hydraulic jack to the lift's jack base pad with the (#12) spring washers
and (#13) bolts provided.
2. Raise the lift rails so the top cross member tube of the lift linkage will rest on top of the hydraulic jack's ram piston. Align the hole in the top of
the jack's ram with the holes in the top cross member tube (#19) and secure them with the (#15) pin, (#4) washer and (#16) spring clip provided. It
may be necessary to slightly extend the jack's ram to align all holes together. This may be accomplished by securing the pump pedal (#14) in the
hydraulic jack's pump linkage with the (#12) spring washer and (#20) bolt provided. Pump the pedal slightly to align the holes.
3. The cross member tube and lift linkage (#19) rotate on two rivets on the base of the lift. Remove the (#27) washers and (#28) spring clips on the two
(#25) pins on the base of the lift. Spread the arms of the lock bar (#23) so the holes in the arms will fit over the two pins (#25), and secure the lock
bar to the pins with the (#27) washers and (#28) spring clips.
4. Install the T-handle (#34) on top of the pushing rod (#21).
PURGING AIR FROM THE HYDRAULIC SYSTEM:
Sometimes air can get trapped in the hydraulic jack's system during shipping and handling. An air trapped system can prevent the jack from
getting a complete incremental pump stoke and the lift rails feel spongy. Follow these instructions:
1. Depress the release pedal while simultaneously activating the pump pedal about 15 to 20 times.
2. Stop depressing the release pedal. Continue activating the pump pedal so the lift rails rise to maximum extension.
3. If the condition seems better but not fully corrected, repeat steps 1 and 2 until all air is purged from the system.
OPERATING INSTRUCTIONS
This is the safety alert symbol used for the OPERATING INSTRUCTIONS section of this manual to alert you to potential personal
injury hazards. Obey all instructions to avoid possible injury or death.
IMPORTANT: Before attempting to raise any vehicle, check vehicle service manual for recommended lifting surfaces.
GENERAL INSTRUCTIONS:
1. Once the lift is in the proper work location, the T-handle can be used to roll the lift under the vehicle. Since the jack is only designed to be used on a
hard level surface, there should be no difficulty in rolling the lift under a vehicle. Make sure there are no obstructions, cracks or crevices in the
floor underneath the vehicle.
2. The lift is raised by activating the foot pedal. The locking arms slide over the notched lock positions as the lift rises. Once the desired work height
has been reached, slowly depress the release pedal until the locking arms engage with the closest notch.
3. In order to lower the lift, the locking arms must be disengaged by pumping the jack up so the locking arm assembly can be clipped in the retaining
latch. Once the assembly is retained in the latch, depress the release pedal slowly to lower the load.
LIFTING A MOTORCYCLE OR ATV:
Removal or installation of any heavy motorcycle components that would affect and change the weight distribution and balance of the motorcycle on
the lift will require additional support equipment. FOR EXAMPLE: Removing one tire and wheel combination will shift the weight of the motorcycle to
the opposite side of the lift rails. Make sure to support the tire and wheel combination not being removed with stands or other means of support before
performing the work.
1. Lift only on areas of the vehicle as specified by the vehicle manufacturer. This lift is designed for lifting vehicles with an exposed frame
undercarriage. The weight of the vehicle must be evenly balanced on the two lift rails. The center of balance on an engine is not necessarily the
center of balance point of the whole vehicle. IMPORTANT: DO NOT ATTEMPT TO RAISE ANY VEHICLE THAT CANNOT BE PROPERLY
BALANCED ON THE LIFT.
2. Since lifting and lowering procedures require two people, one person must hold the motorcycle in a vertical position. The second person must look
underneath the vehicle frame to make sure there are no components extending down beyond the frame that can be damaged by lifting. The
second person can also determine if it is necessary to leave the motorcycle kickstand extended or retracted in order for the lift rails to make
contact with the motorcycle frame. The second person (person operating the lift) must slide the lift under the vehicle making sure the lift arms are
properly positioned under the vehicle frame. The lift can now be pumped up under the frame. There should be equal distance on both sides of
a motorcycle as it is lined up with the lift rails. Since the lift arcs when pumped, the lift operator must compensate for the arcing movement so the
motorcycle is equally spaced on the lift rails when the lift rails come in contact with the motorcycle frame. Once the lift rails make contact with the
motorcycle frame, the motorcycle can be lifted very slowly while the first person continues to hold the motorcycle in a vertical position. During
this initial lift procedure, both people can determine whether the motorcycle is properly balanced. If it is not, the motorcycle should be lowered to
the ground and lift rails should be repositioned under the motorcycle until the center of balance is achieved. This initial lift procedure must be
repeated until the proper balance is achieved. IMPORTANT THE MOTORCYCLE MUST ALWAYS BE HELD IN AN UPRIGHT VERTICAL
POSITION BY ONE PERSON AT ALL TIMES DURING THIS INITIAL LIFT PROCEDURE.
3. Once the center of balance point is achieved, the motorcycle may be lifted only to where both tires clear the ground. The lift operator can now
secure the vehicle to the lift by using nylon motorcycle tie down straps. There are tie down loops fore and aft of each lift pad. The higher the straps
are positioned on the motorcycle, the more stability is achieved. After the two tie down straps are connected to the motorcycle frame and the tie
down loops on the lift rails, make sure to tighten each strap while maintaining the upright vertical position of the vehicle.
OWNER'S MANUAL
MODEL 6616
CAPACITY: 3/4 TON
ATV/MOTORCYCLE LIFT

TROUBLESHOOTING
PROBLEM ACTION
1. Unit will not lift load. Purge air from hydraulic system by following procedure under SETUP.
2. Unit will not sustain load or feels “spongy” under load. Purge air from hydraulic system as above.
3. Unit will not lift to full height. Purge air from hydraulic system as above.
4. Unit still does not operate. Contact an authorized service center.
4. Once the motorcycle is secured with the tie-downs, raise the motorcycle to the desired work height and make sure the locking arms are engaged
with the notches.
LOWERING A MOTORCYCLE OR ATV:
1. Make sure vehicle is properly balanced on lift before removing any additional support equipment.
2. Have one person grab the handle bars of the vehicle in preparation for its lowering and eventual removal from the lift.
3. Follow step 3 under GENERAL INSTRUCTIONS to lower the load.
4. While one person is still stabilizing the motorcycle in a vertical position, the other person should remove the tie down's from the motorcycle and tie
down loops on the lift rails. The motorcycle's kickstand should be pointed down and ready to make contact with the ground. After the tie downs
are removed, lower the motorcycle all the way to the ground so the lift rails clear the motorcycle frame.
5. Slide the lift out from underneath the vehicle.
PREVENTATIVE MAINTENANCE
This is the safety alert symbol used for the PREVENTATIVE MAINTENANCE section of this manual to alert you to potential personal
injury hazards. Obey all instructions to avoid possible injury or death.
1. Always store the lift in a well protected area where it will not be exposed to inclement weather, corrosive vapors, abrasive dust, or any
other harmful elements. The jack must be cleaned of water, snow, sand or grit before using.
2. Lubricate all moving parts and joints monthly with the exception of the hydraulic jack. Use a waterproof lubricating grease.
3. Visual inspection should be made before each use of the lift, checking for leaking hydraulic fluid and damaged, loose or missing parts.
Each lift must be inspected by a manufacturer’s repair facility immediately, if subjected to an abnormal load or shock. Any lift 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 manufacturer’s authorized repair facility. It is recommended that an annual inspection of the lift 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.
4. It should not be necessary to refill or top off the reservoir with hydraulic fluid unless there is an external leak. An external leak requires
immediate repair which must be performed in a dirt-free environment by an authorized service center.
5. Every jack owner is responsible for keeping the jack labels clean and readable. Use a mild soap solution to wash external surfaces of
the jack but not any moving hydraulic components.

PARTS LIST AND DRAWINg
MODEL 6616
CAPACITY: 3/4 TON
ATV/MOTORCYCLE LIFT
Index No. Part No. Description Qty.
1 Pin Shaft 6
2 RS661602 Front Wheel (incl. #1,4,5) 2
3 Back Ring 8
4 * Washer 11
5 Back Ring 10
6 RS661606 Rear Caster Assembly (incl. #7,8) 2
7 Spring Washer 2
8 Nut (M12) 2
9 Spring 2
10 Leveling Screw 2
11 RS661611 Pump Assembly 1
12 * Spring Washer 5
13 * Bolt (M8X18) 2
14 RS661614 Pump Pedal Assembly (incl. #12,20) 1
15 * Pin Shaft 1
16 * Spring Clip 1
17 RS661617 Lock Retaining Clip (incl. #18) 1
18 Screw (M6X10) 2
19 Pulling Frame 1
20 * Bolt (M8x12) 3
Index No. Part No. Description Qty.
21 Pushing Rod 1
22 Pin (4X25) 1
23 RS661623 Lock Bar 1
24 Lifting Arm Assembly 1
25 * Pin Shaft 2
26 Bushing 2
27 * Washer 2
28 * Spring Clip 2
29 Supporting Rod 2
30 Bushing (Short) 4
31 Bushing (Long) 2
32 Pin Shaft 4
33 RS661633 Bracket Assembly (incl. 4 ea. #4,5,32) 1
34 RS661634 Handle 1
35 RS661635 Spring 1
36 Pin Shaft 8
37 RS661637 Tie Down Loop (incl. #3,36) 4
38 RS661638 Tie Down Strap
(not shown) 2
39 RS6616LK Product Label Kit
(not shown) 1
*Available in RS6616BK Bolt Kit, incl. #4, 12, 13, 15, 16, 20, 25, 27, 28.
Only index numbers identified by part number are available individually.
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