Sunex Tools 7800A User manual

7800A 1 rev. 02/09/17
CONTENTS:
Page 1 Specifications
2 Warning Information
3 Setup, Operating and Maintenance
4 Trouble Shooting and Warranty Information
5 Exploded View Drawing and Parts List
6 Replacement Parts
© Copyright 2017, Sunex Tools®
SPECIFICATIONS
Capacity...................................................................... 800 Lbs.
Low Height..........................................................................8.5"
Raised Height ...................................................................24.5"
Length..................................................................................30"
Overall Width .......................................................................17"
Saddle Tilt Fore and Aft............................................ 55° by 8°
Saddle Tilt Side to Side ......................................................30°
Shipping Weight ............................................................ 84 lbs.
7800A
800 LB. LOW PROFILE
TRANSMISSION JACK
OWNER'S MANUAL

7800A 2 rev. 02/09/17
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 responsibility 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 secured 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.
• Inspect the jack before each use. Do not use jack if damaged, altered, modified, in poor condition, leaking hydraulic fluid, or
unstable due to loose or missing components. Make corrections before using.
• Consult the vehicle manufacturer for the transmission's center of balance.
• Secure the transmission to the jack's saddle with the anchorage restraint system provided before raising or lowering
the transmission.
• Center load on saddle. Be sure setup is stable before working on vehicle.
• Never use a power tool to activate the saddle tilt screws. Operate by hand or socket wrench.
• Support the engine with a stand before unbolting the transmission from the engine.
• Wear eye protection that meets ANSI Z87.1 and OSHA standards (users and bystanders).
• Do not use jack beyond its rated capacity. Do not shock load.
• Use only on a hard level surface.
• Adequately support the vehicle before starting repairs.
• Use of this product is limited to the removal, installation and transportation in the lowered position, of transmissions, transfer
cases and transaxles.
• Do not use any adapters unless approved or supplied by Sunex.
• Always lower the jack slowly and carefully.
• Do not use (or modify) the product for any other purpose than that for which it was designed without consulting the
manufacturer's authorized representative.
• 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 these markings 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 and failure to understand its OPERATING INSTRUCTIONS, SAFETY WARNINGS,
MAINTENANCE INSTRUCTIONS and 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

7800A 3 rev. 02/09/17
SETUP
PLEASE REFER TO THE EXPLODED VIEW DRAWING IN THIS MANUAL IN ORDER TO IDENTIFY PARTS.
1. Secure the #22 fingers to the #21 saddle with the #24 bolts and #23 washers provided.
2. Secure the #28 end chain link to the #21 saddle with the #25 bolt, #26 washer and #27 nut as shown in the exploded view drawing.
3. Insert the #34 handle in the pump handle receiver of the #32 hydraulic assembly.
4. Air may get trapped in the hydraulic system during shipping and/or handling. An air trapped system prevents the lift arm from
raising high enough through each incremental pump stroke, or the pump operation feels spongy, or the lift arm cannot be raised to
maximum height. Follow the procedure below to purge air out of the hydraulic system:
a. Turn the #33 release valve clockwise until it stops. Now turn the release valve counterclockwise two complete revolutions.
b. Pump the handle approximately 15 times. Turn the #33 release valve in a clockwise direction until it stops.
c. Pump the jack until the lift arm is raised to maximum height.
d. Repeat steps a) through c) until all air is removed.
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.
1. Lift the vehicle to the desired work height, and support the vehicle in accordance with the lift manufacturer's recommended lifting
and support procedures.
2. Position the transmission jack directly under the transmission. Turn the (#33) release valve knob all the way in a clockwise direction
until it stops. Pump the handle (#34), and the saddle assembly will start to rise. Raise the saddle to a height very close to the center
of balance point of the transmission, but do not touch the transmission.
3. Loosen the four bolts that secure the four fingers to the saddle. The fingers can be adjusted in and out to help position the
transmission on the saddle. Now gently raise the saddle so it supports the transmission. Adjust the four fingers in position against
the transmission, and tighten the bolts that secure the fingers to the saddle. Fore and aft saddle tilt adjustments are sometimes
necessary to properly position the transmission on the saddle. Side to side tilt positioning may be necessary for the same reason
and can be accomplished by activating the side to side tilt knob.
4. The chain should be pulled over the center of balance portion of the transmission and pulled on the chain hook tightly so the
transmission is secured to the saddle.
5. Remove the transmission from the engine according to instructions in the vehicle service manual.
6. Once the transmission has been disconnected from the engine, very slowly turn the jack's (#33) release knob in a counterclockwise
direction to make sure the jack's saddle and transmission do not hang up on any under vehicle components, wiring, fuel lines, etc.
Continue to lower the jack all the way down.
7. Remember to secure the transmission to the saddle before installing, and follow the vehicle manufacturer's installation instructions.
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 jack 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, grit, oil, grease or other foreign matter before using.
2. The jack must be lubricated periodically in order to prevent premature wearing of parts. A general purpose grease must be applied
to all zerk grease fittings, caster wheels, elevator arm, release mechanism and all other bearing surfaces. Jacks found to be
defective due to worn parts resulting from inadequate or no lubrication are not eligible for warranty consideration.
3. 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 qualified hydraulic repair personnel who are
familiar with this equipment.
7800A
800 LB. LOW PROFILE
TRANSMISSION JACK
OWNER'S MANUAL

7800A 4 rev. 02/09/17
TROUBLESHOOTING
PROBLEM ACTION
1. Unit will not lift rated load. Purge air from hydraulic system by following procedure under SETUP.
2. Unit will not sustain rated load or feels “spongy” under rated load. Purge air from hydraulic system as above.
3. Unit will not lift to full height. Purge air from hydraulic system as above.
4. Handle tends to raise up while the unit is under rated load. Pump the handle rapidly several times to push oil past ball
valves in power unit.
5. Unit still does not operate. Contact Sunex authorized hydraulic service center.
OWNER'S MANUAL
IMPORTANT: In order to prevent seal damage and jack failure, never use alcohol, hydraulic brake fluid, or transmission oil in the
jack. Use Hydraulic Jack Oil.
4. 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. Contact Sunex for a replacement label if your jack's label is
unreadable.
5. Inspect the jack before each use. Do not use the jack if any component is cracked, broken, bent, shows sign of damage or leaks
hydraulic fluid. Do not use the jack if it has loose or missing hardware or components, or is modified in any way. Take corrective
action before using the jack again.
NOTE: Disassembly of this tool by other than an authorized service center will void the warranty on this tool.

7800A 5 rev. 02/09/17
7800A
800 LB. LOW PROFILE
TRANSMISSION JACK
PARTS DRAWING AND PARTS LIST
Ref No. Part No. Description Qty
1 Body Frame 1
2 Lift Arm 1
3 Long Connecting Rod 2
4 Short Connecting Rod 2
5 Oil Cup M6 2
6 Square Shaft 1
7 Bearing 8100 3
8 Nylon Lock Nuts M10 2
9 Shaft 1
10 Elastic Cylindrical Pin 4*28 2
11 Washer M10 2
12 Screw 1
13 Shaft 1
14 Circlip d=16 8
15 Connecting Frame 1
16 Shaft 1
17 Circlip d=18 6
18 Shaft 1
19 Shaft 1
20 Screw 1
21 Saddle 1
22 RS7800A02 Finger 4
Ref No. Part No. Description Qty
23 Washer M10 4
24 M10×20 Hex Bolt 4
25 M6×20 Hex Bolt 1
26 Washer M6 1
27 M6 Hex Nut 1
28 RS7800A01 Chain Kit (incl. #25-28) 1
29 Shaft 1
30 Circlip d=22 2
31 Split Pin 4*50 1
32 RS7800A03BK Hydraulic Unit Assembly
(incl. #32-34) 1
33 Release Valve 1
34 RS7800A05 Handle 1
35 M8×20 Hex Bolt 2
36 Spring Washer M8 2
37 M6×14 Hex Bolt 16
38 Washer M6 16
39 RS7800A04 2" Swivel Caster 4
40 Spring Washer M6 16
41 M6 Hex Nut 16
not shown RS7800APLK Product Label Kit 1
Only Ref. No.'s identified by Part No. are available separately.

7800A 6
PARTS DRAWING AND PARTS LIST
7800A
800 LB. LOW PROFILE
TRANSMISSION JACK
RS7800AO3 -
Hydraulic
Unit Assembly
Ref No. Part No. Description Qty
14 RS7800A06 Clip 1
15-17 RS7800A07 Pump Plunger with Seals 1
20 RS7800A08 Handle Swivel Seat 1
Only Ref. No.'s identified above are available separately.
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