Harbor Freight Tools Air Compressor 65549 User Manual

1-ton  
aIr/HYdraulIc  
strut sprInG  
coMpressor  
65549  
InstructIons and precautIons  
®
distributed exclusively by Harbor Freight tools .  
3491 Mission Oaks Blvd., Camarillo, CA 93011  
Visit our website at: http://www.harborfreight.com  
saVe tHese InstructIons. read all  
precautIons and InstructIons.  
Copyright 2008 by Harbor Freight Tools . All rights reserved. No portion of this document or any artwork contained  
herein may be reproduced in any shape or form without the express written consent of Harbor Freight Tools.  
Diagrams within this document may not be drawn proportionally. Due to continuing improvements, actual product  
may differ slightly from the product described herein. Tools required for assembly and service may not be included.  
©
®
For technical questions or replacement parts, please call 1-800-444-3353.  
 
WarnInG indicates a  
hazardous situation  
specIFIcatIons  
which, if not avoided,  
could result in death or serious  
injury.  
Air Pressure  
120 PSI  
Maximum Compression  
Ram Travel  
2200 lbs.  
12.8"  
cautIon, used with  
the safety alert symbol,  
indicates a hazardous  
Coil Spring Sizes Accepted  
Spring Length Accepted  
4" Dia. to 6.3" Dia.  
5" Long to 18" Long  
Small Set (4" Springs)  
Large Set (6.3" Springs)  
Shoes  
situation which, if not avoided,  
could result in minor or moderate  
injury.  
unpackInG  
notIce is used to  
address practices not  
related to personal  
injury.  
When unpacking, make sure that the item  
is intact and undamaged. If any parts are missing  
or broken, please call Harbor Freight Tools at the  
number shown on the cover of this document as  
soon as possible.  
cautIon, without the  
safety alert symbol, is  
used to address  
asseMblY precautIons  
Use only according to these instructions.  
Improper use can create hazards.  
practices not related to personal  
injury.  
1.  
2.  
General saFetY.  
Wear ANSI-approved safety goggles and  
heavy-duty work gloves during use.  
1.  
WarnInG! Ensure Health & Safety, local  
authority, and general workshop practice  
regulations are adhered to when using this  
equipment.  
3.  
4.  
5.  
Keep work area clean and well lit.  
Keep bystanders out of the area during use.  
Do not use when tired or when under the  
influence of drugs or medication.  
2.  
3.  
WarnInG! Wear approved safety hand and  
eye protection (standard spectacles are not  
adequate).  
IMportant saFetY  
InForMatIon  
In this manual, on the labeling, and all  
other information provided with this  
product:  
WarnInG! trappInG danGer ─ Keep  
hands and fingers away from the spring and  
compressing Shoes when in use.  
4.  
5.  
Keep the work area clean, uncluttered and  
ensure there is adequate lighting.  
Maintain correct balance and footing. Ensure  
the floor is not slippery and wear non-slip  
shoes.  
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.  
6.  
Remove ill-fitting clothes. Remove ties,  
watches, rings and other loose jewellery.  
Contain and/or tie back long hair.  
7.  
8.  
Wear appropriate protective clothing.  
Familiarize yourself with the applications,  
limitations and potential hazards of the  
Spring Compressor.  
danGer indicates a  
hazardous situation  
which, if not avoided,  
9.  
do not force the spring compressor to  
achieve a task it was not designed to per-  
form.  
will result in death or serious injury.  
10. do not allow untrained persons to use the  
spring compressor.  
SKU 65549  
For technical questions, please call 1-800-444-3353.  
Page 3  
 
14. Harbor Freight Tools recommends use of an  
appropriate tool, to be supplied by user, to  
remove top cap nut from upper strut mount.  
pre-operatIonal saFetY.  
1.  
This product is not a toy. Do not allow chil-  
dren to play with or near this item.  
15. Once compressed and strut is removed, it  
is a good idea to release the tension on the  
spring.  
2.  
3.  
Use for intended purpose(s) only.  
Inspect before use; do not use if parts are  
loose or damaged.  
a. Do not leave the spring under compression  
in the machine unattended and do not leave  
in compression for prolonged periods, i.e.  
overnight.  
4.  
5.  
Strut and Spring Compression station should  
be securely bolted to the workshop floor  
before use.  
16. Before releasing the compression, ensure  
that the top cap nut is securely fastened ac-  
cording to the manufacturer’s specs.  
Apply grease to the front and rear faces of  
the main Upright (14) to assist the smooth  
sliding of upper and lower strut support (24,  
31) Rollers (27).  
17. Release the compression slowly, keeping  
your hands and fingers away from the spring  
assembly.  
6.  
7.  
do not operate Spring Compressor if parts  
are damaged or missing as this may cause  
failure and/or personal injury.  
18. Be sure the tension on the spring is fully held  
by the strut assembly before removing the  
strut from the Shoes (28) of the compressor.  
Before compressing, make visual inspec-  
tion of machine to ensure pins are securely  
positioned and that there is no sign of wear  
or fatigue. If found, do not use the unit until it  
is replaced or repaired by a qualified techni-  
cian.  
post operatIonal saFetY.  
1.  
2.  
When not in use, clean and store the Spring  
Compressor in a safe, dry, childproof location.  
8.  
9.  
Ensure upper and lower Shoes (28, 28A),  
Strut Supports (31, 24) and their Retaining  
Pins (30, 23, 26) are properly positioned.  
Their R-Clips (32) and Circlips (29, 22, 25)  
must be properly installed.  
Maintain the Spring Compressor in good  
condition.  
a. Replace or repair damaged parts. Use  
genuine Harbor Freight Tools parts only.  
b. Unauthorized parts may present a hazard  
and will invalidate the warranty.  
Before commencing compression of a spring,  
ensure ends of the spring are seated and be-  
ing held securely in upper and lower Shoes  
(28, 28A) of the compressor and cannot slide  
out during compression.  
change shoes  
a. Two sets of Shoes (28, 28A), one large  
(28A) and one small (28), are provided.  
One set handles springs as small as 4" in  
diameter and the larger set handles springs  
as large as 6.3" in diameter.  
10. Always fit the Safety Chain (37) around strut  
and spring (see Fig. 2). Ensure Chain is not  
trapped in the coils of the spring being com-  
pressed.  
b. To change to the second pair of Shoes, first  
undo and remove the Socket Cap Screw  
(33) that secures the Upper to the Upper  
Strut Support (31). Remove the R-Clip (32).  
Support the Shoe with one hand and slide  
the Retaining Pin (23) out.  
11. Maintain product labels and nameplates.  
These carry important safety information.  
If unreadable or missing, contact Harbor  
Freight Tools for a replacement.  
12. When compressing the spring, always stand  
to one side of the unit.  
c. The Circlip (22) will remain in place on the  
other end.  
danGer! Stop compressing the spring before the  
coils touch. do not over compress.  
d. Remove the Shoe (28). Hold the alternative  
Shoe in place within the support bracket and  
slide the Retaining Pin (23) back into place  
and lock it with the R-Clip (32). Replace  
the Socket Cap Screw (33). The Shoes are  
13. Before attempting to remove top cap nut,  
always use some type of tool or short stick  
to test if the compression has been relieved,  
DO NOT use your fingers.  
SKU 65549  
For technical questions, please call 1-800-444-3353.  
Page 4  
 
designed to be used as matched pairs and  
should not be mixed.  
9.  
WarnInG! Ensure air supply is clean and  
does not exceed 120 PSI.  
a. Too high an air pressure and unclean air will  
shorten the life of the unit due to excessive  
wear, and may be dangerous causing pos-  
sible damage and/or personal injury.  
IntroductIon  
1.  
The 1-Ton Air/Hydraulic Spring Compressor  
is an air actuated hydraulic unit with alterna-  
tive foot operation.  
b. Drain the air supply tank daily and clean the  
Air Inlet Filter (A16) weekly.  
asseMblY  
c. When used, drain air filter at least once a  
1.  
2.  
The unit requires minimal assembly before  
use.  
day.  
Attach the Angle Steel (21) to the base of  
the Upright (14) by using Bolts (20), Nuts  
(18) and Washers (19). Be sure Angle Steel  
(21) are fixed securely to the base as they  
provide stability and will be used to secure  
the unit to the floor.  
3.  
Insert the Foot Pedal (5) into the Socket  
(B28) on the hydraulic jack and secure with  
the Bolt (10) and Washer (11).  
4.  
5.  
Push Circlips (29) into the groove on each  
retaining Pin (30).  
Slide the Upper Strut Support (31) over the  
Upright (14) to the required height and align  
the two holes in the support with two holes  
in the Upright. Slide the two Retaining Pins  
(30) through the assembly and retain them in  
position using the R-clips (32).  
6.  
7.  
Two pairs of shoes (28,28A) are supplied.  
Choose one pair of shoes and attach them  
to the upper and lower support bracket by  
using the socket cap Screw (33), the R-clip  
(32), the Retaining Pin (23) and the Circlip  
(22). The shoes are designed to be used as  
matched pairs and should not be mixed.  
Fig.1  
10. For recommended air source and automatic  
oiler hook-up, refer to Fig. 1.  
11. Keep hose away from heat, oil and sharp  
edges.  
12. Check hoses for wear and make certain that  
all connections are secure.  
The unit must now be fixed securely to the  
ground in order to ensure the safety of the  
user. Mounting holes are to be found in the  
brackets, which allow the unit to be secured  
by way of masonry bolts or sinking pins (not  
included) into concrete.  
read the entIre IMportant  
saFetY InForMatIon section at  
the beginning of this document  
including all text under  
subheadings therein before set up  
or use of this product.  
WarnInG! Whichever method is used, ensure the  
unit is adequately fixed and cannot topple.  
aIr supplY set up  
saVe tHese  
InstructIons.  
8.  
Ensure the Air Valve (1) is in the “Off” posi-  
tion before connecting to the air supply. The  
Spring Compressor requires 120 PSI to oper-  
ate at full capacity.  
SKU 65549  
For technical questions, please call 1-800-444-3353.  
Page 5  
 
a. If wear or fatigue is found, do not use the  
Tool. Have the tool replaced or repaired by  
a qualified technician.  
operatInG InstructIons  
Measure the outer diameter of the spring to  
be compressed and select the correct set of  
Shoes.  
1.  
2.  
5.  
Fit the strut into the Shoes (28) and ensure  
that the lower coil used lies behind the inner  
retaining rim at the back of the Shoe (28).  
Operate the Foot Pedal (5) to raise the upper  
coil end into contact with the upper spring  
seat, ensuring the coil at both ends are se-  
curely retained by the raised inner and outer  
rims within the Shoes (28, 28A).  
Press down on the Release Valve Pedal (6)  
releasing air pressure to lower the Under  
Strut Support until the Ram is fully retracted  
and the Under Strut Support (24) is at its low-  
est position.  
Upper Strut Mount  
Top Cap Nut  
Upper Shoe (9)  
6.  
7.  
Wrap one Safety Chain (37) around the por-  
tion of the spring and strut protruding from  
the upper Shoe (28) ensuring that the Chain  
lies above the Shoe. (See Fig. 2.)  
Upper  
Spring  
Seat  
Dust  
Cover  
Wrap the other Safety Chain around the  
spring and strut protruding from the lower  
Shoe ensuring that the Chain lies below the  
Shoe.  
Lower  
Spring  
Seat  
a. Fasten each Chain behind the Upright (14)  
using the attached spring catches. Make  
sure each Chain is as tight as possible.  
Do not position the Chain in the coils held  
between the Shoes (28, 28A).  
Under  
Strut  
Support  
Ram  
spring  
spring  
un-compressed  
compressed  
8.  
9.  
When applying compression to the spring,  
always stand to one side of the unit.  
Lower Strut  
Strut Housing  
Mount  
a
b
Gradually compress the spring by pumping  
the Foot Pedal (5) or operating the Air Valve  
(1) ensuring that the spring and strut remain  
securely held at all times.  
Fig. 2  
3.  
The upper Shoe (28) should bear down on  
the first full coil down from the top of the  
strut. The lower Shoe should be pushing up  
on the first full coil up from the bottom of the  
strut. (See Fig. 2.)  
10. Ensure that the strut and the Upright (14) of  
the compressor are correctly aligned at all  
times during spring compression.  
a. Measure the distance between these coils  
and adjust the position of the upper strut  
support so that the distance between the  
Shoes is slightly larger than required.  
a. For conical springs, the center line of the  
spring should remain parallel to the com-  
pressor body.  
danGer! Stop compressing the spring before the  
coil windings touch. You need only compress  
the spring until the upper spring seat is free  
from spring pressure.  
b. Ensure that the Retaining Pins (30) hold-  
ing the Upper Strut Support (31) are fully  
inserted and secured with the R-Clip (32)  
and Circlips (29) provided.  
11. Before attempting to remove top cap nut on  
the strut, use a tool or short stick to test if the  
spring compression has been relieved from  
the upper spring seat. Do not use your hands  
or fingers.  
c. Use the Foot Pedal (5) to raise the Under  
Strut Support (24) to finely adjust the dis-  
tance between the Shoes.  
4.  
Before compressing, make a visual inspec-  
tion of the tool to ensure all Retaining Pins  
are securely positioned and that there is no  
sign of wear or metal fatigue.  
12. Harbor Freight Tools recommends the use of  
properly designed strut tools to remove the  
top cap nut from the shock absorber piston.  
SKU 65549  
For technical questions, please call 1-800-444-3353.  
Page 6  
 
a. Ensure that the shock absorber is supported  
as the top cap nut is removed to prevent it  
falling down through the coils and causing  
injury.  
serious damage to the jack and invalidate the  
warranty!  
bleeding the Hydraulic system  
13. Once compressed and the strut removed, it  
is recommended to release the tension on  
the spring.  
3.  
4.  
5.  
6.  
7.  
The Strut Spring Compressor must be se-  
curely mounted on a flat and level surface.  
Wipe the Oil Filler Plug (38) and its surround-  
ing area at the side of the Ram (7).  
a. Do not leave the spring under compression  
unattended and do not leave in compres-  
sion for prolonged periods. I.e. overnight.  
With the tip of a flat tip screwdriver, pry and  
remove the rubber Oil Filler Plug.  
14. Allow the spring to gradually decompress by  
carefully pressing the Valve Release Pedal  
(6) keeping your hands and fingers away  
from the spring assembly.  
Pour fresh hydraulic jack oil into the Ram (7)  
until it starts to overflow.  
Step on the Valve Release Pedal (6) and  
allow the Under Strut Support (24) to be  
lowered completely.  
15. Replace the spring or shock absorber as  
necessary and reassemble the strut by first  
compressing the spring and then introduc-  
ing the shock absorber up through the lower  
Shoe (28) and compressed spring coils.  
8.  
While holding the Valve Release Pedal (6)  
down, rapidly pump the Foot Pedal (5) at  
least five full strokes. This should purge the  
air out of the system.  
a. Re-position the upper strut mount and se-  
cure with the top cap nut.  
9.  
Repeat step 6 above to make sure that the  
Ram (7) is filled with oil.  
16. Before releasing the compression, ensure  
that the top cap nut is securely tightened ac-  
cording to the manufacturer’s specs.  
10. Wipe the plug and place its edge against  
the fill-hole and while applying thumb force  
behind the plug, work the rubber plug back  
into the fill-hole with the aid of the flat tipped  
screwdriver.  
17. Release the compression slowly keeping  
your hands and fingers away from the spring  
assembly.  
11.  
After the plug is inserted, wipe off spilled oil  
from jack exterior with a clean and dry rag.  
18. Be sure that the spring ends are firmly and  
securely seated in the upper and lower  
Shoes of the Compressor before removing  
the strut from the Spring Compressor.  
cautIon: DO NOT operate the jack when the Oil  
Filler Plug (38) is removed.  
please read tHe FolloWInG  
careFullY  
MaIntenance  
1.  
Before each use, check the compressor to  
ensure it is not damaged or worn. If in any  
doubt DO NOT use the tool.  
THE MANUFACTURER AND/OR DISTRIBUTOR HAS  
PROVIDED THE PARTS LIST AND ASSEMBLY DIAGRAM  
IN THIS DOCUMENT AS A REFERENCE TOOL ONLY.  
NEITHER THE MANUFACTURER OR DISTRIBUTOR  
MAKES ANY REPRESENTATION OR WARRANTY OF ANY  
KIND TO THE BUYER THAT HE OR SHE IS qUALIFIED  
TO MAKE ANY REPAIRS TO THE PRODUCT, OR THAT  
HE OR SHE IS qUALIFIED TO REPLACE ANY PARTS OF  
THE PRODUCT. IN FACT, THE MANUFACTURER AND/OR  
DISTRIBUTOR ExPRESSLY STATES THAT ALL REPAIRS  
AND PARTS REPLACEMENTS SHOULD BE UNDERTAKEN  
BY CERTIFIED AND LICENSED TECHNICIANS, AND NOT  
BY THE BUYER. THE BUYER ASSUMES ALL RISK AND  
a. Remove it from service immediately and  
have it replaced or repaired by a qualified  
technician.  
2.  
Refilling the hydraulic system with oil is rarely  
necessary but the oil level should be checked  
in the event of a loss of performance.  
a. To check oil level, ensure the Under Strut  
Support (24) is fully lowered, remove filler  
plug and check that level is within .4" of filler LIABILITY ARISING OUT OF HIS OR HER REPAIRS TO THE  
ORIGINAL PRODUCT OR REPLACEMENT PARTS THERETO,  
OR ARISING OUT OF HIS OR HER INSTALLATION OF  
hole. Add hydraulic jack oil if necessary.  
WarnInG: DO NOT use brake fluid, or any fluid  
REPLACEMENT PARTS THERETO.  
other than hydraulic jack oil as this will cause  
SKU 65549  
For technical questions, please call 1-800-444-3353.  
Page 7  
 
parts lIst - sprInG  
coMpressor  
description  
Air Valve  
Air Hose  
Air Motor  
Washer  
Foot Pedal  
Valve Release Pedal  
Ram  
Pin  
Ram  
Bolt  
Washer  
Screw  
T-Connector  
Upright  
Washer  
Lock Washer  
Bolt  
Nut  
Washer  
Bolt  
Angle Steel  
Circlip  
Retaining Pin  
Under Strut Support  
Circlip  
Retaining Pin  
Roller  
Shoe - Small 4"  
Shoe - Large 6.3"  
Circlip  
Retaining Pin  
Upper Strut Support  
R-Clip  
Socket Cap Screw  
Safety Ring  
Bolt  
parts lIst - aIr Motor  
part  
A01  
A02  
A03  
A04  
A05  
A06  
A07  
A08  
A09  
A10  
A11  
A12  
A13  
A14  
A15  
A16  
A17  
A18  
A19  
A20  
A21  
A22  
A23  
A24  
A25  
A26  
A27  
A28  
A29  
A30  
A31  
A32  
A33  
A34  
A35  
A36  
A37  
A38  
A39  
A40  
A41  
A42  
A43  
A44  
A45  
A46  
A47  
A48  
description  
Air Pump Cylinder  
Nut  
Sealing Ring  
Nylon Ring  
Copper Ring  
Air Cylinder Seat  
Nut  
Spring  
Air Pump Piston  
O-Ring  
Big Piston  
Air Cylinder  
Screw  
Lock Washer  
Safety Cover  
Filter  
Silencing Pad  
Small Piston  
O-Ring  
O-Ring  
Sealing Ring  
Bolt  
Nylon Ring  
O-Ring  
O-Ring  
Air Cylinder Cap  
Bolt  
Coupler Seat  
Retaining Ring  
O-ring  
Coupler  
Air Hose  
Lock Lever  
Lever  
Nut  
O-ring  
O-ring  
Packing  
Throttle  
Spring  
Lock Nut  
Bolt  
Valve Body  
Screw  
Screen  
O-Ring  
quick Coupler-Male  
Coupler Seat  
Qty.  
1
1
1
1
1
1
1
1
1
2
1
1
2
2
1
1
1
1
1
1
1
3
1
2
1
1
4
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
part  
1
2
3
4
5
6
7
8
Qty.  
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
2
4
4
4
2
2
2
1
6
3
2
2
2
2
2
1
4
1
1
2
2
2
1
9
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
22  
23  
24  
25  
26  
27  
28  
28A  
29  
30  
31  
32  
33  
34  
35  
36  
37  
38  
Washer  
Safety Chain  
Oil Filler Plug (Hidden)  
SKU 65549  
For technical questions, please call 1-800-444-3353.  
Page 8  
 
parts lIst - HYdraulIc Jack  
part  
B1  
B2  
B3  
B4  
B5  
B6  
B7  
B8  
description  
Qty.  
1
1
1
1
1
1
1
1
3
1
4
1
1
1
1
1
1
6
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
2
1
1
1
1
1
1
1
Screw Protector  
Screw  
O-ring  
Screw  
Spring  
Ballcap  
Ball  
Base  
Pin  
B9  
B10  
B11  
B12  
B13  
B14  
B15  
B16  
B17  
B18  
B19  
B20  
B21  
B22  
B23  
B24  
B25  
B27  
B28  
B29  
B30  
B31  
B32  
B33  
B34  
B35  
B36  
B37  
B38  
B39  
B40  
B41  
B42  
B43  
B44  
B45  
Release Pedal  
R-pin  
Screw  
O-ring  
Screw  
Rubber Pad  
Ballcap  
Spring  
Ball  
Copper Washer  
Piston Housing  
O-ring  
Nylon Ring  
Dust Seal  
Small Piston  
Pin  
Link  
Socket  
Washer  
Cylinder  
Pump Pedal  
Washer  
Screw  
Oil Plug  
Recervoir  
Spring  
Copper Washer  
Screw  
O-ring  
Nylon Ring  
Circlip  
Ram  
O-ring  
Nylon Ring  
Cylinder Cap  
SKU 65549  
For technical questions, please call 1-800-444-3353.  
Page 9  
 
assembly drawing 1-ton strut spring compressor  
1
2
36  
37  
31  
32  
35  
12  
30  
13  
33  
29  
34  
23  
38  
28  
3
4
24  
27  
26  
10  
11  
7
25  
8
23  
9
22  
6
5
14  
15  
16  
17  
21  
18  
20  
19  
SKU 65549  
For technical questions, please call 1-800-444-3353.  
Page 10  
 
assembly drawing - air Motor  
SKU 65549  
For technical questions, please call 1-800-444-3353.  
Page 11  
 
assembly drawing - Hydraulic Jack  
SKU 65549  
For technical questions, please call 1-800-444-3353.  
Page 12  
 
lIMIted 90 daY WarrantY  
Harbor Freight Tools Co. makes every effort to assure that its products meet high quality and dura-  
bility standards, and warrants to the original purchaser that this product is free from defects in materials  
and workmanship for the period of 90 days from the date of purchase. This warranty does not apply to  
damage due directly or indirectly, to misuse, abuse, negligence or accidents, repairs or alterations outside  
our facilities, criminal activity, improper installation, normal wear and tear, or to lack of maintenance. We  
shall in no event be liable for death, injuries to persons or property, or for incidental, contingent, special  
or consequential damages arising from the use of our product. Some states do not allow the exclusion or  
limitation of incidental or consequential damages, so the above limitation of exclusion may not apply to  
you. THIS WARRANTY IS ExPRESSLY IN LIEU OF ALL OTHER WARRANTIES, ExPRESS OR IM-  
PLIED, INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS.  
To take advantage of this warranty, the product or part must be returned to us with transportation  
charges prepaid. Proof of purchase date and an explanation of the complaint must accompany the mer-  
chandise. If our inspection verifies the defect, we will either repair or replace the product at our election  
or we may elect to refund the purchase price if we cannot readily and quickly provide you with a replace-  
ment. We will return repaired products at our expense, but if we determine there is no defect, or that the  
defect resulted from causes not within the scope of our warranty, then you must bear the cost of returning  
the product.  
This warranty gives you specific legal rights and you may also have other rights which vary from  
state to state.  
3491 Mission Oaks Blvd. • PO Box 6009 • Camarillo, CA 93011 • (800) 444-3353  
record serial number Here:  
note:If product has no serial number, record month and year of purchase instead.  
note:Some parts are listed and shown for illustration purposes only, and are not available individually as  
replacement parts.  
SKU 65549  
For technical questions, please call 1-800-444-3353.  
Page 13  
 

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