1-ton
aIr/HYdraulIc
strut sprInG
coMpressor
65549
InstructIons and precautIons
®
distributed exclusively by Harbor Freight tools .
3491 Mission Oaks Blvd., Camarillo, CA 93011
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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