Harbor Freight Tools 65549 Air Compressor User Manual
Contents
1. CAUTION safety alert symbol is used to address ASSEMBLY PRECAUTIONS practices not related to personal 1 Use only according to these instructions injury Improper use can create hazards o 2 Wear ANSI approved safety goggles and GENERAL SAFETY heavy duty work gloves during use 1 WARNING Ensure Health amp Safety local 3 Keep work area clean and well lit authority and general workshop practice 4 Keep bystanders out of the area during use 2 are adhered to when using this 5 Do not use when tired or when under the Tm eye protection standard spectacles are not adequate IMPO RTANT SAF ETY 3 WARNING TRAPPING DANGER Keep hands and fingers away from the spring and ____ INFORMATION __ compressing Shoes when in use In this manual on the labeling and all 4 Keep the work area clean uncluttered and other information provided with this ensure there is adequate lighting product 5 Maintain correct balance and footing Ensure This is the safety alert symbol whale is not slippery and wear non slip It is used to alert you to potential personal injury hazards Obey 6 Remove ill fitting clothes Remove ties all safety messages that follow watches rings and other loose jewellery this symbol to avoid possible Contain and or tie back long hair injury or death 7 Wear appropriate protective clothing 8 Familiarize yourself with the applications A DANGER 22 limitations and potential hazards2. lt 22 lt lt 6 Lui gg hi eme 7 PLEASE READ THE FOLLOWING CAREFULLY eene 7 PARTS LIST SPRING 8 PARTS LIST AIR doe nsn xit ha 8 PARTS LIST HYDRAULIC JACK eere 9 ASSEMBLY DRAWING 1 STRUT SPRING COMPRESSOR 10 ASSEMBLY DRAWING 2 2 22 2 ro Fad anc a 11 ASSEMBLY DRAWING HYDRAULIC JACK eese 12 LIMITED 90 DAY WARRANTY 2 2 2 2 2 13 SKU 65549 For technical questions please call 1 800 444 3353 Page 2 WARNING indicates a SPECIFICATIONS AWARNING situation ee could result in death or serious EEUU CAUTION used with Small Set 4 Springs Large Set 6 3 Springs situation which if not avoided could result in minor or moderate injury UNPACKING Re ee NOTICE is used to When unpacking make sure that the item NOTICE address practices not is intact and undamaged If any parts are missing related to personal or broken please call Harbor Freight Tools at the injury ber sh th f this d t number shown on the cover of this document as CAUTION without the
3. A17 A18 A19 A20 A21 A22 A23 Lock Lever A24 A25 A26 A27 A28 A29 A30 32 A31 A A33 A35 A34 A36 A37 A38 A39 44 A40 A41 A42 A43 A A45 A46 A47 A48 Page 8 PARTS LIST HYDRAULIC JACK Partt Description B1 Screw Protector Screw B2 Screw Base B10 Release Pedal B11 B B3 B4 B5 7 B8 Ww o 12 B13 B14 B15 B16 B17 B18 B19 B20 B21 B22 B23 B24 B25 B27 Link B28 B29 B30 B31 B32 Washer 1 83 Screw 1 B34 B35 B36 B37 B38 B39 B40 B41 Circlip Ram B43 Oring 1 1 B44 NyonRng 1 _ B45 1 ajo A 2 2 SKU 65549 For technical questions please call 1 800 444 3353 Page 9 1 Ton Strut Spring Compressor Drawin Assembl Page 10 For technical questions please call 1 800 444 3353 SKU 65549 Assembly Drawing Air Motor 5 5 ew d COP Y D 0 0 65 00 zx lt lt 5 _ lt i s x 5 CY Y 0 9 e 48205 u E 4 3 7 4 SKU 65549 For technical questions please call 1 800 444 3353 44 B dO OD 2 3 e lt lt lt 0 6 fe 6 0 8 24 3 A31 Page 11 Assembly Drawing Hydraulic Jack B43 B35 B34 B42 B4 B4 B39 Air Motor Ass y BIO BI8 7
4. Spring Compressed lt mw Lower Strut Strut Housing Mount Fig 2 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 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 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 c Use the Foot Pedal 5 to raise the Under Strut Support 24 to finely adjust the dis tance between the Shoes 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 5 6 10 11 12 For technical questions please call 1 800 444 3353 a If wear or fatigue is found do not use the Tool Have the tool replaced or repaired by a qualified technician 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
5. PSI to oper ate at full capacity SKU 65549 For technical questions please call 1 800 444 3353 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 b Drain the air supply tank daily and clean the Air Inlet Filter A16 weekly c When used drain air filter at least once a day Male Connector ub Quick Coupler Male Connector 22 Coupler Regulator with Pressure Gauge Recommended Air Line Components 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 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 SAVE THESE INSTRUCTIONS Page 5 Upper Shoe 9 SKU 65549 OPERATING INSTRUCTIONS Measure the outer diameter of the spring to be compressed and select the correct set of Shoes 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 Top Cap Nut Upper Strut Mount
6. 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 pro
7. absorber piston 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 13 Once compressed and the strut removed it is recommended to release the tension on the spring a Do not leave the spring under compression unattended and do not leave in compres sion for prolonged periods l e overnight 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 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 a Re position the upper strut mount and se cure with the top cap nut 16 Before releasing the compression ensure that the top cap nut is securely tightened ac cording to the manufacturer s specs 17 Release the compression slowly keeping your hands and fingers away from the spring assembly 18 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 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 a Remove it from service immediately and have it replaced or repaired by a qu
8. 28 28A 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 Wrap the other Safety Chain around the spring and strut protruding from the lower Shoe ensuring that the Chain lies below the Shoe 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 When applying compression to the spring always stand to one side of the unit 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 Ensure that the strut and the Upright 14 of the compressor are correctly aligned at all times during spring compression 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 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 Harbor Freight Tools recommends the use of properly designed strut tools to remove the top cap nut from the shock
9. Hydraulics 1 TON AIR HYDRAULIC STRUT SPRING COMPRESSOR 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 CONTENTS SPECIFICATIONS cc 3 isl cm M 3 ASSEMBLY PRECAUTIONS ce bb E Eve E epo cbe s crees Reve eee c 3 IMPORTANT SAFETY INFORMATION enne 3 GENERAL SAPET Y iu airea erebre E eaaa aeS 3 PRE OPERATIONAL 4 POST cid 4 INTRODUC ttc crc 5 S 5
10. alified 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 hole Add hydraulic jack oil if necessary WARNING DO NOT use brake fluid or any fluid other than hydraulic jack oil as this will cause SKU 65549 For technical questions please call 1 800 444 3353 serious damage to the jack and invalidate the warranty Bleeding the Hydraulic System 3 The Strut Spring Compressor must be se curely mounted on a flat and level surface 4 Wipe the Oil Filler Plug 38 and its surround ing area at the side of the Ram 7 5 With the tip of a flat tip screwdriver pry and remove the rubber Oil Filler Plug 6 Pour fresh hydraulic jack oil into the Ram 7 until it starts to overflow T Step on the Valve Release Pedal 6 and allow the Under Strut Support 24 to be lowered completely 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 9 Repeat step 6 above to make sure that the Ram 7 is filled with oil 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 fla
11. ld by the strut assembly before removing the strut from the Shoes 28 of the compressor POST OPERATIONAL SAFETY 1 When not in use clean and store the Spring Compressor in a safe dry childproof location 2 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 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 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 c The Circlip 22 will remain in place on the other end 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 Page 4 designed to be used as matched pairs and should not be mixed INTRODUCTION T The 1 Ton Air Hydraulic Spring Compressor is an air actuated hydraulic unit with alterna tive foot operation ASSEMBLY 1 The unit requires minimal assembly before use 2 Attach the Angle S
12. of the which if not avoided prng Compressor will result in death or serious injury 9 NOT force the spring compressor to achieve a task it was not designed to per form 10 DO NOT allow untrained persons to use the spring compressor SKU 65549 For technical questions please call 1 800 444 3353 Page 3 PRE OPERATIONAL SAFETY 1 This product is not a toy Do not allow chil dren to play with or near this item Use for intended purpose s only Inspect before use do not use if parts are loose or damaged 4 Strut and Spring Compression station should be securely bolted to the workshop floor before use 5 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 6 DO NOT operate Spring Compressor if parts are damaged or missing as this may cause failure and or personal injury T 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 8 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 9 Before commencing compression of a spring ensure ends of the spring are seated and be ing held sec
13. t tipped screwdriver 11 After the plug is inserted wipe off spilled oil from jack exterior with a clean and dry rag CAUTION DO NOT operate the jack when the Oil Filler Plug 38 is removed PLEASE READ THE FOLLOWING CAREFULLY 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 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 REPLACEMENT PARTS THERETO Page 7 PARTS LIST SPRING COMPRESSOR Partt Description Qty 1 jArvave 712 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 SKU 65549 For technical questions please call 1 800 444 3353 PARTS LIST AIR MOTOR Part Description art A01 Cylinder 02 A03 A04 A05 A06 Nut 07 Nut A08 09 10 11 12 A13 A14 A15 A16
14. teel 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 Push Circlips 29 into the groove on each retaining Pin 30 5 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 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 Te 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 WARNING Whichever method is used ensure the unit is adequately fixed and cannot topple AIR SUPPLY SET UP 8 Ensure the Air Valve 1 is in the Off posi tion before connecting to the air supply The Spring Compressor requires 120
15. urely in upper and lower Shoes 28 28A of the compressor and cannot slide out during compression 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 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 DANGER Stop compressing the spring before the coils touch Do not over compress 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 14 Harbor Freight Tools recommends use of an appropriate tool to be supplied by user to remove top cap nut from upper strut mount 15 Once compressed and strut is removed it is a good idea to release the tension on the spring a Do not leave the spring under compression in the machine unattended and do not leave in compression for prolonged periods i e overnight 16 Before releasing the compression ensure that the top cap nut is securely fastened ac cording to the manufacturer s specs 17 Release the compression slowly keeping your hands and fingers away from the spring assembly 18 sure the tension on the spring is fully he
16. vide 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 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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