How to Replace the Bellows on the Wacker Neuson Jumping Jack Rammer

The bellows on a Jumping Jack rammer serve as a flexible joint between the ramming system, and the upper driveline of the machine. The bellows act as a seal, keeping out silt, dust, and dirt. The bellows protects the ramming system and provides a clean path for recirculating oil.

Damage to the bellows, whether on the worksite, or from improper storage, can compromise the Jumping Jack ramming system. That's why it's important to clean and inspect the bellows regularly for any signs of damage or leaks. Most importantly, keep the clamps tight.

We're going to give step-by-step instructions on how to replace your Jumping Jack bellows. These instructions are the recommended method by Wacker Neuson on how to replace the Jumping Jack rammer bellows.

The tools you should have on hand are:

• Socket Wrench: 11mm & 19mm
  
• Allen Wrench: 8mm
  
• 3/8" Punch
  
• Screwdriver
  
• Rubber Mallet 
  
• Hammer
  

When replacing the bellows on your Jumping Jack rammer, it's important to know that you will be separating the ramming section from the upper driveline. Find a method to support each system while you separate them. Usually an engine hoist is the most popular choice, but you can also lay the machine down, and use wooden blocks.

Disassembly Instructions:

1. Drain the oil from the rammer.

2. Use an 8mm allen wrench to remove the four bolts holding the rammer guide cylinder to the crankcase.

3. Pull the guide cylinder away from the crankcase, until the pin that holds the connecting rod to the guide piston is visible.

4. Hold the rammer system open using wooden blocks. Drive the pin and end plugs free of the guide piston.

5 Separate the lower remaining ramming system from the crankcase.

6. Remove the top bellows clamp. Stand on the rammer shoe and pull the guide cylinder free of the bellows.

7. Remove the bottom bellows clamp. Pull the bellows free of protective pipe. Note: Use a rubber mallet if the bellows resist separation.

Assembly Instructions:

1. Lightly oil the upper lip of the rammer protective pipe. Align the small end of the bellows with the rammer pipe lip.

2. Lightly oil the guide cylinder lip. Lower the guide cylinder over the spring cylinder and align the bellows vertically with the rammer protective pipe and guide cylinder.

3. With a fast, quick snap, push the guide cylinder down. The bellows will pop up, over the rammer protective pipe lip and guide cylinder lip.

4. Tighten the lower and upper bellows clamps.

5. Install the new o-ring on the rammer guide cylinder.

6. Install one end plug on the bottom side of the guide piston. Recess the end plug into the guide piston by 1/8". If you doing this repair with the machine suspended by an engine hoist, you can skip this step.

7. Align the connecting rod inside the guide piston. Install the piston pin. Install the second end plug until it is flush with outside of the guide piston, (or install both end plugs if the rammer is suspended by an engine hoist.). At this point, the bottom, or second end plug should also be flush with the outside of the guide piston. Note: Use new end plugs whenever the piston pin has been removed.

8. Fasten the crankcase to the rammer guide cylinder. Secure the bolts with Loctite. Call DHS Equipment 866-611-9369 for bolt torque specifications. Each machine is different.

9. Fill the ramming system with oil to the correct level. Use SAE 40W for above 50°F, and SAE 10W40 for below 50°F. DO NOT OVERFILL.

10. Run the Jumping Jack rammer and inspect for leaks.

DHS Equipment has created a how-to video on replacing the rammer bellows. We take you step-by-step through the disassembly, repair, and assembly procedures. While our method differs slightly from the Wacker Neuson Jumping Jack rammer bellows replacement instructions, the method is essentially the same.

As always, if you have any questions about the instructions you've read here, or the instructions found in our video, or information on Jumping Jack rammer bellows parts, please feel free to call us toll free at 866-611-9369.