The bellows on a Jumping Jack rammer is a critical component, serving as a flexible seal between the ramming system and the upper driveline. The bellows main job is to keep out dust, dirt, and debris, protecting the internal mechanisms and ensuring a clean path for recirculating oil. Over time, the bellows can become damaged from worksite hazards or improper storage, which may compromise the performance and longevity of your rammer. Regular inspection and maintenance are essential - especially making sure the clamps remain tight and the bellows is free from leaks or tears. Below is an updated, easy-to-follow guide on how to replace the bellows on a Wacker Neuson Jumping Jack rammer.
Preparation and Safety
Before starting, remember that you’ll be separating the ramming section from the upper driveline. Secure both sections safely - an engine hoist is ideal, but you can also lay the machine on its side and support it with wooden blocks.
Disassembly Instructions
- Drain the Oil: Start by draining the oil from the rammer to avoid spills and contamination.
- Remove Guide Cylinder Bolts: Use the 8mm Allen wrench to remove the four bolts connecting the rammer guide cylinder to the crankcase.
- Expose the Connecting Rod Pin: Gently pull the guide cylinder away from the crankcase until you can see the pin that connects the rod to the guide piston.
- Secure and Separate: Use wooden blocks to hold the rammer system open. Drive out the pin and end plugs from the guide piston with your punch and hammer.
- Separate Assemblies: Detach the lower ramming system from the crankcase.
- Remove Top Bellows Clamp: Take off the upper clamp. Stand on the rammer shoe and pull the guide cylinder out of the bellows.
- Remove Bottom Clamp and Bellows: Remove the lower clamp, then pull the bellows free from the protective pipe. If it’s stuck, use a rubber mallet to help loosen it.
- Clean Protective Pipe: This would be a great time to carefully clean out any residual dirty oil left in the protective pipe.
Assembly Instructions
- Oil and Position Bellows: Lightly oil the upper lip of the rammer protective pipe. Align the small end of the new bellows with the pipe lip. Only some models have a small and big end to a bellows.
- Oil Guide Cylinder Lip: Apply a light coat of oil to the guide cylinder lip. Lower the guide cylinder over the spring cylinder, aligning the bellows vertically with both the protective pipe and the guide cylinder.
- Seat the Bellows: With a quick, firm motion, push the guide cylinder down so the bellows snaps securely over both lips.
- Tighten Clamps: Secure the lower clamp to appropriate torque, lightly tighten the top clamp for now.
- Install New O-Ring: Place a new O-ring on the rammer guide cylinder.
- Install End Plug: If you are not using the hoist method, insert one push in plug into the side of the ram that will be facing downward towards the floor. Recess the plug about 1/8".
- Reconnect Rod and Piston: Align the connecting rod inside the guide piston and install the piston pin. Insert the second end plug until it’s flush with the outside of the guide piston. Always use new end plugs if the piston pin was removed.
- Reattach Guide Cylinder: Fasten the crankcase to the rammer guide cylinder. Use Loctite on the bolts. For torque specifications, consult your manual or call DHS Equipment at 866-611-9369—specs vary by model.
- Aligning the Ramming Shoe: Lay the rammer down with the front of the guide handle on level ground. Make sure the front edge of the ramming shoe is level with the ground and not twisted. With the top bellows clamp not tightened yet, the shoe can rotate until the proper alignment is achieved. You can now secure the top bellows clamp to the specified torque.
- Refill Oil: Fill the ramming system with oil to the recommended level using SAE 10W-30. Be careful not to overfill. The recommended oil level is between 1/2 - 3/4 in the sight glass.
- Final Inspection: Run the rammer briefly and check for leaks or abnormal noises.
Additional Tips
- Cleanliness is Key: Always clean the internal area before installing the new bellows to prevent contamination.
- Alignment: After reassembly, ensure the shoe and bellows are properly aligned. Misalignment can lead to operational issues or premature wear.
- Replacement Video: For a visual walkthrough, DHS Equipment offers a detailed how-to video covering these steps.
Need Help?
If you have questions about these instructions, need torque specs, or want to order replacement parts, contact DHS Equipment at 866-611-9369 or email [email protected]. Regular maintenance and timely bellows replacement will keep your Jumping Jack rammer running efficiently and extend its service life.
How-To Video
Author: David Schatz
David Schatz is the founder of DHS Equipment and a technical content expert in light construction equipment, small engines, and professional-grade replacement parts. With more than 30 years of hands-on experience servicing concrete saws, generators, water pumps, and plate compactors, he helps contractors, rental fleets, and serious DIY users keep their equipment running safely and efficiently.
Through practical, no-nonsense articles, step-by-step guides, and maintenance tips, David focuses on real-world troubleshooting, small engine repair, and clear recommendations on OEM and high-quality aftermarket replacement components that reduce downtime, extend equipment life, and improve job site productivity.