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9. Remove the springbox tool rods from the assembly.
10. The springbox warning decal (page 2, #01326)
should be clean and highly visible. If not, the old
decal should be completely removed and replaced
with a new decal.
11. Lightly oil a new o-ring (#9) and place it into the
groove in the springbox guard (#12).
12. Slide the springbox guard over the ram head onto the
springbox. Be careful not to damage the o-ring
during installation.
13. Place the springbox assembly onto the shoe (page
18 #13) with the fill plug (#4) pointing toward the back
of the shoe.
14. Install six hex head cap screws and lockwashers
(page 18 #11 & #12) with medium strength lock-tite.
Torque the cap screws to 40 ft lbs (56 N•m).
Gearbox and Lower Unit Assembly
NOTE: If replacing gearbox housing, install engine
studs with high strength (red) Loctite.
Refer to Gearbox and Lower Unit Assembly, page 18.
1. Rotate the ram head (page 16, #16) in the lower unit
so the threaded hole on top is positioned toward the
front of the shoe (#6).
2. Slide the gearbox assembly onto the lower unit.
3. Align the connecting rod (page 14, #5) with the ram
head and install the piston pin (#3) with the groove in
the pin facing out.
4. Align the groove in the piston pin with the hole for the
setscrew (#9).
5. Install the setscrew into the ram head finger tight,
then back off 1/4 turn. Lock the setscrew in place with
the hex nut (#10). Make sure setscrew is in groove.
The piston pin must be able to rotate.
6. Rotate the gearbox assembly so the front of the
gearbox is aligned with the front of the lower unit.
7. Secure the lower bellows mount to the springbox
guard using six hex head flange screws (page 16,
#19). Torque to 12 ft lbs (16 N•m).
8. Apply a light coat of oil to all of the bearings in the
gearbox assembly.
9. Tip the assembly back and place a new gasket (#4)
over the gearbox face.
10. Insert the dowel pins (#1) into the gearbox through
the holes in the gasket.
11. Align the holes in the cover (#2) with the dowel pins
and place the cover on the gasket.
12. Secure the cover to the gearbox using four hex head
flange screws (#8) with medium strength thread
locker. Tighten the flange screws equally and torque
to 12 ft lbs (16 N•m).
13. The gasket will compress slightly after initial
tightening, re-torque the flange screws after 5
minutes.
14. If the handle brackets (page 20, #17 and #18) were
removed, apply medium strength thread locker to the
four socket head cap screws (page 20, #27) before
assembly. Torque to 35 ft lbs (47 N•m).
15. Fill the unit with oil according to the Changing
Percussion System Oil section on page 6.
