Vibrating Rammer

LT 600/700/800

Workshop Manual
WLTALLEN2, February 2002
These instructions apply from:
LT 600 PIN (S/N) *76000001*
LT 700 PIN (S/N) *77000001*
LT 800 PIN (S/N) *77500001*

We reserve the right to change specifications without notice.

Printed in Sweden.
 CONTENTS
Page
Technical specifications ................................................... 3
Fuel and lubricants ........................................................... 4
Engine .............................................................................. 5
Carburetor – Parts list LT 600 ...................................... 6, 7
Carburetor – Parts list LT 700 ...................................... 8, 9
Carburetor – LT 600 ....................................................... 10
Carburetor – LT 700 ....................................................... 11
Recoil starter, Honda ............................................... 12, 13
Valve clearance LT 600 ............................................ 14, 15
Valve clearance LT 700 .................................................. 16
Valve clearance LT 800 .................................................. 17
Rammer leg .............................................................. 18, 19
Foot ................................................................................ 20
Replacing the complete foot ........................................... 20
Replacing the "bottom" steel plate .................................. 20

WARNING SYMBOLS

WARNING

Safety instructions – Personal safety

CAUTION

Special caution – Machine or component damage

2 WLTALLEN2
 TECHNICAL SPECIFICATIONS

LT 600 LT 700 LT 800

Engine

Model Honda GX 100 Honda GX 120 Hatz 1B20

4-stroke 4-stroke Diesel
Manual start Manual start Manual start

Idling revs 1550 1400

Operating speed 3600 3600 3600

Tightening torque

Rammer foot M8 15 Nm
Rammer foot M12 78 Nm

Centrifugal clutch 60 Nm

Tightening torque in Nm (lbf.ft) for oiled, bright

galvanized bolts tightened with a torque wrench.

M STRENGTH CLASS

thread 8.8 10.9

M6 8,4 (6.2) 12 (8.9)

M8 21 (15.5) 28 (20.7)
M10 40 (15.5) 56 (41.3)
M12 70 (51.6) 98 (72.3)
M16 169 (124.7) 240 (177)
M20 330 (243.4) 470 (346.7)
M24 570 (420.4) 800 (590.1)
M30 1130 (833.5) 1580 (1165.4)
M36 1960 (1445.7) 2800 (2065.3)

WLTALLEN2 3
 FUEL AND LUBRICANTS

LT 600 LT 700 LT 800

Volumes

Fuel tank, lit. (qts) 2,5 (2.65) 2,5 (2.65) 3,0 (3.17)

Engine oil, lit. (qts) 0,4 (0.42) 0,4 (0.42) 0,9 (0.95)

Rammer leg, lit. (qts) 0,9 (0.95) 0,9 (0.95) 0,9 (0.95)

Oil LT 600/700/800

Engine oil Shell Universal Engine oil API - CF-4/SG, ACEA - E2/B2, SAE
15W-40 or equivalent.

Rammer leg Shell Universal Engine oil API - CF-4/SG, ACEA - E2/B2, SAE
15W-40 or equivalent.

4 WLTALLEN2
 ENGINE

Separating the engine from the

gear housing
1. Close the fuel valve on the tank.
2
2. Remove the throttle lever from the handle.

3. Remove the fuel hose from the tank.

4. Remove engine support (4) (only on LT 700).

5. Remove the nuts (3) attaches engine to the gear

housing.
1
3 6. The nuts that holds together engine and gear
4 housing torque 45 Nm
W000001A

Fig. 1 Engine with gear housing.

1. Gear housing
2. Engine
3. Nut x4
4. Engine support

Exchange the centrifugal clutch

1. Seperate engine from gear housing (see above).

2. Unscrew the center nut (1) on the engine shaft.

2

3. Remove the washer (3) and the clutch (4).

CAUTION

Fastening is little different on 600/700 and 800.

4. Mount the new clutch and torque 60 Nm.

4 3 1
W000002A

Fig. 2 Engine
1. Nut
2. Key
3. Washer
4. Centrifugal clutch

WLTALLEN2 5
 CARBURETOR – PARTS LIST LT 600

1
20
19 3
2
4
5
18 17 6

7
16 8
15
9

10
14 12
13
11

W000003A

Fig. 3 Carburetor LT 600

6 WLTALLEN2
 CARBURETOR – PARTS LIST LT 600

Pos Qty Part No Description Notes

Carburetor assy
1 Screw
2 Jet set, pilot
3 Plate, lever setting
4 Spring cock lever
5 Lever, cock
6 Packing, fuel cock
7 Choke set
8 Nozzle, main
9 Jet, main
10 Valve set, float
11 Float set
12 Screw set, drain
13 Screw set
14 Tube
15 Chamber set, float
16 Screw throttle stop
17 Screw set
18 Packing, carburetor
19 Insulator, carburetor
20 Packing, insulator

WLTALLEN2 7
 CARBURETOR – PARTS LIST LT 700

28
1
29 2
4
27 3
5

6
8
7
9
22 10
24 23 21 12
11
20

19 13
14
25 18
26
16
15

17

W000004A

Fig. 4 Carburetor LT 700

8 WLTALLEN2
 CARBURETOR – PARTS LIST LT 700

Pos Qty Part No Description Notes

Carburetor assy
1 Screw
2 Plate, lever setting
3 Spring, cock lever
4 Lever, cock
5 Packing, fuel cock
6 Lever comp. choke
7 Spring, return
8 Packing, fuel strainer cup
9 Cup, fuel strainer
10 Choke set
11 Spacer comp, carburetor
12 Valve set, float
13 Holder, control cabel
14 Screw
15 Stay, choke control
16 Screw set, drain
17 Screw set
18 Chamber set, float
19 Float set
20 Jet, main
21 Nozzle, main
22 Screw, throttle stop
23 Screw set, pilot
24 Packing, carburetor
25 Clip, tube
26 Tube, vinyl
27 Insulator, carburetor
28 Packing, insulator
29 Jet set, pilot

WLTALLEN2 9
 CARBURETOR – LT 600

Adjustment of carburetor LT 600

The pilot screw is fitted with a limiter cap that prevents
excessive enrichment of the air-furl mixture in order to
comply with emissions regulations.

Do not attempt to remove the limiter cap for pilot screw

adjustment. The limiter cap cannot be removed without
breaking the pilot screw.

Pilot screw adjustment must be preformed only when

the carburetor is disassembled and the pilot screw is
replace.

Revs:
1 Idling revs 1550 ± 150 v/min
W000005A
Engagement revs of
Fig. 5 Carburetor
1. Pilot screw
centrifugal clutch about 2500 rpm
Operating speed about 3750 rpm

Idle speed adjustment

2
1. Start the engine and allow it to warm up to normal
operating temperature.

2. With the engine idling, turn the throttle stop screw to

obtain yhe standard idle speed.

W000006A

Fig. 6 Carburetor
2. Throttle stop screw

10 WLTALLEN2
 CARBURETOR – LT 700

Adjustment of carburetor LT 700 CAUTION

The air cleaner must be clean before making
any adjustment. The engine must be warm
before adjusting the speed.

Revs:
Idling revs 1400 ± 150 rpm
Engagement revs of
centrifugal clutch about 2500 rpm
Operating speed about 3600 rpm

CAUTION

1 When adjusting, do not tighten the nozzles too

W000007A hard, its seating will be damaged.
Fig. 7 Carburetor
1. Pilot screw

Idle speed adjustment

1. Start the engine and allow it to warm up to normal

operating temperature.

2. With the engine idling, turn the pilot screw in or out to

the setting that produces the highest idle min (rpm).
The correct setting will usually be obtained at
approximately the following number of turns out from
the fully closed (lightly seated) position.

3. After the pilot screw is correctly adjusted, turn the

throttle stop screw to obtain the standard idle speed.
1
W000008A

Fig. 8 Carburetor
1. Throttle stop screw

WLTALLEN2 11
 RECOIL STARTER, HONDA

1. Insert the hook (1) on the outer side of the spring

2 1 into the groove (2) inside the reel.

W000009A

Fig. 9 Recoil starter

1. Hook
2. Groove

2. Pass the starter rope through the starter reel and tie
1
(1) it as shown. Wind the starter rope around the
starter reel in direction of arrow. Leave approxi-
mately 30 cm of the starter rope outside of the
starter reel.

W000010A

Fig. 10 Recoil starter

1. Tie

3. Install the starter reel on the starter case (1) so that

the spring inner hook is hooked to the case tab (2).

1 2
W000011A

Fig. 11 Recoil starter

1. Starter case
2. Case tab
4. Hold the starter case and rotate the starter reel two
revolutions in the direction of the arrow for prelimi-
nary winding.

W000012A

Fig. 12 Recoil starter

12 WLTALLEN2
 RECOIL STARTER, HONDA

5. Pass the starter rope end through the starter case

rope guide and pull it outwards. Pass the starter
rope though the starter grip and tie the rope as
shown.

WARNING
Do not separate the starter reel from the
starter case. Otherwise the return spring
inside the case will come off, which could
cause injuries.
W000013A

Fig. 13 Recoil starter

6. Install the ratchet (1) with the spring (2) and reel
cover (3). Tighten the reel cover bolt (4).
4
3 7. Check the operation of the ratchet by pulling the
starter rope several times.
1

W000014A

Fig. 14 Recoil starter

1. Ratchet x2
2. Friction spring x2
3. Reel cover
4. Reel cover bolt

8. Hold the starter case and rotate the starter reel two
revolutions in the direction of the arrow for prelimi-
nary winding.

W000015A

Fig. 15 Recoil starter

WLTALLEN2 13
 VALVE CLEARANCE LT 600

CAUTION
1
Valve clearance inspection and adjustment
must be performed with the engine cold.

1. Loosen the four 6 x14 mm flange bolts(1).

2

W000016A

Fig. 16 Valve
1. Flange bolts x4
2. Cylinder head cover

2. To remove the head cover, insert a screw driver or

equivalent tool into the recess in the position of
cylinder shown. Remove the head cover slowly.
CAUTION

Do not remove the head cover with force,

because that can deform the head cover.
Replace the head cover if it is deformed.

3. Remove the recoil starter.

W000017A
Fig. 17 Cylinder head cover

4. Set the piston at top dead center of the compression

2 stroke (both valves fully closed). Top dead center of
the compression stroke is the the point there where
the cutout (1) in the starter pully (i.e. opposite side
from the mark (2) on the flywheel) is in alignment
with the lower bolt hole (3) of the fan cover.

If the exhaust is opens when the cutout in the starter

pulley is aligned with the lower bolt hole on the fan
1 cover, turn the flywheel one turn and align the
3 marks.
W000018A

Fig. 18 Mark The top dead center of the compression stroke is in

1. Cutout the position where the head cover mating surface
2. Alignment mark aligns with the cam pulley alignment marks.
3. Lower bolt hole

14 WLTALLEN2
 VALVE CLEARANCE LT 600

4. Insert the feeler gauge (1) between the valve adjust-

1 ing screw and the valve and measure the valve
clearence.

0,15 ± 0,02 mm
In (0,006 ± 0,001 in)
Standard valve
clearance
0,20 ± 0,02 mm
Ex
(0,008 ± 0,001 in)

W000019A

Fig. 19 Valve adjustment

1. Feeler gauge

5. If adjustment is necessary, proceed as follows.

1 2 A. Hold the valve adjusting screw (1), and loosen

the lock nut (2).

B. Turn the adjusting screw to obtain the specified

intake and exhaust valve clearance.

C. Hold the valve adjusting screw, and tighten the

lock nut.

W000020A D. Recheck valve clearance after tightening the

Fig. 20 Valve adjustment lock nut.
1. Adjusting screw
2. Lock nut 6. Install the head cover and recoil starter.

WLTALLEN2 15
 VALVE CLEARANCE LT 700

CAUTION
1
Valve clearance inspection and adjustment
must be performed with the engine cold.

1. Remove the four cylinder bolts, cylinder head cover

and gasket.

3
2
W000021A

Fig. 21 Valve
1. Bolts
2. Cylinder head cover
3. Gasket

2
2. Set the piston at top dead center of the compression
stroke (both valves fully closed). The triangular
mark on the starter pulley will align with the top hole
on the fan cover when the piston is at top dead
center of the compression or exhaust stroke.

1
W000022A

Fig. 22 Mark
1. Triangular mark
2. Top hole
3. Insert a feeler gauge between the rocker arm and
valve to measure valve clearance.
1

0,15 ± 0,02 mm
In (0,006 ± 0,001 in)
Standard valve
clearance
0,20 ± 0,02 mm
Ex
(0,008 ± 0,001 in)

W000023A

Fig. 23 Valve adjustment 5. If adjustment is necessary, proceed as follows.

1. Feeler gauge
A. Hold the rocker arm pivot (1) and loosen the
rocker arm pivot lock nut (2).
1
2 B. Turn the rocker arm pivot (1) to obtain the
specified clearance.

C. Retighten the rocker arm pivot lock nut (2)

while holding the rocker arm pivot (1).

D. Recheck valve clearance after tightening the

W000024A
rocker arm pivot lock nut (2).
Fig. 24 Valve adjustment
1. Rocker arm pivot
6. Install the head cover and recoil starter.
2. Rocker arm pivot lock nut

16 WLTALLEN2
 VALVE CLEARANCE LT 800

CAUTION

Valve clearance inspection and adjustment

must be performed with the engine cold.

1. Remove air cleaner cover and noiseinsulating hood.

2. Remove any contamination adhering to the cover

for the cylinder head.

3. Remove screws and take off the cylnder head civer

with gasket.
W000025A

Fig. 25 4. Remove rubber cap from the inspection hole cover.

5. Turn the engine over in the normal direction of

rotation until the valves are in the overlap position
(exhaust valve not yet closed, inlet valve start to
3 open).

3 6. Turn the crankshaft through 360° in the normal

direction of rotation and align exactly to the
● ● ● -marking.

7. Check valve clearances with feeler gauge.

W000026A

Fig. 26

0,10 mm
In (0,004 in)
Standard valve
clearance
0,10 mm
Ex
(0,004 in)

8. If valve clearances require adjusting, slacken of

screw and turn hex nut until feeler gauge can be
pulled through with just slight resistance when
W000027A
screw is retightened.
Fig. 27
9. Fit cover for cylinder head and tighten evently,
always using a new gasket.
8 8 10. Re-attach parts previously removed from engine.
Do not forget: Replace the rubber cap at the inspec-
7 tion hole cover.
8
11. Carry out a breif test run, then check the cover for
leaks.

8
W000028A

Fig. 28

WLTALLEN2 17
 RAMMER LEG

Changing the bellows

1. Remove the engine from gear house (see page 4).

2. Unscrew the four screws holding gear house (1) to

1 the leg.
2

3
3. Turn the clutch (2) as that crankshaft (3) comes in
it`s outermost position. Lift up crankcase and press
4 down outer tube (4). Dismantle pistonbolt (5) thats
5
hold crankshaft. Lift away crankcase from the leg.

4. Remove upper hose clamp (6). Tap the bellow loose

6 from outer tube. Lift away the outer tube.

5. Remove lower hose clamp and change the bellows.

6. Refit the outer tube.

W000029A 7. Align the machine and tighten the hose clamps (6).
Fig. 29 Rammer leg CAUTION
1. Crankcase
2. Clutch Opposite directions for the hose clamps (6).
3. Crankshaft
4. Outer tube
5. Pistonbolt
6. Hose clamps
8. Mount the crankcase.

Changing the pinion /

gear wheel / connecting rod
1. Remove the crankcase. (see above).
4 5 3 6
2. Unscrew the four screws (1) and remove the cover
(2).

3. Remove crankshaft (3). Remove the snap ring (4)

as holding bearing (5). Remove crankshaft use a
puller.
7
8
4. Remove gear wheel (6). Use two M8 screws to
press out gear wheel from bearing.

5. Dismantle of pinion (7). Remove snap ring (8) as

holding pinion. Remove pinion shaft from gear
housing by hitting the pinion shaft from the gear side
1 using a steel bar and a hammer.
2
W000030A

Fig. 30 Crankcase
1. Screw x4
2. Cover
3. Crankshaft
4. Snap ring
5. Bearing
6. Gear wheel
7. Pinion shaft
8. Snap ring

18 WLTALLEN2
 RAMMER LEG

Dismantling the spring assembly

1. Dismantling is the same as change of bellows.

2. Remove rod piston head (1).

1 2
3. Drain the oil from spring cylinder assy before turning
it upside down.

W000031A

Fig. 31 Rammer leg

1. Rod piston head
2. Oil plug

WARNING
The spring assembly is pre-tensioned, ie, it
is pressed together 125 mm.
1 2

4. Remove three screws (1) and replace this with three

2 1
fully treaded screws M8x150 mm with washer and
nuts and retighten.

1 2 WARNING

Spring load. DO NOT remove the other

three screws at this moment.

W000032A

Fig. 32 Screws bottom side tamper leg

1. Screws M8x150 mm
2. Screws M8X20 mm

5. Loosen the remaining three screws (2) M8x20 mm

6. Then loosen the three "long" screws alternately until

the spring load is released.

W000033A

Fig. 33 Screws bottom side tamper leg

1. Screws M8x150 mm
2. Screws M8X20 mm

WLTALLEN2 19
 FOOT

Replacing the complete foot

1. Unscrew the six (1) M12 nuts holding the foot to the
bellows bracket.

2. Replace the old foot with a new one.

3. Reassemble and torque with 78 Nm.

Replacing the "bottom" steel plate

1. Loosen the eight (2) M8 nuts holding the plate.

2. Replace the old plate with a new one.

2. Reassemble the new plate and torque with 15 Nm.

2
2
1
W000034A

Fig. 34 Foot
1. M12 nuts x 6
2. M8 nuts x 8

20 WLTALLEN2
Box 504, SE-371 23 Karlskrona, Sweden
Phone: +46 455 30 60 00
Fax: +46 455 30 60 30
www.dynapac.com