DYNAPAC
Rammer
WORKSHOP MANUAL
WLT6000-1EN1
Box 504, SE-371 23 Karlskrona, Sweden
Phone: +46 455 30 60 00, Fax: +46 455 30 60 30
www.dynapac.com
LT6000/7000
We reserve the right to change specifications without notice.
Printed in Sweden.
Vibrating Rammer
LT 6000/7000
Workshop Manual
WLT6000-1EN1
Published workshop issues valid for these tampers:
Work shop Issue date
WLT6000 - 1EN1 2003 - 01
This workshop is valid from SN:
LT6000 PIN (S/N) *76100020*
LT7000 PIN (S/N) *77100020*
2
WLT6000-1EN1
Safety instructions - Personal safety
Special caution - Machine or component damage
WARNING SYMBOLS
CONTENTS
Page
Technical specifications ................................................. 3
Oil specifications ............................................................. 3
Torque values ................................................................. 3
Tools ............................................................................... 4
Sign plate ........................................................................ 4
Disassembly the engine (LT6000/7000) ......................... 5
Reassembly the engine (LT6000/7000) .......................... 5
Disassembly and reassymbly the clutch ........................ 6
Exchange the centrifugal clutch ...................................... 6
General view for the clutch, LT6000/7000....................... 6
Carburetor LT 6000 ......................................................... 7
Carburetor LT 7000 ......................................................... 7
Recoil starter, honda ....................................................... 8
Recoil starter, honda ....................................................... 9
Valve clearance LT 6000 .............................................. 10
Valve clearance LT 6000 .............................................. 11
Valve clearance LT 7000 .............................................. 12
Disassembly the bellow ................................................ 13
Changing the bellows .................................................... 13
Reassembly the bellow ................................................. 14
Changing the bellows .................................................... 14
Disassembly the crank case ........................................ 15
Diassembly the crank case .......................................... 16
Reassembly the crank case ......................................... 17
Spring unit ..................................................................... 18
Foot ............................................................................... 19
3
WLT6000-1EN1
Torque Nm
Property class Property class
Thread x Pitch 8.8 10.9
M Oiled Dry Oiled Dry
M4 x 0,7 2,5 2,8 3,4 3,8
M5 x 0,8 4,9 5,5 7,0 7,8
M6 x1 6,4 9,4 12 13,4
M8 x 1,25 21 23 28 32
M10 x 1,5 40 45 56 62
M12 x 1,75 70 78 98 110
Model Engine Idling revs/ Fueltank Engine oil Rammer leg
Operating lit. (qts) lit. (qts) lit. (qts)
speed
LT 6000 Honda GX 100 1550/3600 2,5 (2,65) 0,3 (0,32) 0,9 (0,95)
LT 7000 Honda GX 120 1400/3600 2,5 (2,65) 0,4 (0,42) 0,9 (0.95)
TECHNICAL SPECIFICATIONS
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.
Rammer foot M8 15Nm
Rammer foot M12 78Nm
Level glass 40Nm
Centrifugal clutch 60Nm
Crank case torque cross-wise 45 Nm
Shock absorber 25Nm
Metric thread
Bright zinc plated fzb
TORQUE VALUES
OIL SPECIFICATIONS
4
WLT6000-1EN1
TOOLS
General information:
Alwys use plastic hammer when disassembly or reassembly parts.
SIGN PLATE
The sign plate is mounted on the left side of the housing.
Always state Serial Number before ordering new parts
from the Spare Parts Catalogue.
W000049A
5
WLT6000-1EN1
DISASSEMBLY THE ENGINE (LT6000/7000)
1. Close the fuel valve on the tank.
2. Remove the throttle lever from the handle.
3. Remove the fuel hose from the tank.
4. Remove engine support (4) (only on LT 7000).
5. Remove the nuts (3) attaches engine to the gear
housing.
Separating the engine from the
gear housing
2
1
4
3
Fig. 1 Engine with gear housing.
1. Gear housing
2. Engine
3. Nut x4
4. Engine support (LT700)
REASSEMBLY THE ENGINE (LT6000/7000)
Fig. 2 Engine with gear housing.
1. Gear housing
2. Engine
3. Nut x4
4. Engine support (LT700)
5. Nut x4
6. Screw x4
1. Clean surfaces between engine, engine support and
gear housing.
2. Mount engine and torgue nuts (3) crosswise to 45 Nm.
3. Only for LT7000:
Mount engine support first by hand. When mounting
the engine support, it is important to check
parallelism between engine, gear housing and
support before the final torque. (see arrows)
4. Torque nuts (5) and screws (6) crosswise
dry to 23 Nm
1
2
3
5
6
4
W000037A
W000037A
6
WLT6000-1EN1
1. Seperate engine from gear housing
(see previous side).
2. Unscrew the center nut (1) on the engine shaft.
3. Remove the washer (3) and the clutch (4). In some
case it is necessarily to use a puller to loosen the
clutch. The washer (3) is not valid for LT6000
4. Mount the new clutch and torque 60 Nm.
Fig. 3 Engine
1. Nut
2. Key
3. Washer
4. Centrifugal clutch
Exchange the centrifugal clutch
13
4
2
DISASSEMBLY AND REASSYMBLY THE CLUTCH
General instructions for LT6000/7000
GENERAL VIEW FOR THE CLUTCH, LT6000/7000
1. Cover
2. Clutch lining
3. Centrifugal weight
4. Retaining ring
5. Spring
6. Hub
6
5
4
3
2
1
Clutch
Fig. 4 Clutch
W000002A
W000039A
7
WLT6000-1EN1
The air cleaner must be clean before making
any adjustment. The engine must be warm
before adjusting the speed.
1
1
CARBURETOR LT 6000
Revs:
Idling revs 1550 ± 150 v/min
Engagement revs of
centrifugal clutch about 2500 rpm
Operating speed about 3750 rpm
Idle speed adjustment
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.
Fig. 5 Carburetor
1. Throttle stop screw
Adjustment of carburetor LT 6000
CARBURETOR LT 7000
Adjustment of carburetor LT 7000
The air cleaner must be clean before making
any adjustment. The engine must be warm
before adjusting the speed.
Revs:
Idling revs 1400 ± 150 v/min
Engagement revs of
centrifugal clutch about 2500 rpm
Operating speed about 3600 rpm
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 the standard idle speed.
Fig. 6 Carburetor
1. Throttle stop screw.
W000006A
W000008A
8
WLT6000-1EN1
RECOIL STARTER, HONDA
1. Insert the hook (1) on the outer side of the spring
into the groove (2) inside the reel.
2
1
1
2
1
Fig. 7 Recoil starter
1. Hook
2. Groove
Fig. 8 Recoil starter
1. Tie
Fig. 9 Recoil starter
1. Starter case
2. Case tab
Fig. 10 Recoil starter
2. Pass the starter rope through the starter reel and tie
(1) it as shown. Wind the starter rope around the
starter reel in direction of arrow. Leave
approximately 30 cm of the starter rope outside of
the starter reel.
3. Install the starter reel on the starter case (1) so that
the spring inner hook is hooked to the case tab (2).
4. Hold the starter case and rotate the starter reel two
revolutions in the direction of the arrow for
preliminary winding.
W000009A
W000010A
W000011A
W000012A
9
WLT6000-1EN1
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.
Do not separate the starter reel from the
starter case. Otherwise the return spring
inside the case will come off, which could
cause injuries.
3
2
1
4
Fig. 12 Recoil starter
1. Ratchet x2
2. Friction spring x2
3. Reel cover
4. Reel cover bolt
RECOIL STARTER, HONDA
Fig. 11 Recoil starter
Fig. 13 Recoil starter
6. Install the ratchet (1) with the spring (2) and reel
cover (3). Tighten the reel cover bolt (4).
7. Check the operation of the ratchet by pulling the
starter rope several times.
8. Hold the starter case and rotate the starter reel two
revolutions in the direction of the arrow for
preliminary winding.
W000013A
W000014A
W000015A
10
WLT6000-1EN1
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.
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.
VALVE CLEARANCE LT 6000
Fig. 14 Valve.
1. Flange bolts x4
2. Cylinder head cover
Valve clearance inspection and adjustment
must be performed with the engine cold.
1. Loosen the four 6 x14 mm flange bolts(1).
Fig. 15 Cylinder head cover.
1
2
Fig. 16 Mark
1. Cutout
2. Alignment mark
3. Lower bolt hole
4. Set the piston at top dead center of the compression
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
cover, turn the flywheel one turn and align the
marks.
The top dead center of the compression stroke is in
the position where the head cover mating surface
aligns with the cam pulley alignment marks.
2
1
3
W000016A
W000017A
W000018A
11
WLT6000-1EN1
Fig. 17 Valve adjustment
1. Feeler gauge
Fig. 18 Valve adjustment
1. Adjusting screw.
2. Lock nut.
6. If adjustment is necessary, proceed as follows.
1. Hold the valve adjusting screw (1), and loosen the
lock nut (2).
2. Turn the adjusting screw to obtain the specified
intake and exhaust valve clearance.
3. Hold the valve adjusting screw, and tighten the
lock nut.
4. Recheck valve clearance after tightening the lock
nut.
7. Install the head cover and recoil starter.
1
1
2
VALVE CLEARANCE LT 6000
5. Insert the feeler gauge (1) between the valve
adjusting screw and the valve and measure the
valve clearence.
In 0,15 ± 0,02 mm
(0,006 ± 0,001 in)
Standard
valve
clearance
Ex 0,20 ± 0,02 mm
(0,008 ± 0,001 in)
W000019A
W000020A
12
WLT6000-1EN1
Valve clearance inspection and adjustment
must be performed with the engine cold.
1. Remove the four cylinder bolts, cylinder head cover
and gasket.
VALVE CLEARANCE LT 7000
1
23
Fig. 19 Valve
1. Bolts
2. Cylinder head cover
3. Gasket
Fig. 21 Valve adjustment
1. Feeler gauge
1
Fig. 22 Valve adjustment
1. Rocker arm pivot
2. Rocker arm pivot lock nut
2
Fig. 20 Mark
1. Triangular mark
2. Top hole
2
1
1
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.
In 0,15 ± 0,02 mm
(0,006 ± 0,001 in)
Standard
valve
clearance
Ex 0,20 ± 0,02 mm
(0,008 ± 0,001 in)
3. Insert a feeler gauge between the rocker arm and
valve to measure valve clearance.
4. IF adjustment is necessary, proceed as follows:
1. Hold the rocker arm pivot and loosen the rocker
arm pivot lock nut.
2. Turn the rocker arm pivot to obtain the specified
clearance.
3. Retighten the rocker arm pivot lock nut while
holding the rocker arm pivot.
4. Recheck valve clearance after tightening the
rocker arm pivot lock nut.
W000021A
W000022A
W000023A
W000024A
13
WLT6000-1EN1
DISASSEMBLY THE BELLOW
Fig. 23 Rammer leg
1. Crankcase
2. Clutch
3. Crankshaft
4. Outer tube
5. Pistonbolt
6. Hose clamps
7. Screw
Changing the bellows
1. Remove the engine from gear house (see page 4).
2. Loosen the four screws crosswise (7).
3. Turn the clutch (2) so the crankshaft (3) comes in
it`s outermost position. Lift up crankcase and press
down outer tube (4). Dismantle pistonbolt (5) thats
hold crankshaft. Lift away crankcase from the leg.
Tip!
Create an U-shaped tool made of 10-12 mm
plywood, it makes it easier to hold down the outer
tube (4). See fig.
4. Remove upper hose clamp (6). Tap the bellow loose
from outer tube. Lift away the outer tube.
5. Remove lower hose clamp.
6
3
5
4
2
1
Fig. 24 U-tool
1. U-tool
7
1
W000029A
W000040A
14
WLT6000-1EN1
REASSEMBLY THE BELLOW
Fig. 25 Rammer leg
1. Bellow
2. Bellow support
3. Outer tube
4. Outer tube
5. Pistonbolt
6. Hose clamps
Changing the bellows
1. Clean surfaces between bellow (1), bellow support
(2) and outer tube (3)
2. Change the bellows.
3. Refit the outer tube.
4. Align the machine and tighten the hose clamps (6).
Opposite directions for the hose clamps (6).
5. Mount the crankcase.
3
2
1
Tip!
Create an U-shaped tool made of 10-12 mm
plywood, so not the bellow presses down when
mounting the outer tube. See fig.
Fig. 26 Rammer leg
1. U-tool
W000029A
W000041A
15
WLT6000-1EN1
DISASSEMBLY THE CRANK CASE
Fig. 27 Crankcase
1. Screw x4
2. Cover
Fig. 28 Crankcase
3. Snap ring
Fig. 29 Crankshaft
4. Ball bearing
5. Crankshaft
Fig. 30 Crankshaft
6. Gear wheel
7. Needle bearing
8. Snap ring
9. Ball bearing
10. Snap ring
1. Remove the crank case. (see previous side).
2. Unscrew the four screws crosswise (1) and remove
the cover unit (2).
2
1
3. Remove the snap ring (3) and remove the crank
shaft. Use a puller to remove the crankshaft from
the gear.
3
5
4
4. Remove the ball bearing (4) from the crank shaft (5).
8
7
9
10
6
5. Loosen snap ring (10)
6. Remove gear wheel (6), Use two M8 screws to
press out gear wheel from the bearing (7). This
needle bearing is mounted in the cover .
Remove snap ring (8) and pull of bearing (9)
W000042A
W000043A
W000044A
W000043A
16
WLT6000-1EN1
DIASSEMBLY THE CRANK CASE
7. Dismantle of pinion (10).
Remove snap ring (11) as holding pinion. Remove
pinion shaft from gear housing by hitting the pinion
shaft from the gear side using a steel bar and a
plastic hammer.
Fig. 31 Crankshaft
10. Clutch drum
11. Snap ring
10
11
W000045A
17
WLT6000-1EN1
REASSEMBLY THE CRANK CASE
Fig. 32 Crank shaft
1. Ball bering
2. Snap ring
3. Snap ring
1. Before reassemblying the crank case, clean
parts and surfaces.
Check the O-ring so it is in good conditions.
Before reassembly the bearing (1) don't forget
the snap ring (2)
Mount the bearing (1) and the snap ring (3)
Mount the snap ring (2) in the cover unit
2. Clean parts and mount the ball bering in the
crank shaft.
Fig. 33 Ball bearing
4. Ball bearing
5. Crank shaft
Fig. 34 Crank shaft
6. Crank shaft
7. Snap ring
8. Flange
9. Cover
3. Mount the crankshaft (6) and lock it with the snap
ring (7).
Important:
Mount the crankshaft with the flange against the
cover (9).
4. Mount the O-ring between cover unit and
crank case, torque screws (10) dry crosswise
to 45 Nm.
Don't forget the pin (11)
Fig. 35 Crank shaft
10. Scews x4
11. Pin
3
1
2
4
5
10
11
W000043A
W000046A
W000048A
7
9
6
8
W000047A
18
WLT6000-1EN1
4. Remove three screws (1) and replace this with three
fully treaded screws M8x150 mm with washer and
nuts and retighten.
Spring load. DO NOT remove the other
three screws at this moment.
5. Loosen the remaining three screws (2) M8x20 mm
SPRING UNIT
Fig. 36 Tamper leg.
1. Rod piston head
2. oil plug
Dismantling the spring assembly
1. Dismantling is the same as change of bellows.
2. Remove rod piston head (1).Use an open end
spanner (size 23) to hold the piston shaft
3. Drain the oil from spring cylinder assy before turning
it upside down.
Fig. 37 Screws bottom side tamper leg.
1. Screws M8x150 mm
2. Screws M8X20 mm
1
2
2
2
2
1
1
1
Fig. 38 Screws bottom side tamper leg.
1. Screws M8x150 mm
2. Screws M8X20 mm
The spring assembly is pre-tensioned, ie, it
is pressed together 125 mm.
6. Then loosen the three "long" screws alternately until
the spring load is released.
7. Refil oil in the leg. (sight plug).
W000035A
W000032A
W000033A
19
WLT6000-1EN1
FOOT
Fig. 39 Foot
1. M12 nuts x 6
2. M8 nuts x 8
1. Loosen the eight (2) M8 nuts holding the plate.
2. Replace the old plate with a new one.
3. Reassemble the new plate and torque with 15 Nm.
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
W000034A
1
2 2
Box 504, SE-371 23 Karlskrona, Sweden
Phone: +46 455 30 60 00
Fax: +46 455 30 60 30
www.dynapac.com
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