BTI TC151, Owner'S Manual

Page 1: ...OWNER S MANUAL TC SERIES HYDRAULIC COMPACTORS Revision 05 2004 Manual 150 1010 BREAKER TECHNOLOGY For Models TC51 TC71 TC80 TC91 TC151 TC301 ...

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Page 3: ...1H Specifications Hazard Alerts Sizing the Compactor Typical Hydraulic Circuits Installation Setting Flow Pressure Start Up Operation Removal Storage Product Warranty Bracket Options TC51 Parts TC71 Parts TC80 Parts TC91S Parts TC151S Parts TC151SH Parts TC301 Parts TC301H Parts 4 5 6 7 8 9 10 11 15 17 20 21 23 24 27 28 29 30 32 34 36 38 40 42 44 CONTENTS ...

Page 4: ...or pile sheet drivers The compactor has 3 basic components Mounting Bracket attaches the compactor to the carrier boom and is complete with adjustable mounting pins Rubber Isolators act as suspension between the base and the mount isolate the compactor forces from the carrier Base includes a hydraulic motor coupled to an eccentric encased in a steel housing with the base plate attached GENERAL ...

Page 5: ...ctions 8 JIC Male 8 JIC Male Minimum Tube I D 1 2 1 2 Operating Pressure 1 500 2 200 psi 1 500 2 200 psi 102 150 bar 102 150 bar Base Plate Dimension 12 5 x 22 12 5 x 22 317 5 x 558 5 mm 317 5 x 558 5 mm Compaction Area 1 91 sq ft 1 91 sq ft 0 177 sq M 0 177 sq M Weight 295 lb 295 lb 158 kg 158 kg Swivel Rotation N A N A Locking Positions N A N A Carrier Weight 2 000 10 000 lb 2 000 10 000 lb 907 ...

Page 6: ...lic Connections 12 JIC Male 12 JIC Male Minimum Tube I D Operating Pressure 1 200 2 000 psi 1 200 2 000 psi 81 136 bar 81 136 bar Base Plate Dimension 15 x 26 15 x 26 381 x 660 mm 381 x 660 mm Compaction Area 2 71 sq ft 2 71 sq ft 0 252 sq M 0 252 sq M Weight 610 lb 610 lb 277 kg 277 kg Swivel Rotation N A N A Locking Positions N A N A Carrier Weight 5 500 15 500 lb 5 500 15 500 lb 2 492 7 030 kg ...

Page 7: ...Cycles Minute 1 659 2 200 Hydraulic Connections 12 JIC Male Minimum Tube I D Operating Pressure 1 300 2 000 psi 88 136 bar Base Plate Dimension 23 x 26 584 x 660 mm Compaction Area 4 15 sq ft 0 39 sq M Weight 969 lb 441 kg Swivel Rotation Floating Optional Locking Positions 90o 0o 90o Carrier Weight 7 700 25 300 lb 3 500 11 500 kg ...

Page 8: ...Cycles Minute 1 659 2 200 Hydraulic Connections 12 JIC Male Minimum Tube I D Operating Pressure 1 300 2 000 psi 88 136 bar Base Plate Dimension 23 x 27 584 x 686 mm Compaction Area 4 3 sq ft 0 40 sq M Weight 1 130 lb 514 kg Swivel Rotation 180o Locking Positions 90o 45o 0o 45o 90o Carrier Weight 7 700 25 300 lb 3 500 11 500 kg ...

Page 9: ...inimum Tube I D 1 1 Operating Pressure 1 500 2 000 psi 1 100 1 600 psi 102 136 bar 75 109 bar Base Plate Dimension 28 x 36 5 28 x 36 5 711 x 927mm 711 x 927mm Compaction Area 7 1 sq ft 7 1 sq ft 0 66 sq M 0 66 sq M Weight 1 825 lb 1 830 lb 830 kg 832 kg Swivel Rotation 180o 180o Locking Positions 90o 45o 0o 45o 90o 90o 45o 0o 45o 90o Carrier Weight 15 400 48 400 lb 15 400 48 400 lb 7 000 22 000 kg...

Page 10: ... Connections 16 JIC Male 20 JIC Male Minimum Tube I D 1 11 4 Operating Pressure 1 500 2 000 psi 1100 1600 psi 102 136 bar 75 109 bar Base Plate Dimension 34 x 37 34 x 37 864 x 940 mm 864 x 940 mm Compaction Area 8 74 sq ft 8 74 sq ft 0 812 sq M 0 812 sq M Weight 2 150 lb 2 155 lb 978 kg 980 Carrier Weight 31 900 105 600 lb 31 900 105 600 lb 14 500 48 000 kg 14 500 48 000 kg TC301 TC301H TC301 TC30...

Page 11: ...n Caution Hazards or unsafe practices which COULD result in product or property damage if the proper precautions are not taken BTI cannot anticipate every possible circumstance that might involve a hazard The hazard alerts in this publication and on the product are there fore not all inclusive If a tool procedure work method or operating technique not specifically recommended by BTI is used you mu...

Page 12: ...lines etc When operating close to electrical lines underground cables water mains or gas lines contact the responsible authority and request assis tance Do not operate this machine unless you have read and understood the instructions and warnings in the Compactor Owner s Manual Failure to follow the instructions or heed the warnings could result in injury or death Proper care is your responsibilit...

Page 13: ...t within a few hours or gangrene may set in Do not attempt to repair or modify the compactor unless you are a quali fied service technician Read and understand your owner s manuals Failure to follow the instructions or heed the warnings could result in severe personal injury or death Proper care is your responsibility Contact your distributor or BTI for replacement parts Some compactor components ...

Page 14: ...in moving parts Jewelry may also ground a live circuit Know and use the protective equipment that is to be worn when operat ing or servicing the carrier Hard hats protective glasses protective shoes gloves reflector type vests and ear protection are types of equip ment that may be required Never drive or operate any carrier while you are under the influence of alcohol or drugs Consult your supervi...

Page 15: ... should be less than ten percent for best results A typical production rate to compact soils to over 95 their original den sity TC51 14 22 cu yds hr 11 17 cu M hr TC71 18 27 cu yds hr 14 21 cu M hr TC80 23 32 cu yds hr 18 25 cu M hr TC91S 25 35 cu yds hr 19 27 cu M hr TC151S 65 75 cu yds hr 50 57 cu M hr TC151SH 65 75 cu yds hr 50 57 cu M hr TC301 110 130 cu yds hr 84 99 cu M hr TC301H 110 130 cu ...

Page 16: ...ange the carrier s lifting capaci ty and oil flow will need to be verified to ensure a proper fit Provided the weight of the compactor does not exceed the maximum lift ing capacity of the carrier at any position the carrier is assumed to be stable On most loader backhoes and excavators the maximum lifting capacity is lowest when the boom is at full reach This is the value that must be compared to ...

Page 17: ...ion within a work ing pressure range When installing the compactor the carrier hydraulic circuit must have the following The carrier must have a hydraulic circuit which will provide the correct flow A switch to activate the compactor A circuit relief valve TYPICAL HYDRAULIC CIRCUITS ...

Page 18: ...ic components Make sure that oil is not routed back through the return port of this auxil iary valve Instead send the oil directly back to the tank via the cooler and filter If the circuit is plumbed using both ports on the auxiliary valve the return line should have a bleed line connected to tank to prevent damag ing pressure spikes from the returning oil Carrier with Auxiliary Circuit Figure 1 C...

Page 19: ... the normal circuit to the compactor The priority flow control valve is usual ly equipped with a flow adjustment and pressure relief These auxiliary control valves often need a check valve on the regulated port to completely close the flow If too much flow is divided excess heat is generated in which case the oil needs to be cooled Figure 2 Carrier without Auxiliary Circuit TYPICAL HYDRAULIC CIRCU...

Page 20: ...s allows the line to be disconnected without losing too much oil BTI does not recommend hydraulic quick disconnects However if they are installed ensure the flush face style is used and then only on the TC91S or smaller models Mounting the Compactor Compactors are easily mounted by doing the following Orient the compactor with its hose connections pointed towards the carrier Remove the pins and bu...

Page 21: ... 75 109 bar 132 163 l min TC301 1500 2000 psi 35 43 USgpm 102 136 bar 125 163 l min TC301H 1100 1600 psi 50 61 USgpm 75 109 bar 189 231 l min To begin connect a flow meter into the circuit in place of the compactor Measure the no load flow by pressing the compactor fire which activates the control valve and simulates the compactor working While still activating the compactor fire adjust the flow m...

Page 22: ...ing is at least 350 psi or greater than the maximum working pressure of the compactor your machine is ready If not you need to adjust the carrier s pressure relief setting TC51 2200 350 psi 2550 psi 176 24 200 bar relief TC71 2000 350 psi 2350 psi 136 24 160 bar relief TC80 2000 350 psi 2350 psi 136 24 160 bar relief TC91S 2000 350 psi 2350 psi 136 24 160 bar relief TC151S 2000 350 psi 2350 psi 13...

Page 23: ...he lines bleed all air from the hydraulic system Initially pump grease to the pins in the bracket until it oozes out around the pins Then grease with 10 15 shots daily Check torque of bolts and fasteners at installation and again after the first 10 hours of operation Operate all boom functions to ensure clearances are good and they allow the compactor to swivel START UP ...

Page 24: ...11 17 cu M per hour TC71 TC71FC 18 27 cu yds 14 21 cu M per hour TC80 23 32 cu yds 18 25 cu M per hour TC91S 25 35 cu yds 19 27 cu M per hour TC151S TC151SH 65 75 cu yds 50 57 cu M per hour TC301 TC301H 110 130 cu yds 84 99 cu M per hour Always operate the carrier engine at the minimum speed required to achieve the desired result This allows the hydraulic system to run cooler Excess flow beyond re...

Page 25: ...el with the material being compacted Compactors can operate on an angle if you keep the carrier boom down force at 90o to the compactor base Start by operating the compactor in one position Release the down force and lift the unit to a new spot Re apply down force and start compact ing Two passes are usually required During the initial pass the com pactor should be held in each position for 8 10 s...

Page 26: ...for a hammering effect Do not use the compactor to extract pilings Cold Weather Operation Oils for use in cold weather operation should have a viscosity not exceeding 7500 SSU at the minimum start up temperature And the ambi ent temperature should be at least 20 o F above the pour point of the oil Start with a gradual warm up until the oil reaches a reasonably fluid state Shut off Compactor Before...

Page 27: ... s Manual OPERATION Maintenance Every 40 Hours of Operation Check hoses for wear and leaks replace and tighten as required The eccentric housing is filled with gear oil This oil must be changed after the initial 50 hours Then change oil every year Use 80W90 gear oil Do not overfill the oil reservoir Check the rubber isolators for cracks or fatigue Clean away any soil and material that has built up...

Page 28: ...ate of installation 3 BTI will at it s option repair or refurbish the defective part s without charge to the initial user or may elect to issue full or partial credit toward the purchase of a new part s The extent of credit issued which will be in the form of a Credit Memo will be determined by pro rating against the normal life of the part s in question 4 BTI is not responsible for mileage travel...

Page 29: ...Bolt On Rigid Top Mount Shown on TC80 Standard equipment on TC51 TC71 TC80 TC301 Bolt On QA Non Swivel Top Mount Available as an option on the TC71 TC80 QA Swivel Top Mount Standard equipment on TC91S TC151S Optional Bolt On on the TC71 and TC80 ...

Page 30: ...30 www rockbreaker com TC51 PARTS TC51 When ordering give Part Number Part Name Model and Serial ...

Page 31: ... 5 Nordlock Washer Set Button Head Cap Screw Flat Washer Isolator Locknut Hose Assembly Motor Repair Kit Low Flow Kit L FC 9 0 gpm High Flow Kit H FC 13 5 gpm Not Shown Qty 1 2 1 1 1 1 2 2 1 2 1 2 2 1 8 8 32 64 4 32 2 REF Part Number 350 0007 1800424 9006862 650 8780 350 0002 650 8795 1008414 1008453 650 8796 1800288 1009488 1912007 1001856 1008798 1911113 1001856 1912270 1941002 1009487 1932008 H...

Page 32: ...32 www rockbreaker com TC71 PARTS TC71 When ordering give Part Number Part Name Model and Serial ...

Page 33: ...draulic Motor Bolt Grade 8 Nordlock Washer Set Fitting Fitting Not Shown Hose Assembly Hose Assemvly Motor Repair Kit Flow Control Kit Included in Hydraulic Kit P N 360 0100 Qty 1 4 1 32 32 34 1 1 2 2 2 1 2 2 1 1 2 1 4 4 2 2 1 1 REF Part Number 360 0002 1008925 220 2708 1912271 1932014 1941004 360 0003 220 2713 1008936 1008935 1800849 220 2707 1912009 1001856 1008798 1801470 1800288 1009505 191212...

Page 34: ...34 www rockbreaker com TC80 PARTS TC80 When ordering give Part Number Part Name Model and Serial ...

Page 35: ...ng Retaining Ring Eccentric Assembly Hose Assembly Drum Weldment Plug Bearing Housing Fitting Fitting Motor Repair Kit Qty REF 1 4 32 64 32 1 2 4 1 8 1 1 2 2 2 1 1 1 1 1 1 1 REF Part Number 370 0007 1008925 1912261 1941004 1932014 H409 KKK 021 1800289 650 8641 1009833 1912020 1801983 650 8619 1801982 1001531 1007793 650 8618 H409 KKK 029 370 0005 1801470 650 8620 1800255 1800418 370 0110 NOTE For ...

Page 36: ...36 www rockbreaker com TC91S PARTS When ordering give Part Number Part Name Model and Serial TC91S ...

Page 37: ... Set M20 Locknut 3 4 NC Base Plate Weldment Stud Hex Nut 3 4 NF Bearing Housing External Retaining Ring O Ring Fitting Hose Assembly Hydraulic Motor Stud Locknut 1 2 20UNF Hose Assembly Decal Kit Motor Repair Kit Qty 14 1 14 1 1 REF 1 1 1 44 40 REF 4 1 1 1 2 1 1 2 2 2 2 2 1 2 20 8 1 12 12 1 1 1 2 1 1 4 4 1 REF REF Part Number 1912048 1801016 1941015 650 5569 1001534 1001535 650 8501 1001536 100185...

Page 38: ...38 www rockbreaker com TC151S PARTS When ordering give Part Number Part Name Model and Serial TC151S ...

Page 39: ... Nordlock Washer Set M20 Locknut 3 4 NC Base Plate Stud Hex Nut 3 4 NF Hose Assembly Fitting O Ring Hydraulic Motor Bolt 1 2 NF x 1 4 GR 8 Nordlock Washer Set M12 Hose Assembly Retaining Ring Bearing Housing Motor Side Decal Kit Motor Repair Kit Qty 6 1 14 1 1 1 1 2 4 1 1 1 2 2 1 2 8 8 8 1 2 2 2 2 1 2 1 2 20 8 1 12 12 1 2 1 1 4 4 1 1 1 REF REF Part Number 1912048 1801016 1941015 650 5569 1001534 1...

Page 40: ...40 www rockbreaker com TC151SH TC151SH PARTS ...

Page 41: ... Nordlock Washer Set M20 Locknut 3 4 NC Base Plate Stud Hex Nut 3 4 NF Hose Assembly Fitting O Ring Hydraulic Motor Bolt 1 2 NF x 1 4 GR 8 Nordlock Washer Set M12 Hose Assembly Retaining Ring Bearing Housing Motor Side Decal Kit Motor Repair Kit Qty 6 1 14 1 1 1 1 2 4 1 1 1 2 2 1 2 8 8 8 1 2 2 2 2 1 2 1 2 20 8 1 12 12 1 2 1 1 4 4 1 1 1 REF REF Part Number 1912048 1801016 1941015 650 5569 1001534 1...

Page 42: ...42 www rockbreaker com TC301 PARTS When ordering give Part Number Part Name Model and Serial TC301 ...

Page 43: ...g Ring Hydraulic Motor Fitting Hose Assembly O Ring Locknut Rubber Mount Bolt 3 4 NC x 2 3 4 GR 5 Bolt 1 2 20 UNF x 1 1 2 GR 5 Nordlock Washer Set M12 Decal Kit Motor Repair Kit Qty 1 2 2 72 8 1 2 2 2 2 1 1 2 1 1 1 2 2 1 32 4 32 4 4 REF REF Part Number 390 0002 1800262 1800419 1001858 1912046 650 8526 1801020 1801855 1006886 1006919 650 8527 650 8679 1801223 650 8525 1006920 1009835 1800292 H405 L...

Page 44: ...44 www rockbreaker com TC301H TC301H PARTS ...

Page 45: ...ng Ring Hydraulic Motor Fitting Hose Assembly O Ring Locknut Rubber Mount Bolt 3 4 NC x 2 3 4 GR 5 Bolt 1 2 20 UNF x 1 1 2 GR 5 Nordlock Washer Set M12 Decal Kit Motor Repair Kit Qty 1 2 2 72 8 1 2 2 2 2 1 1 2 1 1 1 2 2 1 32 4 32 4 4 REF REF Part Number 650 8680 1801591 1800420 1001858 1912046 650 8526 1801020 1801855 1006886 1006919 650 8527 650 8679 1801223 650 8525 1006920 1009836 1800294 H405 ...

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Page 48: ...FACILITY 30625 Solon Industrial Drive 3464 DURAHART ST 35 ELGIN ST SOLON OHIO RIVERSIDE CALIF THORNBURY ONT 44139 U S A 92507 U S A N0H 2P0 CANADA PH 440 542 3720 PH 909 369 0878 PH 519 599 2015 FAX 440 542 3721 FAX 909 369 8281 FAX 519 599 6803 ...