Revision : 05/2004 Manual # : 150-1010 TC SERIES HYDRAULIC COMPACTORS For Models : TC51, TC71, TC80, TC91, TC151 & TC301 BREAKER TECHNOLOGY OWNER’S MANUAL
CONTENTS General ................................................. 4 TC51 Specifications .............................. 5 TC71 Specifications .............................. 6 TC80 Specifications .............................. 7 TC91S Specifications ............................ 8 TC151S / TC151SH Specifications ....... 9 TC301 / TC301H Specifications ............ 10 Hazard Alerts ........................................ 11 Sizing the Compactor ........................... 15 Typical Hydraulic Circuits ......
GENERAL BTI compactors are designed to mount on mini-excavators, backhoes and excavators. BTI compactors combine impulse force, down pressure, and vibration to work as soil compactors 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.
TC51 SPECIFICATIONS TC51L/FC TC51H/FC Impulse Force: 2,250 - 3,000 lb 1,020 - 1,360 kg 2,250 - 3,000 lb 1,020 - 1,360 kg Oil Flow Req'd: 8 - 12 US gpm 30 - 45 l/min 12 - 18 USgpm 44 - 68 l/min Cycles/Minute: 1,940 - 2,200 1,940 - 2,200 Hydraulic Connections: #8 JIC Male #8 JIC Male Minimum Tube I.D.: 1/2" 1/2" Operating Pressure: 1,500 - 2,200 psi 102 - 150 bar 1,500 - 2,200 psi 102 - 150 bar Base Plate Dimension: 12.5 x 22" 317.5 x 558.5 mm 12.5 x 22" 317.5 x 558.
TC71S SPECIFICATIONS 6 TC71S TC71FC Impulse Force: 3,300 - 5,000 lb 1,497 - 2,268 kg 3,300 - 5,000 lb 1,497 - 2,268 kg Oil Flow Req'd: 13 - 17 US gpm 49 - 63 l/min 13 - 22 USgpm 50 - 83 l/min Cycles/Minute: 2,020 - 2,500 2,020 - 2,500 Hydraulic Connections: #12 JIC Male #12 JIC Male Minimum Tube I.D.: ¾" ¾" Operating Pressure: 1,200 - 2,000 psi 81 - 136 bar 1,200 - 2,000 psi 81 - 136 bar Base Plate Dimension: 15 x 26" 381 x 660 mm 15 x 26" 381 x 660 mm Compaction Area: 2.
TC80 SPECIFICATIONS Impulse Force: 5,000 - 8,200 lb 2,270 - 3,727 kg Oil Flow Req'd: 20 - 26 US gpm 75 - 97 l/min Cycles/Minute: 1,659 - 2,200 Hydraulic Connections: #12 JIC Male Minimum Tube I.D.: ¾" 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.
TC91S SPECIFICATIONS 8 Impulse Force: 5,000 - 8,200 lb 2,270 - 3,727 kg Oil Flow Req'd: 20 - 26 US gpm 75 - 97 l/min Cycles/Minute: 1,659 - 2,200 Hydraulic Connections: #12 JIC Male Minimum Tube I.D.: ¾" 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: Swivel Rotation: 1,130 lb 514 kg 180o Locking Positions: 90o, 45o, 0o, 45o, 90o Carrier Weight: 7,700 - 25,300 lb 3,500 - 11, 500 kg www.
TC151S / 151SH SPECIFICATIONS TC151S TC151SH Impulse Force: 11,120 - 16,610 lb 5,055 - 7,550 kg 11,120 - 16,610 lb 5,055 - 7,550 kg Oil Flow Req'd: 25 - 31 US gpm 95 - 117 l/min 35 - 43 US gpm 132 - 163 l/min Cycles/Minute: 1,800 - 2,200 1,800 - 2,200 Hydraulic Connections: #16 JIC Male Minimum Tube I.D.: 1" 1” Operating Pressure: 1,500 - 2,000 psi 102 - 136 bar 1,100 - 1,600 psi 75 - 109 bar Base Plate Dimension: 28 x 36.5" 711 x 927mm 28 x 36.5” 711 x 927mm Compaction Area: 7.
TC301 / TC301H SPECIFICATIONS TC301 TC301H Impulse Force: 16,300 - 24,300 lb 7,409 - 11,000 kg 16,300 - 24,300 lb 7,409 - 11,000 kg Oil Flow Req'd: 35 - 43 US gpm 132 - 163 l/min 50 - 61 gpm 189 - 231 l/min Cycles/Minute: 1,800 - 2,200 1,800 - 2,200 Hydraulic Connections: #16 JIC Male Minimum Tube I.D.: 1" 11/4” Operating Pressure: 1,500 - 2,000 psi 102 - 136 bar 1100 - 1600 psi 75 - 109 bar Base Plate Dimension: 34 x 37" 864 x 940 mm 34 x 37" 864 x 940 mm Compaction Area: 8.
HAZARD ALERTS Danger, Warning, and Caution are hazard alerts used in this manual and on the compactor decals to identify hazards on or near the carrier and compactor. Danger - Immediate hazards, which WILL result in severe personal injury or death if the proper precautions are not taken. Warning - Hazards or unsafe practices, which COULD result in personal injury or death if the proper precautions are not taken.
HAZARD ALERTS Do not operate the compactor with personnel in the immediate area of the carrier and compactor. Note and avoid all hazards and obstructions such as overhangs, ledges, slide areas, electrical lines, underground cables, water mains, gas lines, etc. When operating close to electrical lines, underground cables, water mains or gas lines, contact the responsible authority and request assistance.
HAZARD ALERTS Hydraulic fluids are under high pressure. Fluid escaping under pressure can penetrate the skin causing serious injury. Relieve all pressure before disconnecting hoses. Do not use your hand to check for hydraulic leaks. If any fluid is injected into the skin, a doctor must surgically remove it within a few hours or gangrene may set in. Do not attempt to repair or modify the compactor unless you are a qualified service technician. Read and understand your owner's manuals.
HAZARD ALERTS Head Protection Foot Protection Eye Protection Hearing Protection Do not operate or service the compactor unless you are qualified. Avoid loose fitting clothing, loose or uncovered long hair, jewelry and loose personal articles. These can get caught in moving parts. Jewelry may also ground a live circuit. Know and use the protective equipment that is to be worn when operating or servicing the carrier.
SIZING THE COMPACTOR The compactor must be sized properly for both the carrier on which it will be mounted and the work to be done. Sizing the Compactor based on the Type of Work Most applications require the soil under a road or load bearing surface to be compacted to 95% or greater than the density of the original material removed. This can be achieved with a compactor, provided the soil is the correct type and moisture. Uniform materials like clay and sand are difficult to compact.
SIZING THE COMPACTOR Always use a compactor sized to the carrier. A compactor that is too small for the carrier will damage the compactor, while a compactor too big will damage the carrier. Ensure you have the proper installation kit for attaching the compactor and that the carrier's hydraulic system meets the compactor flow and pressure requirements. The carrier that is selected to operate the compactor must have sufficient reach to compact the deepest area of the trench or excavation.
TYPICAL HYDRAULIC CIRCUITS To run, a compactor needs hydraulic flow in one direction within a working pressure range.
TYPICAL HYDRAULIC CIRCUITS Carrier with Auxiliary Circuit Often a carrier is equipped with an auxiliary control valve (see Figure 1), this valve can be adjusted to provide the correct amount of oil flow to the compactor. A pressure relief cartridge can also be installed to protect the hydraulic components. Make sure that oil is not routed back through the return port of this auxiliary valve. Instead, send the oil directly back to the tank, via the cooler and filter.
TYPICAL HYDRAULIC CIRCUITS Carrier without Auxiliary Circuit If the carrier does not have an auxiliary control valve (see Figure 2), a priority flow control valve must be installed to direct oil flow from the normal circuit to the compactor. The priority flow control valve is usually 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.
INSTALLATION There is no separate pressure adjustment on the compactor. The compactor's supply oil should be directed out the left side of the boom and the return line back on the boom's right side. A combination of hoses and steel tubing is recommended to keep the installation neat and cost effective. Hoses and tubes should be secured to the carrier boom with steel clamps. Attaching mounting clamps or bulkhead fittings to the ends of the tubes will prevent the tubes from sliding.
SETTING FLOW & PRESSURE For a compactor to operate properly it requires a specific oil flow and sufficient oil pressure.
SETTING FLOW & PRESSURE Now adjust the oil flow on the carrier, so the flow meter reading equals: TC51L/FC: 8-12 USgpm (30-45 l/min) TC51H/FC: 12-18 gpm (44-68 l/min) TC71: 13-17 USgpm (49-63 l/min) TC71FC: 13-22 gpm (49-83 l/min) TC80: 20-26 USgpm (75-97 l/min) TC91S: 18-24 USgpm (68-91 l/min) TC151S: 25-31 USgpm (95-117 l/min) TC151SH: 35-43 gpm (132-163 l/min) TC301: 35-43 USgpm (132-163 l/min) TC301H: 50-61 gpm (189-231 l/min) To ensure the carrier's pressure relief valve does not activate while the c
START-UP Carrier oil should be clean and in accordance with the manufacturer's recommendations. After mounting the compactor on the boom and connecting the 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.
OPERATION Compaction of Materials BTI compactors achieve material compaction by using impulse force and vibration to displace air and water pockets in the material. Compaction performance depends on 3 items: • Type and size of material being compacted • Moisture content of the material • Depths of lifts being compacted Use a short trial of the compactor to determine the optimum depth of lift and speed of boom travel to achieve the required density.
OPERATION Shut off the compactor and lift it into the air to a new position, or using minimum boom down-force slide the compactor along the ground. Avoid dragging the compactor's plate across the material surface ('ironing') while the motor is running. Forces exerted on the compactor by 'ironing' can cause premature failure.
OPERATION When compaction is complete, shut off compactor before lifting it from the ground. Shut-off Compactor Before Lifting Do not pound the ground with the compactor. Do not start in the middle of an un-compacted area. Always start at the edge, near a solid wall, bank, or a previously compacted area.
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 in this area. Check that mounting pins and bushings are receiving lubrication.
PRODUCT WARRANTY 1. BREAKER TECHNOLOGY Company (hereinafter referred to as BTI) warrants this product against defects in materials and workmanship for a period of twelve (12) months from the date of installation. This warranty does not cover o-rings, seals, fittings, hoses, or other items considered normal wear items. These are covered by the Limited Warranty period of thirty (30) days.
BRACKET OPTIONS 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.
TC51 TC51 PARTS When ordering give Part Number, Part Name, Model and Serial #. 30 www.rockbreaker.
TC51 PARTS NOTE: For Mounting Bracket options and parts information contact BTI. Item Part Number Description Qty.
TC71 TC71 PARTS When ordering give Part Number, Part Name, Model and Serial #. 32 www.rockbreaker.
TC71 PARTS NOTE: For Mounting Bracket options and parts information contact BTI. Item Part Number Description Qty.
TC80 TC80 PARTS When ordering give Part Number, Part Name, Model and Serial #. 34 www.rockbreaker.
TC80 PARTS Item NOTE: For Mounting Bracket options and parts information contact BTI. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 Part Number Description Qty.
TC91S TC91S PARTS When ordering give Part Number, Part Name, Model and Serial #. 36 www.rockbreaker.
TC91S PARTS NOTE: For Mounting Bracket options and parts information contact BTI. Item Part Number Description Qty.
TC151S TC151S PARTS When ordering give Part Number, Part Name, Model and Serial #. 38 www.rockbreaker.
TC151S PARTS Item Part Number NOTE: For Mounting Bracket options and parts information contact BTI.
TC151SH TC151SH PARTS 40 www.rockbreaker.
TC151SH PARTS Item Part Number NOTE: For Mounting Bracket options and parts information contact BTI.
TC301 TC301 PARTS When ordering give Part Number, Part Name, Model and Serial #. 42 www.rockbreaker.
TC301 PARTS NOTE: For Mounting Bracket options and parts information contact BTI. Item Part Number Description Qty. 1 2 3 4 5 6 7 8 9 10 11 12 13 17 19 22 24 25 26 29 31 33 34 35 390-0002 1800262 1800419 1001858 1912046 650-8526 1801020 1801855 1006886 1006919 650-8527 650-8679 1801223 650-8525 1006920 1009835 1800292 H405-LLL-033 1800947 1932052 1007828 1911185 1912097 1001857 650-8683 380-0110 Top Weldment Fitting Fitting Nordlock Washer Set M20 Bolt 3/4” -10UNC x 2 1/2” GR.
TC301H TC301H PARTS 44 www.rockbreaker.
TC301H PARTS NOTE: For Mounting Bracket options and parts information contact BTI. Item Part Number Description Qty. 1 2 3 4 5 6 7 8 9 10 11 12 13 17 19 22 24 25 26 29 31 33 34 35 650-8680 1801591 1800420 1001858 1912046 650-8526 1801020 1801855 1006886 1006919 650-8527 650-8679 1801223 650-8525 1006920 1009836 1800294 H405-MMM-033 1800947 1932052 1007828 1911185 1912097 1001857 650-8683 390-0110 Top Weldment Fitting Fitting Nordlock Washer Set M20 Bolt 3/4” -10UNC x 2 1/2” GR.
SOLON FACILITY 30625 Solon Industrial Drive, SOLON OHIO, 44139 U.S.A. PH. 440-542-3720 FAX. 440-542-3721 RIVERSIDE FACILITY 3464 DURAHART ST. RIVERSIDE,CALIF. 92507 U.S.A. PH. 909-369-0878 FAX. 909-369-8281 THORNBURY FACILITY 35 ELGIN ST., THORNBURY,ONT. N0H 2P0 CANADA PH. 519-599-2015 FAX.