LG TC151, TC80, TC71, TC91, TC51 User Manual

OWNER’S MANUAL

TC SERIES HYDRAULIC COMPACTORS

Revision : 05/2004

Manual # : 150-1010

BREAKER TECHNOLOGY

For Models :

TC51, TC71, TC80, TC91, TC151 & TC301

3

Compactor Owner’s Manual

General .................................................

TC51 Specifications ..............................

TC71 Specifications ..............................

TC80 Specifications ..............................

TC91S Specifications ............................

TC151S / TC151SH Specifications .......

TC301 / TC301H 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 .......................................

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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

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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.

• Base: includes a hydraulic motor coupled to an eccentric, encased in
a steel housing with the base plate attached.

GENERAL

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Compactor Owner’s Manual

TC51 SPECIFICATIONS

Impulse Force: 2,250 - 3,000 lb 2,250 - 3,000 lb

1,020 - 1,360 kg 1,020 - 1,360 kg

Oil Flow Req'd: 8 - 12 US gpm 12 - 18 USgpm

30 - 45 l/min 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 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 - 4, 536 kg 907 - 4, 536 kg

TC51L/FC TC51H/FC

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TC71S SPECIFICATIONS

Impulse Force: 3,300 - 5,000 lb 3,300 - 5,000 lb

1,497 - 2,268 kg 1,497 - 2,268 kg

Oil Flow Req'd: 13 - 17 US gpm 13 - 22 USgpm

49 - 63 l/min 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 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 2,492 - 7,030 kg

TC71S TC71FC

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Compactor Owner’s Manual

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

0.39 sq M

Weight: 969 lb

441 kg

Swivel Rotation: Floating (Optional)

Locking Positions: 90o, 0o, 90

o

Carrier Weight: 7,700 - 25,300 lb

3,500 - 11, 500 kg

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TC91S 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 27"

584 x 686 mm

Compaction Area: 4.3 sq ft

0.40 sq M

Weight: 1,130 lb

514 kg

Swivel Rotation: 180

o

Locking Positions: 90o, 45o, 0o, 45o, 90

o

Carrier Weight: 7,700 - 25,300 lb

3,500 - 11, 500 kg

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Compactor Owner’s Manual

Impulse Force: 11,120 - 16,610 lb 11,120 - 16,610 lb

5,055 - 7,550 kg 5,055 - 7,550 kg

Oil Flow Req'd: 25 - 31 US gpm 35 - 43 US gpm

95 - 117 l/min 132 - 163 l/min

Cycles/Minute: 1,800 - 2,200 1,800 - 2,200

Hydraulic Connections: #16 JIC Male #16 JIC Male

Minimum 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: 180

o

180

o

Locking Positions: 90o,45o,0o,45o,90

o

90o,45o,0o,45o,90

o

Carrier Weight: 15,400 - 48,400 lb 15,400 - 48,400 lb

7,000 - 22,000 kg 7,000 - 22,000 kg

TC151S TC151SH

TC151S / 151SH SPECIFICATIONS

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Impulse Force: 16,300 - 24,300 lb 16,300 - 24,300 lb

7,409 - 11,000 kg 7,409 - 11,000 kg

Oil Flow Req'd: 35 - 43 US gpm 50 - 61 gpm

132 - 163 l/min 189 - 231 l/min

Cycles/Minute: 1,800 - 2,200 1,800 - 2,200

Hydraulic Connections: #16 JIC Male #20 JIC Male

Minimum Tube I.D.: 1" 1

1/4”

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 / TC301H SPECIFICATIONS

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Compactor Owner’s Manual

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.

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 there­fore not all inclusive. If a tool, procedure, work method or operating
technique not specifically recommended by BTI is used, you must satisfy
yourself that it is safe for you and others. You should also ensure that the
compactor and carrier will not be damaged or made unsafe by the opera­tion, maintenance or repair procedures you choose.

HAZARD ALERTS

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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.

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 responsibility. Contact your distributor or BTI
for replacement manuals or decals.

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Compactor Owner’s Manual

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.
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 are heavy or awkward, plan carefully how
you will handle them when installing, removing, or disassembling.

HAZARD ALERTS

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Head Foot Eye Hearing
Protection Protection Protection 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. Hard hats, protective glasses, protective
shoes, gloves, reflector type vests and ear protection are types of equip­ment that may be required.

Never drive or operate any carrier while you are under the influence of
alcohol or drugs.

Consult your supervisor if you do not understand the Compactor Owner's
Manual.

HAZARD ALERTS

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Compactor Owner’s Manual

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. Virgin dirt,
pit run gravel, or soil with non-uniform particle size is preferred. The
moisture content in most material should be less than ten percent for best
results.

A typical production rate to compact soils to over 95% their original den­sity;

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 yds/hr (84 - 99 cu M/hr)

For proper compaction we recommend the following lift size;

TC51: .5- 1 foot (0.15 - 0.3 M)

TC71: .5- 1 foot (0.15 - 0.3 M)

TC80: 1- 2 foot (0.3 - 0.6 M)

TC91S: 1- 2 foot (0.3 - 0.6 M)

TC151S: 2- 3 foot (0.6 - 0.9 M)

TC151SH: 2- 3 foot (0.6 - 0.9 M)

TC301: 2- 4 foot (0.6 - 1.2 M)

TC301H: 2- 4 foot (0.6 - 1.2 M)

Using a higher depth of material may result in less than 95% compaction.

Typical

Production Rate

Lift Sizes

SIZING THE COMPACTOR

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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. Therefore,

sizing the compactor based on the carrier size becomes the most
important factor in choosing the correct sized compactor.

BTI has assigned a 'Recommended Carrier Weight' range to each com­pactor. If the operating weight of the carrier falls within this range, the
carrier will safely handle this model. If the desired compactor falls out­side of the recommended carrier weight range, the carrier's lifting capaci­ty and oil flow will need to be verified to ensure a proper fit.

Provided the weight of the compactor does not exceed the maximum lift­ing 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 the operating weight of the compactor.

A required oil flow range is specified for each compactor, oil flow to the
compactor within this range is adequate for operation. However, for max­imum productivity the carrier should be capable of providing the maxi­mum required flow. Compare the maximum oil flow requirement of the
compactor with the oil flow capacity of the carrier. Remember the com­pactor will be operating at 1100-2100-psi (75-136 bar), therefore, oil flow
should be evaluated at the operating pressure.

Below is the Carrier Sizing Chart, outlining the recommended carrier
weight range for the compactor models.

Carrier

Lifting Capacity

Carrier

Oil Flow

SIZING THE COMPACTOR

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Compactor Owner’s Manual

To run, a compactor needs hydraulic flow in one direction within a work­ing 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

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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.
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 damag­ing pressure spikes from the returning oil.

Carrier with Auxiliary Circuit

Figure 1, Carrier with Auxiliary Circuit

TYPICAL HYDRAULIC CIRCUITS

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Compactor Owner’s Manual

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. 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 CIRCUITS

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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. Check the hoses to ensure they are
not being rubbed or pinched by other components.

BTI recommends the use of high-pressure ball valves at the outer end of
the stick where the hydraulic lines are disconnected to attach the com­pactor. This 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 bushings from the compactor top mount bracket
(Note: the compactor mounting pins and bushings are custom made to
match the carrier stick).

Insert the bushings into the boom and link of the carrier. (If Required).

Place the carrier boom into the compactor top mount bracket.

Push the pins through the bracket and boom (do not force the pins, if they
do not enter easily, try realigning).

Insert the pin retainers.

If the carrier is equipped with a Quick Attach system, ensure the device is
securely locking in position before operation.

INSTALLATION

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Compactor Owner’s Manual

Carrier

Oil Flow

Working

Pressure Range

Oil Flow &

Oil Pressure

SETTING FLOW & PRESSURE

For a compactor to operate properly it requires a specific oil flow and
sufficient oil pressure.

TC51L/FC: 1500-2200 psi @ 8-12 USgpm

(102-150 bar) @ (30-45 l/min)

TC51H/FC: 1500-2200 psi @ 12-18 USgpm

(102-150 bar) @ (44-68 l/min)

TC71: 1200-2000 psi @ 13-17 USgpm

(81-136 bar) @ (49-63 l/min)

TC71FC: 1200-2000 psi @ 13-22 USgpm

(81-136 bar) @ (50-83 l/min)

TC80 : 1300-2000 psi @ 20-26 USgpm

(88-136 bar) @ (75-97 l/min)

TC91S: 1300-2000 psi @ 20-26 USgpm

(88-136 bar) @ (75-97 l/min)

TC151S: 1500-2000 psi @ 25-31 USgpm

(102-136 bar) @ (98-121 l/min)

TC151SH: 1100-1600 psi @ 35-43 USgpm

(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 meter putting a load on the circuit. Adjust the flow meter
pressure until it falls within the working pressure range:

TC51L/FC: 1500-2200 psi (102-150 bar) TC51H/FC: 1500-2200 psi (102-150 bar)

TC71: 1200-2000 psi (81-136 bar) TC71FC: 1200-2000 psi (81-136 bar)

TC80: 1300-2000 psi (88-136 bar)

TC91S: 1300-2000 psi (88-136 bar)

TC151S: 1500-2000 psi (102-136 bar) TC151SH: 1100-1600 psi (75-109 bar)

TC301: 1500-2000 psi (102-136 bar) TC301H: 1100-1600 psi (75-109 bar)

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BTI

Service Centers

Adjust Carrier’s

Pressure Relief

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 compactor
is working, the pressure relief must be set at least 350 psi above the maximum
working pressure of the compactor.Continue to load the circuit pressure by adjust­ing the flow meter. Eventually the carrier's relief valve will activate and the oil
flow will drop to zero. The pressure at which the oil goes over relief will be dis­played on the flow meter. If this pressure setting 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 (136 + 24 = 160 bar) relief

TC151SH: 1600 + 350 psi = 1950 psi (109 + 24 = 133 bar) relief

TC301: 2000 + 350 psi = 2350 psi (136 + 24 = 160 bar) relief

TC301H: 1600 + 350 psi = 1950 psi (109 + 24 = 133 bar) relief

If more than one attachment with different flow requirements is to be connected
to this carrier, you will need to measure the flow and note the adjustments of
each. Mark these two locations directly on the flow control valve.

Record the oil flow and relief pressure settings when filling out the BTI
Compactor Installation Notice form.

If you are unable to obtain the proper flow when installing or adjusting the
hydraulic circuit, contact your BTI dealer for technical support.

Thornbury, Ontario . . .[phone]
Riverside, California . .[phone]

Solon, Ohio . . . . . . . . .[phone]

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Compactor Owner’s Manual

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.

Operate all boom functions to ensure clearances are good and they allow
the compactor to swivel.

START-UP

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Hourly

Production Rates

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. This value will
vary depending on the material's composition and size. For example,
marbles being a uniform shape do not pack as well as gravel, which has
uneven shapes allowing the stones to interlock with each other.

You can reach nearly 100% of the maximum material density with a BTI
compactor by using smaller lifts, and increasing the holding time in each
spot. Typical hourly production rates to compact soil to over 95% its
original density are;

TC51L/FC / TC51H/FC: 14-22 cu yds (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 recommended levels can damage the compactor
motor.

Ensure the compactor base plate is in contact with the soil before operat­ing.

When using a BTI compactor it is the amplitude (up and down motion)
of the plate, which does the compaction and not the compactor weight or
the carrier boom down-force. As you apply down-force to the compactor,
the carrier will lift slightly giving you an indication that the compactor is
properly pressed onto the material. Too much boom down-force inhibits
the up and down motion, reducing the compactor's impact force.
(Improper operation of the compactor can result in premature failure of
the rubber isolators.)

Test the

Compactor First

Operate Carrier at

Minimum Speed

Compactor Base

Must Contact Soil

Use Proper

Boom Down-Force

OPERATION

25

Compactor Owner’s Manual

Lift Depths

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.

Another cause of premature mount failure occurs when working in very
wet soil and/or a very tight trench. Suction or drag when the compactor
is lifted can cause the mounts to tear. In these situations fasten a chain
between the compactor's upper and lower sections to relieve the lifting
strain on the rubber isolators.

Never grade the trench or level backfill with the compactor. Extreme side
forces can damage the rubber isolators.

Always keep the plate of the compactor parallel with the material being
compacted. Compactors can operate on an angle if you keep the carrier
boom down-force at 90oto 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 compact­ing. Two passes are usually required. During the initial pass the com­pactor should be held in each position for 8-10 seconds or as long as
compaction is apparent. The second-pass should be with greater boom
down-force, focusing on areas missed during the first pass.

Compact in lift depths of:

TC51: .5-1 ft (0.15-0.3 M)

TC71: .5-1 ft (0.15-0.3 M)

TC80: 1-2 ft (0.3-0.6 M)

TC91S: 1-2 ft (0.3-0.6 M)

TC151S / TC151SH: 2-3 ft (0.6-0.9 M)

TC301 / TC301H: 2-4 ft (0.6-1.2 M)

Note: using a higher material lift depth may give less than 95% soil com­paction. Materials with 5% moisture give better compaction. Narrow
excavations can use higher lifts.

Working in Wet Soil

or Tight Trench

Do Not Grade

with Compactor

Keep Compactor

Parallel with Material

Initial Compacting

OPERATION

When compaction is complete, shut off compactor before lifting it from
the ground.

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.

Compacting Clay Materials

Clay type materials have a different composition and will not transmit
vibration as well as granular materials; therefore, it is necessary to
decrease the lift height and hold the compactor position for 15 seconds in
each spot. Two passes are usually sufficient.

Sheet or Pile Driving

Compactors are effective in driving timber sheeting, steel sheet piles, 'H'
or 'I' beams, and they drive into most soils including fine sand and rocky
material. Best results are achieved by keeping the compactor base 90

O

to
the pile and use down-force and vibration to hammer the material. If you
come across excessive resistance, lift the compactor slightly and let it
'bounce' on the pile 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 ambi­ent 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 Lifting

26

www.rockbreaker.com

Bolt Loctite

Requirements

At the end of each shift check the following:

Check rubber isolators for cracks. Replace as necessary.

Check the mounting pins and bushings for proper fit to the carrier. Check
that the pin locks are in place and secure.

Check that all hose connections are tight and there are no leaks.

If your compactor is equipped with a swivel mount, grease this connec­tion with 5 shots dependent on the amount of compactor use.

Always use standard EP2 grease.

Check that all bolts are tight. If necessary, remove the bolt and install
using Loctite and tighten to the specified torque.

• Red Loctite: motor and eccentric housing bolts

• Blue Loctite: rubber isolator bolts and all others

OPERATION

Daily Inspection

Disconnect the pressure and return lines. Cap the lines on the machine
and on the compactor to prevent dirt from entering.

Remove pins to disconnect compactor from boom. Spread grease on pins
and bushings after removal to prevent corrosion.

Removal and Storage

27

Compactor Owner’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 in this area.

Check that mounting pins and bushings are receiving lubrication.

28

www.rockbreaker.com

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. Warranty
for propriety items such as valves, filters, installation kits, and componentry that
are not manufactured by BTI, will be governed by the warranty terms of their
manufacturer. This warranty is void if BTI's standard installation specifications
and procedures are not adhered to.

2. BTI's Customer Service Department will authorize return of any defective
components or sufficient evidence of such defect to a BTI warehouse. Such
components or such evidence must clearly show that the defect was caused by
faulty material or poor workmanship. Warranty claim will be accepted only if it
is submitted on a proper claims form with proof of purchase and received within
sixty (60) days from the date of discovery of the defect. Warranty claims will be
considered only if the "Installation Notice" has been duly filled in and returned
to BTI's Customer Service Department within thirty (30) days from the date 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 time, travel expenses, overtime
labor, and any freight expenses required to facilitate the repair.

5. This warranty does not apply if the product has been damaged by accident,
abuse, misuse, misapplication or neglect, or as a result of service, disassembly
or modification, without BTI's express authorization.

6. BTI assumes no liability beyond the replacement of defective parts or materi­als and/or the correction of such defective parts or materials.

7. BTI neither assumes nor authorizes any other person to assume for it any lia­bility in connection with the sale of it's products other than that specifically stat­ed herein.

8. THIS WARRANTY IS EXPRESSLY IN LIEU OF ANY AND ALL OTHER
WARRANTIES.

EXCEPT AS EXPRESSLY SET FORTH HEREIN, BTI MAKES NO REPRE­SENTATION OR

WARRANTY, STATUTORY, EXPRESS OR IMPLIED, WITH RESPECT TO
THE PRODUCTS

MANUFACTURED AND/OR SUPPLIED BY BTI, WHETHER AS TO MER­CHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE OR ANY
OTHER MATTER. IN NO EVENT, INCLUDING IN THE CASE OF A
CLAIM OF NEGLIGENCE, SHALL BTI BE LIABLE FOR INCIDENTAL OR
CONSEQUENTIAL DAMAGES.

PRODUCT WARRANTY

29

Compactor Owner’s Manual

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.

30

www.rockbreaker.com

TC51 PARTS

TC51

When ordering give Part Number, Part Name, Model and Serial #.

31

Compactor Owner’s Manual

TC51 PARTS

Item

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21

Description

Upper Weldment
Cap
Fill/Drain
Bearing Housing
Lower Weldment
Eccentric Assembly
Bearing
Retaining Ring
Bearing Housing
Fitting
Hydraulic Motor
Bolt - Grade 8
Nordlock Washer Set
Gasket
Bolt - Grade 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
H05-KKK-023*
350-0110*

350-1002
350-0103

NOTE:

For Mounting

Bracket options and

parts information

contact BTI.

32

www.rockbreaker.com

TC71 PARTS

TC71

When ordering give Part Number, Part Name, Model and Serial #.

33

Compactor Owner’s Manual

TC71 PARTS

Item

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25

Description

Upper Body
Isolator
Bearing Housing
Bolt - Grade 8
Locknut
Flat Washer
Lower Housing
Eccentric Assembly
Bearing
Reatining Ring
O-Ring
Bearing Housing - Motor Side
Bolt - Grade 8
Nordlock Washer Set
Gasket
Plug
Fitting
Hydraulic 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
1912128
1001857
1800255
1800418*
H409-KKK-025*
H412-KKK-030*
360-0110

360-0101

NOTE:

For Mounting

Bracket options and

parts information

contact BTI.

34

www.rockbreaker.com

TC80 PARTS

TC80

When ordering give Part Number, Part Name, Model and Serial #.

35

Compactor Owner’s Manual

TC80 PARTS

Item

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23

Description

Top Mount
Top Frame Weldment
Isolator
Bolt
Washer
Locknut
Hose Assembly
Fitting
Stud
Motor
Hex Head Bolt
O-Ring
Bearing Housing
O-Ring
Bearing
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 Mounting

Bracket options and

parts information

contact BTI.

36

www.rockbreaker.com

TC91S PARTS

When ordering give Part Number, Part Name, Model and Serial #.

TC91S

TC91S PARTS

Item

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
19
20
25
26
27
28
29
33
34
35
36
37
38
40
44
45
46
47
48
49
50
52
54

Description

Bolt
Grease Fitting 1/8” NPT
Flatwasher
Cap Flange
Top Bearing Washer
Bushing - Contact BTI for Part #
Bushing
Top Mount Weldment
Bottom Bearing Washer
Nordlock Washer Set M12
Bolt 1/2” -13UNC x 1 1/2” LG GR8
Pin - Contact BTI for Part #
Quick Pin c/w Chain
Clevis Pin
Frame Weldment
Fitting
Cap
Fitting
Quick Pin
Bearing Housing
Pipe Plug
O-Ring
Bearing
Retaining Ring
Eccentric Assembly
Lattice Mount (includes 35, 38, 40)
Nordlock Washer 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
1001857
1912020

1002184
650-8296
650-8617
1800261
1800418
1800255
1001529
650-8620
1801020
1801982
1001531
1007793
650-8618
650-8710
1001858
1932020
650-8616
650-8676
1931013
650-8619
1007794
1801983
1800289
H405-KKK-014
1009833
650-8641
1932015
H405-KKK-022
650-8622
370-0110

37

Compactor Owner’s Manual

NOTE:

For Mounting

Bracket options and

parts information

contact BTI.

38

www.rockbreaker.com

TC151S PARTS

When ordering give Part Number, Part Name, Model and Serial #.

TC151S

39

Compactor Owner’s Manual

TC151S PARTS

Item

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
17
18
20
21
22
23
24
25
26
27
28
29
31
32
33
34
36
38
42
43
44
45
46
47
50
51
54

Description

Bolt
Grease Fitting 1/8” NPT
Flatwasher
Cap Flange
Mounting Bracket - Contact BTI
Top Bearing Washer
Bushing
Pin
Quick Pin c/w Chain
Bottom Bearing Washer
Clevis Pin
Frame Weldment
Fitting
Fitting
Quick Pin
Fitting
Bolt 3/4” NC x 3”LG GR.8
Bolt 5/8” NC x 1 1/2” GR.8
Nordlock Washer Set
Bearing Housing
Pipe Plug
O-Ring
Bearing
Retaining Ring Internal
Eccentric Assembly
Fitting
Hose Assembly
Lattice Mount (Includes 32,36,38)
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
1001535
700-0225
1002184
1001536
650-8296
650-8587
1800419
1800262
1001529
1801223
1912086
1912138
1001768
650-8592
1801020
1801980
1002182
1007783
650-8589
1800102
H06-GGG-010
650-8710
1001858
1932020
650-8586
650-8676
1931013
H408-LLL-026
1800943
1800947
1009834
1912097
1001857
H405-LLL-026
1007784
650-8593
650-8591
380-0110

NOTE:

For Mounting

Bracket options and

parts information

contact BTI.

40

www.rockbreaker.com

TC151SH

TC151SH PARTS

41

Compactor Owner’s Manual

TC151SH PARTS

Item

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
17
18
20
21
22
23
24
25
26
27
28
29
31
32
33
34
36
38
42
43
44
45
46
47
50
51
54

Description

Bolt
Grease Fitting 1/8” NPT
Flatwasher
Cap Flange
Mounting Bracket - Contact BTI
Top Bearing Washer
Bushing
Pin
Quick Pin c/w Chain
Bottom Bearing Washer
Clevis Pin
Frame Weldment
Fitting
Fitting
Quick Pin
Fitting
Bolt 3/4” NC x 3”LG GR.8
Bolt 5/8” NC x 1 1/2” GR.8
Nordlock Washer Set
Bearing Housing
Pipe Plug
O-Ring
Bearing
Retaining Ring Internal
Eccentric Assembly
Fitting
Hose Assembly
Lattice Mount (Includes 32,36,38)
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
1001535
700-0225
1002184
1001536
650-8296
650-8587
1800419
1800262
1001529
1801223
1912086
1912138
1001768
650-8592
1801020
1801980
1002182
1007783
650-8589
1800102
H06-GGG-010
650-8710
1001858
1932020
650-8586
650-8676
1931013
H408-LLL-026
1800292
1800947
1009835
1912097
1001857
H405-LLL-026
1007784
650-8593
650-8591
380-0110

NOTE:

For Mounting

Bracket options and

parts information

contact BTI.

42

www.rockbreaker.com

TC301 PARTS

When ordering give Part Number, Part Name, Model and Serial #.

TC301

43

Compactor Owner’s Manual

TC301 PARTS

Item

1
2
3
4
5
6
7
8
9
10
11
12
13
17
19
22
24
25
26
29
31
33
34
35

Description

Top Weldment
Fitting
Fitting
Nordlock Washer Set M20
Bolt 3/4” -10UNC x 2 1/2” GR.8
Bearing Housing
Pipe Plug
O-Ring
Spherical Roller Bearing
Retaining Ring
Eccentric Assembly
Base Weldment
Fitting
Bearing Housing
Retaining 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-LLL-033
1800947
1932052
1007828
1911185
1912097
1001857
650-8683
380-0110

NOTE:

For Mounting

Bracket options and

parts information

contact BTI.

44

www.rockbreaker.com

TC301H

TC301H PARTS

45

Compactor Owner’s Manual

TC301H PARTS

Item

1
2
3
4
5
6
7
8
9
10
11
12
13
17
19
22
24
25
26
29
31
33
34
35

Description

Top Weldment
Fitting
Fitting
Nordlock Washer Set M20
Bolt 3/4” -10UNC x 2 1/2” GR.8
Bearing Housing
Pipe Plug
O-Ring
Spherical Roller Bearing
Retaining Ring
Eccentric Assembly
Base Weldment
Fitting
Bearing Housing
Retaining 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-MMM-033
1800947
1932052
1007828
1911185
1912097
1001857
650-8683
390-0110

NOTE:

For Mounting

Bracket options and

parts information

contact BTI.

SOLON FACILITY RIVERSIDE FACILITY THORNBURY 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. [phone] FAX. [phone] FAX. [phone]