BTI TC151 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

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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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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, 90o
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: 180o
Locking Positions: 90o, 45o, 0o, 45o, 90o
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: 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 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" 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 / 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 per-
sonal 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 there-
fore 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 opera-
tion, 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 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 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 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 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 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 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 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 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 com-
pactor. If the operating weight of the carrier falls within this range, the
carrier will safely handle this model. If the desired compactor falls out-
side of the recommended carrier weight range, 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 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 max-
imum productivity the carrier should be capable of providing the maxi-
mum required flow. Compare the maximum oil flow requirement of the
compactor with the oil flow capacity of the carrier. Remember the com-
pactor 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 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

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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 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, 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 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 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 com-
pactor. 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