LG Electronics 20LH1DC1 Flat Panel Television User Manual
Contents
1. Number Description Qty 1 360 0002 Upper Body 1 2 1008925 Isolator 4 3 220 2708 Bearing Housing 1 4 1912271 Bolt Grade 8 32 5 1932014 Locknut 22 6 1941004 Flat Washer 34 7 360 0003 Lower Housing 1 8 220 2713 Eccentric Assembly 1 9 1008936 Bearing 2 10 1008935 Reatining Ring 2 1800849 O Ring 2 12 220 2707 Bearing Housing Motor Side 1 13 1912009 Bolt Grade 8 2 14 1001856 Nordlock Washer Set 2 15 1008798 Gasket 1 16 1801470 Plug 1 NOTE 17 1800288 Fitting 2 18 1009505 Hydraulic Motor 1 For Mounting 19 1912128 Bolt Grade 8 4 Bracket options and 20 1001857 Nordlock Washer Set 4 parts information 21 1800255 Fitting 2 contact BTI 22 1800418 Fitting Not Shown 2 23 H409 KKK 025 Hose Assembly 1 24 412 030 Assemvly 1 5 25 360 0110 Motor Repair Kit 360 0101 Flow Control Kit Included in Hydraulic Kit P N 360 0100 Compactor Owner s Manual 33 80 5 TC80 When ordering give Part Number Part Name Model and Serial 34 www rockbreaker com For Mounting Bracket options and parts information contact BTI 1 D IS D Part Number 370 0007 1008925 1912261 1941004 1932014 409 021 1800289 650 8641 1009833 1912020 1801983 650 8619 1801982 1001531 1007793 650 8618 409 029 370 0005 1801470 650 8620 1800255 1800418 370 0110 Compactor Owner s Manual TC80 PARTS Description Top Mount Top F2. 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 1515 1500 2000 psi 102 136 bar 1515 1100 1600 psi 75 109 bar TC304 1500 2000 psi 102 136 TC304H 1100 1600 psi 75 109 bar Compactor Owner s Manual 21 FLOW amp PRESSURE Adjust Carrier s Pressure Relief BTI Service Centers Now adjust the oil flow on the carrier so the flow meter reading equals TC51L FC 8 12 USgpm 30 45 l min 51 12 18 gpm 44 68 l min 74 13 17 USgpm 49 63 l min TC71FC 13 22 gpm 49 83 l min 80 20 26 USgpm 75 97 l min TC91S 18 24 USgpm 68 91 l min 1515 25 31 USgpm 95 117 l min 1515 35 43 132 163 l min TC304 35 43 USgpm 132 163 l min TC304H 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 adjust ing 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 dis played on the flow meter If this pressure setting 18 at least 350 psi or greater than the maximum working pressure of the compactor your machine 15 ready If not you need to
3. 3 500 11 500 kg 118 6 472 mm I 25 9 658 mm gt l 23 584 35 6 904 Compactor Owner s Manual 7 TC91S SPECIFICATIONS Impulse Force Oil Flow Req d Cycles Minute Hydraulic Connections Minimum Tube I D Operating Pressure Base Plate Dimension Compaction Area Weight Swivel Rotation Locking Positions Carrier Weight 5 000 8 200 Ib 2 270 3 727 kg 20 26 US gpm 75 97 l min 1 659 2 200 12 JIC Male 34 1 300 2 000 psi 88 136 bar 23 x 27 584 x 686 mm 4 3 sq ft 0 40 sq M 1 130 Ib 514 kg 1809 909 459 00 450 909 7 700 25 300 Ib 3 500 11 500 kg 10 4 264 mm www rockbreaker com Impulse Force Oil Flow Req d Cycles Minute Hydraulic Connections Minimum Tube I D Operating Pressure Base Plate Dimension Compaction Area Weight Swivel Rotation Locking Positions Carrier Weight 1515 151SH SPECIFICATIONS 1515 11 120 16 610 Ib 5 055 7 550 kg 25 31 US 95 117 l min 1 800 2 200 16 JIC Male 1 1 500 2 000 psi 102 136 bar 28 x 36 5 711 x 927mm 7 1 sq ft 0 66 sq M 1 825 Ib 830 kg 1809 909 459 09 450 909 15 400 48 400 Ib 7 000 22 000 kg Compactor Owner s Manual Hd 16 3 gt 414 mm TC151SH 11 120 16 610 Ib 5 055 7 550 kg 35 43 US gpm 132 163 l min 1 800 2 200 16
4. 32 1001858 Nordlock Washer Set M20 20 33 1932020 Locknut 3 4 8 34 650 8586 Base Plate 1 36 650 8676 Stud 12 38 1931013 Hex Nut 3 4 NF 12 42 H408 LLL 026 Hose Assembly 1 43 1800943 Fitting 2 44 1800947 O Ring 1 45 1009834 Hydraulic Motor 1 46 1912097 Bolt 1 2 NF x 1 4 GR 8 4 47 1001857 Nordlock Washer Set M12 4 50 H405 LLL 026 Hose Assembly 1 51 1007784 Retaining Ring 1 54 650 8593 Bearing Housing Motor Side 1 650 8591 Decal Kit REF 380 0110 Motor Repair Kit REF Compactor Owner s Manual TC151SH 50 y gt UU 40 NY 1 27 www rockbreaker com Item Part Number Description 8 1 1912048 Bolt 6 2 1801016 Grease Fitting 1 8 1 3 1941015 Flatwasher 14 4 650 5569 Cap Flange 1 5 Mounting Bracket Contact BTI 1 6 1001534 Bearing Washer 1 7 1001535 Bushing 1 8 700 0225 2 9 1002184 Quick Pin c w Chain 4 10 1001536 Bottom Bearing Washer 1 650 8296 Clevis Pin 1 12 650 8587 Frame Weldment 1 13 1800419 Fitting 2 14 1800262 Fitting 2 15 1001529 Quick Pin 1 17 1801223 Fitting 2 18 1912086 Bolt 3 4 NC x 3 LG GR 8 8 For Mounting 20 1912138 Bolt 5 8 NC x 1 2 GR 8 8 Bracket options and 21 1001768 Nordlock Washer Set 8 parts information 22 650 8592 Bearing Housing 1 contact BTI 23 1801020 Pipe Plug 2 24 1801980 O Ring 2 25 1002182 Bearing 2 26 1007783 Retaining Ring Internal 2 27 650 8589 Eccen
5. JIC Male 4 1 100 1 600 psi 75 109 bar 28 x 36 5 711 x 927mm 7 1 sq ft 0 66 sq M 1 830 Ib 832 kg 1809 909 459 09 450 909 15 400 48 400 Ib 7 000 22 000 kg TC301 TC301H SPECIFICATIONS Impulse Force Oil Flow Req d Cycles Minute Hydraulic Connections Minimum Tube I D Operating Pressure Base Plate Dimension Compaction Area Weight Carrier Weight 10 www rockbreaker com k4 35 1 892 mm sh 47 8 1 1214 mm TC301 16 300 24 300 Ib 7 409 11 000 kg 35 43 US gpm 132 163 l min 1 800 2 200 16 JIC Male 4 1 500 2 000 102 136 bar 34 x 37 864 x 940 mm 8 74 sq ft 0 812 sq M 2 150 Ib 978 kg 31 900 105 600 Ib 14 500 48 000 kg 23 5 597 mm IA 341864 mm TC301H 16 300 24 300 Ib 7 409 11 000 kg 50 61 gpm 189 231 l min 1 800 2 200 20 JIC Male 1 1100 1600 psi 75 109 bar 34 x 37 864 x 940 mm 8 74 sq ft 0 812 sq M 2 155 Ib 980 31 900 105 600 Ib 14 500 48 000 kg 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 AWARNING Warning Hazards or unsafe practices which COULD result in pe
6. 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 connec tion 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 www rockbreaker com 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 A CAUTION 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 Removal and Storage 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 C
7. www rockbreaker com 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 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 A CAUTION Some compactor components are heavy or awkward plan carefully how you will handle them when installing removing or disassembling Compactor Owner s Manual 13 HAZARD ALERTS 14 9 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 th
8. 000 Ib 907 4 536 kg 318 mm TC71S SPECIFICATIONS Impulse Force Oil Flow Req d Cycles Minute Hydraulic Connections Minimum Tube I D Operating Pressure Base Plate Dimension Compaction Area Weight Swivel Rotation Locking Positions Carrier Weight 1627 mm 31 5 800 mm 715 3 300 5 000 Ib 1 497 2 268 kg 13 17 US gpm 49 63 l min 2 020 2 500 12 Male 34 1 200 2 000 psi 81 136 bar 15 x 26 381 x 660 mm 2 71 sqft 0 252 sq M 610 Ib 277 kg N A N A 5 500 15 500 Ib 2 492 7 030 kg 25 1 638 mm i 6 www rockbreaker com 351 mm TC71FC 3 300 5 000 Ib 1 497 2 268 kg 13 22 USgpm 50 83 l min 2 020 2 500 12 Male 1 200 2 000 81 136 bar 15 26 381 660 2 71 sq ft 0 252 sq M 610 Ib 277 kg N A N A 5 500 15 500 Ib 2 492 7 030 kg 19 8 15 381 mm TC80 SPECIFICATIONS Impulse Force 5 000 8 200 Ib 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 3112 JIC Male Minimum Tube I D 3A Operating Pressure 1 300 2 000 psi 88 136 bar Base Plate Dimension 23 x 26 584 660 Compaction Area 4 15 sq ft 0 39 sq M Weight 969 Ib 441 kg Swivel Rotation Floating Optional Locking Positions 900 09 909 Carrier Weight 7 700 25 300 Ib
9. 09 369 0878 PH 519 599 2015 FAX 440 542 3721 FAX 909 369 8281 FAX 519 599 6803
10. 4 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 Compactor Owner s Manual 15 SIZING THE COMPACTOR Carrier Lifting Capacity Carrier Oil Flow 16 Always use a compactor sized to the carrier 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
11. 8676 Stud 12 40 1931013 Hex Nut 3 4 12 44 650 8619 Bearing Housing 1 45 1007794 External Retaining Ring 1 46 1801983 O Ring 1 47 1800289 Fitting 2 48 H405 KKK 014 Hose Assembly 1 49 1009833 Hydraulic Motor 1 50 650 8641 Stud 4 52 1932015 Locknut 1 2 20UNF 4 54 H405 KKK 022 Hose Assembly 1 650 8622 Decal Kit REF 370 0110 Motor Repair Kit REF Compactor Owner s Manual 37 1515 38 2 lt X Nen 3 When ordering give Part Number Part Name Model and Serial www rockbreaker com Item Part Number Description 8 1 1912048 Bolt 6 2 1801016 Grease Fitting 1 8 1 3 1941015 Flatwasher 14 4 650 5569 Cap Flange 1 5 Mounting Bracket Contact BTI 1 6 1001534 Bearing Washer 1 7 1001535 Bushing 1 8 700 0225 2 9 1002184 Quick Pin c w Chain 4 10 1001536 Bottom Bearing Washer 1 650 8296 Clevis Pin 1 12 650 8587 Frame Weldment 1 13 1800419 Fitting 2 14 1800262 Fitting 2 15 1001529 Quick Pin 1 17 1801223 Fitting 2 18 1912086 Bolt 3 4 NC x 3 LG GR 8 8 For Mounting 20 1912138 Bolt 5 8 NC x 1 1 2 GR 8 8 Bracket options and 21 1001768 Nordlock Washer Set 8 parts information 22 650 8592 Bearing Housing contact 23 1801020 Pipe Plug 2 24 1801980 O Ring 2 25 1002182 Bearing 2 26 1007783 Retaining Ring Internal 2 27 650 8589 Eccentric Assembly 1 28 1800102 Fitting 2 29 H06 GGG 010 Assembly 1 21 650 8710 Lattice Mount Includes 32 36 38 2
12. ATION Shut off Compactor Before Lifting Bolt Loctite Requirements When compaction 15 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 beams and they drive into most soils including fine sand and rocky material Best results are achieved by keeping the compactor base 90 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 ambi ent temperature should be at least 20 F above the pour point of oil Start with a gradual warm up until the oil reaches a reasonably fluid state Daily Inspection 26 At the end of
13. Revision 05 2004 For Models TC51 TC71 TC80 TC91 TC151 amp TC301 A9O01ONH23I 332 V339 BREAKER TECHNOLOGY INC General i teas 4 TC51 Specifications 5 TC71 Specifications 6 TC80 Specifications 7 TC91S Specifications 8 1515 TC151SH Specifications 9 TC301 TC301H Specifications 10 Hazard Alerts 11 Sizing the Compactor 15 Typical Hydraulic Circuits 17 Installation 20 Setting Flow amp Pressure 21 Start Up urna l ret ert 23 Operation nn tie erroe 24 Removal amp Storage 27 Product Warranty 28 Bracket Options 29 30 Parts iones 32 TOEO Palts 34 TOITS Parts 36 1515 Parts 38 TOTSISH Parts tss 40 2630 42 TC301H Parts 44 Compactor Owner s Manual compactors designed to mount mini excavators backhoes and excavators BTI compactors combine impulse force down pressu
14. actor 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 Figure 1 Carrier with Auxiliary Circuit from Electric Pilot Circuit E Foot Switch Oil Supply On Off Valve Hydraulic Compactor LJ 5 amp ES a Cooler 18 www rockbreaker com 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 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 Priority Flow Electric Control Valve Foot Switch 4 Hydrauli 1 i PumpjPump Compactor Owner s Manual 19 There is separate pressure adjustment on the compactor The co
15. 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 915 2000 350 psi 2350 psi 136 24 160 bar relief TC151S 2000 350 psi 2350 psi 136 24 160 bar relief 1515 1600 350 psi 1950 psi 109 24 133 bar relief TC3041 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 800 567 8267 Riverside California 909 369 0878 Solon Ohio 440 248 7168 www rockbreaker com 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 sho
16. 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 www rockbreaker com TYPICAL HYDRAULIC CIRCUITS 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 hydraulic circuit which will provide the correct flow switch to activate the compactor circuit relief valve Compactor Owner s Manual 17 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 comp
17. at 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 www rockbreaker com 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 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 51 14 22 cu yds hr 71 18 27 cu yds hr 80 23 32 cu yds hr TC91S 25 35 cu yds hr TC151S 65 75 cu yds hr 1515 65 75 cu yds hr TC301 110 130 cu yds hr TC301H 110 130 cu yds hr 11 17 cu M hr 14 21 cu M hr 18 25 cu M hr 19 27 cu M hr 50 57 cu M hr 50 57 cu M hr 84 99 cu M hr 84 99 cu M hr Typical Production Rate OO Lift Sizes For proper compaction we recommend the following lift size TC51 5 1 foot 0 15 0 3 M 7
18. ers If the carrier is equipped with a Quick Attach system ensure the device is securely locking in position before operation 20 www rockbreaker com Oil Flow Oil Pressure Working Pressure Range Carrier Oil Flow SETTING FLOW amp 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 TC71FC 1200 2000 psi 13 22 USgpm 81 136 bar 50 83 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 1515 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 51
19. mpactor s supply oil should be directed out the left side of the boom and the return line back on the boom s right side 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 TC9IS 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 retain
20. ompactor Owner s Manual 27 PRODUCT WARRANTY 28 1 BREAKER TECHNOLOGY Company hereinafter referred to as BTI war rants 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 elec
21. our TC91S 25 35 cu yds 19 27 cu M per hour 1515 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 operat ing 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 www rockbreaker com 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 Another cause of premature mount failure occurs when working in very Working in Wet Soil wet soil and or a very tight trench Suction or drag when
22. r sonal injury or death if the proper precautions are not taken ACAUTION 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 Compactor Owner s Manual 11 HAZARD ALERTS 12 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
23. r Mount 4 33 1911185 Bolt 3 4 NC x 2 3 4 GR 5 32 34 1912097 Bolt 1 2 20 UNF x 1 1 2 GR 5 4 35 1001857 Nordlock Washer Set M12 4 650 8683 Decal Kit REF 380 0110 Motor Repair Kit REF Compactor Owner s Manual 43 TC301H PARTS 0691 www rockbreaker com TC301H PARTS Part Number Description Qty 1 650 8680 Top Weldment 1 2 1801591 Fitting 2 3 1800420 Fitting 2 4 1001858 Nordlock Washer Set M20 72 5 1912046 Bolt 3 4 10UNC x 2 1 2 GR 8 8 6 650 8526 Bearing Housing 1 7 1801020 Pipe Plug 2 8 1801855 O Ring 2 9 1006886 Spherical Roller Bearing 2 10 1006919 Retaining Ring 2 11 650 8527 Eccentric Assembly 1 12 650 8679 Base Weldment 1 1801223 Fitting 2 17 650 8525 Bearing Housing 1 19 1006920 Retaining Ring 1 22 1009836 Hydraulic Motor 1 NOTE 24 1800294 Fitting 2 For Mounting 2 Assembly 2 Ring 1 Bracket 5 71022052 Locknut 32 parts informadon 1007828 Rubber Mount 4 contact Bre 33 1911185 Bolt 3 4 NC x 2 3 4 GR 5 32 34 1912097 Bolt 1 2 20 UNF x 1 1 2 GR 5 4 35 1001857 Nordlock Washer Set M12 4 650 8683 Decal Kit REF 390 0110 Motor Repair Kit REF Compactor Owner s Manual 45 TECHNOLOGY INC an Astec company ISO 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 NOH 2 0 CANADA PH 440 542 3720 PH 9
24. rame 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 4 DD NO 5 35 TC91S PARTS When ordering give Part Number Part Name Model and Serial www rockbreaker com 36 TC91S PARTS Part Number Description Qty 1 1912048 Bolt 14 2 1801016 Grease Fitting 1 8 1 3 1941015 Flatwasher 14 4 650 5569 Cap Flange 1 5 1001534 Bearing Washer 1 6 Bushing Contact BTI for Part REF 7 1001535 Bushing 1 8 650 8501 Top Mount Weldment 1 9 1001536 Bottom Bearing Washer 1 10 1001857 Nordlock Washer Set M12 44 11 1912020 Bolt 1 2 13UNC x 1 1 2 LG GR8 40 12 Pin Contact BTI for Part REF 13 1002184 Quick Pin c w Chain 4 14 650 8296 Clevis Pin 1 15 650 8617 Frame Weldment 1 16 1800261 Fitting 1 17 1800418 Cap 2 For Mounting 19 1800255 Fitting 1 Bracket options and 20 1001529 Quick Pin 1 parts information 25 650 8620 Bearing Housing 2 contact BTI 26 1801020 Pipe Plug 2 27 1801982 O Ring 2 28 1001531 Bearing 2 29 1007793 Retaining Ring 2 33 650 8618 Eccentric Assembly 1 34 650 8710 Lattice Mount includes 35 38 40 2 35 1001858 Nordlock Washer Set M20 20 36 1932020 Locknut 3 4 NC 8 37 650 8616 Base Plate Weldment 1 38 650
25. re 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 amp 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 Mounting Bracket Rubber Isolator 1 Motor amp Eccentric Base Plate Assemblv 4 www rockbreaker com Impulse Force Oil Flow Req d Cycles Minute Hydraulic Connections Minimum Tube I D Operating Pressure Base Plate Dimension Compaction Area Weight Swivel Rotation Locking Positions Carrier Weight 21 9 556 mm gt I 28 1711 mm TC51 SPECIFICATIONS TC51L FC 2 250 3 000 Ib 1 020 1 360 kg 8 12 US gpm 30 45 l min 1 940 2 200 8 Male 1 2 1 500 2 200 psi 102 150 bar 12 5 x 22 317 5 x 558 5 mm 1 91 sq ft 0 177 sq M 295 Ib 158 kg N A N A 2 000 10 000 Ib 907 4 536 kg 485 mm Compactor Owner s Manual TC51H FC 2 250 3 000 Ib 1 020 1 360 kg 12 18 USgpm 44 68 l min 1 940 2 200 8 Male 1 2 1 500 2 200 psi 102 150 bar 12 5 22 317 5 x 558 5 mm 1 91 sq ft 0 177 sq M 295 lb 158 kg N A N A 2 000 10
26. t 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 materi als and or the correction of such defective parts or materials 7 BTI neither assumes nor authorizes any other person to assume for it any lia bility in connection with the sale of it s products other than that specifically stat ed herein 8 THIS WARRANTY IS EXPRESSLY IN LIEU OF ANY AND ALL OTHER WARRANTIES EXCEPT AS EXPRESSLY SET FORTH HEREIN BTI MAKES NO REPRE SENTATION OR WARRANTY STATUTORY EXPRESS OR IMPLIED WITH RESPECT TO THE PRODUCTS MANUFACTURED AND OR SUPPLIED BY BTI WHETHER AS TO MER CHANTABILITY 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 www rockbreaker com BRACKET OPTIONS Bolt On Rigid Top Mount Shown on TC80 S
27. tandard equipment on TC51 TC71 TC80 amp TC301 Bolt On QA Non Swivel Top Mount Available as an option on the TC71 amp TC80 QA Swivel Top Mount Standard equipment on TC91S amp 1515 Optional Bolt On on the TC71 and TC80 Compactor Owner s Manual 29 TC51 C LQ ee SR SSS Xe mAN 2 QE AN K When ordering give Part Number Part Name Model Serial 30 www rockbreaker com Number Description Qty 1 350 0007 Upper Weldment 1 2 1800424 Cap 2 3 9006862 Fill Drain 1 4 650 8780 Bearing Housing 1 5 350 0002 Lower Weldment 1 6 650 8795 Eccentric Assembly 1 T 1008414 Bearing 2 8 1008453 Retaining Ring 2 9 650 8796 Bearing Housing 1 10 1800288 Fitting 2 11 1009488 Hydraulic Motor 1 12 1912007 Bolt Grade 8 2 13 1001856 Nordlock Washer Set 2 14 1008798 Gasket 1 15 1911113 Bolt Grade 5 8 NOTE 16 1001856 Nordlock Washer Set 8 17 1912270 Button Head Cap Screw 32 For Mounting 18 1941002 Flat Washer 64 Bracket options and 19 1009487 Isolator 4 parts information 20 1932008 Locknut 32 contact BTI 21 H05 KKK 023 Hose Assembly 2 350 0110 Motor Repair Kit REF 350 1002 Low Flow Kit L FC 9 0 gpm 350 0103 High Flow Kit H FC 13 5 gpm Not Shown Compactor Owner s Manual 31 TC71 PARTS When ordering give Part Number Part Name Model and Serial www rockbreaker com 32 TC71 PARTS
28. the compactor or Tight Trench 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 Do Not Grade Never grade the trench or level backfill with the compactor Extreme side with Compactor 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 909 to the compactor base Keep Compactor Parallel with Material 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 Initial Compacting pactor 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 51 5 1 ft 0 15 0 3 71 5 1 ft 0 15 0 3 Lift Depths 80 1 2 ft 0 3 0 6 TC91S 1 2 ft 0 3 0 6 M 1515 1515 2 3 ft 0 6 0 9 TC301 TC304H 2 4 ft 0 6 1 2 Note using a higher material lift depth may give less than 95 soil com paction Materials with 5 moisture give better compaction Narrow excavations can use higher lifts Compactor Owner s Manual 25 OPER
29. tric Assembly 1 28 1800102 Fitting 2 29 H06 GGG 010 Hose Assembly 1 31 650 8710 Lattice Mount Includes 32 36 38 2 32 1001858 Nordlock Washer Set M20 20 33 1932020 Locknut 3 4 NC 8 34 650 8586 Base Plate 1 36 650 8676 Stud 12 38 1931013 Hex Nut 3 4 NF 12 42 H408 LLL 026 Hose Assembly 1 43 1800292 Fitting 2 44 1800947 O Ring 1 45 1009835 Hydraulic Motor 1 46 1912097 Bolt 1 2 NF x 1 4 GR 8 4 47 1001857 Nordlock Washer Set M12 4 50 H405 LLL 026 Hose Assembly 1 51 1007784 Retaining Ring 1 54 650 8593 Bearing Housing Motor Side 1 650 8591 Decal Kit REF 380 0110 Motor Repair Kit REF Compactor Owner s Manual TC301 PARTS 25 When ordering give Part Number Part Name Model and Serial TC301 42 www rockbreaker com TC301 PARTS Part Number Description Qty 1 390 0002 Weldment 1 2 1800262 Fitting 2 3 1800419 Fitting 2 4 1001858 Nordlock Washer Set M20 72 5 1912046 Bolt 3 4 10UNC x 2 1 2 GR 8 8 6 650 8526 Bearing Housing 1 7 1801020 Pipe Plug 2 8 1801855 O Ring 2 9 1006886 Spherical Roller Bearing 2 10 1006919 Retaining Ring 2 11 650 8527 Eccentric Assembly 1 12 650 8679 Base Weldment 1 13 1801223 Fitting 2 17 650 8525 Bearing Housing 1 19 1006920 Retaining Ring 1 22 1009835 Hydraulic Motor 1 24 1800292 Fitting 2 For Mounting 25 H405 LLL 033 Hose Assembly 2 Bracket options and 26 1800947 O Ring 1 parts information 29 1932052 Locknut 32 contact BTI 21 1007828 Rubbe
30. ts 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 Compactor Owner s Manual 23 OPERATION Test the Compactor First Hourly Production Rates Operate Carrier at Minimum Speed Compactor Base Must Contact Soil Use Proper Boom Down Force 24 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 h
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