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LG Electronics TC51 manual

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Table of contents for the manual

  • Page 1

    OWNER ’S MANU AL T C SERIES HYDRAULIC COMP A CTORS Revision : 05/2004 Manual # : 150-1010 BREAKER TECHNOLOG Y For Models : T C51, TC71, T C80, TC91, T C151 & T C301[...]

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    [...]

  • Page 3

    3 Compactor Owner ’s Manual General ................................................. TC51 S pecifications .............................. TC71 S pecifications .............................. TC80 S pecifications .............................. TC91S S pecifications ............................ TC151S / TC151SH S pecifications ....... TC301 / TC301H[...]

  • Page 4

    4 www .rockbreak er .com 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 ad[...]

  • Page 5

    5 Compactor Owner ’s Manual T C51 SPECIFICA TIONS Impulse F orce: 2,250 - 3,000 lb 2,250 - 3,000 lb 1,020 - 1,360 kg 1,020 - 1,360 kg Oil Flow R eq'd: 8 - 12 US gpm 12 - 18 USgpm 30 - 45 l/min 44 - 68 l/min Cyc les/Minute: 1,940 - 2,200 1,940 - 2,200 Hydraulic Connections: #8 JIC Male #8 JIC Male Minimum T ube I.D.: 1/2" 1/2" Opera[...]

  • Page 6

    6 www .rockbreak er .com T C71S SPECIFICA TIONS Impulse F orce: 3,300 - 5,000 lb 3,300 - 5,000 lb 1,497 - 2,268 kg 1,497 - 2,268 kg Oil Flow R eq'd: 13 - 17 US gpm 13 - 22 USgpm 49 - 63 l/min 50 - 83 l/min Cyc les/Minute: 2,020 - 2,500 2,020 - 2,500 Hydraulic Connections: #12 JIC Male #12 JIC Male Minimum T ube I.D.: ¾" ¾" Operatin[...]

  • Page 7

    7 Compactor Owner ’s Manual T C80 SPECIFICA TIONS Impulse F orce: 5,000 - 8,200 lb 2,270 - 3,727 kg Oil Flow R eq'd: 20 - 26 US gpm 75 - 97 l/min Cyc les/Minute: 1,659 - 2,200 Hydraulic Connections: #12 JIC Male Minimum T ube I.D.: ¾" Operating Pressur e: 1,300 - 2,000 psi 88 - 136 bar Base Plate Dimension: 23 x 26" 584 x 660 mm C[...]

  • Page 8

    8 www .rockbreak er .com T C91S SPECIFICA TIONS Impulse F orce: 5,000 - 8,200 lb 2,270 - 3,727 kg Oil Flow R eq'd: 20 - 26 US gpm 75 - 97 l/min Cyc les/Minute: 1,659 - 2,200 Hydraulic Connections: #12 JIC Male Minimum T ube I.D.: ¾" Operating Pressur e: 1,300 - 2,000 psi 88 - 136 bar Base Plate Dimension: 23 x 27" 584 x 686 mm Compa[...]

  • Page 9

    9 Compactor Owner ’s Manual Impulse F orce: 1 1,120 - 16,610 lb 1 1,120 - 16,610 lb 5,055 - 7,550 kg 5,055 - 7,550 kg Oil Flow R eq'd: 25 - 31 US gpm 35 - 43 US gpm 95 - 1 17 l/min 132 - 163 l/min Cyc les/Minute: 1,800 - 2,200 1,800 - 2,200 Hydraulic Connections: #16 JIC Male #16 JIC Male Minimum T ube I.D.: 1 " 1 ” Operating Pressur [...]

  • Page 10

    10 www .rockbreak er .com Impulse F orce: 16,300 - 24,300 lb 16,300 - 24,300 lb 7,409 - 1 1,000 kg 7,409 - 1 1,000 kg Oil Flow R eq'd: 35 - 43 US gpm 50 - 61 gpm 132 - 163 l/min 189 - 231 l/min Cyc les/Minute: 1,800 - 2,200 1,800 - 2,200 Hydraulic Connections: #16 JIC Male #20 JIC Male Minimum T ube I.D.: 1 " 1 1/4” Operating Pressur e:[...]

  • Page 11

    11 Compactor Owner ’s Manual Danger , W arning, 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. War ning - Hazards or unsafe practices, w[...]

  • Page 12

    12 www .rockbreak er .com 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, under ground cables,[...]

  • Page 13

    13 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 ga[...]

  • Page 14

    14 www .rockbreak er .com Head Foot Eye Hearing Protection Protection Protection Protection Do not operate or service the compactor unless you are qualified. A void 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 th[...]

  • Page 15

    15 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 W or k 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. Th[...]

  • Page 16

    16 www .rockbreak er .com 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 pressu[...]

  • Page 17

    17 Compactor Owner ’s Manual T o 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 relie[...]

  • Page 18

    18 www .rockbreak er .com 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 aux[...]

  • Page 19

    19 Compactor Owner ’s Manual Car rier without Auxiliar y 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. The[...]

  • Page 20

    20 www .rockbreak er .com 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[...]

  • Page 21

    21 Compactor Owner ’s Manual Car rier Oil Flow Wo r k in g Pressur e Range Oil Flow & Oil Pressur e SETTING FLO W & PRESSURE For a compactor to operate properly it requires a specific oil flow and sufficient oil pressure. T C51L/FC: 1500-2200 psi @ 8-12 USgpm (102-150 bar) @ (30-45 l/min) T C51H/FC: 1500-2200 psi @ 12-18 USgpm (102-150 ba[...]

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    22 www .rockbreak er .com BTI Ser vice Center s Adjust Car rier’ s Pressur e R elief SETTING FLO W & PRESSURE Now adjust the oil flow on the carrier , so the flow meter reading equals: T C51L/FC: 8-12 USgpm (30-45 l/min) T C51H/FC: 12-18 gpm (44-68 l/min) T C71: 13-17 USgpm (49-63 l/min) T C71FC: 13-22 gpm (49-83 l/min) T C80: 20-26 USgpm (75[...]

  • Page 23

    23 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[...]

  • Page 24

    24 www .rockbreak er .com Hour ly 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: • T ype and size of material being compacted • Moisture content of the material • Depths of lif[...]

  • Page 25

    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. A void dragging the compactor's plate across the material surface ('ironing') while the motor is running. Forces exerted on the compactor by 'ironing[...]

  • Page 26

    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[...]

  • Page 27

    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. R emo val and Stor age 27 Compactor Owner ’s Manual OPERA TION Maintenance- Ev er y 40 Hour s of Operation [...]

  • Page 28

    28 www .rockbreaker .com 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[...]

  • Page 29

    29 Compactor Owner ’s Manual BRACKET OPTIONS Bolt-On Rigid T op Mount: (Shown on TC80) S tandard equipment on TC51, TC71, TC80 & TC301 Bolt-On QA Non-Swivel T op Mount: Available as an option on the TC71 & TC80 QA Swivel T op Mount: S tandard equipment on TC91S & TC151S. Optional Bolt-On on the TC71 and TC80.[...]

  • Page 30

    30 www .rockbreaker .com T C51 P ARTS T C51 When ordering give Part Number , Part Name, Model and Serial #.[...]

  • Page 31

    31 Compactor Owner ’s Manual T C51 P ARTS Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 Description Upper W eldment Cap Fill/Drain Bearing Housing Lower W eldment Eccentric Assembly Bearing Retaining Ring Bearing Housing Fitting Hydraulic Motor Bolt - Grade 8 Nordlock W asher Set Gasket Bolt - Grade 5 Nordlock W asher Set Button Head[...]

  • Page 32

    32 www .rockbreaker .com T C71 P ARTS T C71 When ordering give Part Number , Part Name, Model and Serial #.[...]

  • Page 33

    33 Compactor Owner ’s Manual T C71 P ARTS 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 W asher Lower Housing Eccentric Assembly Bearing Reatining Ring O-Ring Bearing Housing - Motor Side Bolt - Grade 8 Nordlock W asher Set Gasket Plug Fitting Hyd[...]

  • Page 34

    34 www .rockbreaker .com T C80 P ARTS T C80 When ordering give Part Number , Part Name, Model and Serial #.[...]

  • Page 35

    35 Compactor Owner ’s Manual T C80 P ARTS 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 T op Mount T op Frame W eldment Isolator Bolt W asher Locknut Hose Assembly Fitting Stud Motor Hex Head Bolt O-Ring Bearing Housing O-Ring Bearing Retaining Ring Eccentric Assembly Hose Assembly Drum W eldment Plug Bearing Housin[...]

  • Page 36

    36 www .rockbreaker .com T C91S P ARTS When ordering give Part Number , Part Name, Model and Serial #. T C91S[...]

  • Page 37

    T C91S P ARTS 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 T op Bearing W asher Bushing - Contact BTI for Part # Bushing T op Mount W eldment Bottom Bearing W asher Nordlock W asher Set M12 Bolt 1/2” -13UNC x 1 1[...]

  • Page 38

    38 www .rockbreaker .com T C151S P ARTS When ordering give Part Number , Part Name, Model and Serial #. T C151S[...]

  • Page 39

    39 Compactor Owner ’s Manual T C151S P ARTS 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 T op Bearing W asher Bushing Pin Quick Pin c/w Chain Bottom Bearing W asher Clevis Pin[...]

  • Page 40

    40 www .rockbreaker .com T C151SH T C151SH P ARTS[...]

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    41 Compactor Owner ’s Manual T C151SH P ARTS 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 T op Bearing W asher Bushing Pin Quick Pin c/w Chain Bottom Bearing W asher Clevis Pi[...]

  • Page 42

    42 www .rockbreaker .com T C301 P ARTS When ordering give Part Number , Part Name, Model and Serial #. T C301[...]

  • Page 43

    43 Compactor Owner ’s Manual T C301 P ARTS 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 T op W eldment Fitting Fitting Nordlock W asher 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 W eldment Fitting Bearing Housing Ret[...]

  • Page 44

    44 www .rockbreaker .com T C301H T C301H P ARTS[...]

  • Page 45

    45 Compactor Owner ’s Manual T C301H P ARTS 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 T op W eldment Fitting Fitting Nordlock W asher 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 W eldment Fitting Bearing Housing Re[...]

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  • Page 48

    SOLON F ACILITY RIVERSIDE F ACILITY THORNBURY F ACILITY 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 F AX. 440-542-3721 F AX. 909-369-8281 F AX. 519-599-6803[...]