Parts Manual
Contents
1. If necessary the trigger and the lever can be removed from the trigger handle by driving out the spirol pin securing each part 8 To service the foot assembly proceed as follows A The latch detent spring and cone washers are acces sible when the latch bolt is removed 15 16 inch hex Note Before removing the hex bushing note the alignment of hex flats with latch bolt centerline see figure 1 so that the new hex bushing is installed with the same alignment 2 Figure 1 Hex Alignment with Latch Bolt B Use a 1 3 8 inch 35 mm diameter steel rod 10 inches 25 cm long and use the rod to push the hex bushing from the flanged end of the foot toward the latch end A 25 ton press is required C Place the new hex bushing O D tapered end first into the foot bore and press into place D The cup seal and rod wiper should be removed with proper o ring tools to avoid damage to the seal surfaces Note orientation above and below aluminum washer 9 Remove the accumulator diaphragm and on off valve spool from the accumulator valve block taking care not to damage the valve stem The spool bushing and associated seals will 15 SERVICE come out as an assembly 10 Remove the accumulator valve block from the flow sleeve by tapping on the underside of the valve block with a plastic or rubber hammer Tap on alternate sides to ensure that the valve block comes out straight without binding Turn the valve2. full flow filtration 25 microns 25 microns 25 microns 25 microns Sized for flow of at least For cold temp startup and max dirt holding 18 gpm 68lpm 30 gpm Did pm 35 gpm 132 lpm 40 gpm 151 lpm capacit Hydraulic fluid Petroleum based premium grade anti wear non conductive Viscosity at min and max operating temps 100 400 ssu 100 400 ssu 100 400 ssu 100 400 ssu 20 82 centistokes 20 82 centistokes 20 82 centistokes 20 82 centistokes NOTE When choosing hydraulic fluid the expected oil temperature extremes that will be experienced in service determine the most suitable temperature viscosity characteristics Hydraulic fluids with a viscosity index over 140 will meet the requirements over a wide range of operating temperatures NOTE These are general hydraulic system requirements See tool Specification page for tool specific requirements OPERATION The recommended hose size is 500 inch 12 mm I D up to 50 ft 15 m long and 625 inch 16 mm I D minimum up to 100 ft 30 m _ PRE OPERATION PROCEDURES _ CHECK POWER SOURCE 1 Using a calibrated flowmeter and pressure gauge check that the hydraulic power source develops a flow of 7 9 gpm 26 34 lpm at 2000 psi 140 bar 2 Make certain the hydraulic power source is equipped with a relief valve set to open at 2250 psi 155 bar maximum INSTALL TOOL BIT 1 Rotate the latch on the breaker foot downward pointing away from the tool 2 Inser
3. 145 155 bar Tool gets hot Hot fluid going through tool Check power unit Be sure flow rate is not too high causing part of the fluid to go through the relief valve Provide cooler to maintain proper fluid temperature 140 F 60 C max Check relief valve setting Eliminate flow control devices Fluid leakage on tool bit Lower piston seal failure Replace seal Fluid leakage around Valve spool seal failure Replace seals trigger 11 CHARGING THE ACCUMULATOR ACCUMULATOR TESTING PROCEDURE To check or charge the accumulator the following equipment is required 31254 Charge Kit which includes the following e Accumulator Tester Part Number 02835 Charging Assembly Part Number 15304 15304 includes a liquid filled gauge w snub valve hose and fittings NITROGEN bottle with an 800 psi 55 bar minimum charge Not included in 31254 kit 1 Remove the plug from the handle or handle pivot 2 Holding the chuck end of Accumulator Tester Part Number 02835 turn the gauge fully counterclockwise to ensure that the stem inside the chuck is completely re tracted 3 Thread the tester onto the accumulator charging valve Do not advance the gauge end into the chuck end Turn as a unit Seatthe chuck on the accumulator charging valve and hand tighten only 4 Advance the valve stem of the tester by turning the gauge end clockwise until a pressure is read on the gauge charge pressure should be 500 700 psi
4. 34 48 bar 5 If pressure is OK unscrew the gauge end from the chuck to retract the stem then unscrew the entire tester assembly from the accumulator charging valve If pressure is low charge the accumulator as described in the following para graph 6 Install the plug ACCUMULATOR CHARGING 1 Perform steps 1 through 4 of the accumulator testing procedure above 2 Connect the chuck of the charging assembly to the charging valve on the accumulator tester or if preferred remove the tester from the charging valve and connect the charging assembly chuck directly to the charging valve 3 Adjust the snub valve to a charging pressure of 600 psi 42 bar Note While watching the pressure gauge open snub valve slowly until it reaches the proper charge pressure 600 700 psi 12 NOTE It may be necessary to set the gauge at 650 700 psi 45 48 bar to overcome any pressure drop through the charging system 4 When the accumulator is fully charged close the snub valve on the charging assembly hose and remove the charging assembly chuck from the accumulator tester or tool charging valve 5 If the accumulator tester has been used be sure to turn the gauge end fully counterclockwise before removing the tester from the charging valve of the tool Install the valve cap CHARGING THE ACCUMULATOR Charging the Accumulator BR72125S amp BR72135S TESTER CHARGING LOCATION OF CHARGING VALVE Figure 2 Liquid Filled
5. ROD WIPER ROD WIPER O RING BACK UP RING CUP SEAL PART OF BREAKER FOOT ASSEMBLY pop hb ch ch pa WARRANTY Stanley Hydraulic Tools hereinafter called Stanley subject to the exceptions contained below warrants new hydraulic tools for a period of one year from the date of sale to the first retail purchaser or for a period of 2 years from the shipping date from Stanley whichever period expires first to be free of defects in material and or workmanship at the time of delivery and will at its option repair or replace any tool or part of a tool or new part which is found upon examination by a Stanley authorized service outlet or by Stanley s factory in Milwaukie Oregon to be DEFECTIVE IN MATERIALAND OR WORKMANSHIP EXCEPTIONS FROM WARRANTY FREIGHT COSTS Freight costs to return parts to Stanley if requested by Stanley for the purpose of evaluating a warranty claim for warranty credit are covered under this policy if the claimed part or parts are approved for warranty credit Freight costs for any part or parts which are not approved for warranty credit will be the responsibility of the individual SEALS amp DIAPHRAGMS Seals and diaphragms installed in new tools are warranted to be free of defects in material and or workmanship for a period of 6 months after the date of first usage or for a period of 2 years from the shipping date from Stanley whichever period expires first CUTTING ACCESSORIES Cutting accessories
6. attached to the tool and hoses before operation Failure to do so could result in personal injury or equipment damage Wear Ear Protection Wear Dust Mask 47351 Operator must start in a work area without bystanders The operator must be familiar with all prohibited work areas such as excessive slopes and dangerous terrain conditions Establish a training program for all operators to ensure safe operation Do not operate the tool unless thoroughly trained or under the supervision of an instructor Always wear safety equipment such as goggles ear head protection and safety shoes at all times when operating the tool Do not inspect or clean the tool while the hydraulic power source is connected Accidental engagement of the tool can cause serious injury Supply hoses must have a minimum working pressure rating of 2500 psi 175 bar Be sure all hose connections are tight The hydraulic circuit control valve must be in the OFF position when coupling or uncoupling the tool Wipe all couplers clean before connecting Use only lint free cloths Failure to do so may result in damage to the quick couplers and cause overheating of the hydraulic system Do not operate the tool at oil temperatures above 140 F 60 C Operation at higher oil temperatures can cause operator discomfort and may damage the tool Do not operate a damaged improperly adjusted or incompletely assembled tool Do not weld cut with an acetylene tor
7. block upside down to remove the valve spring 11 Remove the piston from the flow sleeve assembly 12 Clamp the accumulator valve block in a bench vise with IN and OUT ports up IMPORTANT Over tightening the vise can distort the block 13 Remove the porting block from the accumulator valve block with a 3 8 16 thread slide hammer or Tamper Sleeve Tool Part Number 01120 14 To disassemble the flow sleeve and automatic valve body assembly proceed as follows A Remove the piston if not previously removed B Place the flow sleeve assembly automatic valve body down on the Flow Sleeve Removal Tool Part Number 04919 which in turn is placed on th Flow Sleeve Removal Tube Part Number 04910 C Using an arbor press and an aluminum disc to protect the flow sleeve push on the flow sleeve to remove the automatic valve body from the flow sleeve tube IMPORTANT Use a rag in the bottom of the Removal tube to protect the Automatic valve body when it Drops out D The automatic valve four 1 4 x 1 1 2 inch 38mm long push pins from the flow sleeve and Two 3 16 x 1 1 4 inch 32mm long push pins from the automatic valve body will come out E To remove the flow sleeve from the flow sleeve tube remove the automatic valve body and associated parts from within the flow sleeve removal tube and continue pushing on the flow sleeve until it drops out IMPORTANT Use a rag in the bottom of the removal t
8. such as breaker tool bits are warranted to be free of defects in material and or workman ship at the time of delivery only ITEMS PRODUCED BY OTHER MANUFACTURERS Components which are not manufactured by Stanley and are warranted by their respective manufacturers a Costs incurred to remove a Stanley manufactured component in order to service an item manufactured by other manufacturers ALTERATIONS amp MODIFICATIONS Alterations or modifications to any tool or part All obligations under this warranty shall be terminated if the new tool or part is altered or modified in any way NORMAL WEAR any failure or performance deficiency attributable to normal wear and tear such as tool bushings retaining pins wear plates bumpers retaining rings and plugs rubber bushings recoil springs etc INCIDENTAL CONSEQUENTIAL DAMAGES To the fullest extent permitted by applicable law in no event will STANLEY be liable for any incidental consequential or special damages and or expenses FREIGHT DAMAGE Damage caused by improper storage or freight handling LOSS TIME Loss of operating time to the user while the tool s is out of service IMPROPER OPERATION Any failure or performance deficiency attributable to a failure to follow the guidelines and or procedures as outlined in the tool s operation and maintenance manual MAINTENANCE Any failure or performance deficiency attributable to not maintaining the tool s in good operating condition as outl
9. 2135S Models Asphalt Cutter 5 in 13 cm Blade 11 in 28 cm Long UN 02335 Meil Point f4 in 3650 LONG UC momo ilatina Dyt FYN HI 02336 3 in Chisel 14 in 36 cm Long UC nen 02337 1 in Chisel Heavy Duty 714in 26enmLongUlt mann 02338 Ground Rod Driver 1 in 25 mm Rod ccc nora rn En kannan LL LL NRK ANNIKA 04367 Mol Point Heavy Duty 18 in 146 cm Long UC uuunsasenssnnannsnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn 04404 Clay Spade 8 in 20 cm Blacde ek 04405 Brick Wedge soii bl Bal la a AR le e en 08118 AsphaltWeddge au gd di LE a yd a GAE a a a GOD a a a MG a a a aa A a aa 08119 EE EE EE SET EE 09262 Detachable Shakira LEERE 17782 Tamping Le RE ET 17783 Test Equipment Accumulator Charge Assembly incl Liquid Filled Gauge wi Valve Hose amp Charge Fitting een 15304 Accumulator Test n uu E LE a ER a a ba Le a Od ei ei ME ea a E SD E 02835 20 apm SP le 03189 Flow and Pressure Tester rrio TE EN E E E EA A E NR 04182 Accumulator Charge Kit aa r ar E 31254 SERVICE Good maintenance practice keeps the breaker on the job and increases its service life The most important maintenance practice is to keep the hydraulic fluid clean at all times Contaminated hydraulic fluid causes rapid wear and or failure of internal parts Follow the procedure contained in the HYDRAULIC SYSTEM REQUIREMENTS section of the manual to ensure peak performance from the tool Never d
10. CONNECTED TO TOOL IN PORT MAINTAINED AS NON CONDUCTIVE THE HOSE SHOULD BE SYSTEM RETURN HOSE MUST ALWAYS BE CONNECTED TO TOOL REGULARLY TESTED FOR ELECTRIC CURRENT LEAKAGE IN OUT PORT REVERSING CONNECTIONS MAY CAUSE REVERSE ACCORDANCE WITH YOUR SAFETY DEPARTMENT INSTRUC TOOL OPERATION WHICH CAN RESULT IN SEVERE PERSONAL TIONS INJURY 2 AHYDRAULIC LEAK OR BURST MAY CAUSE OIL INJECTION 4 DONOT CONNECT OPEN CENTER TOOLS TO CLOSED CENTER INTO THE BODY OR CAUSE OTHER SEVERE PERSONAL INJURY HYDRAULIC SYSTEMS THIS MAY RESULT INLOSS OF OTHER HYDRAULIC FUNCTIONS POWERED BY THE SAME SYSTEM AND A DONOT EXCEED SPECIFIED FLOW AND PRESSURE FOR OR SEVERE PERSONAL INJURY THIS TOOL EXCESS FLOW OR PRESSURE MAY CAUSE A LEAKORBURST 5 BYSTANDERS MAY BE INJURED IN YOUR WORK AREA KEEP BY STANDERS CLEAR OF YOUR WORK AREA DO NOT EXCEED RATED WORKING PRESSURE OF HYDRAU LICHOSE USED WITH THIS TOOL EXCESS PRESSURE MAY 6 WEAR HEARING EYE FOOT HAND AND HEAD PROTECTION CAUSE ALEAK OR BURST 7 TOAVOID PERSONAL INJURY OR EQUIPMENT DAMAGE ALL TOOL CHECK TOOL HOSE COUPLERS AND CONNECTORS DAILY REPAIR MAINTENANCE AND SERVICE MUST ONLY BE PER The safety tag p n 1 5875 FOR LEAKS DONOT FEEL FOR LEAKS WITH YOUR HANDS FORMED BY AUTHORIZED AND PROPERLY TRAINED PERSON CONTACT WITH ALEAK MAY RESULT IN SEVERE PERSONAL NEL INJURY at right is attached to the tool when shipped from the factory Read and under IMPORTANT IMPORTANT sta
11. Gauge w Snub Valve Charge Fitting Nitrogen Tank Not included in Kit Charging Valve Includes Liquid Filled Gauge w Snub Valve Hose Charge Fitting 02835 Tester ad Box not pictured Hose Gauge 02835 TESTER Chuck Charging the Accumulator BR72120 amp BR72130 LOCATION OF CHARGING VALVE ACCUMULATOR TESTER P N 02835 Figure 2 13 SPECIFICATIONS Press re Range diia aida ke an 1500 2000 psi 105 140 bar ele Ve e 7 9 gpm 26 34 Ipm Optimum lO Wisin Y GY Y FY FT FYFYR HF FFRWD aida 8 gpm 30 Ipm Maximum Back EE 250 Psi 17 bar Eet Kee Wate Ata WN a cado re de e decidio HTMA Flush Face Per NFPAT3 20 15 ISO 16028 Connect Size amp Type iptables etn 3 8 in Male Pipe Hose Ends STT EE 59 lbs 27 kg Overall LA A ad g 28 in 71 cm Overall Wii a a CO 14 1 4 in 36 cm Max Fluid Temperature iia ala 140 F 60 C cyu Mu ol Ao HN Open Center POM SZ Est ad IU a Y Rd ba ER CW EE ee Gu SAE 8 O ring y a a RF HR I BH ee EE 7 9 gpm 2000 psi see ee eebe GY RY EN NO CO 30 lpm 138 bar 1 1 8 in Hex x 6 in Shank BR72120 amp BR72125S Models Clay Ee EE KEE EE 02321 Asphalt Cutter 5 in Blade 11 in Long Un 02332 Moil4Point 14in Eong UG 2 a eos 02333 gim Chisel 4 UG tostada nin ea aa a lib ai nda rate 02334 Chisel Point 14 in Long UC enn 03990 Ground Rod Driver Tin Roda at A E 04176 LE el e Ee EE 08106 1 1 4 in Hex x 6 in Shank BR72130 amp BR7
12. STANLEY BR 2 HYDRAULIC BREAKER SERIOUS INJURY OR DEATH COULD RESULT FROM IM PROPER REPAIR OR SERVICE OF THIS TOOL REPAIRS AND OR SERVICE TO THIS TOOL MUST ONLY BE DONE BY AN AUTHORIZED AND CERTIFIED DEALER WARNING To avoid serious injury or death 06 Wear Eye Read the Manual Protection in m SAFETY OPERATION AND MAINTENANCE e SERVICE MANUAL Wear Dust Mask Stanley Hydraulic Tools 3810 SE Naef Road Milwaukie OR 97267 5698 Copyright 2003 The Stanley Works SVCE MAINT USA 503 659 5660 FAX 503 652 1780 24144 11 2003 Ver 1 www stanley hydraulic tools com TABLE OF CONTENTS Safety Symbols and Precautions nen 4 5 Tool Stickers and Tags 0 000 ae tannanna nenna 6 Hydraulic Hose Requirements AA 7 HTMA Requirements AAA 8 Operationen A a 9 Equipment Protection and Care 10 Troubleshooting pis 11 Charging the Accumulator nennen tan 12 Specifications iei Leu ia 14 ACCOSSO MO da 14 elle 15 Parts Illustration BR72125S amp 1358 rsuurssensneennnennnnennnnnnnnennnnnnnnnnnnnnnnnen 18 Parts List BR72125S amp 1358 nati 19 Parts Illustration BR72120 amp 130 unzennnersnenessnenennennnnnnnnnnnn nenn nennen nennen nn 20 Parts List BR72120 amp 130 ic eee el a 21 MAMA annan YNN YNN aa a a gie 22 SERVICING THE STANLEY BREAKER This manual contains safety operation and routine maintenance instructions Stanley Hydraulic Too
13. STORE IN A CLEAN DRY AREA SEE OTHER SIDE SIDE 2 VIL SIHL 3AOWN34 LON OG shown smaller than actual size THE TAG SHOWN BELOW IS ATTACHED TO CONDUCTIVE HOSE DO NOT REMOVE THIS TAG 1 DONOT USE THIS HYDRAULIC HOSE ON OR NEAR ELECTRIC LINES THIS HOSE IS NOT LABELED OR CERTIFIED AS NON CONDUCTIVE USING THIS HOSE ON OR NEAR ELECTRICAL LINES MAY RESULT IN DEATH OR SERIOUS INJURY 2 FORPROPER AND SAFE OPERATION MAKE SURE THAT YOU HAVE BEEN PROPERLY TRAINED IN CORRECT PROCEDURES REQUIRED FOR WORK ON OR AROUND ELECTRIC LINES 3 DO NOT EXCEED HOSE WORKING PRESSURE OR ABUSE HOSE IMPROPER USE OR HANDLING OF HOSE COULD RESULT IN BURST OR OTHER HOSE FAILURE KEEP HOSE AS FAR AWAY AS POSSIBLE FROM BODY AND DO NOT PERMIT DIRECT CONTACT DURING USE CONTACT AT THE BURST CAN CAUSE BODILY INJECTION AND SEVERE PERSONAL INJURY 4 HANDLE AND ROUTE HOSE CAREFULLY TO AVOID KINKING CUTTING OR CONTACT WITH HIGH TEMPERATURE SURFACES DO NOT USE IF KINKED DO NOT USE HOSE TO PULL OR LIFT TOOLS POWER UNITS ETC A SEEOTHERSIDE SIDE 1 5 CHECK ENTIRE HOSE FOR CUTS CRACKS LEAKS ABRASIONS BULGES OR DAMAGETO COUPLINGS IF ANY OF THESE CONDITIONS EXIST REPLACE THE HOSE IMMEDIATELY NEVER USE TAPE OR ANY DEVICE TO ATTEMPT TO MEND THE HOSE 6 AFTER EACH USE STORE IN A CLEAN DRY AREA SEEOTHERSIDE SIDE2 Ovl SIHL 3AOWN3H LON OG The rated working pressure of the hydraulic hose
14. UCTIVE HOSE o lt E D pal E w gt o w cr E o Zz o a 1 FAILURE TO USE HYDRAULIC HOSE LABELED AND CERTIFIED AS NON CONDUCTIVE WHEN USING HYDRAULIC TOOLS ON OR NEAR ELECTRIC LINES MAYRESULT IN DEATH OR SERIOUS INJURY FOR PROPER AND SAFE OPERATION MAKE SURE THAT YOU HAVE BEEN PROPERLY TRAINED IN CORRECT PROCEDURES REQUIRED FOR WORK ON OR AROUND ELECTRIC LINES 2 BEFORE USING HYDRAULIC HOSE LABELED AND CERTIFIED AS NON CONDUCTIVE ON OR NEAR ELECTRIC LINES WIPE THE ENTIRE LENGTH OF THE HOSE AND FITTING WITH A CLEAN DRY ABSORBENT CLOTH TO REMOVE DIRT AND MOSISTURE AND TEST HOSE FOR MAXIMUM ALLOWABLE CURRENT LEAKAGE IN ACCORDANCE WITH SAFETY DEPARTMENT INSTRUCTIONS SEE OTHER SIDE SIDE 1 3 DO NOT EXCEED HOSE WORKING PRESSURE OR ABUSE HOSE IMPROPER USE OR HANDLING OF HOSE COULD RESULT IN BURST OR OTHER HOSE FAILURE KEEP HOSE AS FAR AWAY AS POSSIBLE FROM BODY AND DO NOT PERMIT DIRECT CONTACT DURING USE CONTACT AT THE BURST CAN CAUSE BODILY INJECTION AND SEVERE PERSONAL INJURY 4 HANDLE AND ROUTE HOSE CAREFULLY TO AVOID KINKING ABRASION CUTTING OR CONTACT WITH HIGH TEMPERATURE SURFACES DO NOT USE IF KINKED DO NOT USE HOSE TO PULL OH LIFT TOOLS POWER UNITS ETC 5 CHECK ENTIRE HOSE FOR CUTS CRACKS LEAKS ABRASIONS BULGES OR DAMAGE TO COUPLINGS IF ANY OF THESE CONDITIONS EXIST REPLACE THE HOSE IMMEDIATELY NEVER USE TAPE OR ANY DEVICE TO ATTEMPT TO MEND THE HOSE 6 AFTER EACH USE
15. break portions of the material into the original opening For best productivity the breaking should be done around the original hole The size of the broken material will vary with the strength and thickness of the base material and the amount of any reinforcement wire or rebar Harder material or more reinforcing wire or rebar will require taking smaller bites To determine the most effective bite start with 2 in 50 mm or smaller bites Bites can then be gradually increased until the broken piece becomes too large requiring increased time to break off the piece Sticking of the tool bit occurs when too large a bite is being taken and the tool bit hammers into the material without the material fracturing This causes the tool bit to become trapped in the surrounding material COLD WEATHER OPERATION If the breaker is to be used during cold weather preheat the hydraulic fluid at low engine speed When using the normally recommended fluid fluid temperature should be at or above 50 F 10 C 400 ssu 82 centistokes before use Damage to the hydraulic system or breaker can result from use with fluid that is too viscous or thick EQUIPMENT PROTECTION amp CARE In addition to the Safety Precautions on page 4 8 5 ofthis manual observe the following for equipment protection and care Make sure all couplers are wiped clean before connection The hydraulic circuit control valve must be in the OFF position whe
16. ch or hardface the tool bit To avoid personal injury or equipment damage all tool repair maintenance and service must only be performed by authorized and properly trained personnel Do not exceed the rated limits of the tool or use the tool for applications beyond its design capacity Always keep critical tool markings such as lables and warning stickers legible Always replace parts with replacement parts recommended by Stanley Hydraulic Tools Check fastener tightness often and before each use daily Never operate the tool if you cannot be sure that underground utilities are not present Do not wear loose fitting clothing when operating the tool TOOL STICKERS amp TAGS Stanley Hydraulic Tools Cy ESG 3810 SE Naef Road F Milwaukie OR 97267 FLOW 7 9 GPM 26 34 LPM BR72 PRESSURE 1500 2000 PSI105 140 BAR ACCUMULATOR CHARGE 600 PSI 41 BAR NITROGEN 12142 Name Tag Sticker DANGER DANGER 1 FAILURE TO USE HYDRAULIC HOSE LABELED AND CERTIFIED D DO NOT LIFT OR CARRY TOOL BY THE HOSES DO NOT AS NON CONDUCTIVE WHEN USING HYDRAULIC TOOLS ON ABUSE HOSE DO NOT USE KINKED TORN OR DAMAGED OR NEAR ELECTRICAL LINES MAY RESULT IN DEATH OR SERI HOSE OUS INJURY 3 MAKE SURE HYDRAULIC HOSES ARE PROPERLY CONNECTED BEFORE USING HOSE LABELED AND CERTIFIED AS NON CON TO THE TOOL BEFORE PRESSURING SYSTEM SYSTEM PRES DUCTIVE ON OR NEAR ELECTRIC LINES BE SURE THE HOSE IS SURE HOSE MUST ALWAYS BE
17. ch ch hb in AMPA M A hihi AH AND a a a dl 44 Mi 42pm 2 dodo os 19 BR72120 amp BR72130 PARTS ILLUSTRATION 20 OO JO Om P GO BR72120 amp BR72130 PARTSLIST D D 2 2 2 2 y D NN E hb ch hb P DD A Mi ch ch 2 22 ch 2 nnn niin DESCRIPTION COUPLERSET NO ITEM ROLL PIN 1 8 x 1 2 HOSE ASSEMBLY Incl Item 6 NO ITEM O RING Incl Item 4 SPRING VALVE SPOOOL BUSHING O RING 11 16 x 7 8 x 3 32 O RING 5 16 x 7 16 x 1 16 ROD WIPER PLUG CHARGE VALVE VALVE CAP Not Pictured HANDLE GRIP HANDLE SPIROL PIN 1 4 x 1 NO ITEM NO ITEM NO ITEM LOCKNUT 5 8 18 TRIGGER ACCUMULATOR DIAPHRAGM PISTON NO ITEM NO ITEM PUSH PIN ACCUMULATOR VALVE BLOCK FLOW SLEEVE NOITEM NOITEM NOITEM BACK UP RING O RING 2 9 16 x 2 3 4 x 3 32 PORTING BLOCK AUTOMATIC VALVE BODY PUSH PIN AUTOMATIC VALVE DECAL NAME TAG NOITEM FLOW SLEEVE TUBE ADAPTER BLOCK UPPER ANVIL STOP SPRING ANVIL ANVIL BLOCK LATCH SPRING DETENT BREAKER FOOT SPIROL PIN HEX BUSHING BR72120 HEX BUSHING BR72130 LOCKING FLANGE NUT 5 8 18 SPRING SPRING CAPSCREW 5 8 18 x 6 1 2 HEX SIDE ROD CUP SEAL BACK UP WASHER ROD WIPER O RING 21 BR72120 BR72130 MODEL DESIGNATIONS 1 1 8 T Handle Model 1 1 4 T Handle Model SEAL KIT PART NUMBER 13552 O RING O RING O RING O RING
18. ection of this manual for the charging procedure 17 BR72125S amp BR72135S PARTS ILLUSTRATION BR72125S amp BR72135S PARTS LIST DESCRIPTION LOCK NUT 5 8 18 SIDE RIDE TOP PLATE HANDLE PIVOT SCREW SPRING HANDLE PIVOT BLOCK CHARGE VALVE MODIFIED PLUG SPIROL PIN 1 4 x 1 LEVER TRIGGER HANDLE TRIGGER HANDLE GRIP SPRING BUSHING ASSEMBLY Incl items 16 19 ROD WIPER 5 16 x 9 16 O RING 2 011 R16 BUSHING O RING 2 115 R17 ACCUMLATOR DIAPHRAGM ACCUMULATOR VALVE BLOCK SPRING PIGTAIL HOSE ASSEMBLY VALVE SPOOL PORTING BLOCK O RING 2 145 R17 BACK UP RING PISTON ROLL PIN AUTOMATIC VALVE BODY PUSH PIN PUSH PIN AUTOMATIC VALVE FLOW SLEEVE FLOW SLEEVE TUBE DECAL NAME TAG HHCS 5 8 18 UNF x 6 1 2 O RING 2 228 R16 CUP SEAL BACK UP WASHER WIPER RING ADAPTER BLOCK UPPER ANVIL STOP SPRING ANVIL BREAKER FOOT ASSEMBLY 1 1 8 BREAKER FOOT ASSEMBLY 1 1 4t ANVIL BLOCK LATCH CASTING SPRING DETENT BREAKER FOOT SPIROL PIN HEX BUSHING 1 1 8 HEX BUSING 1 1 4 t LOCKING FLANGE NUT COIL SPRING SPRING MALE COUPLER NU fi PARTOF BREAKER FOOT ASSEMBLY MODEL BR72135S ONLY MODEL DESIGNATIONS BR72125S 1 1 8 Spring Handle Model BR72135S 1 1 4 Spring Handle Model O ON SEAL KIT PART NUMBER 13552 O RING O RING O RING O RING O RING ROD WIPER ROD WIPER O RING BACK UP RING CUPSEAL MM hb ch h Mi Ah A Ah hihi Ah A AA ch sch ch dl nnn Mi s
19. ed 10 TROUBLESHOOTING Tool does not run Power unit not functioning Check power unit for proper flow and pressure 7 9 gpm 26 34 Ipm 1500 2000 psi 105 140 bar Couplers or hoses blocked Pressure and return line hoses reversed at Be sure hoses are connected to their proper ports ports Mechanical failure of piston or automatic Disassemble breaker and inspect for valve damaged parts Tool does not hit Power unit not functioning Check power unit for proper flow and effectively pressure 7 9 gpm 26 34 Ipm 1500 2000 psi 105 140 bar Couples orhoses blocked Low accumulator charge pressure hose will Recharge accumulator Replace diaphragm if pulse more than normal charge loss continues Fluid too hot above 140 F 60 C Provide cooler to maintain proper Ke temperature 130 F 55 C maximum The anvil is not sliding properly in the foot Remove clean and lubricate with anti bore seize replace as required Tool operates slow Low gpm supply from power unit Check power unit for proper flow 7 9 gpm 26 34 Ipm High backpressure Check hydraulic system for excessive backpressure over 200 psi 14 bar Couplers or hoses blocked Orifice plug Blocked Fluid too hot above 140 F 60 C or too cold Check power unit for proper fluid temperature below 60 F 16 C Bypass cooler to warm the fluid or provide cooler to maintain proper temperature Relief valve set too low Adjust relief valve to 2100 2250 psi
20. ed or implied including merchantabil ity or fitness for a particular purpose except for that provided herein There is no other warranty This warranty gives the purchaser specific legal rights and other rights may be available which might vary depending upon applicable law Stanley Hydraulic Tools 3810 SE Naef Road STAN LEY Milwaukie OR 97267 5698 503 659 5660 FAX 503 652 1780 www stanley hydraulic tools com
21. ined in the Operation and Maintenance Manual HYDRAULIC PRESSURE amp FLOW Any failure or performance deficiency attributable to excess hydraulic pressure excess hydraulic back pressure or excess hydraulic flow REPAIRS OR ALTERATIONS Any failure or performance deficiency attributable to repairs by anyone which in Stanley s sole judgement caused or contributed to the failure or deficiency MIS APPLICATION Any failure or performance deficiency attributable to mis application Mis application is defined as usage of products for which they were not originally intended or usage of products in such a matter which exposes them to abuse or accident without first obtaining the written consent of Stanley WARRANTY REGISTRATION STANLEY ASSUMES NO LIABILITY FOR WARRANTY CLAIMS SUBMITTED FOR WHICH NO TOOL REGISTRA TION IS ON RECORD In the event a warranty claim is submitted and no tool registration is on record no warranty credit will be issued without first receiving documentation which proves the sale of the tool or the tools first date of usage The term DOCUMENTATION as used in this paragraph is defined as a bill of sale or letter of intent from the first retail customer AWARRANTY REGISTRATION FORM THAT IS NOT ALSO ON RECORD WITH STANLEY WILL NOT BE ACCEPTED AS DOCUMENTATION NO ADDITIONAL WARRANTIES OR REPRESENTATIONS This limited warranty and the obligation of Stanley thereunder is in lieu of all other warranties express
22. isassemble the tool unless proper trouble shooting procedures have isolated the problem to an internal part Disassemble it only to the extent necessary to replace the defective part KEEP CONTAMINANTS SUCH AS DIRT AND GRIT AWAY FROM INTERNAL PARTS AT ALL TIMES Always determine and correct the cause of the problem prior to assembly Further wear and tool failure can result if the original cause is not corrected BREAKER DISASSEMBLY PRIOR TO DISASSEMBLY Clean exterior of tool Obtain Seal Kit Part Number 13552 Replace all seals exposed during disassembly Note orientation of seals before removing them Install new seals in the same way DISASSEMBLY 1 Secure the breaker in a bench vise with the IN and OUT ports up clamping on the flow sleeve tube between the side rods Soft vise jaws are recommended 2 Remove the pigtail hose assemblies 3 Remove the plug from the side of the handle pivot block BR72125S amp BR72135S or remove the plug from the top of the handle BR72120 amp BR72130 and discharge the accu mulator 4 Remove the four side rods A WARNING Discharge the accumulator 5 Remove the top plate then remove the handle pivot block with the two handles attached BR72125S amp BR72135S On the BR72120 amp BR72130 remove the handle 6 If necessary remove the two handles from the pivot block by removing the pivot screw securing each handle BR72120S amp BR72135S only 7
23. ls recommends that servicing of hydraulic tools other than routine maintenance must be performed by an authorized and certified dealer Please read the following warning SERIOUS INJURY OR DEATH COULD RESULT FROM THE IM PROPER REPAIR OR SERVICE OF THIS TOOL REPAIRS AND OR SERVICE TO THIS TOOL MUST ONLY BE DONE BY AN AUTHORIZED AND CERTIFIED DEALER For the nearest authorized and certified dealer call Stanley Hydraulic Tools at one of the numbers listed on the back of this manual and ask for a Customer Service Representative SAFETY SYMBOLS Safety symbols and signal words as shown below are used to emphasize all operator maintenance and repair actions which if not strictly followed could result in a life threatening situation bodily injury or damage to equip ment IMPORTANT A DANGER WARNING A CAUTION cam NOTICE IMPORTANT This is the safety alert symbol It is used to alert you to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death This safety alert and signal word indicate an imminently hazardous situa tion which if not avoided will result in death or serious injury This safety alert and signal word indicate a potentially hazardous situation which if not avoided could result in death or serious injury This safety alert and signal word indicate a potentially hazardous situation which if not avoided may result i
24. must be equal to or higher than the relief valve setting on the shown smaller than actual size HOSE PRESSURE RATING hydraulic system HTMA REQUIREMENTS Tool Category Hyd raulic System BATNA CATEGORY BEIN CATEGORY Requirements Type I Type ll Type Ill 20Lpm at 138bar BHTMA CATEGORY Flow rate 4 6gpm 7 9gpm 10 5 11 69pm 11 13gpm Tool Operating Pressure 15 23 Ipm 26 34 Ipm 36 44 Ipm 42 49 Ipm at the power supply outlet 2000 psi 2000 psi 2000 psi 2000 psi 138 bar 138 bar 138 bar 138 bar System relief valve setting 2100 2250 psi 2100 2250 psi 2100 2250 psi 2100 2250 psi at the power supply outlet 145 155 bar 145 155 bar 145 155 bar 145 155 bar Maximum back pressure 200 psi 200 psi 200 psi 200 psi at tool end of the return hose 14 bar 14 bar 14 bar 14 bar Measured at a max fluid viscosity of 400 ssu at min operating temperature Temperature Sulfjeient Neal rejection capacity 140 F 60 C 140 F 0 C 140 F 60 C 140 F 60 C to limit max fluid temperature to at max expected ambient temperature Min cooling capacity 3 hp 2 24 kw 5 hp 3 73 kW 6 hp 4 47 kw 7 hp 5 22 kw ata temperature difference of 40 F 22 C 40 F 22 C 40 F 22 C 40 F 22 C between ambient and fluid temps NOTE Do not operate the tool at oil temperatures above 140 F 60 C Operation at higher temperatures can cause operator discomfort at the tool Filter Min
25. n coupling or uncoupling hydraulic tools Failure to do so may result in damage to the quick couples and cause overheating of the hydraulic system Always store the tool in a clean dry space safe from damage or pilferage Make sure the circuit PRESSURE hose with male quick disconnect is connected to the IN port The circuit RETURN hose with female quick disconnect is connected to the opposite port Do not reverse circuit flow This can cause damage to internal seals Always replace hoses couplings and other parts with replacement parts recommended by Stanley Hydraulic Tools Supply hoses must have a minimum working pressure rating of 2500 psi 172 bar Do not exceed the rated flow see Specifications page 14 in the manual for correct flow rate and model number Rapid failure of the internal seals may result Always keep critical tool markings such as warning stickers and tags legible Do not force a small breaker to do the job of a large breaker Keep tool bit sharp for maximum breaker performance Make sure that tool bits are not chipped or rounded on the striking end Never operate a breaker without a tool bit or without holding it against the work surface This puts excessive strain on the breaker foot Tool repair should be performed by experienced personnel only Make certain that the recommended relief valves are installed in the pressure side of the system Do not use the tool for applications for which it was not intend
26. n minor or moderate injury This signal word indicates a potentially hazardous situation which if not avoided may result in property damage This signal word indicates a situation which if not avoided will result in damage to the equipment This signal word indicates a situation which if not avoided may result in damage to the equipment Always observe safety symbols They are included for your safety and for the protection of the tool LOCAL SAFETY REGULATIONS Enter any local safety regulations here Keep these instructions in an area accessible to the operator and mainte nance personnel SAFETY PRECAUTIONS Tool operators and maintenance personnel must always comply with the safety A WARNING precautions given in this manual and on the stickers and tags attached to the tool and hose To avoid serious injury or death These safety precautions are given for your safety Review them carefully before operating the tool and before performing general maintenance or repairs Supervising personnel should develop additional precautions relating to the specific work area and local safety regulations If so place the added precautions in the Wear Eye space provided on page 4 Read the Manual Protection The BR72 Hydraulic Breaker will provide safe and dependable service if operated in accordance with the instructions given in this manual Read and understand this manual and any stickers and tags
27. nd the safety nstruc READ OPERATION MANUAL AND READ OPERATION MANUAL AND tions listed on this tag SAFETY INSTRUCTIONS FOR THIS SAFETY INSTRUCTIONS FOR THIS TOOL BEFORE USING IT TOOL BEFORE USING IT before removal We USE ONLY PARTS AND REPAIR USE ONLY PARTS AND REPAIR suggest you retain this tag PROCEDURES APPROVED BY PROCEDURES APPROVED BY STANLEY AND DESCRIBED IN THE OPERATION STANLEY AND DESCRIBED IN THE OPERATION and attach it to the tool gt se EE 3 Mie SH when not in use TAG TO BE REMOVED ONLY BY TAG TO BE REMOVED ONLY BY TOOL OPERATOR TOOL OPERATOR SEE OTHER SIDE SEE OTHER SIDE SAFETY TAG P N 15875 shown smaller then actual size HYDRAULIC HOSE REQUIREMENTS HOSE TYPES Hydraulic hose types authorized for use with Stanley Hydraulic Tools are as follows O Certified non conductive Wire braided conductive Fabric braided not certified or labeled non conductive Hose listed above is the only hose authorized for use near electrical conductors Hoses and 6 listed above are conductive and must never be used near electrical conductors HOSE SAFETY TAGS To help ensure your safety the following DANGER tags are attached to all hose purchased from Stanley Hydraulic Tools DO NOT REMOVE THESE TAGS If the information on a tag is illegible because of wear or damage replace the tag immediately Anew tag may be obtained from your Stanley Distributor THE TAG SHOWN BELOW IS ATTACHED TO CERTIFIED NON COND
28. ort the block 9 Push the flow sleeve assembly into the accumulator valve block It may be necessary to tap on the end of the flow sleeve tube with a rubber or plastic hammer Be sure to tap on opposite sides to make sure that the assembly seats properly 10 Remove assembly from the vise and clamp on the flow sleeve tube with IN and OUT ports facing up 11 Slide the foot assembly over the piston and drive the foot into the flow sleeve tube by tapping the end of the foot with a plastic or rubber hammer Align the foot latch with the trigger 12 Replace in this order the spring valve spool and bushing with rod wiper facing out of the accumulator valve block in valve spool bore The bushing should project from the accumulator valve block approximately 0 200 inch 5mm 13 Apply a light coating of WD40 lubricant to the accumu lator diaphragm and install in the accumulator bore 14 BR72125S amp BR72135S Place the handle pivot block with handles attached on the accumulator valve block Then position the top plate on the pivot block Lubricate the pivot screw O D And the rubbing surfaces of the handles with anti seize compound BR72120 amp BR72130 Place the handle on the accumulator valve block with the trigger side facing the latch on the breaker foot 15 Install the four side rods Tighten the side rods in 15 ft 10 20 Nm increments to 60 ft Ib 80 Nm 16 Charge the accumulator See the maintenance s
29. ress and an aluminum disc or Accumula tor Cylinder Puller Part Number 05640 to protect the flow sleeve push the flow sleeve with seven holes on its end facing up into flow sleeve tube o ring groove up until it is flush with the tube Be sure to lubricate the entire bore of the flow sleeve tube prior to assembly 2 Install the four 1 4 x 1 1 2 inch 38mm push pins with ground face end up in the flow sleeve 3 Install the two 3 16 x 1 1 4 inch 32 mm push pins with the ground face end up in the automatic valve body Install the automatic valve small diameter first into the automatic valve body IMPORTANT The push pins must be installed such that the flat ground surfaces bear on the flange of the automatic valve 4 Place the automatic valve body with proper roll pin alignment and with the side holes up on top of the flow sleeve Allow the automatic valve to drop and pilot into the bore of the flow sleeve 5 Use an aluminum disc or Accumulator Cylinder Puller Part Number 05640 to protect parts then push the auto matic valve body into the flow sleeve tube until the valve body shoulder stops on the top of the flow sleeve tube 6 Install the piston small end first into flow sleeve assem bly from the automatic valve body end 7 Install the porting block into the flow sleeve assembly with proper roll pin alignment 8 Place the accumulator valve block in a bench vise being careful not to over tighten or dist
30. t the tool bit into the foot and pull the latch up to lock the tool bit in place CONNECT HOSES 1 Wipe all hose couplers with a clean lint free cloth before making connections 2 Connect the hoses from the hydraulic power source to the tool fittings or quick disconnects It is a good practice to connect return hoses first and disconnect them last to minimize or avoid trapped pressure within the tool 3 Observe flow indicators stamped on hose couplers to ensure that fluid flow is in the proper direction The female coupler on the tool hose is the inlet coupler 4 Move the hydraulic circuit control valve to the ON position to operate the tool NOTE If uncoupled hoses are left in the sun pressure in crease within the hoses may make them difficult to connect When possible connect the free ends of the hoses together OPERATION PROCEDURES 1 Observe all safety precautions 2 Install the appropriate tool bit for the job 3 Place the bit firmly on the surface to be broken 4 Squeeze the trigger to start the breaker Adequate down pressure is very important When the tool bit breaks through the obstruction or becomes bound release the trigger and reposition the tool bit NOTE Partially depressing the trigger allows the tool to run at slow speed Slow speed operation permits easier starting of the tool bit into the work surface 5 To start break an opening hole in the center of the surface After making a hole
31. ube to protect the flow sleeve BREAKER ASSEMBLY PRIOR TO ASSEMBLY Clean all parts with a degreasing solvent Obtain seal kit Part Number 13552 so all seals exposed during disassembly can be replaced during assembly Ensure that all seals that were exposed have been re placed with new parts Apply clean grease or o ring lubricant to all parts during reassembly Note For orientation of parts identified in the following proce dures see the parts exploded view at the back of this manual 1 Check all parts for evidence of excessive wear scoring or obvious damage Pay particular attention to seal and other running surfaces looking for scratches or other signs of fluid contamination caused defects Dirty or water contaminated fluid can cause scratches on running component surfaces 2 Examine all exposed seals and o rings for worn spots or damage caused by overheating or ingestion of contaminants Although all exposed o rings and seals must be replaced during assembly of the unit this inspection should be performed to help identify related faulty components and the cause of an experienced or potential malfunction 3 All components exhibiting excessive wear or deep scratches can usually be touched up using emery cloth Thoroughly clean all parts before assembly 4 Apply clean grease or o ring lubricant to all close fitting parts and seals during assembly 16 SERVICE ASSEMBLY 1 Using an arbor p
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