BR40 User Manual 4-2009.indb
Contents
1. 14 ACCUMULATOR TESTING PROCEDURE asian 14 ACCUMUCATOR CHARGING 0 5 ee ree 14 al eee ene ee ee ___ ____ ____ ____________ ___ 16 8 So renee ene een NR E ener ere cere aaa er E 16 BR40 T HANDLE PARTS ILLUSTRATION seta sa ________________ x EUPINPIEpEDA CSS 17 SAND PARTS cape GRG ER SG MD 18 BHAO ANTIEVIBRATION HANDLE PARTS ILLUSTBATIQOD ai Ga 19 BR40 ANTI VIBRATION HANDLE PARTS LIST E nanna 20 ly c ET 21 SERVICING THE STANLEY HYDRAULIC breaker This manual contains safety operation and routine maintenance instructions Stanley Hydraulic Tools recommends that servicing of hydraulic tools other than routine maintenance must be performed by an authorized and certified dealer Please read the fol lowing 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 the number listed on the back of this manual and ask for a Customer Service Representative 3 CERTIFICATE OF CONFORMITY CERTIFICATE OF CONFORMITY C 6 Hydraulic Tools Winterling David T Surname and First names Hereby certify that the construction plant2. OTHER SIDE shown smaller than actual size HYDRAULIC CIRCUIT RETURN PRESSURE Suonoouuo eso eoid eJnssaeJg lt lt lt MOT num MO14 gt gt gt 09 08 cec erae 1 54010 9 1 21410313 YVAN ASN LON OG 06 0 00 001 901 9 pieig 19914 10 311M SOH SJONAL 1exong ALIN 20 10913 2 55 J9 9WeIG RETURN PRESSURE LLGf AWS Aq uno 195 se 5 10945 peeoxe jsnui 8504 LU IS S y 5 Je snw oineJp u suoneoidde Aue pesn 104 5 pue sjueuJaJinboJ 00 51001 uo 100 pesn s yeyo siu OO ejqe1doeooe e 01 eunssaJd 95941 ein UIW Jed Jad uo peseq
3. SERIOUS INJURY OR DEATH COULD RESULT FROM IM PROPER REPAIR OR SERVICE OF THIS TOOL REPAIRS AND OR SERVICE TO THIS TOGL MUST ONLY BE DONE BY AN AUTHORIZED AND CERTIFIED DEALER Stanley Hydraulic Tools 2004 OPS MAINT USA CE Printed in U S A 62399 4 2009 ver 4 BR40 HYDRAULIC BREAKER SAFETY OPERATION AND MAINTENANCE USER S MANUAL Stanley Hydraulic Tools 3810 SE Naef Road Milwaukie OR 97267 5698 503 659 5660 FAX 503 652 1780 www stanleyhydraulic com TABLE OF CONTENTS CERTIFICATE OF CONFORMITY 4 SAFETY o NB OL 5 viixcibdgimtuggo 6 TOOL STICKERS TAGS ____ __ ___ in 7 HYDRAULIC HOSE REQUIREMENT at RN RN RD UMS 8 PRIMA REQUIRE MEN T 10 OPERA NON oee E AAA E E E E E gt 11 PREOPERA NON PROCEDURE 448 5 _ 11 S 4506 OO 0 8G 4 11 IN TAE TOOL SRS S 11 CONNEC I HOSE c 11 COLD WEATHER OP e ______ 11 0 12 I 19 CHARGING THE ACCUMULATOR
4. Torsion Spring Used on Model ending in A or AA Roll Pin Used on Model ending in A or AA BREAKER FOOT ASSEMBLY T Handle and Anti Vibration Handle 07489 07510 1 in Standard Rotated Hex 1 in Standard BR40558BT BR40550 Includes 53 59 amp 62 67 BR4056801 BR4056201 BR4056801 A BR4056801 AA Includes 53 59 amp 62 67 PART NUMBER 04595 WARRANT Y 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 MATERIAL AND OR WORKMANSHIP EXCEPTIONS FROM WARRANTY NEW PARTS New parts which are obtained individually are warranted subject to the exceptions herein to be free of defects in material and or workmanship at the time of delivery and for a period of 6 months after the date of first usage Seals and diaphragms are warranted to be free of defects in material and or workmanship at the time of delivery and for a period of 6 months after the date of first usage or 2 y
5. esou 10 SJ JALUBIP esou IUILU SMOUS eui yeyo 941 01 00 REQUIREMENTS TOOL CATEGORY HYDRAULIC SYSTEM REQUIREMENTS TYPE 11 TYPE III FLOW RATE 4 6 gpm 11 13 gpm 9 10 5 gpm 15 23 lpm 26 34 lpm 42 49 lpm 34 40 lpm TOOL OPERATING PRESSURE 2000 psi 2000 psi 2000 psi 2000 psi at the power supply outlet 138 bar 138 bar 138 bar 138 bar SYSTEM RELIEF VALVE SETTING 2100 2250 psi 2100 2250 psi 2100 2250 psi 2200 2300 psi at the power supply outlet 145 155 bar 145 155 bar 145 155 bar 152 159 bar MAXIMUM BACK PRESSURE 250 psi 250 psi 250 psi 250 psi at tool end of the return hose 17 bar 17 bar 17 bar 17 bar Measured at a max fluid viscosity of 400 ssu 400 ssu 400 ssu 400 ssu at min operating temperature TEMPERATURE Sufficient heat rejection capacity 82 centistokes 82 centistokes 82 centistokes 82 centistokes 140 F 60 C to limit max fluid temperature to at max expected ambient temperature Min cooling capacity 3 hp 5 hp 7 hp 6 hp at a temperature difference of 2 24 kW 3 73 kW 4 47 kW 5 22 kW between ambient and fluid temps 40 F 40 F 40 F 40 F 22 C 22 C 22 C 22 C NOTE Do not operate the tool at oil temperatures above 140 F 60 C Operation at higher temperatures can cause operator
6. 138bar ff CATEGORY 107 Circuit N CE Tool Only 28409 CE Tool Only Composite Decal CE Tool Only Sound Level Decal 28322 BR40 BREAKER CE Decal CE Tool Only WEIGHT 44 Ib 20 kg FLOW 6 gpm 23 Ipm PRESSURE 2000 psi 140 bar Stanley Hydraulic tools 28374 Division of the Stanley Works 3810 SE Naef Road BR40 Milwaukie OR 97267 05152 Stanley Decal FAILURE USE HYDRAULIC HOSE LABELED AND CERTIFIED AS NON CONDUCTIVE WHEN USING HYDRAULIC TOOLS ON OR NEAR ELECTRICAL LINES MAY RESULT IN DEATH OR SERIOUS INJURY BEFORE USING HOSE LABELED AND CERTIFIED AS NON CONDUCTIVE ON OR NEAR ELECTRIC LINES BE SURE THE HOSE IS MAINTAINED AS NON CONDUCTIVE THE HOSE SHOULD BE REGULARLY TESTED FOR ELECTRIC CURRENT LEAKAGE IN ACCORDANCE WITH YOUR SAFETY DEPART MENT INSTRUCTIONS AHYDRAULIC LEAK OR BURST MAY CAUSE OIL INJECTION INTO THE BODY OR CAUSE OTHER SEVERE PERSONAL INJURY A DO NOT EXCEED SPECIFIED FLOW AND PRESSURE FOR THIS TOOL EXCESS FLOW OR PRESSURE MAY CAUSE A LEAK OR BURST DO NOT EXCEED RATED WORKING PRESSURE OF HYDRAULIC HOSE USED WITH THIS TOOL EXCESS PRESSURE MAY CAUSE A LEAK OR BURST CHECK TOOL HOSE COUPLERS AND CONNECTORS DAILY FOR LEAKS DO NOT FEEL FOR LEAKS WITH YOUR HANDS CONTACT WITH A LEAK MAY RESULT IN SEVERE PERSONAL INJURY The
7. 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 Guarded Spirol Pin 1 4 x 1 Lever Slotted Machine Screw Trigger Lock Model Top Plate Lock Nut 5 8 18 Trigger Trigger Used on Model ending in A or AA SAE O Ring Plug 10 Trigger Lock Models Spring Trigger Lock Models Pin Trigger Lock Models Trigger Handle Trigger Lock Models Trigger Handle Non Trigger Lock Models Trigger Handle Used on Model ending in A or AA Trigger Lock Trigger Lock Models Trigger Pin Trigger Lock Models Roll Pin 1 4 x 1 3 8 Trigger Lock Models Spring Spring Spring Trigger Lock Models Handle Pivot Pivot Screw Accumulator Diaphragm Piston Guaranteed Sound Power Level CE Model Composite Safety Label CE Models Push Pin 20 8840 ANTI VIBRATION HANDLE PARTS LIST Item Part Qty Description No No Accumulator Valve Block Flow Sleeve CE Decal Circuit C Decal No Item Back Up Ring O Ring 2 9 16 x 2 3 4 x 3 32 Porting Block Automatic Valve Body Push Pin Automatic Valve Stanley Decal BR40 Model Number Decal Flow Sleeve Tube Hex Bushing Stop Breaker Foot with Insert Assy O Ring 2 1 4 x 2 1 2 x 1 8 228 16 Rod Wiper Back Up Washer Cup Seal Side Rod No Item Latch Spring Washer Foot Latch Bolt Rubber Sleeve Spring Detent Trigger Lock Used on Model ending in A or AA
8. Charging the Accumulator BR40 with T Handles TESTER CHARGING ACCUMULATOR TESTER P N 02835 LOCATION OF CHARGING VALVE Figure 2 15 SPECIFICATIONS Pecce RO ch oe etre eat cc 1300 2000 psi 90 140 bar mel RAMOS ES 4 6 gpm 15 23 Ipm A a E 5 gpm 20 lpm Maximum Back PIeSS 250 Psi 1 7 bar OS sanns EEE E E A AGF a SN ER ee ee ee HTMA Flush Face 20 15 50 16028 CON la 3 8 in Male Pipe Hose Ends len T jan jan T Handle 41 lbs 18 kg Anti Vibration Handle 44 lbs 20 kg Overall Length PNE rm T Handle 23 5 in 60 Anti Vibration Handle 25 2 in 65 Overall Width at iris sana a nia an T Handle 14 in 35 cm Anti Vibration Handle 17 5 10 44 5 Max Fluid L ARE nnne KENNA 140 60 C Open Glosed Center gps SAE 8 O ring GAS Ga sets a a i 4 6 gpm 2 1300 2000 psi Guaranteed Sound Power LAKE sinn seen snis sns anna 107 dBA PIN a LE MORE T I pn apa T Handle 10 0 m sec Anti Vibration Handle 9 2 m sec 1in Hex x 4 1 4 in Shank MOON L
9. D REPAIR PROCEDURES APPROVED BY STANLEY AND DESCRIBED IN THE OPERA TION MANUAL TAG TO BE REMOVED ONLY BY TOOL OPERATOR SEE OTHER SIDE SAFETY TAG P N 15875 shown smaller then actual size 7 TOOL HOSE INFORMATION HOSE TYPES The rated working pressure of the hydraulic hose must be equal to or higher than the relief valve setting on the hydraulic system There are three types of hydraulic hose that meet this requirement and are authorized for use with Stanley Hydraulic Tools They are Certified non conductive constructed of thermoplastic or synthetic rubber inner tube synthetic fiber braid rein forcement and weather resistant thermoplastic or synthetic rubber cover Hose labeled certified non conductive is the only hose authorized for use near electrical conductors Wire braided conductive constructed of synthetic rubber inner tube single or double wire braid reinforcement and weather resistant synthetic rubber cover This hose is conductive and must never be used near electrical conduc tors Fabric braided not certified or labeled non conductive constructed of thermoplastic or synthetic rubber inner tube synthetic fiber braid reinforcement and weather resistant thermoplastic or synthetic rubber cover This hose is not certified non 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
10. ONS NEVER USE TAPE OR ANY DEVICE TO ATTEMPT TO MEND THE HOSE 6 AFTER USE STORE IN A CLEAN DRY AREA Oo lt 2 gt O IT O O OVI SIHL LON OG shown smaller than actual size THE TAG SHOWN BELOW IS ATTACHED TO CONDUCTIVE HOSE DO NOT 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 5 CHECK ENTIRE HOSE FOR CUTS CRACKS LEAKS ABRASIONS BULGES OR DAMAGE TO ELECTRICAL LINES MAY RESULT IN DEATH OR SERIOUS INJURY COUPLINGS IF ANY OF THESE CONDITIONS EXIST REPLACE THE HOSE IMMEDIATELY FOR PROPER AND SAFE OPERATION MAKE SURE THAT YOU HAVE BEEN i died TPAINED IN CORRECT PROCEDURES REQUIRED FOR WORK ON OR AROU 6 AFTER EACH USE STORE IN A CLEAN DRY AREA NEVER USE TAPE OR ANY DEVICE TO ATTEMPT TO MEND THE HOSE DO NOT EXCEED HOSE WORKING PRESSURE OR ABUSE HOSE MEROEER M OR HANDLING OF HOSE COULD RESULT IN BURST On OTHER HOSE FAILUR HOSE AS FAR AWAY AS POSSIBLE FROM BODY AND DO NOT PERMIT DIRECT CONTACT DURING USE CONTASI 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 DVL SIHL LON OG 9 lt I gt ke O
11. OR CHARGING 1 Perform steps 1 through 4 of the accumulator testing pro cedure above 2 Connect the chuck of the charging assembly to the charg ing 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 NOTE It may be necessary to set the gauge at 650 700 psi 45 48 bar to overcome any pressure drop through the charg ing system 4 When the accumulator is fully charged close the snub valve on the charging assembly hose and remove the charging as sembly 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 BR40 with Anti Vibration Handles TESTER CHARGING LOCATION OF CHARGING VALVE Figure 2 Liquid Filled Gauge w Snub Valve Charge Fitting Nitrogen Tank Not included in Kit Charging Valve 31254 ACCUMULATDR CHARGE KI Includes Liquid Filled Gauge w Snub Valve Hose Charge Fitting 02835 Tester Box not pictured Gauge s 02835 TESTER Chuck
12. ORD Casares 07702 Narrow Chisel Point 14 in Long 07703 CSL EM aetla csr __ _ __ __________ _ _____ 07704 Clay Spade 5 1 2 I asic sesso ce ___________________________ _ ___ 07705 Asphalt We s Tos _____ ____ ___ _ _ 64 66_ ________ 07706 Test Equipment Accumulator Charge Assembly incl Liquid Filled Gauge w Valve Hose amp Charge Fitting 15304 TESTE TII 02835 Flow and Pressure TEST ___ _ _ ____ Dmm 04182 Accumulator Chade gas _________ __________ _ 31254 Service Tools Tamper 0 01120 10601 TE Rom 04337 Flow Sleeve Removal TIGA ga a a A al hann 04910 Flow Sleeve Removal Tool al 04919 Accumulator Cynder PuUlGI ____________ ____ _ ___ ______ 05640 8840 T HANDLE PARTS ILLUSTRATION C UN en Ya cO ON FP 8840 T HANDLE PARTS LIST Coupler Set No Item Roll Pin Alternate Hose Assy 12 inch Orifice Plug O Ring Included with Item 4 Spring Valve Spool Bushing Bushing Assy Includes Items 9 thru 12 O Ring 11 16 x 7 8 x 3 32 O Ring 5 16 x 7 16 x 1 16 Rod Wipe
13. Stanley Hydraulic Tools DO NOT REMOVE THESE TAGS lf the information on a tag is illegible because of wear or damage replace the tag immediately A new tag may be ob tained from your Stanley Distributor THE TAG SHOWN BELOW IS ATTACHED TO CERTIFIED NON CONDUCTIVE HOSE 1 FAILURE TO USE HYDRAULIC HOSE LABELED AND CERTIFIED AS NON CONDUCTIVE 3 DO NOT EXCEED HOSE WORKING PRESSURE OR ABUSE HOSE IMPROPER USE OR WHEN USING HYDRAULIC TOOLS ON OR NEAR ELECTRIC LINES MAYRESULT IN DEATH HANDLING OF HOSE COULD RESULT IN BURST OR OTHER HOSE FAILURE KEEP OR SERIOUS INJURY HOSE AS FAR AWAY AS POSSIBLE FROM BODY AND DO NOT PERMIT DIRECT CONTACT FOR PROPER AND SAFE OPERATION MAKE SURE THAT YOU HAVE BEEN PROPERLY DURING USE CONTACT AT THE BURST CAN CAUSE BODILY INJECTION AND SEVERE TRAINED IN CORRECT PROCEDURES REQUIRED FOR WORK ON OR AROUND PERSONAL INJURY INES CINES 4 HANDLE AND ROUTE HOSE CAREFULLY TO AVOID KINKING ABRASION CUTTING OR BEFORE USING HYDRAULIC HOSE LABELED AND CERTIFIED AS NON CONDUCTIVE E a S ER NOT USE IF KINKED DO NOT USE OR NEAR ELECTRIC LINES WIPE THE ENTIRE LENGTH OF THE HOSE AND FITTING WITH A CLEAN CLOTH TO REMOVE DIRT AND MOSISTURE AND TEST 5 CHECK ENTIRE HOSE FOR CUTS CRACKS LEAKS ABRASIONS BULGES OR DAMAGE TO HOSE FOR MAXIMUM ALLOWABLE CURRENT LEAKAGE IN ACCORDANCE WITH SAFETY COUPLINGS IF ANY OF THESE CONDITIONS EXIST REPLACE THE HOSE IMMEDIATELY DEPARTMENT INSTRUCTI
14. discomfort at the tool FILTER 25 microns 25 microns 25 microns 25 microns Min full flow filtration 30 gpm 30 gpm 30 gpm 30 gpm Sized for flow of at least 114 lpm 114 lpm 114 lpm 114 lpm For cold temp startup and max dirt holding capacity HYDRAULIC FLUID 100 400 ssu 100 400 ssu 100 400 664 100 400 ssu Petroleum based 20 82 centistokes premium grade anti wear non conductive VISCOSITY at min and max operating temps 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 require ments over a wide range of operating temperatures SSU Saybolt Seconds Universal NOTE These are general hydraulic system requirements See tool Specification page for tool specific requirements 10 The recommended hose size is 500 inch 12 mm 1 0 up to 50 ft 15 m long and 625 inch 16 mm 1 0 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 4 6 gpm 15 23 lpm at 1300 psi 90 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 th
15. e surface After making a hole 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 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 NOTICE In addition to the Safety Precautions found in this manual observe the following for equipment protection and care Make sure all couplers are wiped clean before connection The hydraulic circuit control
16. e tool 2 Insert 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 con nect 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 increase within the hoses may make them difficult to connect When possible connect the free ends of the hoses to gether 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 11 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 start break an opening hole in the center of th
17. ears after the date of delivery whichever period expires first Warranty for new parts is limited to replacement of defective parts only Labor is not covered 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 such as breaker tool bits are warranted to be free of defects in material and or workmanship 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 perfo
18. g 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 torch or hard face 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 labels 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 6 TOOL STICKERS 8 TAGS Please refer to the Parts Illustration for location of stickers To avoid serious injury or death 7 20Lpm at
19. his manual and on the stickers and tags attached to the tool and hose To avoid serious injury or death 122 These safety precautions are given for your safety Review them carefully before 4 WA E 7 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 space provided in this manual The BR40 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 attached to the tool and hoses before operation Failure to do so could result in personal injury or equipment damage 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 workin
20. inally intended or usage of products in such a matter which exposes them to abuse or accident without first obtaining the written consent of Stanley PERMISSION TO APPLY ANY PRODUCT FOR WHICH IT WAS NOT ORIGINALLY INTENDED CAN ONLY BE OBTAINED FROM STANLEY ENGINEERING WARRANTY REGISTRATION STANLEY ASSUMES NO LIABILITY FOR WARRANTY CLAIMS SUBMITTED FOR WHICH NO TOOL REGISTRATION 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 A WARRANTY 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 expressed or implied including merchantability 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 21 Stanley Hydraulic Tools 3810 SE Naef Road Milwaukie Oregon 503 659 5660 Fax 503 652 1780 www stanleyhydraulic com
21. liminate flow control devices Fluid leakage on tool bit Lower piston seal failure Replace seal Fluid leakage around trigger Valve spool seal failure Replace seals CHARGING THE ACCUMULATOR ACCUMULATOR TESTING PROCEDURE To check or charge the accumulator the following equipment is required 31254 Charge Kit which includes the following Accumulator Tester Part Number 02835 e 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 retracted 3 Thread the tester onto the accumulator charging valve Do not advance the gauge end into the chuck end Turn as aunit Seat the 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 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 paragraph 6 Install the plug ACCUMULAT
22. or equipment specified hereunder 1 Manufacturer Stanley Hydraulic Tools 3810 Naef Road Milwaukie Oregon USA 2 Representative in the Union Stanley Dubuis 17 19 rue Jules Berthonneau BP 3406 41034 Blois Cedex France 3 Category Hydraulic Hand Held Concrete Breaker 4 Make Stanley Hydraulic Tools 5 Type BR40558BT A BR4056201 BR4056801 A BR4056801 AA 6 Type serial number of equipment ALL 7 Year of manufacture Beginning 2006 Has been manufactured in conformity with the provisions of the Machinery Directive 98 37 EC Harmonized standard applied 792 4 We also declare that it meets the specification of Noise Directive 200014 measured in accordance to the Conformity Evaluation Method set out in Annex VI para 5 and evaluated during production as in Annex VI para 6 2 procedure 8 Noise related value 21 kg 9 Measured sound power on equipment representative of this type 106 LwA 10 Guaranteed sound power level for this equipment 107 LwA 11 Notified body for EC directive 2000 14 EC 0404 SMP Svensk Maskinprovning AB Fyrisborgsgatan 3 754 50 Uppsala SWEDEN 12 Special Provisions None Issued at Stanley Hydraulic Tools Milwaukie Oregon USA Date 8 21 02 oignature 2 7 4 Position Engineering Manager P N 52570 Rev 1 8 21 02 Rev 2 4 4 06 SAFETY SYMBOLS Safety symbols and signal words as shown below are used to emphasize all operator maintenance and repair actions which if not s
23. r Plug Charge Valve Handle Grip Handle Handle Trigger Lock Models Spirol Pin 1 4 x 1 Trigger Lock Spring Retainer Ring Locknut 5 8 18 Trigger Accumulator Diaphragm Piston Sound Power Level Decal Composite Safety Decal Push Pin Accumulator Valve Block Flow Sleeve CE Decal No Item Circuit Type C Decal Back Up Ring O Ring 2 9 16 x 2 3 4 x 3 32 Porting Block Automatic Valve Body Push Pin Automatic Valve Stanley Decal Model Number Decal Name Tag 40550 18 v Flow Sleeve Tube Hex Bushing No Item Breaker Foot O Ring 2 1 4 x 2 1 2 x 1 8 Rod Wiper Back Up Washer Cup Seal Side Rod No Item Latch Spring Washer Foot Latch Bolt Rubber Sleeve Spring Detent Part of Breaker Foot Assembly BREAKER FOOT ASSEMBLY T Handle and Anti Vibration Handle 07489 1 in Standard Rotated Hex BR40558BT BR40550 Includes 42 48 amp 51 56 BR4056801 BR4056201 Includes 42 48 amp 51 56 07510 1 in Standard SEAL KIT PART NUMBER 04595 8840 ANTI VIBRATION HANDLE PARTS ILLUSTRATION Ny US M 0O Ua F M SJ NM 19 Item Part Qty Description No No Coupler Set Roll Pin Hose Assembly 12 inch Hose Assembly 18 inch O Ring Included with Item 4 Spring Valve Spool Bushing O Ring 11
24. rmance 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 outlined in the Operation and Maintenance Manual HYDRAULIC PRESSURE amp FLOW HEAT TYPE OF FLUID Any failure or performance deficiency attributable to excess hydraulic pressure excess hydraulic back pres sure excess hydraulic flow excessive heat or incorrect hydraulic fluid 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 orig
25. safety tag p n D DO NOT LIFT OR CARRY TOOL BY THE HOSES DO NOT ABUSE HOSE DO NOT USE KINKED TORN OR DAMAGED HOSE MAKE SURE HYDRAULIC HOSES ARE PROPERLY CONNECTED TO THE TOOL BEFORE PRESSURING SYSTEM SYSTEM PRESSURE HOSE MUST ALWAYS BE CONNECTED TO TOOL IN PORT SYSTEM RETURN HOSE MUST ALWAYS BE CONNECTED TO TOOL OUT PORT REVERSING CONNEC TIONS MAY CAUSE REVERSE TOOL OPERATION WHICH CAN RESULT IN SEVERE PERSONAL INJURY DO NOT CONNECT OPEN CENTER TOOLS TO CLOSED CEN TER HYDRAULIC SYSTEMS THIS MAY RESULT IN LOSS OF OTHER HYDRAULIC FUNCTIONS POWERED BY THE SAME SYSTEM AND OR SEVERE PERSONAL INJURY BYSTANDERS MAY BE INJURED IN YOUR WORK AREA KEEP BYSTANDERS CLEAR OF YOUR WORK AREA WEAR HEARING EYE FOOT HAND AND HEAD PROTEC TION TO AVOID PERSONAL INJURY OR EQUIPMENT DAMAGE ALL TOOL REPAIR MAINTENANCE AND SERVICE MUST ONLY BE PERFORMED BY AUTHORIZED AND PROPERLY TRAINED PERSONNEL 15875 at right is attached IMPORTANT IMPORTANT to the tool when shipped READ OPERATION MANUAL AND from the factory Read PH OOL BEFORE USING IT and understand the safety USE ONLY PARTS AND REPAIR instructions listed on this st CHOSE URES APPROVED tag before removal We TION MANUAL suggest you retain this tag TAG TO BE REMOVED ONLY BY and attach it to the tool TOUL OPERATOR when not in use SEE OTHER SIDE READ OPERATION MANUAL AND SAFETY INSTRUCTIONS FOR THIS TOOL BEFORE USING IT USE ONLY PARTS AN
26. tions for which it was not intended TROUBLESHOOTING PROBLEM CAUSE REMEDY Tool does not run Power unit not functioning Check power unit for porer flow and pressure 4 6 gpm 15 23 1010 1300 2000 psi 90 140 bar Pressure and return line hoses reversed Be sure hoses are connected to their proper ports at ports Mechanical failure of piston or automatic Disassemble breaker and inpsect for damaged parts valve Tool does not hit effectively Power unit not functioning Check power unit for porer flow and pressure 4 6 gpm 15 23 1300 2000 psi 90 140 bar Low accumulator charge pressure hose will Recharge accumulator Replace diaphragm if charge pulse more than normal loss continues Fluid too hot above 140 F 60 Provide cooler to maintain proper fluid temperature 1307 55 30 Tool operates slow Check power unit for proper flow 4 6 15 23 lpm over 200 psi 14 bar Fluid too hot above 140 F 60 C or too cold Check power unit for proper fluid temperature Bypass below 60 16 cooler to warm the fluid or provide cooler to maintain proper temperature Relief valve set too low Adjust relief valve to 2100 2250 psi 145 155 bar 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 Tool gets hot 140 F 60 C max Check the relief valve setting E
27. trictly followed could result in a life threatening situation bodily injury or damage to equip ment DANGER NOTICE IMPORTANT THTIL 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 in 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 pre cautions given in t
28. valve must be in the position when coupling or uncoupling hydraulic tools Failure to do so may result in damage to the quick couplers 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 in this 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 applica
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