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User Manual - Truck Utilities Inc

1. Charging Valve Includes Liquid Filled Gauge w Snub Valve Hose Charge Fitting 02835 Tester ad Box not pictured Hose Gauge ui 02835 TESTER Chuck Charging the Accumulator BR72120 amp BR72130 LOCATION OF CHARGING VALVE ACCUMULATOR TESTER P N 02835 Figure 2 13 SPECIFICATIONS Pressure Range scan laine alia iii iaia iii 1500 2000 psi 105 140 bar FOW BANG a na noe di cn Sees eel a ava vien iii 7 9 gpm 26 34 lpm Optimum lO Wisin aida aida 8 gpm 30 Ipm Maxim um Back Pressure sieste ne iii arci aa iaia ac 250 Psi 17 bar Gouplers i a A i ii HTMA Flush Face Per NFPA T3 20 15 ISO 16028 Gonnect Size amp Type share ri eso esi aaa ao 3 8 in Male Pipe Hose Ends Wed prec neat dite ri ei are reer ane 59 lbs 27 kg Overall LA A ad g 28 in 71 cm Overall Wii a fi ea e 14 1 4 in 36 cm Made Fluid Temperature iia ala 140 F 60 C SYSTEM a Ao RE a anse MN eee sta Open Center PO SIZE SAR ii a iii ia i n ei ii a SAE 8 O ring RR TE TR TIRA O a GORI A AR E ARI 7 9 gom 2000 psi REA EEA E ERE UR IN NI A EI EIA ie RANA IRE A FIA 30 lpm O 138 bar 1 1 8 in Hex x 6 in Shank BR72120 amp BR72125S Models Clay Spade 51 21 Blade cocida ai da Addenda 02321 Asphalt Cutter 5 in Blade 11 in Long UC ii 02332 Moil Point 14 in Eong UE a eos 02333 gin Ghisel 14 UG tostada nin ea aa a lib elia rate 02334 Chisel Point 14 in Long UC nc cnc 03990 Ground
2. 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 break portions of the material into the original opening For best productivity t
3. ONoOoRWND BR72120 amp BR72130 PARTS LIST Dim mn a a y D NN 422 222 DD D 2 22 22 2 2 2 dd 0 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 NOITEM NOITEM NOITEM LOCKNUT 5 8 18 TRIGGER ACCUMULATOR DIAPHRAGM PISTON NOITEM NOITEM 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 18 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 ROD WIPER ROD WIPER O RING BACK UP RING CUP SEAL ND D PART OF BREAKER FOOT ASSEMBLY WARRANTY Stanley Hydraulic Tools hereinafter called Stanley subject to the exceptions contained below warrants new hydraulic
4. Check power unit for proper flow and pressure 7 9 gpm 26 34 lpm 1500 2000 psi 105 140 bar Couples 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 hi 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 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 145 155 bar Tool gets hot Hot fluid going through tool Check power unit Be
5. of at least For cold temp startup and max dirt holding 18 gpm 68lpm 30 gpm 114lpm 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 Insert the tool bit into the foot and pull the latch up to lock the tool bit in place
6. 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 e Charging Assembly Part Number 15304 15304 includes a liquid filled gauge w snub valve hose and fittings e 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 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 retr
7. 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 RL ST 3 Mie ee 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 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 CONDUCTIVE HOSE O lt E 2 pal E w gt o w ec E o Zz o a 1 F
8. 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 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 respect
9. AILURE 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 OA 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 STORE IN A CLEAN DRY AREA SEE OTHER SIDE SIDE 2 VIL SIHL 3AOWN34 LO
10. E 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 DO NOT 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 DONOTEXCEED SPECIFIED FLOW AND PRESSURE FOR OR SEVERE PERSONAL INJURY THIS TOOL EXCESS FLOW OR PRESSURE MAY CAUSE A LEAK OR BURST 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 LIC HOSE USED WITH THIS TOOL EXCESS PRESSURE MAY 6 WEAR HEARING EYE FOOT HAND AND HEAD PROTECTION CAUSE A LEAK 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 stand the safety i nstruc READ OPERATION MANUAL AND READ OPERATION MANUAL AND tions listed on
11. K 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 LOCKING FLANGE NUT COIL SPRING SPRING MALE COUPLER LT PART OF BREAKER FOOT ASSEMBLY MODEL BR72135S ONLY MODEL DESIGNATIONS BR72125S 1 1 8 Spring Handle Model BR72135S 1 1 4 Spring Handle Model 0 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 CUP SEAL ND D mn A ND ND ND AA iii Nm nm nm BD IN DD ni ND I AA mm a RS po 42pm Hic a a an in ua 16 BR72120 amp BR72130 PARTS ILLUSTRATION DU x 3 OR ly 17
12. N OG shown smaller than actual size THE TAG SHOWN BELOW IS ATTACHED TO CONDUCTIVE HOSE DO NOT REMOVE THIS TAG 1 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 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 SEE OTHERSIDE SIDE 1 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 STORE IN A CLEAN DRY AREA SEE OTHER SIDE SIDE 2 Ovl SIHL JAOWSY LON OG The rated working pressure of the hydraulic hose must be equal to or higher than the relief valve setting on the shown smaller tha
13. Rod Driver Tin Roda at iaia aiar 04176 A ERA E 1a EE E EE E E AE i i e oi ie eil i 08106 1 1 4 in Hex x 6 in Shank BR72130 amp BR72135S Models Asphalt Cutter 5 in 13 cm Blade 11 in 28 cm Long UC iii 02335 Moil Point 14 in 96 cm LONG UO ile raan ilatina fe du 02336 3 in Chisel 14 in 36 cm Long US 02337 1 in Chisel Heavy Duty 14 in 36 cm Long UC iii 02338 Ground Rod Driver 1 in 25 mm Rod NANNA NRK ANNIKA 04367 Moil Point Heavy Duty 18 in 146 cm Long UC sise 04404 Clay Spade 8 in 20 cm Blade iii 04405 Bnek Wedge sara LR nn n BR B R AR alla li MN boda ee a ie ian 08118 Aspal Wedde a wii li eni il Soi ne i na ei e 08119 Glay Spad b 1 2 in 4cm Blade aciatnelnafaglalazica dii dii lana talia 09262 Detachable Shan tin ra ai 17782 Tamping Pad Gini Square she it ea usi eit ieee aie he hits i eni eo ai 17783 Test Equipment Accumulator Charge Assembly incl Liquid Filled Gauge w Valve Hose amp Charge Fitting een 15304 Accumulator Tester iris rahe abi i ih ha ei shed i 02835 20 gpm 751pmFlowme t r a skilanna Hensel teen ner entre nan Ski a aa 03189 Flow and Pressure Tester iii 04182 Accumulator Gharge Kit aa a nei Dn ii 31254 BR72125S amp BR72135S PARTS ILLUSTRATION BR72125S 8 BR72135S PARTS LIST DESCRIPTION LOCK NUT 5 8 18 SIDE RIDE TOP PLATE HANDLE PIVOT SCREW SPRING HANDLE PIVOT BLOC
14. STANLEY BR 72 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 OO Wear Eye Read the Manual Protection ur 4 SAFETY OPERATION AND MAINTENANCE s USER S MANUAL Wear Dust Mask Ta Stanley Hydraulic Tools 3810 SE Naef Road Milwaukie OR 97267 5698 Copyright 2003 The Stanley Works 503 659 5660 OPS MAINT USA FAX 503 652 1780 62212 11 2003 Ver 2 www stanley hydraulic tools com TABLE OF CONTENTS Safety Symbols and Precautions i 4 5 Tool Stickersand Tags ili ie 6 Hydraulic Hose Requirements i 7 ATMA Reguirements u ad ellie 8 Operations riu 9 Equipment Protection and Care 10 Troubleshooting 2 55 ee een 11 Charging the Accumulator acicate 12 Soete lilere rilon Le 2222 eee nen 14 ACCESSONOS ir A E A 14 Parts Illustration BR72125S amp 1358 LL 15 Parts List BR721255 amp 1355 san en ur 16 Parts Illustration BR72120 8 130 i 17 Parts List BR72120 amp 130 2 4 aaa aa 18 MAN RE EE nen a FSA 19 SERVICING THE STANLEY 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 perfor
15. act 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 Gauge w Snub Valve Charge Fitting Nitrogen Tank Not included in Kit
16. ailure 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 expressed 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 dep
17. aintenance 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 gp Vv 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 DONOT 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 CONNECTED TO TOOL IN PORT MAINTAINED AS NON CONDUCTIVE THE HOSE SHOULD BE SYSTEM RETURN HOS
18. ending upon applicable law 19 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
19. ge 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 intended 10 TROUBLESHOOTING Tool does not run Power unit not functioning
20. he 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 amp 5 of this 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 when coupling or uncoupling hydraulic tools Failure to do so may result in dama
21. ich 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 attached to the tool and hoses before operation Failure to do so could result in personal inju
22. ive 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 outlined 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 f
23. med 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 AUN 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 in minor or moderate injury This signal word indicates a potentially hazardous situation wh
24. n actual size HOSE PRESSURE RATING hydraulic system HTMA REQUIREMENTS Tool Category Hyd raulic System BATNA CATEGORY EMA CATEGORY Requirements Type Type ll Type Ill 20Lpm at 188bar BHTMA CATEGORY Flow rate 4 6gpm 7 9gpm 10 5 11 6gpm 11 13 gpm Tool Operating Pressure 15 23 Ipm 26 34 Ipm 36 44 Ipm 42 49 lpm 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 22kW ata temperature difference of 40 F 22 0 40 F 22 0 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 full flow filtration 25 microns 25 microns 25 microns 25 microns Sized for flow
25. ry 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 torch or hardface the tool bit To avoid personal injury or equipment damage all tool repair m

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