MOUNTED HYDRAULIC BREAKER
Contents
1. ya 30 MB25600 SIDE PLATES PARTS ILLUSTRATION a a aa 898 utn 31 MB25603 SIDE PLATES PARTS ILLUSTRATION 56 9 6 1 2 9 32 99 MODEL MOUNTING BRACKETS 8 33 IMPORTANT To fill out a Product Warranty Recording form and for information on your warranty visit Stanleyhydraulic com and select the Warranty tab NOTE The warranty recording form must be submitted to validate the warranty SERVICING THE STANLEY MOUNTED 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 following warning SERIOUS INJURY OR DEATH COULD RESULT FROM THE IMPROPER 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 man2. Do not use underwater without supplying air to breaker Figure 10 Underwater Restrictions 14 MB256 User Manual water Underwater usage of the breaker will cause internal damage to the breaker Consult Stanley for modifications and specific warranty coverage if you have an underwater requirement GREASE THE BIT Grease should be applied to the upper end of the break er tool bit each time it is installed Thereafter the tool should be greased at the fitting to reduce wear in the lower body and bushings of the tool See Greasing The Tool Bit in the sections titled Pre Operation Procedures IMPORTANT UNDERWATER USE No part of the Stanley MB256 Breaker may be submerged in water without first modifying the breaker for underwater use Use of the breaker underwater requires an underwater application kit and an air compressor capable of producing 150 cfm 75 psi Underwater usage of the breaker without the underwater kit and air compressor will cause internal damage to the breaker See the Accessories section of this manual to order the underwater kit TROUBLESHOOTING This section describes how to find and resolve problems If symptoms of poor performance develop the following users may experience If a situation occurs that is not chart can be used as a guide to correct the problem covered call your Stanley Customer Service represen tative for assistance When diagnosing faults in operation of the tool a
3. MB256 MOUNTED HYDRAULIC BREAKER STANLEY SAFETY OPERATION AND MAINTENANCE USER MANUAL nley Black amp Decker Inc New Britain CT 06053 DECLARATION OF CONFORMITY DECLARATION OF CONFORMITY UBEREINSTIMMUNGS ERKLARUNG C DECLARATION DE CONFORMITE CEE DECLARACION DE CONFORMIDAD DICHIARAZIONE DI CONFORMITA the undersigned i Ich der Unterzeichnende Weisbeck Andy Je soussign El abajo firmante lo sottoscritto Hydraulic Tools Surname and First names Familiennname und Vornamen Nom et pr nom Nombre y apellido Cognome e nome hereby declare that the equipment specified hereunder bestatige hiermit 86 erklaren Produkt genannten Werk oder Gerat d clare que l quipement vis ci dessous Por la presente declaro que el equipo se especifica a continuaci n Dichiaro che le apparecchiature specificate di seguito 1 Category Hydraulic Hammer Breaker Kategorie Cat gorie Categoria Categoria 2 M Make Marke Marque Marca Marca Stanley 3 Type Typ Type Tipo Tipo MB256 MB25616 4 Serial number of equipment Seriennummer des Ger ts Num ro de s rie de l quipement Numero de serie del equipo Matricola dell attrezzatura 5 Mass Masse Masse Masa Massa 493 Ibs 224 kg Has been manufactured in conformity with Wurde hergestellt in bereinstimmung mit Est fabriqu conform ment Ha sido fabricado de acuerdo con E stata costruita in conformit con Directive Standa
4. STANLEY MB256 User Manual lt 23 FLOW TEST PROCEDURES The correct performance of this procedure will verify if the auxiliary circuit of the carrier is adequate to properly operate a Stanley attachment This procedure is generic in form It is the end users responsibility to ensure that this procedure will work with his specific type of equipment If an adequate flow meter is not available contact your Stanley Hydraulic Distributor for assistance TEST PROCEDURE 1 With the auxiliary circuit or kit completely installed connect the flow meter between the tool inlet and outlet hoses NOTE Always use the hoses that are supplied for the at tachment and make sure the machine hydraulic oil is between 90 to 120 F This will assure correct readings and adjustments 2 With the machine setting at the mode that s going to be used to operate the attachment record the GPM Locate the correct flow for the attachment in the manual under the specification section Adjust the machine to the correct GPM NOTE If possible always set the machine to the highest GPM output mode This will prevent the operator from over flowing the attachments 3 Once the correct GPM flow is achieved fully open the restrictor on the flow meter 4 With the machine in the attachment mode set in step 2 record the back pressure At this point the pressure reading on the pressure gauge Is the back pressure in the circuit This pressure must n
5. or too far from the edge the energy will be absorbed into the material without cracking it Do not run the breaker longer than 15 20 seconds If breakout does not occur within this time move the breaker to another position MB256 User Manual lt 11 OPERATION On flat material such as concrete runways starting to break in the middle of the material may cause vibrations to be transmitted throughout the breaker and excavator because the material has no place to break to Always try to start at a point which will permit the material to break out MAINTAIN DOWN PRESSURE Maintaining hard contact with the surface of the material to be broken in addition to maintaining adequate down force is very important Always keep down pressure or down force on the point of the breaker by lifting the wheels tracks or stabilizers slightly above the ground This method takes the slack out of the bracket and boom pivots and reduces the impact on the pivots in the boom The operator needs to be constantly aware of the amount of down pressure being applied and be able to adjust it if necessary Not enough down pressure results in low production and accelerates wear and tear on the equip ment Too much down pressure may cause the breaker housing to violently crash into the broken material when break through occurs In any breaking job the operator should make every ef fort to follow the breaker with down p
6. position the backhoe so the boom is halfway up 45 and the dipper holds the breaker almost vertical Lower the loader bucket until the weight is off the front tires Apply down pressure Figure 4 Backhoe Apply down force to the boom dipper until the rear of the backhoe is raised off the ground Rear tires and stabiliz ers should be off the ground so the total rear weight of the backhoe is on the breaker tool The breaker is more efficient when adequate down force is applied EXCAVATORS With the breaker tool in place on the material to be worked position the excavator so the dipper is at ap proximately 45 and the breaker is almost vertical The tracks of the excavator should be in line with the boom and the breaker STANLEY Apply down force Figure 5 Excavator POSITIONING THE BREAKER TOOL ON THE WORK MATERIAL Position the tool bit near the edge of the work material not in the center or far from the edge Position the tool 6 18 inches depending on the material from the edge Breaking off smaller pieces of rock or concrete usually accomplishes more than trying to break larger pieces Break near the edge Figure 6 Position the Tool Bit On flat material or rock the breaker should be vertical or curled back slightly to direct the impact force down ward and toward the backhoe This directs the force back toward the edge of the work material If the tool is positioned in the center of the work
7. PROTECTOR HERE 9 amp 10 11 MB256 User Manual 4 33 Stanley Hydraulic Tools 3810 SE Naef Road Milwaukie Oregon 97267 503 659 5660 Fax 503 652 1780 www stanleyhydraulic com IMPORTANT To fill out a Product Warranty Recording form and for information on your warranty visit Stanleyhydraulic com and select the Warranty tab NOTE The warranty recording form must be submitted to validate the warranty
8. With the installation kit properly installed and adjusted per the above procedure conduct the heat load test as follows 1 Connect the flow meter between the tool inlet and outlet hoses 2 With the carrier set in the attachment mode re strict the flow meter until a pressure of 1000 psi is achieved This pressure must be maintained throughout the heat test NOTE Closing of the restrictor may be required as the tem perature increases Monitor the oil temperature from the flow meter until no change is noted Record the time required for oil to stabilize Record the surrounding temperature ambi ent temperature Record the time required to stabilize minutes Record the stabilized oil temperature F Record the ambient temperature F The heat rise is calculated as the stabilized tempera ture minus the ambient temperature Example Stabilized Temperature 160 Ambient Temperature 80 Heat Rise 80 The normal operating temperature range of this circuit will be the typical ambient temperature range for the geographical area plus the heat rise calculated above Ensure that the operating temperature range is lower than 180 for optimum operation of the attachment TROUBLESHOOTING If adequate pump flow is available from the carrier pump s but is not getting to the attachment consult your service representative and review the following 1 Attachment valve s are not actuating Review all electrical
9. are usually the result of heat build up mushrooming or improp er contact with the work Figure 26 Diagram of Tool Bit Failures PROPER CARE amp USE OF TOOL BITS Stanley Breakers are available with several different types of tool bits The most common are the moil chisel and the blunt Each of these working steels has its own purpose as described below To obtain the maximum production from the breaker it is important to select the proper working steel Consult your Stanley representative for assistance in selecting the proper working steel for your application MOIL This is by far the most popular working steel It is a general purpose point used to break anything from concrete to hard rock Its pencil type point is used to fracture the material The tool is best where penetra tion speed is important CHISEL This style of point is used gen erally used for trench work where a controlled break is re quired and for rock breaking on materials with a definite line of cleavage A chisel bit also works well in softer concretes where a moil might penetrate quickly but not cause a frac ture line BLUNT This flat type of point is used to break softer material such as coal or shale A moil or chisel will tend to punch holes in this type of material where a flat blunt will shatter the material It is also useful when break ing irregularly shaped material where its broad tip makes it easier to position
10. line where you want the crack to occur Most materials break sooner when struck several places along a line than when struck repeatedly in one location On each line the breaker tool should be continually repositioned Practice determines the best length of time to stay in one spot 15 20 seconds and how far to move the breaker tool Scoring with the breake Figure 8 Scoring with the Breaker STANLEY OPERATION Breaker tool binding can cause erratic breaker opera tion and premature wear on the tool shank Breaker tool binding is caused by failure to direct the down force in the direction of the tool bit Figure 9 Breaker Tool Bit Binding Do not pry with bit and breaker The tool bit may break causing injury Excessive side force cocks the tool in its bore prevents proper movement and causes premature tool shank and bushing wear Since the breaker tool bit must be pushed up into the breaker to operate a binding tool prevents the breaker from operating correctly Binding also causes the tool bit and tool bushings to seize and often results in breakage of one or more breaker components Always direct the down pressure force in a line toward the point of tool contact with the work Moving rocks with the tool bit is another method of bind ing the tool bit This practice should be avoided as it may cause tool bit failure Rebar reinforced concrete introduces the problem of concrete chunks being held together b
11. the preparation instructions can result in severe damage to the breaker and carrier and void the warranties of both Tool Stop Tool Bit Figure 2 Positioning the Tool Bit with Lubrication SECURING THE TOOL BIT POSITIONING THE CARRIER 1 The tool retainer 17 is shipped installed in the breaker see parts illustration SKIDSTEER LOADERS 2 Drive out the tool retainer using a punch and ham With the breaker tool in place on the material to be UH worked position the skidsteer loader arms and the 3 Grease the top area of the tool bit as shown in Fig breaker bracket so the breaker is almost vertical and the ure 1 page 9 front tires of the skidsteer are off of the ground 4 Install the tool bit making sure the notch is aligned Keep lowering the loader arms as the tool penetrates with the lower body retainer pin hole the work material so the skidsteer weight stays on the tool The breaker is more efficient when adequate down force is applied 5 Install the tool retainer Always wear eye protection when installing or removing the tool retaining pin LOW TEMPERATURE WARM UP PROCEDURE 1 After starting the carrier warm up the hydraulic sys tem at engine idle until hydraulic lines are warm to the touch 10 MB256 User Manual STANLEY OPERATION Figure 3 Skidsteer Loader BACKHOES With the breaker tool in place on the material to be worked
12. the starting point of failure like that in the fatigue failure The other parts of the broken surface are brittle This is the only kind of tool bit failure that is always covered under warranty Figure 25 Internal Material Flaw As a rule working steel failures can be diagnosed by looking at the break itself and at the place on the steel where the break occurred Discoloration like rainbow effects or blue bands is the result of extreme heat 22 MB256 User Manual Look for surface cracks galling or gouge marks Breaks that start as surface damage have a sea shell pattern with the damaged spot at the center A large sea shell indicates a slow growing break a small one indicates one compounded by side stress Stress failures start small and spread into the center of the steel In a stress failure the coarser the grain the greater the stress was and the more rapid was the failure Failures in this area are usually the result of blank firing worn bushing s worn re tainer pin s or the lack of lubrication Failures in this area are usually the result of worn retainer pin s or blank firing Failures in this area are usually the result of prying metal to metal contact or corro sion Prying failures often exhibit a shell like formation near the edge of the steel diameter where the break began and a tail opposite that where the remaining steel bent and tore Failures in this area
13. 8 OPERATION 9 OOO TING 15 MAINTENANCE c 16 CHARGING THE AGCUNULAION 17 FLOW CONTROL KIFT INSTRUCTIONS uu uuu eases esc toe uie eai cc eee 18 WEAR TOLERANCE uuu aa usis 13 PROPER CARE OF 11 ee 0 FEOW III 24 DEFINITON TERN 26 are 27 ueezocl 28 MB296 FARTS 1 T 5 9
14. E WORK CONDITIONS The operator must know any prohibited uses or work areas for the machine For example exces sive slopes and poor or dangerous terrain condi tions must be avoided 6 MB256 User Manual OBEY SAFETY RULES Operate the breaker in accordance with all laws and regulations which affect you your equipment and the work site Do not operate the breaker until you have read this manual and thoroughly understand all safety opera tion and maintenance instructions The operator must be familiar with all prohibited work areas such as excessive slopes and danger ous terrain conditions Do not operate the breaker until you have read the carrier equipment manual and thoroughly under stand all safety operation and maintenance instruc tions The word carrier as used in this manual means a backhoe or excavator or similar equipment used to operate the breaker Ensure that all maintenance procedures recom mended in this manual are completed before using the equipment The operator must not operate the breaker or carrier if any people are within the area where they may be injured by flying debris or movement of the equip ment Know the limits of your equipment Establish a training program for all operators to en sure safe operation Warning Use of this tool on certain materials during demolition could generate dust potentially contain ing a variety of hazardous substances such as as bestos sili
15. If your equipment does not contain an attaching kit ask your Stanley dealer for information installation and pricing on a kit which matches your equipment needs TEST THE HYDRAULIC SYSTEM 1 Have your Stanley dealer test the carrier hydraulic system to make sure the system is operating at the manufacturers specified capacity and pressure rat ings 2 Be sure the fluid in the hydraulic system is filtered to at least 10 micro meters Particles found in fluid should not exceed 10 micro meters in size 3 Check the hydraulic filter Replace the filter if dirty or deteriorated 4 Have your Stanley dealer test the circuit to which the breaker will be connected to make sure that the circuit is supplying the specified flow and pressure rating for the breaker See the Specifications section of this manual STANLEY PRE OPERATION PROCEDURES NITROGEN CHARGE The breaker has been properly charged with nitrogen at the factory and is ready to use TOOL BIT LUBRICATION Grease the top 10 in 250 mm of the breaker tool bit be fore installing During operation the tool can be greased through the grease fitting Grease is required Make sure the tool bit is against the piston by placing the tool bit against the ground and then putting down pres sure on the breaker See the illustrations below Grease This Area of Bit 10 inches 250 mm Tool Bit NN V Figure 1 Greasing the Top of the Tool Bit Greasing the to
16. Operation at higher temperatures can damage the internal components of the breaker and carrier and will result in reduced breaker per formance Do not operate a damaged leaking improperly ad justed or incompletely assembled breaker Do not modify the breaker in any manner Use only tool bits supplied by Stanley Hydraulic Tools Use of tool bits supplied by another manu facturer may damage the breaker and will void the warranty To avoid personal injury or equipment damage all breaker repair maintenance and service must only be performed by authorized and properly trained personnel If you do not understand how to safely operate your breaker contact an authorized Stanley Dealer for assistance Keep this manual with the breaker Do not operate this equipment if you are taking med ication which may affect your mental judgement or physical performance Do not operate this equipment if you are under the influence of drugs or alcohol MB256 User Manual 4 7 TOOL STICKERS amp TAGS OPS Div of The Stanle We rks 56595 GN cis Accumulator Pressure Sticker 300 PSI MODEL NO SERIAL NO OPERATING WEIGHT NITROGEN ONLY INPUT FLOW CIRCUIT RELIEF PRESSURE 66218 Sound Power Level 126 dBA 350 PSI 2 711 Accumulator Pressure Sticker 350 PSI 29177 CE Specification Plate 1000 PSI 34522 Accumulator Pressure Sticker 1000 PSI DO NOT USE UNDERWATER NOTE NO PAR
17. POWERCELL ASSY DECAL COMPOSITE WARNING MB25600 SIDE PLATES NOTE WHEN ORDERING ITEM 15 SIDE PLATE BOLTS CHECK THE LENGTH THE OAL SHOULD BE 8 450 AND THE LENGTH FROM THE BOLT HEAD TO THE END OF THE THREADS IS 7 800 ITEM P N DESCRIPTION 47352 DECAL LIFT POINT 56595 1 PRESSURE SPEC STICKER 300 PSI 62374 4 SIDEPLATE BOLT Check Length Before Ordering See Note on Drawing 66218 GUARANTEED SOUND POWER LEVEL 2 7072 2 23 WASHER 3 4 1 0 MB256 User Manual 4 31 2 1 14 1 1 1 1 1 0 2 3 5 6 it 8 9 1 NO MB25603 SIDE PLATE PARTS ILLUSTRATION NOTE WHEN ORDERING ITEM 14 SIDE PLATE BOLTS CHECK THE LENGTH THE OAL SHOULD BE 9 150 AND THE LENGTH FROM THE BOLT HEAD TO THE END OF THE THREADS IS 8 500 66218 GUARANTEED SOUND POWER LEV EL 27 371052 4 WASHER 3 4 I D 0 LN Lm Hs m EN 25 ae FA PSI 14 37915 ii SIDEPLATE BOLT Check Length Be fore Ordering See Note 4 15 137916 4 SIDEPLATE NUT 32 MB256 User Manual SS MODEL MOUNTING BRACKETS TTT oh OOOO C 1 7 SITET _ bl 2 Ey ad Lee LES HA u OO 65918 1 2 65918 6 1 EN L8 1 NEN 10 Description Hose Assy ly 1 1 Hose Assy 1 32387 Adapter Weldment Bracket 380522 1 Hose Clamp 34839 2 EN 3667 1 Capscrew 1 1 10 3 1516 1 Nut 380526 Grommet INSTALL 58593 HOSE
18. T FRONT BUSHING S OR RETAINER PIN S Worn out front bushing s will cause the tool to become misaligned inside the hammer This misalignment will cause uneven contact between the piston and tool thus causing stress to concentrate on one particular area of the tool This can also cause the tool to bind inside the hammer Call your dealer for acceptable wear allow ances 20 MB256 User Manual Worn out retainer pin s will cause uneven loading on the pin s themselves causing failure of the tool or re tainer pin s This will also cause excessive wear to the front bushing s METAL TO METAL CONTACT Extreme caution should be used to avoid scratches or gouges on the surface of the tool These areas create a stress concentration Metal to Metal Contact point thus weakening the tool Another form of metal to metal contact is galling which usually occurs from the lack of lubrication Special care should be taken to keep the tool shank lubricated every two 2 to three 3 hours Steel failures that were caused by surface damage take two main forms The simplest form is caused by deep scratches on working steel surface The broken surface has a shell pattern around the starting point of failure similar to the one in the fatigue failure The other parts of the broken surface are brittle These failures work slowly through the steel until it suddenly parts completely The second form of failure caused by surface damage occurs wh
19. T OF THE STANLEY BREAKER MAY BE SUBMERGED IN WATER WITHOUT 47352 FIRST ADAPTING THE BREAKER FOR k A oe UNDERWATER USE USE OF THE BREAKER W Lifting Point Decal UNDERWATER REQUIRES AN UNDERWATER W APPLICATION KIT CONSULT YOUR DEALER W 72074 Grease Sticker MADE k WITH GLOBAL MATERIALS 70752 Stanley Decal 66764 Made in USA Decal 73004 MB256 Decal 8 MB256 User Manual STANLEY OPERATION PRE INSTALLATION INSTRUCTIONS BACKHOE OR EXCAVATOR SIZE Check the Specifications section of this manual to de termine correct carrier size hydraulic flow and pressure requirements If hydraulic pressure hydraulic back pressure hydraulic flow or carrier weight class are exceeded the tool warranty is void EXISTING EQUIPMENT HYDRAULICS VS APPLICATION ATTACHING KITS Using existing equipment hydraulic auxiliary systems for operating hydraulic tools could cause problems for the hydraulic tool and the hydraulic system if not set up properly Simply plugging into the hydraulic system with out confirming pressure and flow to the hydraulic tool is not a good practice Spare spool valves dipper circuits etc are just a few examples of easily accessible hy draulic circuits which could prove to cause problems for hydraulic tool usage Stanley Hydraulic Tools has for many years developed ATTACHING KITS for adapting to existing hydraulic sys tems of many popular carriers
20. ations here Keep these instructions in an area accessible to the operator and mainte nance personnel 4 MB256 User Manual SAFETY PRECAUTIONS Do not operate the breaker unless the following safety instructions have been thoroughly read and understood Read this manual before installing operating or maintaining this equipment s A flying projectile from the breaker breaker tool rock or other material may enter the operator s compartment and cause serious or fatal injury to the operator Personal protection equipment must be used A flying projectile from the breaker breaker tool rock or other material may cause serious or fatal injury to bystanders Never operate the breaker when bystanders are in the work area On some machines carriers the breaker can enter the operator s compartment if it breaks loose and swings toward the operator Make sure that suitable impact shields are used when operating the breaker with this type of equipment Do not operate the breaker unless all safety decals described in this manual are in place The decals must be inspected periodically to ensure that all wording is legible The decals must be replaced if illegible Replacement decals can be obtained from your authorized Stanley Distributor When operating the breaker you must use ear protection eye protection and breathing protection STANLEY MB256 User Manual 4 5 SAFETY PRECAUTIONS Tool operators and maintenan
21. ca or lead Inhalation of dust containing these or other hazardous substances could result in serious injury cancer or death Protect yourself and those around you Research and understand the materials you are cutting Follow correct safety procedures and comply with all applicable national state or provisional health and safety regulations relating to them including if appropriate arranging for the safe disposal of the materials by a qualified person SAFETY PRECAUTIONS Do not operate the tool unless thoroughly trained or under the supervision of an instructor Become familiar with the carrier controls before op erating the carrier and the breaker When operating the breaker you must use ear pro tection eye protection and breathing protection While learning to operate the breaker and carrier do so at a slow pace If necessary set the carrier mode selector to the slow position Make sure all controls levers and pedals are in the NEUTRAL position before starting the carrier While operating the breaker and carrier keep hands and feet on the controls at all times Before leaving the carrier always lower the boom and insure the carrier is stable Never leave the ma chine with the engine running ALWAYS ENGAGE THE PARKING BRAKE Stop the engine before attempting to make any re pairs adjustments or servicing to either the carrier or the breaker Do not operate the tool at oil temperatures above 190 F 88 C
22. ce personnel must always comply with the safety precautions given in this manual and on the stickers and tags attached to the tool and hose These safety precautions are given for your safety Re view them carefully before operating the tool and before performing general maintenance or repairs Supervising personnel should develop additional pre cautions relating to the specific work area and local safety regulations If so place the added precautions in the space provided in this manual The Mounted 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 re sult in personal injury or equipment damage To avoid serious injury or death 2 Read the Manual Wear Eye Protection Wear a Dust Mask Wear Ear Protection Check the rules and regulations at your location The rules might include an employer s work safety program Regulations may identify hazards such as working around utility supply lines or hazardous slopes BE THOROUGHLY TRAINED BEFORE OPERATING THE UNIT ALONE e Operator training must start in an area without by standers and use all the controls until he she can control the machine fully under the conditions of the work area e When learning to operate a machine do so at a slow pace KNOW TH
23. connections that are part of the attach ment kit Ensure proper voltage to the valve s Ensure the REG port of the valve is not blocked Check to make sure the carriers main relief is set to the manufacturers recommendation and that this value is equal or greater than the attachment circuit relief o If the valve will not turn off check the drain tank line of the valve to ensure that the pressure is 50 psi or less MB256 User Manual lt 25 DEFINITION OF TERMS Tool Operating Pressure Relief Pressure Back Pressure Flow Meter Restrictor Valve V60 V65 V100 Valves Inlet Flow Regulated Flow By Pass Flow Pressure Line Return Line Cracking Pressure Full Open Pressure Ambient Air Temperature Stabilized Temperature 26 MB256 User Manual The hydraulic attachment that the auxiliary circuit is intended to power These may include hydraulic breakers compactors shears etc That pressure at which the tool will naturally operate without influence of out side pressure relief mechanisms This pressure is an operating characteristic of the tool and cannot be altered by the end user without changing the tool design The relief pressure is that pressure at which the circuit will dump fluid in order to protect itself from damage The pressure at the tool s connection to the return circuit of the carrier Instrument for testing the operating characteristics of a hydraulic circu
24. en there are deep scratches on working steel surface and there was also excessive bending stress The broken surface also shows the shell pattern but the other parts of the broken surface are brittle and usually have a lip like that in a stress failure C DNE ZZ Pv ME SS Figure 19 Metal to Metal Contact Examples PROPER CARE amp USE OF TOOL BITS In its most extreme forms the combination of surface damage and severe bending can quickly break even the best working steels The illustrations below show examples of severe stress breaks Figure 20 Severe Stress Breaks PRYING This is the most common cause of tool failure Even when there is no surface damage the stress from pry ing can easily break a working steel This kind of failure generally results from any type of side pressure such as an incorrect breaking angle or from using the tool to re position material The tool should not be used as a pivot point when repositioning the carrier The power gener ated by the carrier will far exceed the strength of the tool Figure 21 Prying Damage Example Similar failures can also occur when the steel is used with extreme down pressure and the steel repeated ly slips off the work at an angle or the material itself moves from under the working steel Figure 22 Extreme Down Pressure Breakage As the next illustration shows fatigue failures take many forms but they all exhibit similar fea
25. er Follow the instructions below to install the kit e Install the flow control block between the breaker and the loader s hydraulics using the 7 16 in capscrews washers and nuts provided Torque to 41 ft lbs Connect the hoses The parts list for the Flow Control Kit is shown below HOSE ROUTINGS R Return Route to the breaker OUT port S Supply Route to the breaker IN port P Pressure Route to the tractor s hydraulic pressure T Tank Route to the tractor s hydraulic reservoir Figure 13 Flow Control Kit NO ROT ja NO NO QTY DESCRIPTION 2 we fe ws _ _ FITTING DESIGNATED AS S s sez s capsorew s ses 5 nose 18 MB256 User Manual WEAR TOLERANCES LOWER BUSHING ITEM 14 MEASURE AT CENTER 2 525 in 64 1 mm 2 650 in 67 3 mm LOWER BUSHING TOOL STOP ITEM 15 Wear Areas A 2 525 in 64 1 mm A 2 650 in 67 3 mm Inside Diameter Inside Diameter C Measure at 1 2 in 30 mm TOOL STOP B 60 in 15 2 mm Depth B 48 in 12 mm Depth RETAINER PIN ITEM 17 MEASURE DIAMETER 1 745 in 44 mm Outside 1 66 in 42 mm Outside Diameter Diameter RETAINER PIN RETAINER PIN ITEM 16 25 in 6 mm Outside 18 in 4 6 mm Diameter Outside Diameter PISTON ITEM 44 at ear Limit 1 80 in 46 mm Depth 1 76 in 45 mm New Par
26. it The data usually available from this device are pressure psi bar flow gpm lpm and temperature F C A valve on the flow meter which allows the user to simulate an operating tool by adding a pressure load through restriction to the circuit This feature is used to evaluate relief settings and flow ratings at pressure A priority flow control valve manufactured by Stanley Hydraulic Tools Allows for optimum operation of any attachment by providing the proper amount of flow for operation of the tool the priority aspect allows the attachment to func tion properly if another control function is activated The hydraulic oil supplied to the IN port of the tool or valve The flow of oil supplied to the tool by the V60 V100 valve The oil flow that is supplied by the carriers pump but not used in the opera tion of the attachment By pass flow equals inlet flow to the valve minus the regulated flow The hydraulic line s that supply pressurized oil from the pump to the valve or tool The hydraulic line that connects the OUT port of the tool to the tank circuit of the carrier The pressure at which the relief valve starts to open Can be seen by a drop in the flow rate as shown by the flow meter The pressure at which the relief valve is completely open dumping all system flow to the tank The temperature of the outside air The temperature at which the carrier hydraulic system temperature will stop rising during testing
27. k Firing of this type can be experienced in trench work where obtain ing striking contact with the work surface is difficult or the wrong tool bit is used or in flat rock work where the operator fails to stop operation of the breaker when slip page fracturing or material break through occurs Blank Firing as a result of operator error occurs when the tool bit is not in contact with the work surface to be broken and is allowed to drop down in the lower body cavity so that the piston is not able to strike it Instead the downward movement of the piston will be stopped by an internal oil cushion located at the bottom of the piston s stroke and the energy of the piston will be ab sorbed by breaker components and excavator boom components Blank Firing of this type can be experi enced when the operator fails to stop operation of the breaker when the material fractures or material break through occurs or during re positioning of the breaker While Blank Firing cannot always be avoided it can be kept to a minimum by avoiding the above conditions as much as possible MB256 User Manual 4 13 OPERATION No part of the breaker may be submerged in UNDERWATER USAGE Underwater usage of the breaker will cause damage to internal components Even if the breaker is partially submerged water is introduced to an area between the tool bit and piston On the piston down cycle the water becomes compressed and damages adjacent compo nents
28. lways check that the hydraulic power source is supplying the correct hydraulic flow and pressure to the tool as listed WARNING in the table below Use a flowmeter known to be accu rate Check the flow with the hydraulic oil temperature at Inspecting the tool or installing parts with the least 80 F 27 C hydraulic hoses connected can result in severe personal injury or equipment damage To prevent accidental startup disconnect the hydraulic power before beginning any inspection or installation task PROBLEM CAUSE SOLUTION Breaker will not fire Low hydraulic oil level No flow to breaker Have hydraulic circuit tested by Main relief set low authorized dealer distributor per approved procedure Internal damage Have unit serviced by an authorized dealer distributor Damaged quick couplers Breaker runs slowly Low hydraulic flow Have hydraulic circuit tested by an Excessive heat build up authorized dealer distributor per approved procedure Excessive nitrogen pressure Have unit serviced by an authorized Internal leakage dealer distributor Breaker runs erratically Low or excessive back pressure Have carrier serviced by an authorized Damaged switch or connection dealer distributor Relief set too low Internal damage Tool binding Add grease to tool shank Do not pry while operating Breaker runs but at reduced Low accumulator charge Have unit serviced by an authorized power Excessive back pressu
29. nassrcuasaycbeleaueniensued EERE RN ENEE aA OAAR EM RUPEE Eds 4000 10000 Ib 1816 4500 kg Carrier Size BACKMOC RT 4000 10000 Ib 1816 4500 kg NOTE Weights dimensions and operating specifications listed on this sheet are subject to change without notice Where specifications are critical to your application please consult the dealer STANLEY MB256 User Manual lt 27 ACCESSORIES LO C i lon RERO Ee Part No Tool Bits ASHALE AGO ue T TET 25170 ferme 81 1 DEIN i o 25171 uj 2 281 NSS ies els ERR NRRRTTRP aqa TS 2 282 ai eUdRUmRMK e 2 283 BII E S 27284 Tamping Fad Assy 12mm GNI 2 286 Miscellaneous AHIM A O ERN EE OE D mE Consult Dealer AdapierASsemby TT 33300 Charge Hose Assembly Includes Valve and Hose for Nitrogen Tank amp Charge Valve Connections 905232 Charge Kit Assembly Includes p n 505232 28257 and 372047 Charge Kit Box 34892 PACCUIMUIALOF TO SCCM RN ERE 28257 Service Kit For Rebuild MB156 256 356 cente conse ion eUaS d aedis 2 40372 Conversion Kit to Adapt Breaker to Skid
30. ol bit without down pressure on the breaker results in grease filling the space between the piston and the tool bit When the breaker is next activated the piston will strike the grease at a speed which will pressurize the grease resulting in seal and grease zerk failure MB256 User Manual 4 9 OPERATION Pison n Donn Poston 2 With the carrier at idle and the breaker suspended Against Tool Bit in the air or with minimal down pressure turn on the breaker to gradually warm up its internal compo nents Tool Stop 3 When the hydraulic system and breaker are warm proceed with operation LONG TERM STORAGE 1 Remove the tool bit clean the tool stop and the low er bushing Thoroughly coat the surfaces of the tool stop and the lower bushing with grease Lower Bushing Tool Bit 2 If hoses are attached to the breaker install plugs Grease Will Fill Piston Not Against on the hose ends If hoses are removed from the This Space Tool Bit Leaving Space breaker install plugs on the hose ends and install the Piston and plugs in the breaker IN and OUT ports 3 Store the breaker in a vertical position Do not store the breaker horizontally for extended periods Lower Bushing OPERATING A BREAKER PREPARATION FOR USE Read the section in this manual titled Pre Operation Pro cedures before operating a breaker Failure to follow
31. or operation SPECIFICATIONS MB256 Dimensions and Weights Weight w Tool Bit amp Mounting Bracket ses eee eee eee ee 493 55 224 kg Length w Tool Bit amp Mounting BIO KL Bogdan eee 51 in 1295 mm gs VV OM FM MS ep ENT sss sss asss 15 in 381 mm FOO AIMS uuu u u uu E m mm 2 5 in 64 mm Hydraulic Pressure WOrKING ccccssccccsseeeceeseeceseeceeseecceececsaueecsagsecseuseesseeessageessageesssaeeessaeees 1400 1700 psi 96 117 bar Flow Range Kalaa ED er n 9 gpm 34 Ipm RIE 16 gpm 60 Ipm System Relief min CRACIMNG MNT ee eee 2500 psi 172 bar ISeturm Line Pressure MaX sssini nina ei ERA E a i aaa eead 200 psi 13 8 bar Operating Oil Temperature max maleta ME MORE nice miM 190 88 C Adapter FINNO SizgGeu uuu uuu u o uu EAE NU DURER ERO Rota al een tects EEE E N EE DONORUM bansa 12 SAE O Ring Recommended Min Hose ID 8 3 4 in BOWS Per MiNUlG NER 700 min 1200 max Iwlezredzeje lcWc 350 ft Ib 475 J SoOli d OW Si LEVE MEET SS 122 dBA Carner Size SKIdSsteer Uu u u TE TEE 3000 7000 Ib 1362 3178 kg Carrier Size Mint Excavator k inocssdseduor
32. ot ex ceed 200 psi 13 5 bar Excessive back pressure will slow the attachments operation and lead to premature seal failures and over heating Record the back pressure psi 24 MB256 User Manual 5 Close the restrictor valve on the flow meter until the attachment relief starts to crack or open The relief valve opens when the flow rate GPM indicated on the flow meter begins to decline rapidly Locate the tools operating system relief pressure in the specifi cation section in the manual Adjust attachment re lief to specification NOTE The relief valve pressure must be greater than the operating pressure of the attachment and three times the back pressure Never use the relief valve to control the flow rate in the circuit Cracking pres sure means the loss of 4 or more GPM Record the relief cracking pressure psi Example Operation pressure of a breaker is 2700 psi Back pres sure is 150 psi A good rule to follow when setting the relief multiply the back pressure by 3 then add this num ber to the operation pressure of the attachment Operating Pressure 2 00 psi Back pressure 450 psi Operating pressure of the tool 3150 psi The relief valve setting must be greater than the estimat ed operating pressure of the tool If the setting is lower damage to the circuit may occur Excess heat will be generated in the circuit which will damage the attach ment and carrier FLOW TEST PROCEDURES HEAT LOAD TEST
33. place the tool bit or the lower bushing individually as this will result in premature wear of the replaced component It is recommended to replace ALL worn components 16 MB256 User Manual STANLEY CHARGING THE ACCUMULATOR The tools required to charge the breaker accumulators are the 505232 charge hose assy and the 28257 accu mulator tester which are used with other Stanley model breakers When charging the accumulators make sure the tools and charge valves are clean Dirt can contami nate the charge valves and cause leakage 1 Remove the protective plug from the accumulator charge valve NOTE There are three accumulators on this breaker the main accumulator the manifold accumulator and the surge accumulator 2 Hold the chuck end of the tester and turn the gauge fully counter clockwise to ensure the plunger inside the chuck is completely retracted 3 Screw the tester into the breaker charge valve by turning the chuck Do not use the gauge for turning as this will advance the plunger in the chuck Tighten the chuck lightly against the breaker charge valve 4 Turn the gauge clockwise to advance the plunger until a pressure is indicated on the gauge Do not over tighten 2825 Tester 9 Surge Accumulator Manifold Accumulator 5 If the pressure is correct unscrew the gauge to retract the plunger Then loosen and remove the tester from the charge valve If the pres
34. rds No Approved body Richtlinie Standards Nr Pr fung durch Directives Normes Num ro Organisme agr Directriz Los Normas No Aprobado Direttiva Norme n Collaudato 12100 1 2009 12100 2 2009 982 2008 Noise Directive 2000 14 EC 2005 Machinery Directive 2006 42 EC 2006 6 Special Provisions None 7 Measurements Measured Sound Power Level 122 LwA Spezielle Bestimmungen Messungen Guaranteed Sound Power Level 126 LWA Dispositions particulieres Mesures Measured in accordance to Directive 2000 14 EC Provisiones especiales Mediciones Disposizioni speciali Misurazioni 8 Representative in the Union Patrick Vervier Stanley Dubuis 17 19 rue Jules Berthonneau BP 3406 41034 Blois Cedex France Vertreter in der Union Repr sentant dans l union Representante en la Union Rappresentante presso l Unione Done at Ort Fait Dado en Fatto a Stanley Hydraulic Tools Milwaukie Oregon USA Date Datum le Fecha Data 3 22 11 Signature Unterschrift Signature Firma Firma J las oe Position Position Fonction Cargo Posizione Engineering Manager 2 MB256 User Manual STANLEY TABLE OF CONTENTS DECLARATION OF CONFORMITY argasas gcc gets ea se ee ee 2 11 1 4 SAFETY PRECAYTION DS e D TOOLS TOKER wp c m
35. re dealer distributor Relief set too low Breaker leaks oil around tool bit Lower seals failed Have unit serviced by an authorized and tool bushing dealer distributor Hydraulic system overheats Main relief set low Have unit serviced by an authorized Insufficient cooling capability in dealer distributor hydraulic circuit Line hose size too small Excessive back pressure STANLEY MB256 User Manual lt 15 MAINTENANCE DAILY MAINTENANCE CHECKS e Check for loose or missing fasteners Tighten or re place as needed e Inspect tool retaining pins and pockets for wear e Check for hydraulic leaks at all fittings and hoses Replace any defective hoses Apply grease to the grease fitting in the lower body each morning Grease as needed throughout the i work day 18 inches TOOL STOP AND LOWER BUSHING Inspect the tool stop and lower bushing for excessive v galling and metal pickup on the tool bit Also check for I cracks If cracks are present the part must be replaced 11416 max The extent of wear of the tool stop and lower bushings A N and the tool bit can be checked by moving a NEW tool bit back and forth and measuring the gap between the Figure 11 Measuring Tool Bit Gap tool bit and the lower bushing If the gap is more than 250 in 6 mm the upper bushing lower bushing and tool bit should be replaced A gap in excess of 250 in 6 mm will cause damage to the piston Do not just re
36. ressure as the machine breaks farther into the material The breaker should be stopped as soon as break through occurs or if it is apparent that good solid blows are not occurring BREAKING The operator should note the sound of the blow when the breaker is running With experience the operator will be able to tell the difference between a good solid blow and a hollow sounding blow A hollow blow means that solid blows are not occurring and breaker should be re positioned Continuous tool penetration usually does not do much good If the material does not break with 3 6 inches of tool penetration it usually won t break with full penetra tion The time used for additional penetration could be better used to strike blows in another place Many materials do not respond well to continued ham mering in one place The breaker tool should be repo sitioned on the work each time the tool penetrates but does not crack the material 12 MB256 User Manual Do not break continuously in one place Figure 7 Breaking Continuous penetration in the same area for lengthy periods will create excessive temperatures at the tip of the tool bit resulting in loss of temper hardness of the bit mushrooming of the tip of the bit and may lead to failure of the bit Use a scoring method of breaking when cracking the material becomes difficult This technique involves strik ing the rock or concrete at several places along a
37. steer nne nennen sena 56599 TORQUE TABLE Item No Illustration Description Power Cel Kopr Kote 26 PowerCel Capscrew Locite 242 60 81 280 66 PowerCel Accumulator Cap Anti Seize 28 MB256 User Manual STANLEY MB256 User Manual 4 29 Giaa er amp 9550 9 N lt O H lt x v lt lt LLI n O an LO N m MB256 POWER CELL PARTS LIST 2 13054 0 6298 278 18 21 3 1659 1 DOWELPIN 2X V4LG 4 1905 1 ORNG Sex anaa n 22004 1 UPPERACCUMULATOR e 296 PISTON SLEEVE Fr m4 PISTON s 296 t SEALCARRER e 2296 1 VODIFIDQUADRNG Pw 296 4 rero ITEMS 32 33 amp 41 thru 46 rie 25492 8 HSHCS7hG MXt34 21 22 28 thru 31 and 34 thru 39 30 MB256 User Manual see 1 POWERCELLASSY VALVE ASSY INCLUDES ITEMS 26 amp js ACCUMULATOR ASSY 66121 INCLUDED ITEMS 21 22 23 25 also item 14 from side plate illustration and 04858 Hex Plug 66407 SURGE ACCUMULATOR ASSY INCLUDES ITEMS 21 22 31 34 PRESSURE SPEC STICKER 350 PSI RETAINING RING EXTERNAL CE PLATE MB25600 PRESSURE SPEC STICKER 1000 PSI SIDEPLATE NUT
38. sure is not correct proceed to step 6 NOTE When disengaging the tester a POP of nitrogen is normal 6 Connect the charge hose assembly to the charging valve on the tester Make sure the valve on the charge hose as sembly is closed Open the valve on the nitrogen bottle 7 Very slowly open the valve on the charge hose assembly and slowly meter the nitrogen into the breaker charge valve until the tester reads the correct charge pressure 8 When the correct pressure is obtained close the valve on the charge hose assembly and on the nitrogen bottle Unscrew the gauge to retract the plunger Loosen and remove the tester from the charge valve Before replacing the protective plug inspect the plug o ring If damaged or deformed replace the plug Apply Loctite 242 to plug and cap CHARGE PRESSURE SPECIFICATION Main Accumulator 350 PSI 20 PSI 24 BAR 1 4 BAR Manifold Accumulator 300 PSI 20 PSI 21 BAR 1 4 BAR Surge Accumulator 1000 PSI 20 PSI 69 BAR 1 4 BAR gt 3 Nitrogen Bottle locally obtained 505232 Charge Hose Assy includes gauge valve hose and charge valve adapter Figure 12 Charge Pressure Specification For the MB256 MB256 User Manual 4 17 FLOW CONTROL KIT INSTRUCTIONS The Flow Control Kit is an option for Skid Steer Models The Flow Control Kit regulates the flow from the skid steer hydraulics to the breaker to prevent over speeding of the break
39. t PISTON MB256 User Manual lt 19 PROPER USE amp CARE OF TOOL BITS Tool bits are made and heat treated to specification Tool bits however well made are wear parts and are used in the most destructive applications Even when the hydraulic breaker is used properly and the operator is an experienced one a tool bit may become damaged When a tool bit has been damaged it is useful to de termine the cause immediately in order to prevent the damage from occurring again All Stanley tool bits are machined and hardened for maximum performance Care must be taken to maintain the tools original condition for optimum productivity and life expectancy It is not uncommon for an operator who is unfamiliar with using a hammer to break a point This is part of the learning experience Listed below are several methods to determine tool fail ure and will quickly aid in warranty determination TOOL FAILURE NOT COVERED UNDER WARRANTY BLANK FIRING OR FREE RUNNING This occurs when the tool is not in proper contact with the work thus causing the energy produced by the ham mer to be concentrated on the tool retainer s and the retainer slot s on the tool itself Caution should be used to prevent the hammer from sliding off slanted surfaces or when breaking through thin material The illustration below is typical of the kind of breakage that occurs from excessive blank firing Figure 18 Excessive Blank Firing Breakage WORN OU
40. tures Generally the broken surface is brittle and has a lip like that in the bending failure even though in some cases the lip has been broken Figure 23 Fatigue Failures CORROSION Tools should be greased and stored out of the weather Corrosion tends to accelerate the fatigue fractures of the tool MUSHROOMING Driving the tool into a hard material for a long period of time generates an intense heat indicated by a blue tone just above the point This will soften the steel and cause the point to fold over or mushroom the end of the tool Avoid hammering in one location for too long If material does not break after a short period approximately 15 to 20 seconds reposition the tool P Figure 24 Mushrooming If the overheated steel is suddenly cooled by being dipped in standing water for example the metal will harden and become brittle These are some examples of failure caused by temper changes occurring on the job MB256 User Manual lt 21 PROPER USE amp CARE OF TOOL BITS TOOL FAILURE COVERED UNDER WARRANTY INTERNAL MATERIAL FLAW This failure occurs when a foreign material is rolled into the steel during the manufacturing process causing an imperfection in the internal material flaw grain The re sult is an inherent weakness in the tool shank and even tual breakage The fatigue failure is started by the defects within the tool bit The broken surface exhibits a shell pattern around
41. ual and ask for a Customer Service Representative STANLEY MB256 User Manual 4 3 SAFETY SYMBOLS Safety symbols and signal words as shown below are used to emphasize all operator maintenance and repair ac tions which if not strictly followed could result in a life threatening situation bodily injury or damage to equipment A DANGER IMPORTANT Y 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 situation 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 could result in death or serious injury This signal word indicates a potentially hazardous situation which if not avoid ed 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 dam age 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 regul
42. y the rebar after the concrete has been broken The best approach to this problem is to use a chisel point tool which permits cut ting the rebar with the breaker Another method is to pe riodically cut the rebar with an oxy acetylene torch BLANK FIRING To understand Blank Firing the operator needs to be STANLEY aware that the tool bit is able to drop down in the lower body cavity far enough so that the piston cannot strike it when the tool bit is not in contact with the work surface Blank Firing occurs whenever the breaker is operating and the piston is not able to strike the tool bit solidly or not strike the tool bit at all Blank Firing accelerates wear and tear on breaker and carrier components and may result in failure of one or more components Exces sive Blank Firing may be considered equipment abuse and may result in voiding warranties Break through or difficult surface contact results in Blank Firing when the material being broken fractures and the tool bit is no longer in hard contact with the material but is still pushed high enough in the lower body cavity so that the piston can strike it In this position the piston strikes the tool bit and the tool bit in turn is driven against the retaining pins because it is not in sufficient contact with the material to be broken The energy is ab sorbed by the retaining pins other breaker components and the carrier boom components Blan
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