BR47-48 Service-ver2
Contents
1. 250 Psi 17bar T Couplers rrt EHTMAFl shFace Vibration et meis PerNFPAT3 20 15 IS016028 ll n BR47 13 2m sec2 ME HM TNT NU BR48 9 9m sec NOTE Weights dimensionsandoperatingspecificationslistedare subject to changewithout notice Wherespecificationsarecriticalto your application please consult the factory 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 equipment IMPORTANT iub 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 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 da2. 1 28409 Yu Composite L Safety Label 9 11208 Shank Length STANLEY 30Lpm at 138bar BHTMA CATEGORY 11206 Circuit Label C 20Lpm at 138bar BHTMA CATEGORY 28411 BR48 Model No Pa 28410 BR47 Model No 4 BR48 WEIGHT 25 KG FLOW 34 LPM PRESS 140 BAR EASI RIDE PAT No 4614241 28376 Name Tag a 6 Stanley Hydraulic Tools o Division of The Stanley Works 3810 S E Naef Road Milwaukie Oregon 97267 U S A lt 6 1 FAILURE TO USE HYDRAULIC HOSE LABELED AND D DO NOT LIFT OR CARRY TOOL BY THE HOSES DO NOT ABUSE 4 CERTIFIED AS NON CONDUCTIVE WHEN USING HOSE DO NOT USE KINKED TORN OR DAMAGED HOSES 3 MAKE SURE HYDRAULIC HOSES ARE PROPERLY HAY RESULTINDEATHOR SERIOUS IUR CONN ECTED TO THE TOOL BEFORE PRESSURIZING BEFORE USING HOSE LABELED AND CERTIFIED AS OR NEAR ELECTRIC LINES TED TO TOOL PORT SYSTEM BE SURE THE HOSE IS MAINTAINED A CTIVE HOSE SHOULD BE REGULARLY TESTED FOR ELECTRIC CURRENT CTIONS MA LEAKAGE IN ACCORDANCE WITH YOUR SAFETY DEPARTMENT CAUSE REVERSE TOOL OPERATION WHICH CAN CAUSE SEVERE PERSONAL INJURY 2 LIC LEAK OR BURST MAY CAUSE OIL 00 NOT CONNECT CLOSED CENTER TOOLS TO TUECTION INTO THEBODYORCAUSE OTHER SEVERE PERSONAL OPEN CENTER HYDRAULIC SYSTEMS THIS MAY AUSE EXTREME SYSTEM HEAT AND OR SEVERE A DO NOT EXCEED SPECIFIED FLOW AND PERSONALINJURY
3. at min operating temperature 400 SSU 400 SSU 400 SSU 400 SSU 82 centistokes 82 centistokes 82 centistokes 82 centistokes Temperature Sufficient heat rejection capacity to limit max fluid temperature to 140 60 C 140 60 C 140 F 60 C 140 F 60 C at max expected ambient temperature Min cooling capacity 3hp 224kW 5hp 3 73 kW 7 hp 5 22 kw 6 hp 4 5 kW at a temperature difference of 40 F 22 40 22 40 22 C 40 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 M 25 microns 25 microns 25 microns 25 microns Min ul iow nitration 30 GPM 1141 30 GPM 1141 30 GPM 1141 GPM 114 Ipm sized for flow of at least For cold temp startup and max dirt holding capacity 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 te
4. 5 and evaluated during production as in Annex VI para 6 2nd procedure 8 Noise related value 25 kg 9 Measured sound power on equipment representative of this type 106 LWA 10 Guaranteed sound power level for this equipment 109 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 i Position Engineering Manager P N 52572 Rev 1 8 21 02 2 CERTIFICATE CONFORMITY STANLEY Hydraulic Tools the undersigned Winterling David Surname and First names Hereby certify that the construction plant or equipment specified hereunder 1 Manufacturer Stanley Hydraulic Tools 3810 SE Naef Road Milwaukie Oregon USA 2 Representative in the Union Stanley Svenska AB Box 9054 400 92 GOteborg SWEDEN 3 Category Hydraulic Hand Held Concrete Breaker 4 Make Stanley Hydraulic Tools 5 Type BR48 6 Type serial number of equipment ALL 7 Year of Manufacture Beginning 2002 Has been manufactured in conformity with the provisions of the Machinery Directive 98 37 EC Harmonized standard applied EN 792 4 We also declare that it meets the specification of Noise Directive 2000 14 EC 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 2nd procedure 8 Noise
5. 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 Operating Instructions The recommended hose size is 500 inch 12 mm I D up to 50 ft 15 m long and 625 inch 16 mm 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 5 6 18 22 at 1500 2000 psi 105 140 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 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 disc
6. 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 23 For additional Sales amp Service information contact STANLEY Stanley Hydraulic Tools Division of the Stanley Works 3810 SE Naef Road Milwaukie OR 97267 USA Tel 503 659 5660 Fax 503 652 1780
7. related value 25 kg 9 Measured sound power on equipment representative of this type 106 LWA 10 Guaranteed sound power level for this equipment 109 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 Signature Position Engineering Manager P N 52572 Rev 1 8 21 02 3 Specifications PressureRange 1500 2000psi 105 140bar ConnectSize amp Type 3 8 in MalePipeHoseEnds Hose dedo Yes FOW tod e dis Weight BR47 48lbs 21 7kg BR4757201 amp BR4857801 a BR48 53 Ibs 24kg OverallLength BR47 27in 686mm A 5 6 gpm 18 22lpm _ 0 BR48 28 5 in 724mm OverallWidth BR47 13 750in 349mm BR4817801 BR48 17 25 in 438mm OverallHeight BR47 48 4 3in 11cm A 7 9gpm 26 34lpm MaxFluidTemp sene 140 F 60 C SystemType OpenOrClosedCenter O Ptr Sgpmi20lpm POISIZecs ace SAE80 ring Voir asc E idest OR8gpm 30lpm NoiseLevelAtOperator 98dBA MaximumBackPressure
8. the alignment of hex flats with latch bolt centerline see figure 1 so that the new hex bushing is installed with the same alignment Figure 1 Hex Alignment with Latch Bolt B To service the hex bushing the collar support must be removed Press down on the collar support from the latch end to retract it from the retaining ring a long bolt with large washers may be placed through the foot assembly to hold the collar support in the retracted position Push a 3 16 inch 5mm punch through the side hole in the foot to dislodge the round wire retaining ring This allows the ring to be removed with a hooked tool Once the retaining ring has been removed the retaining bolt can be loosened or pressure removed to remove the collar support and spring The collar support is spring loaded Be sure to relax spring tension before removal 12 If the wear rings on the collar support worn or damaged the rings and collar must be replaced as an assembly D Use a 1 3 8 inch 35 mm diameter steel rod 10 inches 25 cm long Remove the latch and use the rod to push the hex bushing from the flanged end of the foot toward the latch end A 25 ton press is required E Place the new hex bushing O D tapered end first into the foot bore and press into place F The cup seal and rod wiper should be removed with proper o ring tools to avoid damage to the seal surfaces Note orientation above and below aluminum
9. 9 gpm 26 34 Ipm 2000 psi 140 bar 5 6 gpm 18 22 Ipm 2000 psi 140 bar Couplers or hoses blocked Remove restriction Pressure and return line hoses Be Sure hoses are connected to reversed at ports their proper ports Mechanical failure of piston or Have inspected and repaired by an automatic valve authorized dealer Tool does not hit Power unit not functioning Check power unit for proper flow effectively and pressure 7 9 gpm 26 34 Ipm 2000 psi 140 bar 5 6 gpm 18 22 Ipm 2000 psi 140 Low accumulator charge pressure Have recharged by authorized hose will pulse more than normal dealer Fluid too hot above 140 F 60 C Provide cooler to maintain proper fluid temperature Collar support not sliding freely in Remove clean and replace as the foot bore Easi Ride required Tool operates Low oil flow from power unit Check power source for proper flow slow High backpressure Check hydraulic system for Exceeding 250 psi 17 bar excessive backpressure and correct as required Orifice Plug Blocked Troubleshooting Continued Symptom Tool operates slow Cont Tool gets hot Fluid leakage on tool bit Possible Cause Solution Fluid too hot above 140 F 60 C Check power source for proper fluid or too cold below 60 16 temperature Bypass cooler to warm fluid up or provide cooler to maintain proper temperature Relief valve set too low Adjust relief valv
10. 97 28494 04374 20502 16607 24964 26599 31565 24948 31917 21089 20540 20541 20505 20508 07479 19443 34583 58603 28409 04605 11588 09611 07485 28322 11207 11206 04381 04379 09640 07480 04571 04382 28376 28411 04383 11230 04984 11636 02022 03127 04387 09642 07480 34092 04386 20517 11208 01837 04985 04983 01269 01744 08411 08158 11234 07522 o lt Description Coupler Set Roll Pin NOTE Orifice Pla Used on BR4857801 Only Numberann rice Plug sed on niy O ring Included With Item 4 Description when ordering Spring Valve Spool Bushing O ring 11 16 x 7 8 x 3 32 Seal Kit Part No 04595 wee 1 16 BR4857801 Plug Charge Valve Part m Handle Grip SEM Handle Guarded o iper Spirol Pin 1 4 x 1 ring Lever O ring Slotted Machine Screw Backup ring Top Plate od Wiper LockNut 5 8 18 O ring Trigger Gang SAE O ring Plug 10 O rino zi Cup Seal Trigger Handle Trigger Lock Trigger Pin Roll Pin 1 4 x 1 3 8 Seal Kit Part 13552 Handle Pivot 4817801 Pivot Screw Part Accumulator Diaphragm inti s S Pusa Qty Piston Model BR4857801 ONLY i Guaranteed Sound Power Level Sticker Composite Safety Label O ring Push Pin Back up ring Accumulator Valve Block Wiper ring Flow Sleeve Model BR4817801 ONLY Flow Sleeve Model BR4857801 ONLY CE Label Circuit D Labe Circuit C Labe Back up Ring O ring 2 9 16 x 2 3 4 x 3 32 Porting Bl
11. BR47 48 Hydraulic Breaker aum 20 Safety Operation Maintenance SERIOUS INJURY OR DEATH User s Manual 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 OOOO Read Wear Wear Wear The Breathing Hearing Eye Manual Protection Protection Protection STANLEY CE Stanley Hydraulic Tools Copyright 2001 The Stanley Works 3910 SF A M OPS Service amp CE Version USA 22 7 22557 02 03 2 503 652 1780 Servicing The BR47 48 Hydraulic Breaker This manual contains Safety Operation Service and Troubleshooting information 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 WARNING on the cover and the SAFETY warning below Copyright 2001 The Stanley Works rights reserved Under copyright law this document may not be copied in whole or in part without the prior written consent of The Stanley Works This exception does not permit copies to be made for others whether or not sold Under the law copying includes translating into another language format or medium This copyright notice must appear on any permitted copies Table of Contents BR47 48 Hydraulic Breaker Contents Certificate of Conformity B
12. E AS FAR AWAY POSSIBLE FROM BODY AND DO NOT PERMIT DIRECT CONTACT DURING USE CONTACT AT THE BURST CAN CAUSE BODILY INJECTION AND SEVERE PERSONAL INJURY SEE OTHER SIDE a wi O 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 OR LIFT TOOLS POWER UNITS ETC 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 a Side 1 Side 2 This Tag attached to Conductive hose shown smaller than actual size p n 29144 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 ELECTRIC LINES MAY RESULT 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 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 CONTACT DURING USE CONTACT AT THE BURST CAN CAUSE BODILY INJECTION AND SEVERE PERSONAL INJURY HANDLE AND ROUTE HOSE CAREFULLY TO AVOID KINKING ABRASION CU
13. PRESSURE FOR THIS TOOL EXCESS FLOW OR DONT CONNECT OPEN CENTERTOOLSTO CLOSED CENTER TENE TES e e OP AvORAULIC HOSE USED WII THIS TOOL SEVERE PERSONAL INJURY EXCESS PRESSURE MAY CAUSE A LEAK OR BYSTANDERS MAY BE INJURED IN YOUR WORK BURST AREA KEEP BYSTANDERS CLEAR OF YOUR WORK CHECK TOOL HOSE COUPLERS AREA CONNECTORS oo DALLY 6 WEAR HEARING EYE FOOT HANDANDHEAD PROTECTION 7 TOAVOID PERSONAL INJURY OREQUIPMENT DAMAGE ALL TOOL YOUR HANDS CONTACT WI REPAIR MAINTENANCE SERVICE MUST RESULT IN SEVERE PERSONAL INJURY PERFORMED BY AUTHORIZED AND PROPERLY TRAINED PERSONNEL READ OPERATION MANUAL AND READ OPERATION MANUAL AND m pec cir The SAFETY TAG P N 15875 shown at right smaller i than actual size is attached to the tool when shipped USE ONLY PARTS AND REPAIR USE ONLY PARTS AND REPAIR PE STANLEY AND DESCRIBED IN THE STANLEY AND DESCRIBED IN THE from the factory Read and understand the safety EY AND DESCRIE DI instructions listed this tag before removal We suggest you retain this tag and attach it to the tool when notin use TAG TO BE REMOVED ONLY BY TOOL TAG TO BE REMOVED ONLY BY TOOL OPERATOR OPERATOR SEE OTHER SIDE 15875 SEE OTHER SIDE 15875 Hydraulic Hose Requirements HOSETYPES Hydraulic hose types authorized for use with Stanley Hydraulic Tools are as follows Certified non conductive Wire braided conductive Fabric braid
14. R47 Certificate of Conformity BR48 Specifications General Safety Instructions Tools Decals and Tags Hydraulic Hose Requirements HTMA Requirements Equipment Protection and Care Operating Instructions Service Troubleshooting Maintenance Parts Illustration Parts List Accessories Warranty 1 2 3 4 5 6 10 11 12 14 15 16 17 19 21 18 20 22 23 SAFETY FIRST is the responsibility of the operator service technician to read rules and instructions for safe and proper operation and maintenance A cautious worker using common sense is the greatest safety device CERTIFICATE CONFORMITY STANLEY Hydraulic Tools the undersigned Winterling David Surname and First names Hereby certify that the construction plant or equipment specified hereunder 1 Manufacturer Stanley Hydraulic Tools 3810 SE Naef Road Milwaukie Oregon USA 2 Representative in the Union Stanley Svenska AB Box 9054 400 92 GOteborg SWEDEN 3 Category Hydraulic Hand Held Concrete Breaker 4 Make Stanley Hydraulic Tools 5 Type BR47 6 Type serial number of equipment ALL 7 Year of Manufacture Beginning 2002 Has been manufactured in conformity with the provisions of the Machinery Directive 98 37 EC Harmonized standard applied EN 792 4 We also declare that it meets the specification of Noise Directive 2000 14 EC measured in accordance to the Conformity Evaluation Method set out in Annex VI para
15. RNAL PARTS AT ALL TIMES Always determine and correct the cause of the problem prior to assembly Further wear and tool failure can result if the original cause is not corrected Breaker Disassembly Prior to Disassembly e Clean exterior of tool Obtain Seal Kit Part Number 13552 Replace all seals exposed during disassembly Note orientation of seals before removing them Install new seals in the same way Disassembly 1 Secure the breaker in a bench vise with the IN and OUT ports up clamping on the flow sleeve tube between the side rods Soft vise jaws are recommended 2 Remove the pigtail hose assemblies 3 Remove the plug from the side of the handle pivot block BR48 or remove the plug from the top of the handle BR47 and discharge the accumulator Discharge accumulator 4 Remove the four side rods 5 Remove the top plate then remove the handle pivot block with the two handles attached BR48 On the BR47 remove the handle 6 If necessary remove the two handles from the pivot block by removing the pivot screw securing each handle BR48 only 7 f necessary the trigger and the lever can be removed from the trigger handle by driving out the spirol pin securing each part 8 To service the foot assembly proceed as follows A The latch detent spring and cone washers are accessible when the latch bolt is removed 15 16 inch hex Note Before removing the hex bushing note
16. TTING OR CONTACT WITH HIGH TEMPERATURE SURFACES DO NOT USE IF KINKED DO NOT USE HOSE TO PULL OR LIFT TOOLS POWER UNITS ETC SEE OTHER SIDE Wa FW 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 AFTER EACH USE STORE IN A CLEAN DRY AREA SCC OTHER SIDE aw Side 1 HOSE PRESSURE RATING Side 2 SVL SIHL SAOWSY LON OG SVL SIHL SAOWSY LON OG The rated working pressure of the hydraulic hose must be equal to or higher than the relief valve setting on the hydraulic system 8 These are general hydraulic system requirements See tool specifications page for tool specific requirements HTMA Requirements Tool Category Hydraulic System EREA Requirements I Type II Type Ill RR Flow rate 4 6 GPM 15 23 7 9 GPM 26 54 11 13 GPM 42 9 9 10 5 GPM 34 40 Tool Operating Pressure lpm Lpm lpm lpm at tho power supply 2000 psi 138 bar 2000 psi 138 bar 2000 psi 138 bar 2000 psi 138 bar relief un 2100 2250 2100 2250 2100 2250 2200 2300 at the power supply outlet 145 155 bar 145 155 bar 145 155 bar 152 159 bar Maximum back pressure at tool end of the return hose 250 psi 250 psi 250 psi 250 psi 17 bar 17 bar 17 bar 17 bar Measured at a max fluid viscosity of
17. als must be replaced during assembly of the unit this inspection should be performed to help identify related faulty components and the cause of an experienced or potential malfunction 3 All components exhibiting excessive wear or deep scratches can usually be touch up using emery cloth Thoroughly clean all parts before assembly 4 Apply clean grease or o ring lubricant to all close fitting parts and seals during assembly Assembly 1 Using and arbor press and an aluminum disc or Accumulator Cylinder Puller Part Number 05640 to protect the flow sleeve push the flow sleeve with seven holes on its end facing up into flow sleeve tube o ring groove up until it is flush with the tube Be sure to lubricate the entire bore of the flow sleeve tube prior to assembly 2 Install the four 1 4 x 1 1 2 inch 38mm push pins with ground face end up in the flow sleeve 3 Install the two 3 16 x 1 1 4 inch 32 mm push pins with the ground face end up in the automatic valve body Install the automatic valve small diameter first into the automatic valve body IMPORTANT The push pins must be installed such that the flat ground surfaces bear on the flange of the automatic valve 4 Place the automatic valve body with proper roll pin alignment and with the side holes up on top of the flow sleeve Allow the automatic valve to drop and pilot into the bore of the flow sleeve 5 Use an aluminum disc or Accumulator Cylinder Pul
18. aulic circuit control valve must be in the OFF position when coupling or uncoupling the tool Wipe all couplers clean before connecting Failure to do so may result in damage to the quick couplers and cause overheating Use only lint free cloths Do not operate the tool at oil temperatures above 140 F 60 C Operation at higher oil temperatures can cause operator discomfort and may cause damage to the tool Do not operate a damaged improperly adjusted or incompletely assembled tool 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 Tool Decals Tags A Model Number Sticker is attached to the tool Never exceed the flow and pressure levels specified on this sticker The information listed on the Model Number sticker must be legible at all times Replace this sticker if it becomes worn or damaged A replacement is available from your local Stanley distributor 11207 28322 Circuit D Label CE Label P 58603 Guaranteed Sound Power B Level Sticker 109
19. e 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 over come any pressure drop through the charging system 4 When 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 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 Replace the plug 1 Maintenance Charging The Accumulator BR48 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 ACCUMULAT Includes Liquid Filled Gauge w Snub Valve Hose Charge Fitting 02835 Tester and Box not pictured Gauge 02835 TESTER Chuck Charging The Accumulator BR47 TESTER CHARGING ACCUMULATOR TESTER P N 02835 LOCATION OF CHARGING VALVE Figure 2 17 BR47 Parts List Description Coupler Set Roll Pin NOTE Hose Assy Use Part Number and Orifice Plug Used on BR4757201 Only O ring Included With Item 4 Description when ordering Spring Valve Sp
20. e to 2100 2250 psi 145 155 bar The collar support is not sliding Remove clean and replace collar freely in the foot bore support as required Make sure hex bushing is in the proper location Hot fluid going through tool Check power unit Be sure flow rate is not too high causing part of the fluid to go through the relief valve Provide cooler to maintain proper fluid temperature 140 F 60 C Max Check relief valve setting Eliminate flow control devices Lower piston seal failure Replace seal Fluid leakage Valve spool seal failure Replace seals around trigger General Maintenance Notes 1 If the breaker Is repainted after servicing do not allow paint to enter the IN and OUT ports or the bore of the foot assembly If the handle grips need be replaced A Remove old grips and clean the handles B Wash the new grips with solvent and follow with soap and water wash C With the grips and the handle clean and dry simply push or drive the grips on DO NOT lubricate the parts The grips will not be secure on the handle if any grease or oil is used The most important maintenance practice is to keep the hydraulic fluid clean at all times Contaminated hydraulic fluid causes rapid wear and or failure of internal parts Charging the Accumulator Accumulator Testing Procedure See Figure 2 To check or charge the accumulator the following equipment is required 31254 Charge Kit which includ
21. e 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 operations Do not operate the tool unless thoroughly trained or under the supervision of an instructor Always wear safety equipment such as goggles 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 Do not operate this tool without first reading the Operating Instructions Do not install or remove Parts on this tool while the hydraulic power source is connected Accidental engagement of the tool can cause serious injury Never operate the tool if you cannot be sure that underground utilities are not present Underground electrical utilities present an electrocution hazard Underground gas utilities present an explosion hazard Other underground utilities may present other hazards Do not wear loose fitting clothing when operating the tool Loose fitting clothing can get entangled with the tool and cause serious injury Supply hoses must have a minimum working pressure rating of 2500 psi 175 bar Besure all hose connections are tight hydr
22. ed not certified or labeled non conductive Hose listed above is the only hose authorized for use near electrical conductors Hoses and listed above are conductive and must never be near electrical conductors HOSE SAFETY TAGS To help ensure your safety the following DANGER tags are attached to all hoses purchased from Stanley Hydraulic Tools DO NOT REMOVE THESE TAGS If the information in a tag is illegible because of wear or damage replace the tag immediately A new tag may be obtained at no charge from your Stanley Distributor DO NOT REMOVE THIS TAG DO NOT REMOVE THIS TAG This Tag attached to Certified Non Conductive hose shown smaller than actual size p n 27987 1 FAILURE TO USE HYDRAULIC HOSE LABELED AND CERTIFIED AS NON CONDUCTIVE WHEN USING HYDRAULIC TOOLS ON OR NEAR ELECTRIC LINES MAY RESULT 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 BEFORE USING HYDRAULIC HOSE LABELED AND CERTIFIED AS NON CONDUCTIVE ON OR NEAR ELECTRIC LINES WIPE THE ENTIRE LENGTH OF THE HOSE AND FITTINGS WITH A CLEAI DRY ABSORBENT CLOTH TO REMOVE DIRT AND MOISTURE AND TEST HOSE FOR MAXIMUM ALLOWABLE CURRENT LEAKAGE IN ACCORDANCE WITH SAFETY DEPARTMENT INSTRUCTIONS DO NOT EXCEED HOSE WORKING PRESSURE OR ABUSE HOSE IMPROPER USE OR HANDLING OF HOSE COULD RESULT IN BURST OR OTHER HOSE FAILURE KEEP HOS
23. eight 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 pressure 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 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 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 REGISTRA TION IS ON RECORD In the event a warranty claim
24. en position the top plate on the pivot block Lubricate the pivot screw O D And the rubbing surfaces of the handles with anti seize compound On the BR47 place the handle on the accumulator valve block with the trigger side facing the latch on the breaker foot 15 Install the four side rods Tighten the side rods in 15 ft 16 20 Nm increments to 60 ft 16 80 Nm 16 Charge the accumulator See the maintenance section of this manual for the charging procedure 14 Troubleshooting This section describes how to find and resolve problems users may experience Ifa situation occurs that is not covered call your Stanley Customer Service representative for assistance Inspecting the tool or installing parts with the 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 If symptoms of poor performance develop the following chart can be used as a guide to correct the problem When diagnosing faults in operation ofthe tool always check that the hydraulic power source is supplying the correct hydraulic flow and pressure to the tool as listed in the table Use a flowmeter known to be accurate Check the flow with the hydraulic oil temperature at least 80 F 27 C Symptom Possible Cause Solution Tool does not run Power unit not functioning Check power source for proper flow and pressure 7
25. es the following Accumulator Tester Part Number 02835 Charging Assembly Part Number 15304 15304 includes a liquid filled gauge w snub valve hose and fittings NITROGEN bottle with an 800 psi 55 bar minimum charge Not included in 31254 kit Remove the plug from the handle BR47 or handle pivot BR48 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 Thread the tester onto the accumulator 6 Maintenance 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 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 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 Install the plug Accumulator Charging 1 Perform steps 1 through 4 of the accumulator testing procedure above 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 valv
26. it drops out D The automatic valve four 1 4 x 1 1 2 inch 38mm long push pins from the flow sleeve and Two 3 16 x 1 1 4 inch 32mm long push pins from the automatic valve body will come out E To remove the flow sleeve from the flow sleeve tube remove the automatic valve body and associated parts from within the flow sleeve removal tube and continue pushing on the flow sleeve until it drops out IMPORTANT Use a rag in the bottom of the removal tube to protect the flow sleeve BREAKER ASSEMBLY PRIOR TO ASSEMBLY e Clean all parts with a degreasing solvent e Obtain seal kit Part Number 13552 so all seals exposed during disassembly can be replaced during assembly e Ensure that all seals that were exposed have been replaced with new parts e Apply clean grease or o ring lubricant to all parts during reassembly Note For orientation of parts identified in the following procedures see the parts list exploded view illustration at the back of this manual 1 Check all parts for evidence of excessive wear scoring or obvious damage Pay particular attention to seal and other running surfaces looking for scratches or other signs of fluid contamination 13 caused defects Dirty or water contaminated fluid can cause scratches on running component surfaces 2 Examine all exposed seals and o rings for worn spots or damage caused by overheating or ingestion of contaminants Although all exposed o rings and se
27. ler Part Number 05640 to protect parts then push the automatic valve body into the flow sleeve tube until the valve body shoulder stops on the top of the flow sleeve tube 6 Install the piston small end first into flow sleeve assembly from the automatic valve body end 7 Install the porting block into the flow sleeve assembly with proper roll pin alignment 8 Place the accumulator valve block in a bench vise being careful not to over tighten or distort the block 9 Push the flow sleeve assembly into the accumulator valve block It may be necessary to tap on the end of the flow sleeve tube with a rubber or plastic hammer Be sure to tap on opposite sides to make sure that the assembly seats properly 10 Remove assembly from the vise and clamp on the flow sleeve tube with IN and OUT ports facing up 11 Shde the foot assembly over the piston and drive the foot into the flow sleeve tube by tapping the end of the foot with a plastic or rubber hammer Align the foot latch with the trigger 12 Replace in this order the spring valve spool and bushing with rod wiper facing out of the accumulator valve block in valve spool bore The bushing should project from the accumulator valve block approximately 0 200 inch 5mm 13 Apply a light coating of WD40 lubricant to the accumulator diaphragm and install in the accumulator bore 14 Place the handle pivot block with handles attached on the accumulator valve block th
28. ls 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 years 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 pa
29. mage 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 SOME HYDRAULIC FLUIDS ARE FLAMMABLE NEVER ALLOW THESE HYDRAULIC FLUIDS TO COME IN CONTACT WITH AN OPEN FLAME IF A HOSE WERE TO BURST OR IF A TOOL LEAK OCCURS NEXT TO AN OPEN FLAME THESE HYDRAULIC FLUIDS WILL IGNITE AND COULD RESULT IN SERIOUS INJURY OR DEATH LOCAL SAFETY REGULATIONS Enter any local safety regulations here Keep these instructions in an area accessible to the operator and maintenance personnel General Safety Instructions Tool operators and maintenance personnel must always comply with the safety precautions ew given in this manual and on the stickers and tags attached to the tool and hose Ty Q Q Supervising personnel should develop additional precautions relating to the specific work These safety precautions are given for your safety Review them carefully before operating the tool and before performing general maintenance or repairs area and local safety regulations If so place the added precautions in the space provided on page 5 This tool 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 Failur
30. mperatures SSU Saybolt Seconds Universal NOTE These are general hydraulic system requirements See tool Specification page for tool specific requirements Equipment Protection and Care IMPORTANT In addition to the Safety Precautions on page 5 amp 6 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 damage to the quick couples and cause overheating of the hydraulic system Always store the tool in a clean dry space safe from damage or pilferage Make sure the circuit PRESSURE hose with male quick disconnect is connected to the IN port The circuit RETURN hose with female quick disconnect is connected to the opposite port Do not reverse circuit flow This can cause damage to internal seals Always replace hoses couplings and other parts with replacement parts recommended by Stanley Hydraulic Tools Supply hoses must have a minimum working pressure rating of 2500 psi 172 bar Do not exceed the rated flow see Specifications page 4 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
31. ne 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 paving 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 11 Service Instructions Good maintenance practice keeps the breaker on the Job and increases its service life The most important maintenance practice 15 to keep the hydraulic fluid clean at all times Contaminated hydraulic fluid causes rapid wear and or failure of internal parts Follow the procedure contained in the HYDRAULIC SYSTEM REQUIREMENTS section of the manual to ensure peak performance from the tool Never disassemble the tool unless proper trouble shooting procedures have isolated the problem to an internal part Disassemble it only to the extent necessary to replace the defective part KEEP CONTAMINANTS SUCH AS DIRT AND GRIT AWAY FROM INTE
32. ock Automatic Valve Body Push Pin Automatic Valve Stanley Label BR48 Model No Label Flow Sleeve Tube Hex Bushing Stop Nut Breaker Foot O ring 2 1 4 x 2 1 2 x 1 8 228 R16 BR4817801 Rod Wiper Model BR4817801 ONLY BR4857801 Rod Wiper Model BR4857801 ONLY Back up Washer Model BR4817801 ONLY Back up Washer Model BR4857801 ONLY Cup Seal Model BR4817801 ONLY Cup Seal Model BR4857801 ONLY Side Rod Hex Shank Length Label Latch Spring Washer Foot Latch Bolt Rubber Sleeve Spring Detent Spring Collar Support Assy Retainer Ring NN Asa M cA DAN ap Bo Aw 2 ni ss a ps AX py Ss Ss A os ss cA NDA pt Ss Se Bs a MN NO pO 33 Aaa anw aaa 9 em DAE Oma BR48 Parts Illustration A Seed 09007 979 20000 21 Part Use Part Number and Description when ordering Part Accessories Description TestEquipment Accumulator Tester Accumulator Charge Kit Includes 02835 Tester 15304 Accumulator Charge Assy and 372047 Box Flow and Pressure Tester Accumulator Charge Assembly Includes Liquid Filled Gauge w Snub Valve Hose amp Charge fitting Service Tools Description Tamper Sleeve Tool O ring Tool Kit Flow Sleeve Removal Tube Flow Sleeve Removal Tool Accumulator Cylinder Puller 22 Warranty Stanley Hydraulic Too
33. onnect 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 together Operation Procedures 1 Observe all safety precautions 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 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 the breaking should be done around the original hole The bite or width 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 determi
34. ool 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 Trigger Lock Spring Retainer Ring LockNut 5 8 18 Trigger Accumulator Diaphragm Piston Sound Power Level Sticker Composite Safety Label Push Pin Accumulator Valve Block Flow Sleeve CE Label ees Seal Kit Part No 13552 Back up Ring Part 2 ay Automatic Valve Body Push Pin Automatic Valve Stanley Label BR47 Model No Label Flow Sleeve Tube i Hex Bushing o ring g Stop Nut O Ring Breaker Foot O ring 2 1 4 x 2 1 2 x 1 8 228 R16 Rod Wiper Back up Washer Cup Seal Side Rod Hex Shank Length Label Latch Part of Breaker Foot Assy Spring Washer Foot Latch Bolt Breaker Foot Assembly Rubber Sleeve Spring Part Model Spring Collar S Assy 48773 BR4757201 O ring O ring Back up ring Wiper ring 1 2 2 1 2 1 1 1 1 1 1 1 1 1 2 1 2 1 1 1 4 1 1 1 1 1 4 1 1 1 1 1 2 2 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 4 1 1 2 1 2 1 1 1 1 1 BR47 Parts Illustration t s V lt e lt Cm BR48 Parts List Item Part No No 24069 02900 01652 11587 01605 04058 20515 04057 00293 01362 04056 20510 20499 09349 02494 28369 20500 20511 322
35. rts 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 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 fr
36. washer 9 Remove the accumulator diaphragm and on off valve spool from the accumulator valve block taking care not to damage the valve stem The spool bushing and associated seals will come out as an assembly 10 Remove the accumulator valve block from the flow sleeve by tapping on the underside of the valve block with a plastic or rubber hammer Tap on alternate sides to ensure that the valve block comes out straight without binding Turn the valve block upside down to remove the valve spring 11 Remove the piston from the flow sleeve assembly 12 Clamp the accumulator valve block in a bench vise with IN and OUT ports up IMPORTANT Over tightening the vise can distort the block 13 Remove the porting block from the accumulator valve block with a 3 8 16 thread slide hammer or Tamper Sleeve Tool Part Number 01120 14 To disassemble the flow sleeve and automatic valve body assembly proceed as follows A Remove the piston if not previously removed B Place the flow sleeve assembly automatic valve body down on the Flow Sleeve Removal Tool Part Number 04919 which in turn is placed on th Flow Sleeve Removal Tube Part Number 04910 C Using an arbor press and an aluminum disc to protect the flow sleeve push on the flow sleeve to remove the automatic valve body from the flow sleeve tube IMPORTANT Use a rag in the bottom of the removal tube to protect the automatic valve body when
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