HYDRAULIC BREAKER - Truck Utilities Inc
Contents
1. 71072 CE Tool Plate Stanley Hydraulic tools Division of the Stanley Works 3810 SE Naef Road Milwaukie OR 97267 Tag CE Only 07487 Name Tag The safety tag P N 15875 at right is attached to the tool when shipped from the factory Read and understand the safety instructions listed on this tag before removal We suggest you retain this tag and attach it to the tool when not in use 28379 BR45 Model Name only DANGER FAILURE TO USE HYDRAULIC HOSE LABELED AND CER TIFIED AS NON CONDUCTIVE WHEN USING HYDRAULIC TOOLS ON OR NEAR ELECTRICAL LINES MAY RESULT IN DEATH OR SERIOUS INJURY BEFORE USING HOSE LABELED AND CERTIFIED AS NON CONDUCTIVE ON OR NEAR ELECTRIC LINES BE SURE THE HOSE IS MAINTAINED AS NON CONDUCTIVE THE HOSE SHOULD BE REGULARLY TESTED FOR ELECTRIC CUR RENT LEAKAGE IN ACCORDANCE WITH YOUR SAFETY DEPARTMENT INSTRUCTIONS A HYDRAULIC LEAK OR BURST MAY CAUSE OIL INJEC TION INTO THE BODY OR CAUSE OTHER SEVERE PERSONAL INJURY DO NOT EXCEED SPECIFIED FLOW AND PRESSURE FOR THIS TOOL EXCESS FLOW OR PRESSURE MAY CAUSE A LEAK OR BURST DO NOT EXCEED RATED WORKING PRESSURE OF HYDRAULIC HOSE USED WITH THIS TOOL EXCESS PRESSURE MAY CAUSE ALEAK OR BURST CHECK TOOL HOSE COUPLERS AND CONNECTORS DAILY FOR LEAKS DO NOT FEEL FOR LEAKS WITH YOUR HANDS CONTACT WITH A LEAK MAY RESULT IN SEVERE PERSONAL INJURY IMPORTANT READ OP2. epueuuuloo8J 2594 Jed sJeli sed uo peseq 9504 sJejeuleip 2504 SMOUS ou yey 941 N92119 001 BR45 User Manual lt 9 HTMA REQUIREMENTS TOOL CATEGORY Jf 30Lpm at 1380 N HTMA CATEGORY HYDRAULIC SYSTEM fosse REQUIREMENTS TYPE I TYPE II TYPE III TYPE RR FLOW RATE 4 6 gpm 11 13 gpm 9 10 5 15 23 Ipm 26 34 42 49 34 40 TOOL OPERATING PRESSURE 2000 psi 2000 psi 2000 psi 2000 psi At the power supply outlet 145 155 bar 138 bar 138 bar 138 bar SYSTEM RELIEF VALVE SETTING 2100 2250 psi 2100 2250 psi 2100 2250 psi 2200 2300 psi At the power supply outlet 145 155 bar 145 155 bar 145 155 bar 145 155 bar MAXIMUM BACK PRESSURE 250 psi 250 psi 250 psi 250 psi At tool end of the return hose 17 bar 17 bar 17 bar 17 bar Measured at a max fluid viscosity of 400 ssu 400 ssu 400 ssu 400 ssu At min operating temperature 82 centistokes 82 centistokes 82 centistokes 82 centistokes TEMPERATURE Sufficient heat rejection capacity to limit max fluid temperature to At max expected ambient temperature Min cooling capacity at a temperature difference of between ambient and fluid temps NOTE Do not operate the tool at oil
3. c Shown smaller than actual size 8 BR45 User Manual STANLEY o 2 q LL x o L suonoeuuo eoid eunDi RETURN HYDRAULIC CIRCUIT PRESSURE lt lt lt gt gt gt 0 8 g dn 09 06 05 91 06 06 00 lt 00 07 61 9049 G 2 0 dn dn Ob SYOLONGNOD 1 21412313 YVAN ASN LON OQ 19914 pIEJg 9JIM 2 3113 404 Jeq 4 2S0H 9Aljonpuo2 uoN 4 9PISUI PRESSURE LES AWS Aq 195 se 4 Bunes 5 eu e 52 16 JSNW esou oi neJp U Aue pesn aq jou pynous pue joo 5100 Inep H uo peseq 1001 104 pesn SI yeyo siu 00 eJnsue 01 2 e oJnssaJd UINJSJ daay
4. i ee HTMA Flush Face Connect Size amp Type RENTE 3 8 in Male Pipe Hose Ends SO ERE E T Handle 48 Ibs 21 kg Anti Vibration Handle 51 Ibs 23 kg Briatore eei i _________________ T Handle 25 5 in 65 cm Anti Vibration Handle 28 25 in 72 cm Overall Width T Handle 14 in 35 cm Anti Vibration Handle 17 5 in 44 5 cm Max Fluid Temperature sas eee 140 60 SO Open Closed Center POS nnn SAE 8 O ring AGE EE 7 9 gpm 1500 2000 psi Guaranteed Sound Power Level 2000 14 107 dBA Sound Pressure Level NEBE a ts 98 dBA Vibration Level ISO 6662 5 joc scccucavencnaddecennsreavesdecadudesunincudesacosssitesasaneevensdaiduasencendieanen With Uncertainty Z Axis 4 2 With Uncertainty 3 Axis 6 6 16 BR45 User Manual STANLEY 1 IN HEX x 4 1 4 IN SHANK Moil Oia 14 in L ng UC dd 07702 Narrow Chisel Point 14 in Long NG 07703 3inch Chisel in Long PC t 07704 Clay Spade 5 1210 To 07705 Asphalt Wedge 3 in Wide NINTH 07706 1 1 8 IN HEX x 6 IN SHANK Moll Point dc mood src 02333 GRP
5. LNU C ea a a eo 03990 Long UC EA 02334 Clay Spade 5 1 2 in Blade 1 tirs 02331 Asphalt Wedge 2006 E M 08106 Asphalt Cutter 02332 Ground Roo Drvar T MAIR OG RECTORE 04176 1 1 4 IN HEX x 6 IN SHANK Moil Point LONG UG LE E 02336 Sele Chisel 14 in Long UC 02337 Clay Spade 5 1 2 in BAG 09262 SA 02335 Ground Rod Driver 1 in TRO 04367 02338 Heavy Duty Moil P int 18 en TE ete 04404 ee 04405 Detachable Shank Requires 17783 17782 Tamping Pad 6 in RENS 17783 TEST EQUIPMENT PAC CUM VC zie SUC ________ _ 02835 Flow and 04182 Accumulator Charge Assembly Includes Liquid Filled Gauge w Valve Hose amp Charge Fitting 15304 Accumulator Charge Kit Includes 02835 Tester 15304 Charge Assy and 372047 Charge Kit box 31254 SERVICE TOOLS Flow Sleeve Removal 04910 912121 8 6 E E E E
6. AFTER EACH USE STORE IN A CLEAN DRY AREA DO NOT REMOVE THIS TAG OVL SIHL AAOWSAY LON OG SEE OTHER SIDE SEE OTHER SIDE Shown smaller than actual size THE TAG SHOWN BELOW IS ATTACHED TO CONDUCTIVE HOSE DO NOT USE THIS HYDRAULIC HOSE ON OR NEAR ELECTRIC LINES THIS HOSE IS CHECK ENTIRE HOSE FOR CUTS CRACKS LEAKS ABRASIONS BULGES OR DAMAGE TO NOT LABELED OR CERTIFIED AS NON CONDUCTIVE USING THIS HOSE ON OR NEAR COUPLINGS IF ANY OF THESE CONDITIONS EXIST REPLACE THE HOSE IMMEDIATELY ELECTRICAL LINES MAY RESULT IN DEATH OR SERIOUS INJURY NEVER USE TAPE OR ANY DEVICE TO ATTEMPT TO MEND THE HOSE PROPER AND SAFE OPERATION MAKE SURE THAT YOU HAVE BEEN PROPERLY AFTER EACH USE STORE IN A CLEAN DRY AREA TRAINED IN CORRECT PROCEDURES REQUIRED FOR WORK ON OR AROUND ELEC TRIC LINES DO EXCEED HOSE WORKING PRESSURE OR ABUSE HOSE IMPROPER USE HANDLING OF HOSE COULD RESULT IN BURST OR OTHER HOSE FAILURE KEEP HOSE AS FAR AWAY AS POSSIBLE FROM BODY AND DO NOT PERMIT DIRECT CONTACT DURING USE CONTACT AT THE BURST CAN CAUSE BODILY INJECTION AND SEVERE PERSONAL INJURY HANDLE AND ROUTE HOSE CAREFULLY TO AVOID KINKING CUTTING OR CONTACT WITH HIGH TEMPERATURE SURFACES DO NOT USE IF KINKED DO NOT USE HOSE TO PULL OR LIFT TOOLS POWER UNITS ETC OTHER SIDE n npu n yn SEE OTHER SIDE OVL SIHL AAOWSY LON OG lt 2 I gt
7. 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 regulations here Keep these instructions in an area accessible to the operator and mainte nance personnel 4 BR45 User Manual SAFETY PRECAUTIONS Tool operators and maintenance 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 BR45 Hydraulic Breaker will provide safe and de pendable service if operated in accordance with the in structions given in this manual Read and understand this manual and any stickers and tags attached to the tool and hoses before operation Failure to do so could result in personal injury or equipment damage Operator must start in a work area without bystand er
8. 43 ITEM PART NO NO QTY DESCRIPTION 44 12298 1 BREAKER FOOT W INSERT ASSY BR45120E BR4512201E BR45125S BR45130E BR135S 58 08115 COLLAR SUPPORT ASSY 1 1 8 BR45120E BR4512201E BR45125S 08116 COLLAR SUPPORT ASSY 1 1 4 2 2 BR45130E BR45135S 59 07522 1 04717 1 04983 04716 04985 SPRING WASHER BR45120 04715 CONE WASHER BR4514801 BR45160 BR4516201 BR4516801 BR45350 01269 CONE WASHER BR45120 04374 1 LOCK NUT BR4514801 BR45160 04984 1 RETAINER RING BREAKER FOOT W INSERT ASSY BR45120 BREAKER FOOT BR45350 BREAKER FOOT BR4514801 BREAKER FOOT BR45160 BR4516201 BR4516801 LATCH BOLT BR4514801 BR45160 BR4516201 BR4516801 BR45350 LATCH BOLT BR45120 NO SPRING WASHER BR4514801 BR45160 BR4516201 BR4516801 BR45350 O O BR4516801 BR45350 SPRING BR4514801 BR45160 BR4516201 BR4516801 BR45350 SPRING BR45120 DETENT BR4514801 BR45160 BR4516201 BR4516801 BR45350 LOCK NUT BR45120 HEX BUSHING 1 1 8 BR45120 ONLY 04392 04393 BR4516201 BR4516801 BR45350 08411 DETENT BR45120 04394 LATCH BR4514801 BR45160 BR4516201 BR4516801 BR45350 01837 LATCH BR45120 HEX BUSHING 7 8 BR4514801 ONLY HEX BUSHING 1 IN BR45160 BR4516201 PART OF BREAKER FOOT ASSEMBLY SEAL KIT PART NUMBER 04595 a BR45 User Manual lt 19 PARTS LIST BR45 ANTI VIBRATION HANDLE PARTS I
9. Relief valve set too low Adjust relief valve to 2100 2250 psi 145 155 bar Hot fluid going through tool Check power unit Be sure flow rate is not too high causing part of the fluid to go through the relief valve Provide cooler to maintain proper fluid temperature 140 F 60 C max Tool gets hot Check the relief valve setting Eliminate flow control devices Fluid leakage on tool bit Lower piston seal failure Replace seal Fluid leakage around trigger Valve spool seal failure Replace seals STANLEY BR45 User Manual lt 13 CHARGING THE ACCUMULATOR AGCUMULATOR TESTING PROCEDURE To check or charge the accumulator the following equip ment is required e 31254 Charge Kit which includes the following Accumulator Tester Part Number 02835 Charging Assembly P N 15304 15304 in cludes a liquid filled gauge with snub valve hose and fittings e NITROGEN bottle with an 800 psi 55 bar minimum charge Not included in 31254 kit This assembly contains nitrogen under pressure Remove the plug from the handle or handle pivot 2 Holding the chuck end of Accumulator Tester P N 02835 turn the gauge fully counterclockwise to en sure that the stem inside the chuck is completely retracted 3 Thread the tester onto the accumulator charg ing 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
10. at a safe distance Do not exceed the rated flow and pressure See Specifications in this manual for correct flow rate and pressure rating Rapid failure of the internal seals may result Exposure to crystalline Silica sometimes called silica dust as a result of breaking drilling or hammering of rock concrete asphalt or other materials may cause Silicosis a serious lung disease silicosis related illnesses cancer or death Respiratory protection is highly recommended when working with materials containing Silica Dust Always wear a respirator approved for protection against crystalline silica 6 BR45 User Manual Please refer to the Parts Illustration for location of stickers Stanley Hydraulic Tools Division of The Stanley Works BR45 BREAKER FLOW 7 9 gpm 26 34 Ipm PRESSURE 1500 2000 psi 105 140 bar ACCUMULATOR CHARGE 600 psi 41 bar Nitrogen EASI RIDE Pat No 46143241 3810 SE Naef Road Milwaukie OR 97267 USA TOOL STICKERS amp TAGS To avoid serious injury or death 28409 Composite Sticker CE Only BR45 BREAKER WEIGHT 48 Ib 22 kg FLOW 7 9 gpm 26 34 Ipm PRESSURE 1500 2000 psi 105 140 bar EASI RIDE Pat No 4614241 58601 Sound Level Sticker CE Only 11207 Circuit Type C Sticker CE Only 4 28322 Sticker CE Only tanl H Milwaukie
11. eee eee Pee 04596 Split Ring Auto Valve Removal sources 04908 Accumulator Cylinder PUNET ee w 05640 Accumulator Disassembly VOOM i __ ren 05508 Spacer Flow Sleeve InstallatlOI ui ooo liens MU tea dad ACE Cd UE 04909 STANLEY BR45 User Manual lt 17 PARTS LIST BR45 T HANDLE PARTS ILLUSTRATION PE cC 9 g e 5 m N a m 52 039 7 NOTE WHEN ORDERING PARTS USE ITEMS 60 THROUGH 69 FOR UNITS NOT EQUIPPED WITH EASI RIDE BREAKER FOOT ASSEMBLY Oy STANDARD FOOT FOUND ON UNDER WATER MODELS ONLY 18 BR45 User Manual PARTS LIST BR45 T HANDLE PARTS LIST EE NO NO QTY DESCRIPTION COUPLER SET for se 2 ALTERNATE eme O e eos 2 omm NOU wn Tews re wor 1 e oor mew gt ores 1 BUSHNGASSYINCLTIEMSSTHEU T ___ 1 HANDLE mecs m we i paw oster m wmv omurmweosmoga Fe omcurrveecsmoem 42 HEX BUSHING 1 1 8 BR45120E BR4512201E BR45125S
12. 11208 HEX SHANK LENGTH STICKER 01837 LATCH 04985 SPRING WASHER 04983 FOOT LATCH BOLT 01269 RUBBER SLEEVE 56 01744 SPRING 08411 DETENT 68 08158 SPRING 08115 COLLAR SUPPORT ASSY 1 1 8 BR45125S 08116 COLLAR SUPPORT ASSY 1 1 4 BR45135S 07522 RETAINER RING 07695 BREAKER FOOT BR4514801 07445 BREAKER FOOT BR4516801 04717 LATCH BOLT 04716 SPRING WASHER 04715 CONE WASHER 04374 LOCK NUT m 01742 HEX BUSHING 7 8 IN BR4514801 07477 HEX BUSHING 1 IN BR4516801 04392 SPRING 04393 DETENT 04394 LATCH 180 71072 CE TOOL PLATE 02004 DRIVE PIN PART OF BREAKER FOOT ASSEMBLY SEAL KIT PART NUMBER 04595 BR45 User Manual 4 21 PARTS LIST BREAKER FOOT ASSEMBLY T HANDLE NO MODEL INCLUDES ITEMS 62334 1 1 8 IN STANDARD BR45120 45 48 AND 60 68 1 1 8 EASY RIDE 45 48 AND 51 68 07510 1 IN STANDARD BR45160 45 48 AND 60 68 11 STANDARD W TRIGGER BR4516201 LOCK 08856 1 IN UW BR45350 45 48 AND 60 68 BREAKER FOOT ASSEMBLY HANDLE PART NO MODEL INCLUDES ITEMS 08154 1 1 8 IN EASY RIDE BR45125S 53 59 AND 62 70 08081 1 1 4 IN EASY RIDE BR45135S 53 59 AND 62 70 07694 7 8 STANDARD BR4514801 56 59 AND 71 79 22 gt BR45 User Manual Stanley Hydraulic Tools 3810 SE Naef Road Milwaukie Oregon 503 659 5660 Fax 503 652 1780 www stanleyhydraulic com IMPORTANT To fill out a Product War
13. 4 Advance the valve stem of the tester by turning the gauge end clockwise until a pressure is read on the gauge charge pressure should be 500 700 psi 34 48 bar 5 If pressure is OK unscrew the gauge end from the chuck to retract the stem then unscrew the entire tester assembly from the accumulator charging valve If pressure is low charge the accumulator as described in the following paragraph 6 Install the plug 14 BR45 User Manual ACCUMULATOR CHARGING 1 Perform steps 1 through 4 of the accumulator test ing procedure above 2 Connect the chuck of the charging assembly to the charging valve on the accumulator tester or if pre ferred remove the tester from the charging valve and connect the charging assembly chuck directly to the charging valve 3 Adjust the snub valve to a charging pressure of 600 psi 42 bar Note While watching the pressure gauge open snub valve slowly until it reaches the proper charge pressure 600 700 psi NOTE It may be necessary to set the gauge at 650 700 psi 45 48 bar to overcome any pressure drop through the charging system 4 When the accumulator is fully charged close the snub valve on the charging assembly hose and re move the charging assembly chuck from the accu mulator tester or tool charging valve 5 If the accumulator tester has been used be sure to turn the gauge end fully counterclockwise before re moving the tester from the charging valve of the tool Inst
14. E stata costruita in conformit con Directive Standards Approved body Richtlinie Standards Pr fung durch Directives Normes Organisme agr Directriz Los Normas Aprobado Direttiva Norme Collaudato EN 792 4 2004 A1 2008 Self Noise Directive 2000 14 EC 2005 SMP Svensk Maskinprovning AB Notified body ID 0404 Annex VI Fyrisborgsgatan 3 754 50 Uppsala Sweden Certificate 20 2 13 004 Machinery Directive 2006 42 EC 2006 Self 6 Special Provisions None 7 Measurements Measured Sound Power Level 106 LwA Spezielle Bestimmungen Messungen Guaranteed Sound Power Level 107 LwA Dispositions particuli res Mesures Measured in accordance to Directive 2000 14 EC Provisiones especiales Mediciones Annex Part B No 10 15 kg m 30 kg 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 12 19 10 Signature Unterschrift Signature Firma Firma J FAR Position Position Fonction Cargo Posizione Engineering Manager P N 52571 Rev 6 12 19 10 2 BR45 User Manual STANLEY TABLE OF CONTENTS DECLARATION OF CON MV 2 oY A a cal Ne Ql Le 6 eT ee 4 SA
15. ERATION MANUAL AND SAFETY INSTRUCTIONS FOR THIS TOOL BEFORE USING IT USE ONLY PARTS AND REPAIR PROCEDURES APPROVED BY STANLEY AND DESCRIBED IN THE OPERATION MANUAL TAG TO BE REMOVED ONLY BY TOOL OPERATOR SEE OTHER SIDE 05152 Stanley Sticker CE 11208 Hex Shank Length Sticker DANGER D DO NOT LIFT OR CARRY TOOL BY THE HOSES DO NOT ABUSE HOSE DO NOT USE KINKED TORN OR DAMAGED HOSE MAKE SURE HYDRAULIC HOSES ARE PROPERLY CON NECTED TO THE TOOL BEFORE PRESSURING SYSTEM SYSTEM PRESSURE HOSE MUST ALWAYS BE CON NECTED TO TOOL IN PORT SYSTEM RETURN HOSE MUST ALWAYS BE CONNECTED TO TOOL OUT PORT REVERSING CONNECTIONS MAY CAUSE REVERSE TOOL OPERATION WHICH CAN RESULT IN SEVERE PERSONAL INJURY DO NOT CONNECT OPEN CENTER TOOLS TO CLOSED CENTER HYDRAULIC SYSTEMS THIS MAY RESULT IN LOSS OF OTHER HYDRAULIC FUNCTIONS POWERED BY THE SAME SYSTEM AND OR SEVERE PERSONAL INJURY BYSTANDERS MAY BE INJURED IN YOUR WORK AREA KEEP BYSTANDERS CLEAR OF YOUR WORK AREA WEAR HEARING EYE FOOT HAND AND HEAD PRO TECTION TO AVOID PERSONAL INJURY OR EQUIPMENT DAMAGE ALL TOOL REPAIR MAINTENANCE AND SERVICE MUST ONLY BE PERFORMED BY AUTHORIZED AND PROPERLY TRAINED PERSONNEL IMPORTANT READ OPERATION MANUAL AND SAFETY INSTRUCTIONS FOR THIS TOOL BEFORE USING IT USE ONLY PARTS AND REPAIR PROCEDURES APPROVED BY STANLEY AND DESCRIBED IN THE OPERATION MANUAL TAG TO BE REMOVED ONLY BY TOOL OPERATOR SEE OTHER
16. FE TY TER UM Mu eee ee ee UICE ID ee E AME D jose dz crx co eee ee 7 8 RECOMMENDATIONS 9 FIGURE TYPICAL HOSE CONNECTIONS 9 S 55 10 OPERATION oes E EU 11 TOOCPROTE CHON CARE 12 TU CT 13 CHARGING THE gt 14 FIGURE 2 CHARGING THE ACCUMULATOR Qvale 15 FEM MUNN 16 ACCESSORIES e 17 PRS T HANDLE PARTS ILLUSTRATION iene eee 18 BR49 RANDLE PARTS CIG M 19 BR45 ANTI VIBRATION HANDLE PARTS _ 20 BR45 ANTI VIBRATION HANDLE PARTS 21 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 HYDRAULIC BREAKER This manual contains safety operation and routine mainte nance instructions Stanley Hydraulic Tools recommends that servicing of hydraulic tools other than routine main tenance must be
17. LLUSTRATION 20 BR45 User Manual NOTE WHEN ORDERING PARTS USE ITEMS 71 THROUGH 79 FOR UNITS NOT EQUIPPED WITH EASI RIDE BREAKER FOOT ASSEMBLY PARTS LIST BR45 ANTI VIBRATION HANDLE PARTS LIST NO NO QTY DESCRIPTION 2 1 EU CU 2 HOSE ASSEMBLY TECH s E s 2 e ss o wes r sums O RING 11 16 x 7 8 x 3 32 orso r faso 2 w fam TRIGGER LOCK MODEL m EC oeme BIN CN NON TRIGGER LOCK MODELS FM MESTE 21089 ROLL PIN 1 4 x 1 3 8 TRIGGER LOCK MODELS s mew z ES 2 SPRING TRIGGERLOCK MODELS De wes ITEM PART NO NO QTY DESCRIPTION 11207 CIRCUIT D STICKER Hs nomen 04381 BACK UP RING 04379 O RING 2 9 16 x 2 3 4 x 3 32 04378 PORTING BLOCK 07480 AUTOMATIC VALVE BODY 04571 PUSH PIN 04382 AUTOMATIC VALVE 05152 STANLEY STICKER 28379 BR45 MODEL NUMBER STICKER 04383 FLOW SLEEVE TUBE 07518 HEX BUSHING 1 1 4 BR45135S 07517 HEX BUSHING 1 1 8 BR45125S 04984 NS NUT nm BREAKER FOOT WITH INSERT ASSY BR45125S BR45135S 02022 O RING 57 04387 DE ROD WIPER 04780 BACK UP WASHER 04386 CUP SEAL 60 20517 SIDE ROD
18. SIDE SAFETY TAG P N 15875 Shown smaller then actual size BR45 User Manual lt 7 HOSE TYPES The rated working pressure of the hydraulic hose must be equal to or higher than the relief valve setting on the hy draulic system There are three types of hydraulic hose that meet this requirement and are authorized for use with Stanley Hydraulic Tools They are Certified non conductive constructed of thermoplastic or synthetic rubber inner tube synthetic fiber braid reinforcement and weather resistant thermoplastic or synthetic rubber cover Hose labeled certified non conductive is the only hose authorized for use near electrical conductors Wire braided conductive constructed of synthetic rubber inner tube single or double wire braid reinforce ment and weather resistant synthetic rubber cover This hose is conductive and must never be used near electrical conductors Fabric braided not certified or labeled non conductive constructed of thermoplastic or synthetic rubber in ner tube synthetic fiber braid reinforcement and weather resistant thermoplastic or synthetic rubber cover This hose is not certified non conductive and must never be used near electrical conductors HOSE SAFETY TAGS To help ensure your safety the following DANGER tags are attached to all hose purchased from Stanley Hydraulic Tools DO NOT REMOVE THESE TAGS If the information on a tag is illegible because of wear or damage replace the ta
19. STANLEY BR45 HYDRAULIG BREAKER SAFETY OPERATION AND MAINTENANCE USER MANUAL O 2010 Stanley Black amp Decker Inc Britain CT 06053 U S A 2388 12 2010 Ver 5 DECLARATION OF CONFORMITY DECLARATION OF CONFORMITY UBEREINSTIMMUNGS ERKLARUNG DECLARATION DE CONFORMITE CEE DECLARACION DE CONFORMIDAD DICHIARAZIONE DI CONFORMITA I the undersigned 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 best tige hiermit da erklaren Produkt genannten Werk oder Ger t 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 Hand Held Concrete Breaker Kategorie Cat gorie Categoria Categoria 2 Make Marke Marque Marca Marca Stanley 3 BR4514801 BR4516801 BR4516807 4 Serial number of equipment Seriennummer des Ger ts Num ro de s rie de l quipement All Numero de serie del equipo Matricola attrezzatura 5 Mass Masse Masse Masa Massa 23 kg Has been manufactured in conformity with Wurde hergestellt in bereinstimmung mit Est fabriqu conform ment Ha sido fabricado de acuerdo con
20. age all tool repair maintenance and service must only be performed by authorized and properly trained per sonnel 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 recom mended by Stanley Hydraulic Tools Check fastener tightness often and before each use daily Never operate the tool if you cannot be sure that underground utilities are not present Do not wear loose fitting clothing when operating the tool BR45 User Manual lt 5 SAFETY PRECAUTIONS Warning Hydraulic fluid under pressure could cause skin injection injury If you are injured by hydraulic fluid get medical attention immediately Keep all body parts away from the working tool When handling material or the tool bit wear your PPE Personal Protection Equipment Be observant of the hydraulic hoses lying about the work area they can be a tripping hazard Always de energize the hydraulic system when changing a tool bit Take caution when changing a tool bit tool bits can get very hot Never use the tool in an explosive atmosphere sparks from the breaking process could ignite ex plosive gas Use proper lifting techniques when handling the tool get help from a co worker and do not over reach Use proper protection from falling or flying debris keep bystanders
21. ain 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 TROUBLESHOOTING PROBLEM CAUSE REMEDY Tool does not run Power unit not functioning Check power unit for power flow and pressure 7 9 26 34 Ipm 1500 2000 psi 105 140 bar Couplers hoses blocked Pressure and return line hoses Be sure hoses are connected to their proper reversed at ports ports Mechanical failure of piston or Disassemble breaker and inspect for automatic valve damaged parts Tool does not hit effectively Power unit not functioning Check power unit for power flow and pressure 7 9 gpm 26 34 Ipm 1500 2000 psi 105 140 bar Low accumulator charge Recharge accumulator Replace diaphragm if pressure hose will pulse more charge loss continues than normal Fluid too hot Provide cooler to maintain proper fluid above 140 F 60 C temperature 130 F 55 C Tool operates slow Low gpm supply from power Check power unit for proper flow 7 9 unit gpm 26 34 Ipm High back pressure Check hydraulic system for excessive back pressure over 200 psi 14 bar Couplers or hoses blocked Orifice plug blocked Fluid too hot Check power unit for proper fluid temperature above 140 F 60 C or too cold Bypass cooler to warm the fluid or provide below 60 F 16 C cooler to maintain proper temperature
22. all the valve cap UNDERWATER MODEL PREVENTATIVE MAINTENANCE After each use the movable portions of the tool that were exposed to water should be flushed with a water displacing oil such as WD40 Remove any remaining water and debris as follows 1 Turn the tool upside down without the tool bit and spray oil through the drive hex and side holes in the breaker foot assembly to displace any remaining water in the lower piston cavity Spray oil into the On Off valve trigger slot area 3 Dip or spray the entire tool Cycle the tool hydraulically several times before storing away CHARGING THE ACCUMULATOR Charging the Accumulator BR45 with Anti Vibration Handles TESTER CHARGING LOCATION OF CHARGING VALVE Figure 2 Liquid Filled Gauge w Snub Valve Charge Fitting Nitrogen Tank Not included in Kit Charging Valve 31254 ACCUMULATOR CHARGE KI Includes Liquid Filled Gauge w Snub Valve Hose Charge Fitting 102835 Tester and Box not pictured Gauge 02835 TESTER Chuck Charging the Accumulator BR45 with T Handles TESTER CHARGING LOCATION OF CHARGING VALVE ACCUMULATOR TESTER P N 02835 Figure 2 Charging the Accumulator BR45 User Manual lt 15 SPEGIFICATIONS Pressure i MEN ass m 1500 2000 psi 105 140 bar FION MNT PEN 7 9 gpm 26 34 lpm 1 8 30 Ipm Maximum B ck FPS SS ee 250 Psi 17 bar
23. away from the tool 2 Insertthe 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 discon nect 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 cou pler 4 Move the hydraulic circuit control valve to the ON position to operate the tool NOTE If uncoupled hoses are left in the sun pressure in crease within the hoses may make them difficult to connect When possible connect the free ends of the hoses together OPERATION PROCEDURES 1 Observe all safety precautions 2 Install the appropriate tool bit for the job 3 Place the bit firmly on the surface to be broken 4 Squeeze the trigger to start the breaker Adequate down pressure is very important When the tool bit breaks through the obstruction or becomes bound release the trigger and reposition the tool bit STANLEY NOTE Partially depressing the trigger allows the tool to run at slow speed Slow speed operation permits easier starting of the tool bit into the work surface 5 To start break an opening ho
24. g immediately A new tag may be obtained from your Stanley Distributor THE TAG SHOWN BELOW IS ATTACHED TO CERTIFIED NON CONDUCTIVE HOSE DANGER DANGER FAILURE TO USE HYDRAULIC HOSE LABELED AND CERTIFIED AS NON CONDUCTIVE DO NOT EXCEED HOSE WORKING PRESSURE OR ABUSE HOSE IMPROPER USE WHEN USING HYDRAULIC TOOLS ON OR NEAR ELECTRIC LINES MAY RESULT IN OR HANDLING OF HOSE COULD RESULT IN BURST OR OTHER HOSE FAILURE DEATH OR SERIOUS INJURY KEEP HOSE AS FAR AWAY AS POSSIBLE FROM BODY AND DO NOT PERMIT DIRECT CONTACT DURING USE CONTACT AT THE BURST CAN CAUSE BODILY INJECTION AND SEVERE PERSONAL INJURY ELECTRIC LINES HANDLE AND ROUTE HOSE CAREFULLY TO AVOID KINKING ABRASION CUTTING OR CONTACT WITH HIGH TEMPERATURE SURFACES DO NOT USE IF KINKED DO NOT BEFORE USING HYDRAULIC HOSE LABELED AND CERTIFIED AS NON CONDUCTIVE USE HOSE TO PULL OR LIFT TOOLS POWER UNITS ETC ON OR NEAR ELECTRIC LINES WIPE THE ENTIRE LENGTH OF THE HOSE AND FIT CHECK ENTIRE HOSE FOR CUTS CRACKS LEAKS ABRASIONS BULGES OR DAM TING WITH A CLEAN DRY ABSORBENT CLOTH TO REMOVE DIRT AND MOISTURE AND TEST HOSE FOR MAXIMUM ALLOWABLE CURRENT LEAKAGE INACCORDANCE WITH AGE TO COUFLINGS IF ANY OF THESE CONDITIONS EXIST REPLACE THE HOSE SAFETY DEPARTMENT INSTRUCTIONS IMMEDIATELY NEVER USE TAPE OR ANY DEVICE TO ATTEMPT TO MEND THE HOSE FOR PROPER AND SAFE OPERATION MAKE SURE THAT YOU HAVE BEEN PROP ERLY TRAINED IN CORRECT PROCEDURES REQUIRED FOR WORK ON OR AROUND
25. le in the center of the surface After making a hole break portions of the material into the original opening For best produc tivity the breaking should be done around the origi nal hole The size of the broken material will vary with the strength and thickness of the base material and the amount of any reinforcement wire or rebar Harder material or more reinforcing wire or rebar will require taking smaller bites To determine the most effective bite start with 2 in 50 mm or smaller bites Bites can then be gradually increased until the bro ken piece becomes too large requiring increased time to break off the piece oticking of the tool bit occurs when too large a bite is being taken and the tool bit hammers into the mate rial without the material fracturing This causes the tool bit to become trapped in the surrounding mate rial COLD WEATHER OPERATION If the breaker is to be used during cold weather preheat the hydraulic fluid at low engine speed When using the normally recommended fluid fluid temperature should be at or above 50 F 10 C 400 ssu 82 centistokes be fore use Damage to the hydraulic system or breaker can result from use with fluid that is too viscous or thick BR45 User Manual lt 11 TOOL PROTECTION amp CARE NOTICE In addition to the Safety Precautions found in this manual observe the following for equipment protection and care Make sure all couplers are wiped clean before c
26. on nection The hydraulic circuit control valve must be in the OFF position when coupling or uncoupling hydrau lic tools Failure to do so may result in damage to the quick couplers and cause overheating of the hy draulic 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 cir cuit 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 mini mum working pressure rating of 2500 psi 172 bar Do not exceed the rated flow and pressure See Specifications in this manual for correct flow rate and pressure rating Rapid failure of the internal seals may result 12 BR45 User Manual Always keep critical tool markings such as warning stickers and tags legible Do not force a small breaker to do the job of a large breaker Keep tool bit sharp for maximum breaker perfor mance 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 exces sive strain on the breaker foot Tool repair should be performed by experienced personnel only Make cert
27. 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 manual and ask for a Customer Service Representative STANLEY BR45 User Manual lt 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 NL ig 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
28. ranty 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
29. s The operator must be familiar with all prohibited work areas such as excessive slopes and danger ous terrain conditions e Establish a training program for all operators to en sure safe operation Do not operate the tool unless thoroughly trained or under the supervision of an instructor Always wear safety equipment such as goggles gloves ear head and breathing protection and safety shoes at all times when operating the tool Do not inspect carry or clean the tool while the hy draulic power source is connected Accidental en gagement of the tool can cause serious injury Supply hoses must have a minimum working pres sure rating of 2500 psi 175 bar e Be sure all hose connections are tight e hydraulic circuit control valve must be in the OFF position when coupling or uncoupling the tool Wipe all couplers clean before connecting Use only lint free cloths Failure to do so may result in dam age to the quick couplers and cause overheating of the hydraulic system STANLEY Do not operate the tool at oil temperatures above 140 F 60 C Operation at higher oil temperatures can cause operator discomfort and may damage the tool Never come in contact with the tool bit the bit can get hot Do not operate a damaged improperly adjusted or incompletely assembled tool Do not weld cut with an acetylene torch or hard face the tool bit To avoid personal injury or equipment dam
30. temperatures above 140 F 60 C Operation at higher temperatures can cause operator discomfort at the tool FILTER Min full flow filtration 25 microns 25 microns 25 microns 25 microns Sized for flow of at least 30 gpm 30 gpm 30 gpm 30 gpm For cold temp start up and max dirt holding 114 lpm 114 lpm 114 Ipm 114 Ipm Capacity HYDRAULIC FLUID 100 400 ssu 100 400 ssu 100 400 ssu 100 400 ssu Petroleum based 20 82 centistokes Premium grade anti wear non conductive VISCOSITY At min and max operating temps NOTE When choosing hydraulic fluid the expected oil temperature extremes that will be experienced in service determine the most suitable temperature viscosity characteristics Hydraulic fluids with a viscosity index over 140 will meet the requirements over a wide range of operating temperatures SSU Saybolt Seconds Universal 10 BR45 User Manual STANLEY OPERATION The recommended hose size is 500 inch 12 mm I D up to 50 15 m long and 625 inch 16 mm 1 0 minimum up to 100 ft 30 m PRE OPERATION PROCEDURES CHECK POWER SOURCE 1 Using a calibrated flowmeter and pressure gauge check that the hydraulic power source develops a flow of 7 9 gpm 26 34 Ipm at 1500 2000 psi 105 140 bar 2 Makecertain 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
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