MB05 User Manual 9-2010 V-1.indb
Contents
1. PROPER USE OF TOOL BITS PROPER USE AND CARE 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 PRYING This is the most common cause of tool failure Even when there is no surface damage the stress from prying 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 reposition material The tool should not be used as a pivot point when repositioning the carrier The power generated by the carrier will far exceed the strength of the tool Similar failures can also occur when the steel is used with extreme down pressure and the steel repeatedly slips off the work at an angle or the material itself moves from under the working steel As the illustration below shows fatigue failures take many forms but they all exhibit similar features Generally the broken surface is brittle and has a lip like that in the bend ing failure even though in some cases the lip has been broken CORROSION Tools should be greased and stored out of the weather Cor rosion 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 jus2. 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 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 2 USER MANUAL STANLEY SAFETY SYMBOLS Safety symbols and signal words as shown below are used to emphasize all operator maintenance and repair actions which if not strictly followed could result in a life threatening situation bodily injury or damage to equip ment This is the safety alert symbol It is used to alert you to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death This safety alert and signal word indicate an imminently hazardous situa A DANGER tion which if not avoided will result in death or serious injury This safety alert and signal word indicate a potentially hazardous situation which if not avoided could result in death or serious injury This safety alert and signal word indicate a potentially hazardous situation which if not avoided may result in minor or moderate injury This signal word indicates a potentially hazardous situation which if not avoided may result in property damage This signal word indic
3. TROUBLESHOOTING This section describes how to find and resolve problems users may experience If a 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 of the tool always check that the hydraulic power source is supplying the correct hydraulic flow and pressure to the tool as listed in the table below Use a flowmeter known to be accurate Check the flow with the hydraulic oil temperature at least 80 F 27 C PROBLEM CAUSE SOLUTION Low hydraulic oil level No flow to breaker Have hydraulic circuit tested by T authorized dealer distributor per Breaker will not fire O oan approved procedure infernal Garage Have unit serviced by an authorized JS dealer distributor Damaged quick couplers Low hydraulic flow Have hydraulic circuit tested by an authorized dealer distributor per Excessive heat build up Breaker runs slowly approved procedure Excessive nitrogren pressure Have unit serviced by an authorized Internal leakage dealer distributor Low or excessive back pressure Dama
4. 2 650 in 67 3 mm 2 760 in 70 1 mm TOOL STOP Item 31 Wear Areas A 2 650 in 67 3 mm A 2 760 in 70 1 mm p 77 Inside Diameter Inside Diameter C Measure at 1 2in 30mm C B 400 in 10 1 mm Depth B 280 in 7 1 mm Depth TOOL STOP RETAINER PIN Item 35 Measure Diameter 1 595 in 40 5 mm 1 510 in 38 3 mm Outside Diameter Outside Diameter RETAINER PIN PISTON Item 18 450 in 11 4 mm Depth 410 in 10 4 mm Wear Limit New Part PISTON IMPORTANT LOWER BUSHING To increase the life of the lower bushing remove the bushing after normal wear has developed and rotate the bushing 90 and lock into the second slot Normal wear on the bushing is usually found from front to back by rotating the bushing 90 will add additional life to the KV bushing In addition to rotating the bushing it is also symmetrical and can be flipped end 90 SLOT ROTATION to end and again rotated 90 resulting in even longer life TOOL STOP To increase the life of the tool stop remove the tool stop after normal wear has developed and rotate the tool stop 90 and lock into the second slot Note the tool stop is not symmetrical and can not be flipped from end to end STANLEY USER MANUAL lt 47 PROPER USE OF TOOL BITS Tool bits are made and heat treated to specification Tool bits however well made are wear parts and are used
5. NITROGEN 200 PSI DECAL CE SPECIFICATION EN L1 DECAL GREASE 1 C amp P027 MOUNTING BRKT USER MANUAL 29 MB05S02 SKID STEER MOUNTING BRACKET PARTNO QTY 70983 CRADLE ASSEMBLY INCLUDES ITEMS 14 thru 16 23 24 and 30 thru 32 13 14 15 16 22 23 24 30 31 32 30 USER MANUAL 3 3 MB05S04 C8 P027 TOP SKID STEER NON SKID 2 X 9 DECAL STANLEY USER MANUAL 31 MB05S05 SKID STEER XCHANGE TOP 70769 MB05S05 70768 MBO5E05 32 gt USER MANUAL USER MANUAL lt 33 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 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
6. 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 operation of the attachment By pass flow equals inlet flow to the valve minus the regulated flow The hydraulic line s which supply pressurized oil from the pump to the valve or tool The hydraulic line which 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 or operation SPECIFICATIONS Impact Energy Class ft Ib 500 Length Excavator with inch 53 J 680 Tool 1350 Blows Per Minute 650 1550 Tool Diameter Flow Range gpm 10 22 67 lom 38 83 Tool Working Length Hydraulic Operating psi 1500 2000 381 Pressure bar 100 140 Main Accumulator 200 10 System Relief Pressure Si 3000 Charge Pressure bar 13 8 0 7 206 m m m Carrier Size Skidsteer 4500 7000 Hose Diameter min ich 3 4 kg 2043 3178 m 19 Carrier Size Excavator 5000 8000 Adapter fitting size and Male JIC 37 Flare k 2270 3632 type 1 1 16x12 UNF Carrier Size Backhoe 6000 11000 Weight Skid Steer with lb 810
7. Record the stabilized oil temperature F Record the ambient temperature F The heat rise is calculated as the stabilized temperature minus the ambient temperature STANLEY FLOW TEST PROCEDURES 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 connections that are part of the attachment kit 2 Ensure proper voltage to the valve s 3 Ensure the REG port of the valve is not blocked 4 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 5 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 USER MANUAL lt 23 DEFINITION OF TERMS Tool Operating Pressure Relief Pressure Back Pressure Flow Meter Restrictor Valve V60 V65 V100 Valves Inlet Flow Regulated Flow By P
8. This is by far the most popular working steel It is a general purpose point used to break anything from concrete to hard rock lts pencil type point is used to fracture the material The tool is best where penetration speed is important CHISEL This style of point is used generally used for trench work where a controlled break is reguired 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 guickly but not cause a fracture 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 breaking irregularly shaped material where its broad tip makes it easier to position USER MANUAL lt 21 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 eguipment 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 con nect the flow meter between the tool inlet and outlet hoses NOTE Always us
9. is stable Never leave the machine with the engine running ALWAYS ENGAGE THE PARKING BRAKE Stop the engine before attempting to make any repairs adjustments or servicing to either the carrier or the breaker Do not operate the tool at oil temperatures above 190 F 88 C Operation at higher temperatures can damage the internal components of the breaker and carrier and will result in reduced breaker performance Do not operate a damaged leaking improperly adjusted 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 manufacturer 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 medication which may affect your mental judgement or physical performance Do not operate this equipment if you are under the influence of drugs or alcohol 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 c
10. 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 10 USER MANUAL EXCAVATORS With the breaker tool in place on the material to be worked position the excavator so the dipper is at approximately 45 and the breaker is almost vertical The tracks of the excavator should be in line with the boom and the breaker Apply down force 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 On flat material or rock the breaker should be vertical or curled back slightly to direct the impact force downward 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 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 STANLEY OPERATION occur within this time move the breaker to another position On flat material such as concrete runways starting to break in the middle of the material may cause vibrations to be transmitted throughout
11. tool bit against the ground and then putting down pressure on the breaker See the illustrations below Grease This Area of Bit 250 mm 10 in Grease ku OPERATION Greasing the tool bit without down pressure on the breaker results in grease filling the space between the piston and the toolbit 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 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 system Piston in Down Position at engine idle until hydraulic lines are warm to the Against Tool Bit touch 2 With the carrier at idle and the breaker suspended in the air or with minimal down pressure turn on the breaker to gradually warm up its internal components Z Lower Bushing M 3 When the hydraulic system and breaker are warm ja Tool Bit proceed with operation Tool Stop LONG TERM STORAGE Grease Will Fill Piston not against 1 Remove the tool bit clean the tool stop and the lower This Space Tool Bit leaving space bushing Thoroughly coat the surfaces of the tool stop the Piston and and the lower bushing with grease Tool Stop 2 If hoses ar
12. HE WORK MATERIRAL haa ron kitlid paides hjaamad dadada 10 MAINTAN DOWN PRESSURE LU uuu usu Susszsasasukasssp sssusssssssnespanansaaassakiqassssanatusshasu nssCatassastakastasasspasqanlansncassassapasaqhssamussa 11 BREAKING nt 11 BLANES FIRIN 000 00009 ii a 12 UNDERWATER USAGE P data iii eee ee eee ere seas 13 GREASE TAE e samay 13 TROUBLE SHOCTUIN Eat eee re 14 vx iiie c aaa a a eae tu a e 15 PAIEEMAINTENANGEGHEGKS ee jaa aima alaalia ta ajama rusos efec 15 TOOL SFOP AND LOWER BUSH CAMA ua O 15 CRARGING THE ASCUMULA TO bee 16 WEAR TOLERANCE 000 oga la 2 2 a n s pl 17 PROPER USE AND CARE OF TOOL BITS stare 18 PEOV TESTE PROCEDURES saa la ai aada alia 22 TROUBLESHOOTNG 202 oo ll ooo 23 siu ese TERMS c 24 14491951 25 o A 26 MBOS POWER GEL IUS TRATION C A 27 MBOS POWER CEB PARTS EST 0 200 oo 06 0 ia 28 MB05 HOUSING ILLUSTRATION 8 PARTS LIST MBO5E04 8 MB05E05 BRACKETS nnn 29 MB05502 SKID STEER MOUNTING BRACKE spice cita 30 M505504 68027 TOP SKID O TEE p M ee ee 31 MB05505 SKID STEER CHANGE TOP uuu u u i naa eee lt eee ee 32 NOTES RR
13. MBOS MOUNTED HYDRAULIC BREAKER SAFETY OPERATION AND MAINTENANCE USER S MANUAL Stanley Hydraulic Tools 2009 OPS MAINT USA CE Printed in U S A 70795 9 2010 Ver 1 TABLE OF CONTENTS SAFET MBOES aaa n a ls 1 em al a eee 3 OA a 4 POOESTIORENS S Wocos 7 OPERAMON a a ll a i a a e 8 PRE INSTALLATION INSTRUCTIONS eee 8 BACKHOE OR EXCAVATOR Pcr 8 EXISTING EQUIPMENT HYDRAULICS VS APPLICATION ATTACHING KITS a rss 8 LEST TAREA DRAE SYSTEM cor aaa al DM ME 8 PRE OPERATMON PROCEDURES ti al iai 8 V RA Cim ET incre amp 8 TGOLB LUBRICACI N 1 9 8 SE CURING THE TOOL s a a ee re aaa 9 LOW TEMPERATURE WARM UP PROCEDURE maaala kus Na 9 LONG TERM STORAGE uuu aaa 9 OPERA CR i mi E ai ii taa H 10 PREFARATION POP USE en muu mmm i a aaa aa aa a a 10 POSITIOBIBG THE CARRIER st parooli S 10 POSITIONING THE BREAKER TOOL ON T
14. ancer or death Respiratory protection is highly recommended when working with materials containing Silica Dust Always wear a respirator approved for protection against crystalline silica Refer to the Parts Illustration page in this manual for proper placement of stickers 70753 Model Number Sticker of Global Components 66764 Made in USA Sticker 70752 Stanley Logo Sticker TOOL STICKERS amp TAGS G N 66218 Sound Power Sticker 70754 Nitrogen Sticker 200 PSI 47352 Lift Point Sticker 70756 CE Specification Plate To avoid serious injury or death Wear Eye Protection Wear Dust Mask 47351 Composite Warning Sticker 72074 Grease Sticker USER MANUAL 7 OPERATION PRE INSTALLATION INSTRUCTIONS CARRIER SIZE Check the Specifications section of this manual to determine correct carrier size hydraulic flow and pressure requirements If hydraulic pressure hydraulic back pressure hydraulic flow or excavator 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 pluoging into the hydraulic system without confirming pressure and flow to the hydraul
15. ass Flow Pressure Line Return Line Cracking Pressure Full Open Pressure Ambient Air Temperature Stabilized Temperature 24 USER MANUAL The hydraulic attachment which 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 outside 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 circuit The data usually available from this device are pressure psi bar flow gom 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 function properly if another control function is activated The hydraulic oil supplied to the
16. ates a situation which if not avoided will result in NOTICE damage to the equipment This signal word indicates a situation which if not avoided may result in IM PO RTANT damage to the equipment A A DANGER a WARNING A CAUTION CAUTIOR NOTICE IMPORTANT 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 USER MANUAL 3 SAFETY PRECAUTIONS SERVICING THE STANLEY HYDRAULIC breaker This manual contains safety operation and routine maintenance instructions Servicing of hydraulic tools other than routine maintenance must be performed by an authorized and certified dealer Please read the following warning 4 USER MANUAL 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 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 Read the Manual e 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 eguip
17. ckwise to advance the plunger until a pressure is indicated on the gauge Do not overtighten Upper Accumulator 16 USER MANUAL 5 Ifthe pressure is correct unscrew the gauge to retract the plunger Then loosen and remove the tester from the charge valve If the pressure is not correct proceed to step number 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 assembly 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 200 psi 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 Nitrogen Bottle locally obtained CHARGE PRESSURE SPECIFICATION Upper Accumulator 200 PSI 10 PSI 13 7 BAR 7 BAR Charge Hose Assembly Part No 505232 Includes Gauge Valve Hose and Charge Valve Adpater Tester Part No 28257 WEAR TOLERANCES LOWER BUSHING Item 32 Measure at Center
18. e attached to the breaker install plugs on the hose ends If hoses are removed from the breaker install Lower Bushing plugs on the hose ends and install 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 Tool Bit SECURING THE TOOL BIT 1 The tool retainer is shipped installed in the breaker 2 Remove the stop pin and plug 3 Drive out the tool retainer 4 Grease the top area of the tool bit as shown in the illustration on page 9 5 Install the tool bit making sure the notch is aligned with the lower body retainer pin holes 6 Install the tool retainers STANLEY USER MANUAL lt 9 OPERATION OPERATING THE BREAKER PREPARATION FOR USE Read the section in this manual titled Pre Operation Procedures before operating a breaker Failure to follow the preparation instructions can result in severe damage to the breaker and carrier and void the warranties of both POSITIONING THE CARRIER BACKHOES With the breaker tool in place on the material to be worked 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 Apply down force to the boom dipper until the rear of the backhoe is raised off the ground Rear tires and stabilizers should be off
19. e attachment and three times the back pressure Never use the relief valve to control the flow rate in the circuit Cracking pressure means the loss of 4 or more GPM Record the relief cracking pressure psi Example Operation pressure of a breaker is 2700 psi Back pressure is 150 psi A good rule to follow when setting the relief multiply the back pressure by 3 then add this number to the operation pressure of the attachment Operating Pressure 2700 psi Back pressure 450 psi Operating pressure of the tool 3150 psi The relief valve setting must be greater than the estimated 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 attachment and carrier HEAT LOAD TEST 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 restrict 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 ambient temperature Record the time required to stabilize minutes
20. e the hoses that are supplied for the attach ment and make sure the machine hydraulic oil is be tween 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 not exceed 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 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 specification section in the manual Adjust attachment relief to specification 22 gt USER MANUAL NOTE The relief valve pressure must be greater than the op erating pressure of th
21. face 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 Excessive 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 absorbed by the retaining pins other breaker components and the carrier boom components Blank Firing of this type can be experienced in trench work where obtaining 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 slippage 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 stri
22. ge 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 20 USER MANUAL Failures in this area are usually the result of blank firing worn bushing s worn retainer 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 corrosion 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 are usually the result of heat build up mushrooming or improper contact with the work PROPER 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
23. ged switch or connection Have carrier serviced by an authorized Relief set too low dealer distributor Breaker runs erratically Internal damage Add grease to tool shank Do not pry IO Med while operating Low accumulator charge Breaker runs but at reduced power Excessive back pressure Relief set too low Breaker leaks oil around tool bit and l Have unit serviced by an authorized l Lower seals failed p tool bushing dealer distributor Main relief set low Insufficient cooling capability in hydraulic Hydraulic system overheats Have unit serviced by an authorized dealer distributor Line hose size too small Excessive back pressure Have unit serviced by an authorized dealer distributor 14 USER MANUAL MAINTENANCE DAILY MAINTENANCE CHECKS Check for loose or missing fasteners Tighten or replace as needed Inspect tool retaining pins and pockets for wear 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 work day TOOL STOP AND LOWER BUSHING Inspect the tool stop and lower bushing for excessive galling and metal pickup on the tool bit Also check for cracks If cracks are present the part must be replaced The extent of wear of the tool stop and lower bushings and the tool bit can be checked by moving a NEW tool bit back and forth and measuri
24. harge Kit Assembly Includes p n 505232 28257 and 372047 Charge Kit Box 34892 acere Vin Plz iio PP Ret 28257 Service Kit For Rebuild MB556 656 856 956 10 a a A anna na nain rris snas nnn ensis 40373 26 USER MANUAL lt j lt x Y l l Li x uj p EA N N Y lt Z lt EE LLI 0 MBOS POWER CELL PARTS LIST SEAL KIT 70984 DESIGNATES PARTS INCLUDED EE 19095 IN SEAL KIT 22980 RETAINER SPRING 8 22993 TIE ROD WASHER 24 eosar 1 VALVE SLEEVE as 60849 1 VAVECAP OC OOO SOSS 26 69860 1 UPPERACCUMULATOR 27 69862 1 MAIN BODY ASSY NOLUDES ITEMS 24 38 840 T 69855 1 LOWER BODY ASSY INCLUDES ITEMS 3 4 7 00 34 39 4 s 69856 1 LOWERBODY ooo ar eesse 1 BUSHNG ToOLSTOP 2 69859 1 BUSHING LOWERTOOL 28 USER MANUAL f I I I MBO5 HOUSING PARTS ILLUSTRATION 70768 MB05E05 DESCRIPTION ADAPTER ATY 20 2 DECAL STANLEY E PART ITEM NO 70753 70754 70766 MB05E04 QTY DESCRIPTION 2 DECAL MB05 DECAL
25. hat solid blows are not occurring and breaker should be repositioned 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 penetration The time used for additional penetration could be better used to strike blows in another place Many materials do not respond well to continued hammering in one place The breaker tool should be repositioned on the work each time the tool penetrates but does not crack the material STANLEY Do not break continuously in one place 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 striking the rock or concrete at several places along a 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 USER MANUAL lt 11 OPERATION Breaker tool binding can cause erratic breaker operati
26. ic tool is not a good prac tice Spare spool valves dipper circuits etc are just a few examples of easily accessible hydraulic 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 systems of many popular carriers If your equipment does not contain an attaching kit ask your Stanley dealer for information installation and pricing on a kit which matches your eguipment 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 ratings 2 Be sure the fluid in the hydraulic system is clean 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 8 gt USER MANUAL 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 250 mm 10 in of the breaker tool bit before 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
27. 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 determine 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 failure 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 hammer 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 WORN OUT 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 partic
28. k 2724 4994 kg 368 Ib Tool Weight Excavator with 480 Tool k 218 TOROUE TABLE m m m p min cracking bar Sound Power Level LW Oil Temperature Max F 190 C 88 g g g Power del Charge vahe Loemaa Power dell HolowHexPhg iZSAE Loctte 202 25 Powerco VaveCap KoprKoew 9 Powerco Pug koprkoem s cradle Na KerKwew 60 _ Tighten in a cross pattern and thread tie rod into lower body by hand use Kopr Kote anti sieze on tie rod threads and the underside of the tie rod flange Coat both sides or ID OD with Kopr Kote anti sieze Use Loctite M to prevent plug from falling out If plug falls out the housing will fill with grease The power cell must be removed to repair NOTE Weights dimensions and operating specifications listed on this sheet are subject to change with out notice Where specifications are critical to your application please consult the dealer C USER MANUAL lt 25 A u eee E E elad aasa Part No Tool Bits Sole A i 69863 CHIS e GI60SS Gljuu mmm m umu O O O O a saus 69864 QU NBI o a E m i sa 69865 Pl 2 ignore O SSS SSS SS SS ee SUE Da 69866 A x u uum PE gece OP Pee E eee OOP Dn PPD ee eee 69867 Miscellaneous jaaa Bro DE eS IEEE mmm Consult Dealer Charge Hose Assembly Includes Valve and Hose for Nitrogen Tank 8 Charge Valve Connections 505232 C
29. ke 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 absorbed by breaker components and excavator boom components Blank Firing of this type can be experienced 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 OPERATION UNDERWATER USAGE Underwater usage of the breaker will cause damage to internal components Even ifthe 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 components DO NOT USE UNDERWATER No part of the breaker may be submerged in 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 breaker tool bit each time it is installed Thereafter the tool should be greased al the fitting to reduce wear in the lower body and bushings of the tool See Greasing The Tool Bit in the sections titted Pre Operation Procedures USER MANUAL lt 13
30. ment must be used A flying projectile from the breaker breaker tool rock or other material may cause Wear Breathing Serious or fatal injury to bystanders Never Protection operate the breaker when bystanders are in the work area breaks loose and swings toward the operator Make sure that suitable impact shields are used when operating the Wear Hearing breaker with this type of eguipment Protection On some machines carriers the breaker can enter the operator s compartment if it 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 Otal Wear Eye Distributor Protection When operating the breaker you must use ear protection eye protection and breathing protection SAFETY PRECAUTIONS Tool operators and maintenance personnel must always comply with the safety A WARNING precautions given in this manual and on the stickers and tags attached to the tool and hose To avoid serious injury or death These safety precautions are given for your safety Review them carefully before operat p ing the tool and before performing general maintenance or repairs LU h A Supervising personnel should develop additional precautions relating to the specific work area and local safety regulatio
31. ng the gap between the 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 repalce the tool bit or the lower bushing individually as this will result in premature wear of the replaced component It is recommended to repalce ALL worn components o 5 xN 1 4 in max Pd Move the tool bit back and forth and measure the gap between tool bit and lower bushing Use a new tool bit USER MANUAL 4 15 CHARGING THE ACCUMULATOR The tools required to charge the breaker accumulators are the 505232 charge hose assy and the 28257 accumulator tester which are used with other Stanley model breakers When charging the accumulators make sure the tools and charge valves are clean Dirt can contaminate the charge valves and cause leakage 1 Remove the protective plug from the accumulator charge valve NOTE There is one accumulator on this breaker the upper accumulator 2 Holdthe 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 turn ing 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 clo
32. ns If so place the added precautions in the space pro Read the Manual Header od vided in this manual The MB05 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 result in personal injury or equipment damage Wear Ear Pretection 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 Operator training must start in an area without bystanders 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 THE WORK CONDITIONS e The operator must know any prohibited uses or work areas for the machine For example excessive slopes and poor or dangerous terrain conditions must be avoided OBEY SAFETY RULES e Operate the breaker in accordance with all laws and regulations which affect you your equipment and the worksite Do not operate the breaker until you have read this manual and thoroughly understand all safety operation and maintenance instructions e The operator must be familiar with all prohibited w
33. on 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 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 binding 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 by the rebar after the concrete has been broken The best approach to this problem is to use a chisel point tool which permits cutting the rebar with the breaker Another method is to periodically cut the rebar with an oxy acetylene torch 12 USER MANUAL BLANK FIRING To understand Blank Firing the operator needs to be 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 sur
34. ork areas such as excessive slopes and dangerous terrain conditions e Do not operate the breaker until you have read the carrier equipment manual and thoroughly understand all safety operation and maintenance instructions The word carrier as used in this manual means a backhoe or excavator or similiar equipment used to operate the breaker Ensure that all maintenance procedures recommended 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 equipment e Know the limits of your equipment Establish a training program for all operators to ensure safe operation SAFETY PRECAUTIONS Do not operate the tool unless thoroughly trained or under the supervision of an instructor 6 USER MANUAL Become familiar with the carrier controls before operating the carrier and the breaker When operating the breaker you must use ear protection 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
35. t 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 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 USER MANUAL lt 19 PROPER USE 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 imperfec tion in the internal material flaw grain The result is an inherent weakness in the tool shank and eventual breakage The fatigue failure is started by the defects within the tool bit The broken surface exhibits a shell pattern around 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 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 Look for surface cracks galling or gouge marks Breaks that start as surface dama
36. 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 neces sary Not enough down pressure results in low production and accelerates wear and tear on the equipment 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 effort to follow the breaker with down pressure 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 t
37. ular area of the tool This can also cause the tool to bind inside the hammer Call your dealer for acceptable wear allowances Worn out retainer pin s will cause uneven loading on the 18 USER MANUAL pin s themselves causing failure of the tool or retainer 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 ever 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 when 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
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