BR37 User Manual 10-2009.indb
Contents
1. DINNEIP H 01 00 REQUIREMENTS TOOL CATEGORY HYDRAULIC SYSTEM REQUIREMENTS TYPE TYPE lll TYPE RR FLOW RATE 4 6 11 13 gom 9 10 5 gom 15 23 lpm 26 34 lpm 42 49 lpm 34 40 lpm TOOL OPERATING PRESSURE 2000 psi 2000 psi 2000 psi 2000 psi at the power supply outlet 138 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 152 159 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 TEMPERATURE Sufficient heat rejection capacity 82 centistokes 82 centistokes 82 centistokes 82 centistokes 140 60 to limit fluid temperature to at max expected ambient temperature Min cooling capacity 3hp 5 hp 7 hp 6 hp at a temperature difference of 2 24 kW 3 73 kW 4 47 kW 5 22 kW between ambient and fluid temps 40 F 40 F 40 F 40 F 22 C 22 C 22 C 22 C NOTE Do not operate the tool at oil temperatures above 140 F 60 Operation at higher temperatures can cause operator discomfort at the tool FILTER 25 microns 25 microns 25 microns 25 microns Min full flow filtration 30 gpm 30 gpm 30 gpm 30 gpm Size2. STICKERS amp TAGS Please refer to the Parts lllustration for location of stickers Stanley Hydraulic tools Division of the Stanley Works 3810 SE Naef Road Milwaukie 97267 05152 Stanley Decal The safety tag p n 15875 at right 15 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 28382 BR37 1 FAILURE TO USE HYDRAULIC HOSE LABELED AND CERTIFIED 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 CURRENT LEAKAGE IN ACCORDANCE WITH YOUR SAFETY DEPART MENT INSTRUCTIONS 2 AHYDRAULIC LEAK OR BURST MAY CAUSE OIL INJECTION INTO THE BODY OR CAUSE OTHER SEVERE PERSONAL INJURY A DO 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 A LEAK 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 PERSONA
3. E O O DVL SIHL JAONAG LON OQ 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 NOT LABELED OR CERTIFIED AS NON CONDUCTIVE USING THIS HOSE ON OR NEAR 5 CHECK ENTIRE HOSE FOR CUTS CRACKS LEAKS ABRASIONS BULGES OR DAMAGE TO ELECTRICAL LINES MAY RESULT IN DEATH OR SERIOUS INJURY COUPLINGS IF ANY OF THESE CONDITIONS EXIST REPLACE THE HOSE IMMEDIATELY FOR PROPER AND SAFE OPERATION MAKE SURE THAT YOU HAVE BEEN ite TRAINED IN CORRECT PROCEDURES REQUIRED FOR WORK ON OR AROU 6 AFTER EACH USE STORE IN A CLEAN DRY AREA NEVER USE TAPE OR ANY DEVICE TO ATTEMPT TO MEND THE HOSE DO NOT EXCEED HOSE WORKING PRESSURE OR ABUSE HOSE ia OR HANDLING OF HOSE COULD RESULT IN BURST On OTHER HOSE FAILUR HOSE AS FAR AWAY AS POSSIBLE FROM BODY AND PERMIT DIRECT CONTACT DURING USE CONTASI AT THE BURST CAN CAUSE BODILY INJECTION AND SEVERE PERSONAL INJURY 4 HANDLE AND ROUTE HOSE CAREFULLY TO AVOID KINKING CUTTING OR CONTACT WITH HIGH TEMPERATURE SURFACES DO NOT USE IF KINKED DO NOT USE HOSE TO PULL OR LIFT TOOLS POWER UNITS ETC DVL SIHL AAOWSY LON OG O lt kE kE gt gt E O OTHER SIDE shown smaller than actual size HYDRAULIC CIRCUIT RETURN PRESSURE Je9Id L 1 5
4. Accumulator Charge Kit Includes 02835 tester 15304 charge assy and 372047 charge kit DOX 31254 Service Tools TOO eee dat 01120 SO a a a TEE 04595 Flow Sleeve Removal TUDO ___ _________ _ ____ _____ 6 04910 Flow Sleeve Removal cat 04919 Acumulator Cylinder Ulla bd 05640 al AMADO BR37 PARTS ILLUSTRATION A A D BR37 PARTS LIST Coupler Set No ltem Roll Pin Alternate Hose Assy 12 inch Washer O Ring Included with Item 4 Spring Valve Spool Bushing Bushing Assy Includes Items 9 thru 12 O Ring 11 16 x 7 8 x 3 82 O Ring 5 16 x 7 16 x 1 16 Rod Wiper Plug Charge Valve Handle Grip Handle Spirol Pin 1 4 x 1 No Item No Item No Item Locknut 5 8 18 Trigger Accumulator Diaphragm Piston No Item No Item Push Pin Accumulator Valve Block Flow Sleeve No Item Capscrew 1 2 13 NC x 5 1 2 HSH No Item Back Up Ring O Ring 2 9 16 x 2 3 4 x 3 32 Porting Block Automatic Valve Body Push Pin Automatic Valve Stanley Sticker GPMSticker Name BR37 Flow Sleeve Tube 18 Hex Bushing Lock Nut Breaker Foot O Ring 2 1 4 x 2 1 2 x 1 8
5. BR3 HYDRAULIC BREAKER SAFETY OPERATION AND MAINTENANCE USER S MANUAL Stanley Hydraulic Tools 2004 OPS MAINT USA GE Printed in U S A 05414 10 2009 ver 2 Read the Manual Wear your PPE TABLE OF CONTENTS oy am a ate MB Sons 4 SAE GAU TON St 5 G TA ies 7 HYDRAULIC HOSE REQUIREMENTS casacas 8 ATI RECUIREMBENTS aii 10 OPERANIN 11 FRE DPERAMON PROCEDURE __ _ __ 11 REO POWER SOUADE naman eae 11 ai a ran sais 11 CONNEC ora rain E ts 11 COLD WEATHER OPERATION ii _ _ _____ 11 EQUIPMENT PROTECTION amp CARE rad 12 TROUBLE GROC 13 CHARGING THE ACCUMULA TOR A SS ARA 14 156 6 Sources A R E AR 16 AOGESSORIE G coito ER ENSEST ERR la 16 HANDLE PARTO ILLUSTRATION a RA A 17 BR37 _________ _ _____ 18 WARNAN ___ _____________________ ____ 19 SERVICING THE STANLEY HYDRAULIC breaker This manual contains safety operation and routine maintenance instructions Stanley Hydraulic Tools recommends that servicing of hydraulic tools other than routine maintenance must be performed by an authorized and certified dealer Please read the fol lowing warning SERIOUS INJURY OR DEATH COULD RESULT FROM TH
6. Rod Wiper Back Up Washer Cup Seal Side Rod No Item Latch Spring Washer Foot Latch Bolt Rubber Sleeve Spring Detent Part of Breaker Foot Assembly ASSEMBLIES 04388 Breaker Foot Assy 7 8 in Hex BR37110 Includes 42 48 amp 51 56 BR37110 Includes 9 12 Bushing Assembly SEAL KIT PART NUMBER 04595 WARRANTY Stanley Hydraulic Tools 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 expire
7. Fluid leakage around trigger Valve spool seal failure Replace seals CHARGING THE ACCUMULATOR ACCUMULATOR TESTING PROCEDURE To check or charge the accumulator the following equipment is required 31254 Charge Kit which includes the following Accumulator Tester Part Number 02835 Charging Assembly Part Number 15304 15304 includes a liquid filled gauge w snub valve hose and fittings e NITROGEN bottle with an 800 psi 55 bar minimum charge Not included in 31254 kit This assembly contains nitrogen under pressure 1 Remove the plug from the handle or handle pivot 2 Holding the chuck end of Accumulator Tester Part Number 02835 turn the gauge fully counterclockwise to ensure that the stem inside the chuck is completely retracted 3 Thread the tester onto the accumulator charging valve Do not advance the gauge end into the chuck end Turn as a unit Seat the chuck on the accumulator charging valve and hand tighten only 4 Advance the valve stem of the tester by turning the gauge end clockwise until a pressure is read on the gauge charge pressure should be 500 700 psi 34 48 bar 5 If pressure is OK unscrew the gauge end from the chuck to 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 ACCUMULATOR CHARGING 1 Perform steps 1 through 4 of t
8. ob tained from your Stanley Distributor THE TAG SHOWN BELOW IS ATTACHED TO CERTIFIED NON CONDUCTIVE HOSE 1 FAILURE TO USE HYDRAULIC HOSE LABELED AND CERTIFIED AS NON CONDUCTIVE 3 DO NOT EXCEED HOSE WORKING PRESSURE OR ABUSE HOSE IMPROPER USE OR WHEN USING HYDRAULIC TOOLS ON OR NEAR ELECTRIC LINES MAYRESULT IN DEATH HANDLING OF HOSE COULD RESULT IN BURST OR OTHER HOSE FAILURE KEEP OR SERIOUS INJURY HOSE AS FAR AWAY AS POSSIBLE FROM BODY AND DO NOT PERMIT DIRECT CONTACT FOR PROPER AND SAFE OPERATION MAKE SURE THAT YOU HAVE BEEN PROPERLY DURING USE CONTACT AT THE BURST CAN CAUSE BODILY INJECTION AND SEVERE TRAINED IN CORRECT PROCEDURES REQUIRED FOR WORK ON OR AROUND PERSONAL INJURY INES CINES 4 HANDLE AND ROUTE HOSE CAREFULLY TO AVOID KINKING ABRASION CUTTING OR BEFORE USING HYDRAULIC HOSE LABELED AND CERTIFIED AS NON CONDUCTIVE ON Cece NOT USE IF KINKED 5 OR NEAR ELECTRIC LINES WIPE THE ENTIRE LENGTH OF THE HOSE AND FITTING WITH A CLEAN DRY ABSORBENT CLOTH TO REMOVE DIRT AND MOSISTURE AND TEST 5 CHECK ENTIRE HOSE FOR CUTS CRACKS LEAKS ABRASIONS BULGES OR DAMAGE TO HOSE FOR MAXIMUM ALLOWABLE CURRENT LEAKAGE IN ACCORDANCE WITH SAFETY COUPLINGS IF ANY OF THESE CONDITIONS EXIST REPLACE THE HOSE IMMEDIATELY DEPARTMENT INSTRUCTIONS NEVER USE TAPE OR ANY DEVICE TO ATTEMPT TO MEND THE HOSE 6 AFTER USE STORE IN A CLEAN DRY AREA O lt E 2 gt gt
9. the quick couplers 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 1 72 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 Always keep critical tool markings such as warning stickers and tags legible Do not force a small breaker to do the job of a large breaker Keep tool bit sharp for maximum breaker performance Make sure that tool bits are not chipped or rounded on the striking end Never operate a breaker without a tool bit or without holding it against the work surface This puts excessive strain on the breaker foot Tool repair should be performed by experienced personnel only Make certain that the recommended relief valves are installed in the pressure side of the system Do not use the tool for applications for which it was not intended TROUBLESHOOTING PROBLEM CAUSE REMEDY Tool does not run Powe
10. word indicates a situation which if not avoided may result in damage to the equipment Always observe safety symbols They are included for your safety and for the protection of the tool LOCAL SAFETY REGULATIONS Enter any local safety regulations here Keep these instructions in an area accessible to the operator and mainte nance personnel SAFETY PRECAUTIONS Tool operators and maintenance personnel must always comply with the safety pre cautions given in this manual and on the stickers and tags attached to the tool and hose To avoid serious injury or death These safety precautions are given for your safety Review them carefully before operating the tool and before performing general maintenance or repairs Supervising personnel should develop additional precautions relating to the specific work area and local safety regulations If so place the added precautions in the space provided in this manual The BR37 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 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 t
11. 5 1 lt lt lt MOT MO 14 gt gt gt 09 08 erae 1 54010 9 1 21410313 YVAN ASN LON OG 06 0 006 00 Ob 6l 901 9 19914 10 311M SOH SA9NAL 1949N9 ALIN 20 1914 2 55 PRESSURE AWS Aq yuo 195 se 10945 pas9xa 15 LU IS S onespAy y jenba pele e 1sea ye aney 15 asoy Aue pasn jou p noys pue 51001 ajue s uo juo 100 JO pasn aq s yeyo 514 100 ajgeidaoo9e e desy 95941 an UIW 199 s 1a11 uwdb Jad paseq 10 SJ JALUBIP IUILU SMOUS ay yeyo 941
12. E IM PROPER REPAIR OR SERVICE OF THIS TOOL REPAIRS AND OR SERVICE TO THIS TOOL MUST ONLY BE DONE BY AN AUTHORIZED AND CERTIFIED DEALER For the nearest authorized and certified dealer call Stanley Hydraulic Tools at the number listed on the back of this manual and ask for a Customer Service Representative 3 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 A DANGER NOTICE IMPORTANT This is the safety alert symbol It is used to alert you to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death This safety alert and signal word indicate an imminently hazardous situa tion which if not avoided will result in death or serious injury This safety alert and signal word indicate a potentially hazardous situation which if not avoided could result in death or serious injury This safety alert and signal word indicate a potentially hazardous situation which if not avoided may result in minor or moderate injury This signal word indicates a potentially hazardous situation which if not avoided may result in property damage This signal word indicates a situation which if not avoided will result in damage to the equipment This signal
13. L INJURY 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 OPERA TION MANUAL TAG TO BE REMOVED ONLY BY TOOL OPERATOR SEE OTHER SIDE 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 CONNECTED TO THE TOOL BEFORE PRESSURING SYSTEM SYSTEM PRESSURE HOSE MUST ALWAYS BE CONNECTED TO TOOL IN PORT SYSTEM RETURN HOSE MUST ALWAYS BE CONNECTED TO TOOL OUT PORT REVERSING CONNEC TIONS MAY CAUSE REVERSE TOOL OPERATION WHICH CAN RESULT IN SEVERE PERSONAL INJURY DO NOT CONNECT OPEN CENTER TOOLS TO CLOSED CEN TER 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 PROTEC TION 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 OPERA TION MANUAL TAG TO BE REMOVED ONLY BY TOOL OPERATOR SEE OTHER SIDE SAFETY TAG
14. P N 15875 shown smaller then actual size 7 TOOL HOSE INFORMATION HOSE TYPES The rated working pressure of the hydraulic hose must be equal to or higher than the relief valve setting on the hydraulic 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 rein forcement 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 reinforcement and weather resistant synthetic rubber cover This hose is conductive and must never be used near electrical conduc tors Fabric braided not certified or labeled non conductive constructed of thermoplastic or synthetic rubber inner 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 lf the information on a tag is illegible because of wear or damage replace the tag immediately A new tag may be
15. ________ 1500 2000 psi 105 140 bar FOW AO o UR UE O 7 9 gpm 26 34 Ipm A 8 gpm 30 Ipm Maximum Back Press operation 250 17 bar A Flush Face Per T3 20 15 ISO 16028 Connect Size A in A 3 8 in Male Pipe Hose Ends e o AE E A T Handle 37 Ibs 17 kg ON SRA A I AGS SA 6 T Handle 22 5 in 57 Overall Width at SS ceo sees D T Handle 14 in 35 Max 140 60 o c IR Open Genter AU REGN SAE 8 O ring o Sn 7 9 1500 2000 psi ACCESSORIES Tools Glay Spade 16 SEM 02328 38 170 mMm ___________ __ 02330 111 291 concreto ER PR cogio 07704 Asphalt Gutter 5 in 12 7 cm Blade x 11 in 27 9 UIC ansans na ida ia 02341 MOI POTS IA IAS 7 04401 Moose 04961 ADA Dover o IMM si sans a a onerous 05255 UC Denotes the under collar dimension measured from bottom tip of tool to bottom surface of collar Test Equipment Accumulator Charge Assembly incl Liquid Filled Gauge w Valve Hose 8 Charge 15304 NOT TOS 02835 Fow dnd Pressure TOS nn la did fkn si 04182
16. 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 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 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 explosive 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 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 re
17. d for flow of at least 114 lpm 114 lpm 114 lpm 114 lpm For cold temp startup and max dirt holding 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 require ments over a wide range of operating temperatures SSU Saybolt Seconds Universal NOTE These are general hydraulic system requirements See tool Specification page for tool specific requirements 10 OPERATION The recommended hose size is 500 inch 12 mm 1 0 up to 50 ft 15 m long and 625 inch 16 mm 1 0 minimum up to 100 ft 30 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 gom 26 34 lpm at 1500 2000 psi 105 140 bar 2 Make certain the hydraulic power source is equipped with a relief valve set to open at 2100 2250 psi 145 155 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 Wi
18. he accumulator testing pro cedure above 2 Connect the chuck of the charging assembly to the charg ing valve on the accumulator tester or if preferred remove the tester from the charging valve and connect the charging assembly chuck directly to the charging valve 3 Adjust the snub valve to a charging pressure of 600 psi 42 bar Note While watching the pressure gauge open snub valve slowly until it reaches the proper charge pressure 600 700 psi NOTE It may be necessary to set the gauge at 650 700 psi 45 48 bar to overcome any pressure drop through the charg ing system 4 When the accumulator is fully charged close the snub valve on the charging assembly hose and remove the charging as sembly chuck from the accumulator tester or tool charging valve 5 If the accumulator tester has been used be sure to turn the gauge end fully counterclockwise before removing the tester from the charging valve of the tool Install the valve cap CHARGING THE ACCUMULATOR Liquid Filled Gauge w Snub Valve Charge Fitting Nitrogen Tank Not included in Kit Charging Valve 31254 ACCUMULAT R CHARGE Includes Liquid Filled Gauge w Snub Valve Hose Charge Fitting J02835 Tester Box not pictured 02835 TESTER Chuck TESTER CHARGING VALVE LOCATION OF CHARGING VALVE ACCUMULATOR TESTER P N 02835 Figure 2 SPECIFICATIONS ____ _____
19. pe 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 con nect return hoses first and disconnect them last to minimize or avoid trapped pressure within the tool 3 Observe flow indicators stamped on hose couplers to ensure that fluid flow is in the proper direction The female coupler on the tool hose is the inlet coupler 4 Move the hydraulic circuit control valve to the ON position to operate the tool NOTE lf 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 to gether OPERATION PROCEDURES 1 Observe all safety precautions 2 Install the appropriate tool bit for the job 11 3 Place the bit firmly on the surface to be broken 4 Squeeze the trigger to start the breaker Adequate down pressure is very important When the tool bit breaks through the obstruction or becomes bound release the trigger and reposition the tool bit NOTE Partially depressing the trigger allows the tool to run at slow speed Slow speed operation permits easier starting of the tool bit into the work surface 5 To start break an opening hole in the center of the surface After making a hole break portions of the material into the original opening For best productivity the breaking
20. r unit not functioning Check power unit for porer flow and pressure 9 gpm 26 34 lom 1500 2000 psi 105 140 bar Pressure and return line hoses reversed Be sure hoses are connected to their proper ports at ports Mechanical failure of piston or automatic Disassemble breaker and inpsect for damaged parts valve Tool does not hit effectively Power unit not functioning Check power unit for porer flow and pressure 7 9 gpm 26 34 lom 1500 2000 psi 105 140 bar Low accumulator charge pressure hose will Recharge accumulator Replace diaphragm if charge pulse more than normal loss continues Fluid too hot above 140 F 60 C Provide cooler to maintain proper fluid temperature 140 60 Tool operates slow Check power unit for proper flow 9 gpm 26 34 lpm over 200 psi 14 bar Fluid too hot above 140 F 60 C or too cold Check power unit for proper fluid temperature Bypass below 60 F 16 C cooler to warm the fluid or provide cooler to maintain proper temperature Relief valve set too low Adjust relief valve to 2100 2250 psi 145 155 bar 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 Tool gets hot 140 F 60 C max Check the relief valve setting Eliminate flow control devices Fluid leakage on tool bit Lower piston seal failure Replace seal
21. raining program for all operators to ensure safe operation Do not operate the tool unless thoroughly trained or under the supervision of an instructor Always wear safety equipment such as goggles 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 hydraulic power source is connected Accidental engagement of the tool can Cause serious injury Supply hoses must have a minimum working pressure rating of 2500 psi 175 bar Be sure all hose connections are tight The hydraulic circuit control valve must be in the OFF position when coupling or uncoupling the tool Wipe all couplers clean before connecting Use only lint free cloths Failure to do so may result in damage to the quick couplers and cause overheating of the hydraulic system Do not operate the tool at oil temperatures above 140 F 60 C Operation at higher oil temperatures can cause operator discomfort and may damage the tool 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 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
22. s 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 parts which are not approved for warranty credit will be the responsibility of the individual SEALS amp DIAPHRAGMS Seals and diaphragms installed in new tools are warranted to be free of defects in material and or workmanship for a period of 6 months after the date of first usage or for a period of 2 years from the shipping date from Stanley whichever period expires first CUTTING ACCESSORIES Cutting accessories such as breaker tool bits are warranted to be free of defects in material and or 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 s
23. should be done around the original hole The size of the broken material will vary with the strength and thickness of the base material and the amount of any reinforcement wire or rebar Harder material or more reinforcing wire or rebar will require taking smaller bites To determine the most effective bite start with 2 in 50 mm or smaller bites Bites can then be gradually increased until the broken piece becomes too large requiring increased time to break off the piece Sticking of the tool bit occurs when too large a bite is being taken and the tool bit hammers into the material without the material fracturing This causes the tool bit to become trapped in the surrounding material COLD WEATHER OPERATION If the breaker is to be used during cold weather preheat the hydraulic fluid at low engine speed When using the normally recommended fluid fluid temperature should be at or above 50 F 10 400 ssu 82 centistokes before use Damage to the hydraulic system or breaker can result from use with fluid that is too viscous or thick 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 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
24. sult of breaking drilling or hammering of rock concrete asphalt or other materi als 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 To reduce silica exposure Use proper engineering controls to reduce the amount of silica in the air and the build up of dust on equipment and surfaces Examples of such controls include exhaust ventilation and dust collection systems water sprays and wet drilling Make sure that controls are properly installed and maintained Wear maintain and correctly use approved particulate respirators when engineering controls alone are not adequate to reduce exposure below permissible levels Participate in air monitoring medical exams and training programs offered by your employer and when required by law Wear washable or disposable protective clothes at the worksite shower and change into clean clothes before leaving the worksite to reduce exposure of silica to yourself other persons cars homes and other areas Do not eat drink or use tobacco products in areas where there is dust containing crystalline silica Wash your hands and face before eating drinking or using tobacco products outside of the exposure area Work with your employer to reduce silica exposure at your worksite
25. tter 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 REGISTRATION IS ON RECORD In the event a warranty claim is submitted and no tool registration is on record no warranty credit will be issued without first receiving documentation which proves the sale of the tool or the tools first date of usage The term DOCUMENTATION as used in this paragraph is defined as a bill of sale or letter of intent from the first retail customer 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 fitness for a particular purpose except for that provided herein There is no other warranty This warranty gives the purchaser specific legal rights and other rights may be available which might vary depending upon applicable law 19 Stanley Hydraulic Tools 3810 SE Naef Road Milwaukie Oregon 503 659 5660 Fax 503 652 1780 www stanleyhydraulic com
26. uch as tool bushings retaining pins wear plates bumpers retaining rings and plugs rubber bushings recoil springs etc INCIDENTAL CONSEQUENTIAL DAMAGES To the fullest extent permitted by applicable law in no event will STANLEY be liable for any incidental consequential or special damages and or expenses FREIGHT DAMAGE Damage caused by improper storage or freight handling LOSS TIME Loss of operating time to the user while the tool s is out of service IMPROPER OPERATION Any failure or performance deficiency attributable to a failure to follow the guidelines and or procedures as outlined in the tool s operation and maintenance manual MAINTENANCE Any failure or performance deficiency attributable to not maintaining the tool s in good operating condition as outlined in the Operation and Maintenance Manual HYDRAULIC PRESSURE amp FLOW HEAT TYPE OF FLUID Any failure or performance deficiency attributable to excess hydraulic pressure excess hydraulic back pres sure 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 ma
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