Stanley Proto Industrial Tools BR89 User's Manual
Contents
1. 0092 unio 61 ve pue sjuauwsaumbal joo s oo Inep 06 06 006 00 0 6 S OL S H ajuejs uo juo joo S L 0092 ainssald QL 8 9 an 10 pasn aq s yeyo siy GLL 0092 u og QL 8 9 06 6 001 18 0 6 901 9 d S L 0092 u og el ZIL G dn 09 dn Or 6L SOL S oe 5 A 91960 97 0092 u og el ZIL 06 91 00 96 9 9 p ainssaid ul d y p pu lui suon S L 0092 u og OL 8 92 o dn Gz dn 9 9 p epu uuuuo5 1 9591 wdi Jed say SYOLINANO9 TVOI2119313 YVAN ISN LON OQ plejg 19014 10 pesg M wid6 194 uo paseq syjBue SSL 0922 OL 8 e 0 dn 0 dn ve SL 6 p sou JO asoy 39499 11 103 plesg 1 A 9npuoS uoN p p p pu uuuu0991 SMOYUS 10614 sul 1160 9 sul avg 193 uinjoy sseid WIN HONI SYL3IN 1333 Wd9 SUOIJEPUSWIWIOD9Y inss id BUIIOM UNA aSN 1919 16 syjbBua7 MO 5 NI o 991 HTMA REQUIREMENTS TOOL CATEGORY HYDRAULIC SYSTEM REQUIREMENTS TYPE FLOW RATE 4 6 gpm 15 23 2000 psi 145 155 bar 2100 2250 psi 145 155 bar 250 psi 17 bar TOOL OPERATING2. 04908 Flow Sleeve Installation L aa 04909 Flow Sleeve Removal nu 04910 16 gt BR89 User Manual STANLEY BR89 PARTS ILLUSTRATION STANLEY BR89 User Manual lt 17 BR89 PARTS LIST PART PART ITEM NO QTY DESCRIPTION TEM NO QTY DESCRIPTION 07973 1 BREAKER HANDLE ASSY 1381 2 FOOT BOLT INCL ITEMS 1 12 13831 1 ADAPTER BLOCK BREAKER HANDLE 04374 4 LOCKNUT ROLL PIN 12143 UPPER ANVIL STOP TRIGGER 1381 OMPRESSION COIL SPRING INCL ITEMS 47 57 amp 59 INCL ITEMS 47 57 amp 59 ACCUMULATOR ASSY INCL ITEMS 14 21 EX BUSHING 1 1 8 x 4 BR89120 EX BUSHING 1 1 4 x 4 BR89130 H ACCUMULATOR CYLINDER H RUBBER SLEEVE S O RING ACCUMULATOR DIAPHRAGM 56 PRING WASHER STOP NUT CHARGING VALVE 57 COMPRESSION COIL SPRING STICKER CAUTION 58 ACCUMULATOR CHAMBER 59 COMPRESSION COIL SPRING OUPLER FEMALE BACK UP WASHER O RING N 0404 0084 0405 0405 0405 0405 0029 0136 0407 0405 0546 22891 0954 0688 4 C A 1383 1383 13821 1382 0183 0174 08411 1382 1483 0126 0498 0498 1381 1890 0397 0397 a 0406 0405 0405 1018 0530 N 21 22 23 24 25 26 27 28 29 0530 1382 0405 0249 0406 2216 2411 0406 04571 0406 0406 0789 2216 1384 1382 0202 1385 3412 1383 0407 N o 46 44 4
3. 9 101199 1 10 SSOH e9Id 4 lt lt lt lt 1 RETURN BR89 User Manual 9 RETURN gt gt gt El 3YNSSTYUA HYDRAULIC CIRCUIT PRESSURE PRESSURE YN 2 F 2 x YN GLL 0092 uny 92 L 0 8 00 96 09 6 9l El GLL 0092 ainssald 6l vIe 97 0092 uny 6l vIe 8 0 dn 92 o dn 09 6 9 L S L 0082 inss iq 9 8 9 List Avs Aq 195 se 0082 voz JO jaau 5 21 09 06 002 001 6196 L OL SLL 00SZ 65 14 6 Bun s jonas SLL 005 Winey 61 IXBW y 61109 5 BunJom unuululuu 0052 rtss rd aL 8 9 09164 e 1959 jsnu SLL oosz 91 8 9 dn 09 0 41 61 96 0 suoneol jdde Aue 104 p sn aq jou
4. ROU 04176 1 1 4 IN HEX x 6 IN SHANK Asphalt Cutter 5 in Blade 11 in Long 02335 14 ima OMG UC 02336 3 inch Chisel 14 in Cong UC a aa aaa 02337 11160 Chisel Heavy Duty 14 11 Long UG uuu l 02338 Ground Rod Driver Wil RO ivi uuu u dic 04367 Moil Point Heavy Duty 16101 Long sby nka aver assay mamaka Sta 04404 Clay Spade 8 in 20 CM Blade uU LNS 04405 Asphalt Wed Etica iaa 08119 TEST EQUIPMENT Accumulator Tester oi 02835 Flow and Pressure Tester 04182 Accumulator Charge Kit Includes 02835 Tester 15304 Accumulator Charge Assy and 372047 31254 Accumulator Charge Assy Includes liquid filled gauge with valve hose and Charge Fitting 15304 UC denotes dimension measured from bottom tip of tool to bottom surface of collar SERVICE TOOLS Tool craic seed el vedas haart O Oban dye 04337 ocal Kit 14830 Accumulator Disassembly Tool uuu a notas E 05508 Accumulator Cylinder un a s aa 05640 23 asset u
5. ALL TIMES REPLACE DECALS IF THEY BECOME WORN OR DAMAGED REPLACEMENTS ARE AVAILABLE FROM YOUR LOCAL STANLEY DISTRIBUTOR 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 Caution Decal DANGER DANGER 1 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 2 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 ALEAK 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 PERSONAL INJURY D DO NOT LIFT OR CARRY TOOL BY THE HOSES DO NOT ABUSE HOSE DO NOT USE KINKED TORN OR DAMAGED
6. 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 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 BR89 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 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 DANGER which if not avoided will
7. age 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 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 BR89 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 hydr
8. 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 1 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 Observe all safety precautions Install the appropriate tool bit for the job Place the bit firmly on the surface to be broken 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 10 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 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
9. result in death or serious injury This safety alert and signal word indicate a potentially hazardous situation which if not avoided could result in death or serious injury This safety alert and signal word indicate a potentially hazardous situation which if not avoided could result in death or serious injury This signal word indicates a potentially hazardous situation which if not avoid ed may result in property damage This signal word indicates a situation which if not avoided will result in damage NOTICE to the equipment This signal word indicates a situation which if not avoided may result in dam IMPORTANT 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 A A DANGER 2 WARNING a CAUTION NOTICE IMPORTANT 4 gt BR89 User Manual STANLEY 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 r
10. 0 F 60 C max Check the relief valve setting Eliminate flow control devices Fluid leakage on tool bit Lower piston seal failure Replace seal Fluid leakage through charge Upper piston seal failure or Replace seals recharge or replace valve cap accumulator O ring failure or accumulator diaphragm accumulator charge loss or failure Fluid leakage around trigger Valve spool seal failure Replace seals STANLEY BR89 User Manual lt 13 CHARGING THE ACCUMULATOR ACCUMULATOR TESTING PROCEDURE To check or charge the accumulator the following equip ment is required 31254 Charge Kit which includes the following Accumulator Tester Part Number 02835 Charging Assembly P N 15304 includes a liquid filled gauge with snub valve hose and fit tings NITROGEN bottle with an 1000 psi 70 bar minimum charge Not included in 31254 Charge Kit This breaker contains nitrogen under pressure Remove the valve cap assembly from the breaker 2 Remove the protective cap and loosen the 5 8 inch hex locking nut on the tool charging valve 1 1 2 turns 3 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 4 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 h
11. 20 82 centistokes 25 microns 30 gpm 114 Ipm 100 400 ssu 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 BR89 User Manual OPERATION The recommended hose size is 500 inch 12 mm ID up to 50 ft 15 m long and 625 inch 16 mm ID minimum up to 100 ft 30 m PRE OPERATION PROCEDURES CHECK POWER SOURCE 1 Using a calibrated flowmeter and pressure gauge check that the hydraulic power source develops a flow of 7 9 gpm 26 34 lpm at 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 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
12. 5 as 49 52 53 55 6 se 59 ES El ES c al o N 00 ES 3 O O A O o 31 2 33 34 35 36 37 38 39 0 NJ Y 2 ooa i 1 _ s one _ o fuor o ons 1 _ 14 foses 46 fosos 1 _ e fioo i 21 osso 22 ias a Pza osso EMM 2 _ 25 ossa EME _ 27 2 osn gt 30 fos _ 32 omo 1 _ 3 2 1 _ 34 fe las ta 1 37 1 _ EME 39 ts 1 _ ao uo S 18 gt BR89 User Manual STANLEY 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
13. EXTRA BR89 HYDRAULIC BREAKER SAFETY OPERATION AND MAINTENANCE USER MANUAL ecker Inc New Britain CT 06053 TABLE OF CONTENTS SAFETY SYMBOLS uE uuu m a 4 SAFETY PRECAUTIONS Q aa dde aday da 5 TOOL STICKERS amp TAGS u u 7 HOSE TYPES a Waa G ag 8 HOSERECOMMENDATIO NA Sicuani 9 FIGURE 1 TYPICAL HOSE afecto 9 ATMA REQUIREMENT 10 OPERATION 11 TOOL PROTECTION amp u 12 TROUBLESHOOTING 13 CHARGING THE ACCUMULATOR iii 14 FIGURE 2 CHARGING THE ACCUNMULATOR u una Gs uay rinda do 15 SPECIFICATIONS A 16 ataa 16 TEST EQUIPMENT 16 SERVICE TOOLS uu ua cas tia aywana awa A AAA A 16 BR89 PARTS ILLUSTRATION cuca aa 17 BR39 PARTS qusqayki qaqa vie 18 IMPORTANT To fill out a Product
14. 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 SIDE 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 SIDE SAFETY TAG P N 15875 Shown smaller then actual size BR89 User Manual lt 7 HOSE TYPES The rated working press
15. IVE HOSE DANGER DANGER 1 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 ROSE FOR CUTS CRACKS LEAKS ABRASIONS BULGES OR DAM TING WITH A CLEAN DRY ABSORBENT CLOTH TO REMOVE DIRT AND MOISTURE AND AGE TO COUPLINGS IE ANY OF THESE CONDITIONS EXIST REPLACE THE HOSE TEST BOSE MAXIMUM Al TOWEBLE CURRENT LEAKAGE INACCORDANCE WITH IMMEDIATELY NEVER USE TAPE OR ANY DEVICE TO ATTEMPT TO MEND THE HOSE SAFETY DEPARTMENT INSTRUCTIONS AFTER EACH USE STORE IN A CLEAN DRY AREA FOR PROPER AND SAFE OPERATION MAKE SURE THAT YOU HAVE BEEN PROP ERLY TRAINED IN CORRECT PROCEDURES REQUIRED FOR WORK ON OR AROUND DO NOT REMOVE THIS TAG Ovl SIHL JAOWSY LON OG SEE OTHER SIDE SEE O
16. PRESSURE At the power supply outlet SYSTEM RELIEF VALVE SETTING At the power supply outlet MAXIMUM BACK PRESSURE At tool end of the return hose 400 ssu 82 centistokes Measured at a max fluid viscosity 01 At min operating temperature 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 bar pasat TYPE 7 9 gpm 26 34 Ipm 2000 psi 138 bar 2100 2250 psi 145 155 bar 250 psi 17 bar 400 ssu 82 centistokes TYPE Ill 11 13 gpm 42 49 Ipm 2000 psi 138 bar 2100 2250 psi 145 155 bar 250 psi 17 bar 400 ssu 82 centistokes TYPE RR 9 10 5 34 40 Ipm 2000 psi 138 bar 2200 2300 psi 145 155 bar 250 psi 17 bar 400 ssu 82 centistokes Do not operate the tool at oil temperatures above 140 F 60 C Operation at higher temperatures can cause operator discomfort at the tool FILTER Min full flow filtration Sized for flow of at least For cold temp start up and max dirt holding capacity HYDRAULIC FLUID Petroleum based Premium grade anti wear non conductive VISCOSITY At min and max operating temps NOTE 25 microns 30 gpm 114 Ipm 100 400 ssu 25 microns 30 gpm 114 Ipm 100 400 ssu 25 microns 30 gpm 114 Ipm 100 400 ssu
17. THER SIDE SIDE 1 SIDE 2 Shown smaller than actual size THE TAG SHOWN BELOW IS ATTACHED TO CONDUCTIVE HOSE DANGER DANGER DO NOT USE THIS HYDRAULIC HOSE ON OR NEAR ELECTRIC LINES THIS HOSE IS 5 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 FOR PROPER AND SAFE OPERATION MAKE SURE THAT YOU HAVE BEEN PROPERLY 6 AFTER EACH USE STORE IN A CLEAN DRY AREA TRAINED IN CORRECT PROCEDURES REQUIRED FOR WORK ON OR AROUND ELEC TRIC LINES DO NOT EXCEED HOSE WORKING PRESSURE OR ABUSE HOSE IMPROPER USE OR HANDLING OF HOSE COULD RESULT IN BURST OR OTHER HOSE FAILURE KEEP HOSE AS FAR AWAY AS POSSIBLE FROM BODY AND DO NOT PERMIT 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 Ce 5566 OTHER SIDE SaaS SSS SEE OTHER SIDE SIDE 1 SIDE 2 Shown smaller than actual size 8 BR89 User Manual STANLEY DO NOT REMOVE THIS TAG SIHL LON OG
18. and tighten only 5 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 700 900 psi 48 62 bar 6 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 procedure 7 Tighten the 5 8 inch hex locking nut on the tool charging valve Be careful not to overtighten Install the protective cap and valve cap assembly 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 14 gt BR89 User Manual and connect the charging assembly chuck directly to the charging valve 3 Adjust the regulator to the charging pressure of 800 psi 55 bar NOTE lt may be necessary to set the gauge at 850 900 psi 59 62 bar to overcome any pressure drop through the charging system 4 Open the valve on the charging assembly hose 5 When the accumulator is fully charged close the valve on the charging assembly hose and remove the charging assembly chuck from the accumulator tester or tool charging valve 6 If the accumulator tester has been used be sure to turn the gauge end fully counterclo
19. aulic 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 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 gt BR89 User Manual TOOL STICKERS amp TAGS Stanley Hydraulic Tools Division of The Stanley Works 3810 S E Naef Road Milwaukie Oregon 97267 U S A 148 6848 10180 13842 BR89 Name Decal NOTE THE INFORMATION LISTED ON THE STICKERS SHOWN MUST BE LEGIBLE AT
20. ckwise before re moving the tester from the charging valve of the tool 7 Tighten the 5 8 inch hex locking nut on the tool charging valve and replace the protective cap 8 Replace the valve cap assembly GENERAL SERVICE NOTES 1 If the breaker is repainted after servicing be sure to mask off the vent in the valve cap assembly Do not allow paint to enter the IN and OUT ports or the bore of the foot assembly 2 Ifthe handle grips need to be replaced a Remove the old grips and clean the handle b Wash the new grips and the handle clean and dry simply push or drive the grips on DO NOT lubricate the parts The grips will not be secure on the handle if any grease or oil is used 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 Dip or spray the entire tool Cycle the tool hydraulically several times before storing away STANLEY CHARGING THE ACCUMULATOR Liquid filled gauge with snub valve Nitrogen tank not included in kit Charge fitting 02835 Tester 15304 Accumulator Charge Ass
21. elating to the specific work area and local safety regulations If so place the added precautions in the space provided in this manual The BR89 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 ers The operator must be familiar with all prohibited work areas such as excessive slopes and danger ous terrain conditions 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 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 dam
22. 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 Sticking 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 BR89 User Manual 11 TOOL PROTECTION amp CARE 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 con nection The hydraulic circuit control valve must be in the OFF position when coupling or uncoupling hydraulic tools Failure to do so may result in damage to the quick couples and cause overheating of the hydrau lic 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 n
23. nspect for automatic valve damaged parts Tool does not hit effectively Power unit not functioning Check power unit for proper flow and pressure 7 9 gpm 26 34 lpm 1500 2000 psi 105 140 bar Low accumulator charge pressure Recharge accumulator Replace hose will pulse more than normal diaphragm if charge loss continues Fluid too hot above 140 F 60 C Provide cooler to maintain proper fluid temperature 130 F 55 C The collar support is not sliding Remove clean and replace as required freely in the foot bore Make sure hex bushing is in the proper location Tool operates slow Low gpm supply from power unit Check power unit for proper flow 7 9 gpm 26 34 Ipm High back pressure Check hydraulic system for excessive back pressure over 250 psi 17 bar Orifice plug blocked Fluid too hot above 140 F 60 C Check power unit for proper fluid or too cold below 60 F 16 C temperature Bypass cooler to warm the fluid or provide cooler to maintain proper temperature The collar support is not sliding Remove clean and replace as required freely in the foot bore Make sure hex bushing is in the proper location Relief valve set too low Adjust relief valve to 2100 2250 psi 145 155 bar Tool gets hot 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 14
24. ot 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 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 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 12 gt BR89 User Manual TROUBLESHOOTING PROBLEM CAUSE SOLUTION Tool does not run Power unit not functioning Check power unit for proper flow and pressure 9 gpm 26 34 Ipm 1500 2000 psi 105 140 bar Pressure and return line hoses Be sure hoses are connected to their reversed at ports proper ports Mechanical failure of piston or Disassemble breaker and i
25. ure 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 tag immediately A new tag may be obtained from your Stanley Distributor THE TAG SHOWN BELOW IS ATTACHED TO CERTIFIED NON CONDUCT
26. y includes liquid filled gauge with snub valve hose and charge fitting 31254 Accumulator Charge Kit includes everything pictured except nitrogen tank and includes a 372047 box TESTER CHARGING ACCUMULATOR TESTER P N 02835 LOCATION OF CHARGING VALVE Figure 2 Charging the Accumulator STANLEY BR89 User Manual lt 15 SPECIFICATIONS Range siii 1500 2000 psi 105 140 bar Flow Range 7 9 gpm 26 34 lpm Optimum FIOW 8 gpm 30 Maximum Back Pressure iia a da ida dina 250 psi 17 bar Connect Size amp Type 3 8 in Male Pipe Hose Ends We yka qha 80 165 36 kg MOM GUN uuu i unu 29 in 73 5 cm VV ll 16 in 40 cm System u Z Z L mu Open or Closed Center HTMA Type II SAE 8 O ring ACCESSORIES 1 1 8 IN HEX x 6 IN SHANK Moil Point Long AA AAA 02333 Chisel Point 14 Long UC u LL L 03990 3 inch Chisel 141 Long UC wand 02334 Clay Spade 5 1 2 02331 Asphalt Cutter 5 im Blade ia odios 02332 Asphalt late 08106 Ground Rod Driven Iin
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