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BR40
HYDRAULIC
BREAKER
Safety , OtiO pera n and Maintenance
US M er U an L a
© 2011 Stanley Black & Decker, Inc.
New Britain, CT 06053
U.S.A.
62399 2/2011 Ver. 6
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DECLARATION OF CONFORMITY DECLARATION OF CONFORMITY ÜBEREINSTIMMUNGS-ERKLARUNG DECLARATION DE CONFORMITE CEE Hydraulic Tools DECLARACION DE CONFORMIDAD DICHIARAzIONE DI CONFORMITA ______________________________________________________________________ I, the undersigned: Weisbeck, Andy Ich, der Unterzeichnende: Je soussigné: Surname and First names/Familiennname und Vornamen/Nom et prénom/Nombre y apellido/Cognome e nome El abajo firmante: lo sottoscritto: hereby declare that t
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TABLE OF CONTENTS DECLARATION OF CONFORMITY ..........................................................................................................................2 SAFETY SYMBOLS ..................................................................................................................................................4 SAFETY PRECAUTIONS ..........................................................................................................................................5 TOOL STICK
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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 si
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SAFETY PRECAUTIONS Tool operators and maintenance personnel must always • The hydraulic circuit control valve must be in the comply with the safety precautions given in this manual OFF position when coupling or uncoupling the tool. and on the stickers and tags attached to the tool and Wipe all couplers clean before connecting. use only hose. lint-free cloths. Failure to do so may result in dam- age to the quick couplers and cause overheating of These safety precautions are given for your saf
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SAFETY PRECAUTIONS • Warning: Hydraulic fluid under pressure could cause • Never use the tool in an explosive atmosphere, skin injection injury. If you are injured by hydraulic sparks from the breaking process could ignite ex- fluid, get medical attention immediately. plosive gas. • Keep all body parts away from the working tool. • Use proper lifting techniques when handling the tool, get help from a co-worker and do not over-reach. • Always wear personal protection equipment (PPE) such as go
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TOOL STICKERS & TAGS Stanley Hydraulic tools division of the Stanley Works 3810 SE Naef Road Milwaukie, OR 97267 05152 Stanley Decal 28374 Name Tag (BR40568YA) 28409 Composite Decal 12835 (CE Tool only) Name Tag (BR40550) 71072 CE Tool Plate 58601 11206 Sound Level Circuit Type C Decal Decal (CE Tool only) (CE Tool only) NOTE: DANGER DANGER THE INFORMATION LISTED on THe STiCKeRS SHoWn, 1. FAILURE TO USE HYDRAULIC HOSE LABELED AND CER- D. DO NOT LIFT OR CARRY TOOL BY THE HOSES. DO MUST B
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DO NOT REMOVE THIS TAG DO NOT REMOVE THIS TAG HOSE TYPES The rated working pressure of the hydraulic hose must be equal to or higher than the relief valve setting on the hy- draulic system. There are three types of hydraulic hose that meet this requirement and are authorized for use with Stanley Hydraulic Tools. They are: Certified non-conductive — constructed of thermoplastic or synthetic rubber inner tube, synthetic fiber braid reinforcement, and weather resistant thermoplastic or synthetic
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HOSE RECOMMENDATIONS BR40 User Manual ◄ 9 Tool to Hydraulic Circuit Hose Oil Flow Hose Lengths Inside Diameter Min. w orking Pressure USE (Press/Return) Recommendations GPM LPM FEET METERS INCH MM PSI BAR Certified Non-Conductive Hose - Fiber Braid - for Utility Bucket Trucks The chart to the right shows recommended minimum hose diameters for various hose 4-9 15-34 up to 10 up to 3 3/8 10 Both 2250 155 lengths based on gallons per minute (gpm)/ Conductive Hose - Wire Braid or Fiber Braid -DO N
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HTMA REQUIREMENTS TOOL CATEGORY HYDRAULIC SYSTEM REQUIREMENTS TYPE I TYPE II TYPE III TYPE RR FloW Ra Te 4–6 gpm 7–9 gpm 11–13 gpm 9–10.5 gpm (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) (145–155 bar) (138 bar) (138 bar) (138 bar) SYSTEM RELIEF VALVE SETTING 2100–2250 psi 2100–2250 psi 2100–2250 psi 2200–2300 psi (At the power supply outlet) (145–155 bar) (145–155 bar) (145–155 bar) (145–155 bar) MAXIMU
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OPERATION The recommended hose size is .500 inch/12 mm I.D. up NOTE: to 50 ft/15 m long and .625 inch/16 mm I.D. minimum up Partially depressing the trigger allows the tool to run to 100 ft/30 m. at slow speed. Slow-speed operation permits easier starting of the tool bit into the work surface. PRE-OPERATION PROCEDURES 5. To start, break an opening (hole) in the center of the CHECK POWER SOURCE surface. After making a hole, break portions of the 1. using a calibrated flowmeter and pressure g
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TOOL PROTECTION & 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 con- • Always keep critical tool markings, such as warning nection. stickers and tags legible. • The hydraulic circuit control valve must be in the • Do not force a small breaker to do the job of a large OFF position when coupling or uncoupling hydrau- breaker. lic tools. Failure to do so may result
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TROUBLESHOOTING PROBLEM CAUSE REMEDY Tool does not run. Power unit not functioning. Check power unit for proper flow and pressure (4–6 gpm/15–23 lpm, 1300– 2000 psi/90–140 bar. Couplers or hoses blocked. Remove restriction. 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 inspect for automatic valve. damaged parts. Tool does not hit effectively. Power unit not functioning. Check power u
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CHARGING THE ACCUMULATOR ACCUMULATOR TESTING ACCUMULATOR CHARGING PROCEDURE 1. Perform Steps 1 through 4 of the accumulator test- ing procedure above. To check or charge the accumulator the following equip- ment is required: 2. Connect the chuck of the charging assembly to the charging valve on the accumulator tester or, if pre- • 31254 Charge Kit: which includes the following. ferred, remove the tester from the charging valve – Accumulator Tester (Part Number 02835). and connect the charging
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CHARGING THE ACCUMULATOR Charging the Accumulator (BR40 with Anti-Vibration Handles) TESTER CHARGING CW VALVE CHUCK GAUGE ACCUMULATOR TESTER ( P/N 02835 ) LOCATION OF CHARGING VALVE Figure 2 Figure 2. Charging the Accumulator (BR40 with Anti-Vibration Handles) Liquid Filled Gauge w/Snub Valve Charge Fitting Nitrogen Tank (Not included in Kit) Charging Valve 31254 ACCUMULATOR CHARGE KIT Includes: Liquid Filled Gauge w/Snub Valve, Hose, Charge Fitting, 02835 Tester, and Box (not pictured) Hose Ga
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SPECIFICATIONS Pressure Range................................................................................................................ 1300–2000 psi/90–140 bar Flow Range ................................................................................................................................. 4–6 gpm/15–23 lpm Optimum Flow ....................................................................................................................................... 5 gpm/20 lpm Maximum Back
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BR40 T-HANDLE PARTS ILLUSTRATION BR40 User Manual ◄ 17
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BR40 T-HANDLE PARTS LIST PART PART ITEM NO. QTY DESCRIPTION ITEM NO. QTY DESCRIPTION 1 03971 1 COUPLER SET 47 04780 1 BaCK-uP WaSHeR 2 — — NO ITEM 48 04386 4 CUP SEAL 3 02900 2 ROLL PIN 49 04373 1 SIDE ROD 4 01652 2 ALTERNATE HOSE ASSY. – 12 INCH. 50 — — NO ITEM 5 12832 1 ORIFICE PLUG 51 04394 1 LATCH* 6 01605 2 o-Ring (inCl W/ iTem 4) 52 04716 1 SPRing WaSHeR* 7 04058 1 SPRING 53 04717 1 FOOT LATCH BOLT* 8 04077 1 VALVE SPOOL 54 04715 2 RUBBER SLEEVE* 9 04057 1 BUSHING 55 04392 1 SPRING* 07699
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BR40 PARTS BR40 ANTI-VIBRATION HANDLE PARTS ILLUSTRATION BR40 User Manual ◄ 19
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BR40 PARTS LIST BR40 ANTI-VIBRATION HANDLE PARTS LIST PART PART ITEM NO. QTY DESCRIPTION ITEM NO. QTY DESCRIPTION 1 03971 1 COUPLER SET 49 04382 1 AUTOMATIC VALVE 2 — — NO ITEM 50 05152 1 STANLEY DECAL 3 02900 2 ROLL PIN 51 28374 1 BR40 MODEL NUMBER DECAL 4 01652 2 HOSE ASSEMBLY, 12 INCH 52 04383 1 FloW SleeVe TuBe 5 — — NO ITEM 53 07477 1 HEX BUSHING * 6 01605 2 o-Ring (inCl WiTH iTem 4) 54 04374 1 STOP NUT * 7 04058 1 SPRING 55 07445 1 BReaKeR FooT WiTH inSeRT aSSY 8 20515 1 VALVE SPOOL 56 02
