Stanley Hardware Automobile Parts Br40 User Manual

BR40  
HYDRAULIC  
BREAKER  
Safety, OperatiOn and Maintenance  
USer ManUaL  
© 2011 Stanley Black & Decker, Inc.  
New Britain, CT 06053  
U.S.A.  
62399 2/2011 Ver. 6  
TABLE OF CONTENTS  
DECLARATION OF CONFORMITY..........................................................................................................................2  
IMPORTANT  
To ll out a Product Warranty Recording form, and for information on your warranty,  
visit Stanleyhydraulic.com and select the Warranty tab.  
(NOTE: The warranty recording form must be submitted to validate the warranty).  
SERVICING THE STANLEY HYDRAULIC BREAKER. This manual contains safety, operation, and routine mainte-  
nance instructions. Stanley Hydraulic Tools recommends that servicing of hydraulic tools, other than routine main-  
tenance, must be performed by an authorized and certified dealer. Please read the following warning.  
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.  
BR40 User Manual ◄ 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  
which, if not avoided, will result in death or serious injury.  
DANGER  
WARNING  
CAUTION  
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.  
CAUTION  
NOTICE  
This signal word indicates a situation which, if not avoided, will result in damage  
to the equipment.  
This signal word indicates a situation which, if not avoided, may result in dam-  
age to the equipment.  
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.  
4 ► BR40 User Manual  
 
SAFETY PRECAUTIONS  
Tool operators and maintenance personnel must always  
comply with the safety precautions given in this manual  
and on the stickers and tags attached to the tool and  
hose.  
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-  
age to the quick couplers and cause overheating of  
the hydraulic system.  
These safety precautions are given for your safety. Re-  
view them carefully before operating the tool and before  
performing general maintenance or repairs.  
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.  
Supervising personnel should develop additional pre-  
cautions relating to the specific work area and local  
safety regulations. If so, place the added precautions in  
the space provided in this manual.  
Do not operate a damaged, improperly adjusted, or  
incompletely assembled tool.  
The BR40 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.  
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.  
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.  
Always replace parts with replacement parts recom-  
mended by Stanley Hydraulic Tools.  
Check fastener tightness often and before each use  
daily.  
Establish a training program for all operators to en-  
sure safe operation.  
Never operate the tool if you cannot be sure that  
underground utilities are not present.  
Do not operate the tool unless thoroughly trained or  
under the supervision of an instructor.  
do not wear loose fitting clothing when operating the  
tool.  
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.  
BR40 User Manual ◄ 5  
 
SAFETY PRECAUTIONS  
Warning: Hydraulic fluid under pressure could cause  
skin injection injury. If you are injured by hydraulic  
fluid, get medical attention immediately.  
Never use the tool in an explosive atmosphere,  
sparks from the breaking process could ignite ex-  
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 goggles, safety shoes, head, eye, breath-  
ing, and ear protection when operating the tool. Use  
gloves and aprons when necessary.  
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.  
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.  
WARNING  
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 ► BR40 User Manual  
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  
(CE Tool only)  
12835  
Name Tag (BR40550)  
71072  
CE Tool Plate  
58601  
11206  
Sound Level  
Decal  
Circuit Type C Decal  
(CE Tool only)  
(CE Tool only)  
NOTE:  
D A N G E R  
D A N G E R  
THE INFORMATION LISTED  
on THe STiCKeRS SHoWn,  
MUST BE LEGIBLE AT ALL  
TIMES.  
1. FAILURE TO USE HYDRAULIC HOSE LABELED AND CER-  
D. DO NOT LIFT OR CARRY TOOL BY THE HOSES. DO  
NOT ABUSE HOSE. DO NOT USE KINKED, TORN OR  
DAMAGED HOSE.  
TiFied aS non-ConduCTiVe WHen uSing HYdRauliC  
TOOLS ON OR NEAR ELECTRICAL LINES MAY RESULT IN  
DEATH OR SERIOUS INJURY.  
3. 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.  
BEFORE USING HOSE LABELEDAND CERTIFIEDAS 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.  
REPLACE DECALS IF  
THeY BeCome WoRn oR  
DAMAGED. REPLACEMENTS  
ARE AVAILABLE FROM  
YOUR LOCAL STANLEY  
DISTRIBUTOR.  
2. A HYDRAULIC LEAK OR BURST MAY CAUSE OIL INJEC-  
TION INTO THE BODY OR CAUSE OTHER SEVERE  
PERSONAL INJURY.  
4. DO NOT CONNECT OPEN-CENTER TOOLS TO CLOSED-  
CENTER HYDRAULIC SYSTEMS. THIS MAY RESULT IN  
loSS oF oTHeR HYdRauliC FunCTionS PoWeRed BY  
THE SAME SYSTEMAND/OR SEVERE PERSONAL INJURY.  
A. DO NOT eXCeed SPeCiFied FloW and PReSSuRe  
FoR THiS Tool. eXCeSS FloW oR PReSSuRe maY  
CAUSE A LEAK OR BURST.  
5. BYSTandeRS maY Be inJuRed in YouR WoRK aRea.  
KeeP BYSTandeRS CleaR oF YouR WoRK aRea.  
B. DO NOT eXCeed RaTed WoRKing PReSSuRe oF  
HYdRauliC HoSe uSed WiTH THiS Tool. eXCeSS  
PRESSURE MAY CAUSE A LEAK OR BURST.  
6. WeaR HeaRing, eYe, FooT, Hand and Head PRo-  
TECTION.  
7. TO AVOID PERSONAL INJURY OR EQUIPMENT DAMAGE,  
ALL TOOL REPAIR MAINTENANCE AND SERVICE MUST  
ONLY BE PERFORMED BY AUTHORIZED AND PROPERLY  
TRAINED PERSONNEL.  
C. 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.  
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.  
I M P O R T A N T  
I M P O R T A N T  
READ OPERATION MANUAL AND  
SAFETY INSTRUCTIONS FOR THIS  
TOOL BEFORE USING IT.  
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.  
USE ONLY PARTS AND REPAIR  
PROCEDURES APPROVED BY  
STANLEY AND DESCRIBED IN THE  
OPERATION MANUAL.  
TAG TO BE REMOVED ONLY BY  
TAG TO BE REMOVED ONLY BY  
TOOL OPERATOR.  
TOOL OPERATOR.  
SEE OTHER SIDE  
SEE OTHER SIDE  
SAFETY TAG P/N 15875 (Shown smaller then actual size)  
BR40 User Manual ◄ 7  
 
HOSE TYPES  
The rated working pressure of the hydraulic hose must be equal to or higher than the relief valve setting on the hy-  
draulic system. There are three types of hydraulic hose that meet this requirement and are authorized for use with  
Stanley Hydraulic Tools. They are:  
Certified non-conductive — constructed of thermoplastic or synthetic rubber inner tube, synthetic fiber braid  
reinforcement, and weather resistant thermoplastic or synthetic rubber cover. Hose labeled certified non-  
conductive is the only hose authorized for use near electrical conductors.  
Wire-braided (conductive) — constructed of synthetic rubber inner tube, single or double wire braid reinforce-  
ment, and weather resistant synthetic rubber cover. This hose is conductive and must never be used near  
electrical conductors.  
Fabric-braided (not certified or labeled non-conductive) — constructed of thermoplastic or synthetic rubber in-  
ner tube, synthetic fiber braid reinforcement, and weather resistant thermoplastic or synthetic rubber cover. This  
hose is not certified non-conductive and must never be used near electrical conductors.  
HOSE SAFETY TAGS  
To help ensure your safety, the following DANGER tags are attached to all hose purchased from Stanley Hydraulic  
Tools. DO NOT REMOVE THESE TAGS.  
If the information on a tag is illegible because of wear or damage, replace the tag immediately. A new tag may be  
obtained from your Stanley Distributor.  
THE TAG SHOWN BELOW IS ATTACHED TO “CERTIFIED NON-CONDUCTIVE” HOSE  
D A N G E R  
D A N G E R  
1. FAILURE TO USE HYDRAULIC HOSE LABELED AND CERTIFIED AS NON-CONDUCTIVE  
WHen uSing HYdRauliC ToolS on oR neaR eleCTRiC lineS maY ReSulT in  
DEATH OR SERIOUS INJURY.  
3. 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.  
FOR PROPER AND SAFE OPERATION MAKE SURE THAT YOU HAVE BEEN PROP-  
eRlY TRained in CoRReCT PRoCeduReS ReQuiRed FoR WoRK on oR aRound  
ELECTRIC LINES.  
4. HANDLE AND ROUTE HOSE CAREFULLY TO AVOID KINKING, ABRASION, CUTTING, OR  
ConTaCT WiTH HigH TemPeRaTuRe SuRFaCeS. DO NOT USE IF KINKED. DO NOT  
uSe HoSe To Pull oR liFT ToolS, PoWeR uniTS, eTC.  
2. BEFORE USING HYDRAULIC HOSE LABELED AND CERTIFIED AS NON-CONDUCTIVE  
on oR neaR eleCTRiC lineS. WiPe THe enTiRe lengTH oF THe HoSe and FiT-  
Ting WiTH a Clean dRY aBSoRBenT CloTH To RemoVe diRT and moiSTuRe and  
TeST HoSe FoR maXimum alloWaBle CuRRenT leaKage in aCCoRdanCe WiTH  
SAFETY DEPARTMENT INSTRUCTIONS.  
5. CHECK ENTIRE HOSE FOR CUTS CRACKS LEAKS ABRASIONS, BULGES, OR DAM-  
AGE TO COUPLINGS IF ANY OF THESE CONDITIONS EXIST, REPLACE THE HOSE  
IMMEDIATELY. NEVER USE TAPE OR ANY DEVICE TO ATTEMPT TO MEND THE HOSE.  
6. AFTER EACH USE STORE IN A CLEAN DRY AREA.  
SEE OTHER SIDE  
SEE OTHER SIDE  
SIDE 1  
SIDE 2  
(Shown smaller than actual size)  
THE TAG SHOwN BELOw IS ATTACHED TO “CONDUCTIVE” HOSE.  
D A N G E R  
D A N G E R  
1. 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  
ELECTRICAL LINES MAY RESULT IN DEATH OR SERIOUS INJURY.  
5. CHECK ENTIRE HOSE FOR CUTS CRACKS LEAKSABRASIONS, BULGES, OR DAMAGE TO  
COUPLINGS IF ANY OF THESE CONDITIONS EXIST, REPLACE THE HOSE IMMEDIATELY.  
NEVER USE TAPE OR ANY DEVICE TO ATTEMPT TO MEND THE HOSE.  
2. FOR PROPER AND SAFE OPERATION MAKE SURE THAT YOU HAVE BEEN PROPERLY  
TRained in CoRReCT PRoCeduReS ReQuiRed FoR WoRK on oR aRound eleC-  
TRIC LINES.  
6. AFTER EACH USE STORE IN A CLEAN DRY AREA.  
3. 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.  
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.  
SEE OTHER SIDE  
SEE OTHER SIDE  
SIDE 1  
SIDE 2  
(Shown smaller than actual size)  
8 ► BR40 User Manual  
 
HOSE RECOMMENDATIONS  
BR40 User Manual ◄ 9  
 
HTMA REQUIREMENTS  
TOOL CATEGORY  
HYDRAULIC SYSTEM  
REQUIREMENTS  
FloW RaTe  
TYPE I  
4–6 gpm  
(15–23 lpm)  
TYPE II  
TYPE III  
TYPE RR  
9–10.5 gpm  
(34–40 lpm)  
7–9 gpm  
(26–34 lpm)  
11–13 gpm  
(42–49 lpm)  
TOOL OPERATING PRESSURE  
(At the power supply outlet)  
2000 psi  
(145–155 bar)  
2000 psi  
(138 bar)  
2000 psi  
(138 bar)  
2000 psi  
(138 bar)  
SYSTEM RELIEF VALVE SETTING  
(At the power supply outlet)  
2100–2250 psi  
(145–155 bar)  
2100–2250 psi 2100–2250 psi 2200–2300 psi  
(145–155 bar)  
(145–155 bar)  
(145–155 bar)  
MAXIMUM BACK PRESSURE  
(At tool end of the return hose)  
250 psi  
(17 bar)  
250 psi  
(17 bar)  
250 psi  
(17 bar)  
250 psi  
(17 bar)  
measured at a max. fluid viscosity of:  
400 ssu*  
400 ssu*  
400 ssu*  
400 ssu*  
(At min. operating temperature)  
(82 centistokes) (82 centistokes) (82 centistokes) (82 centistokes)  
TEMPERATURE  
140 °F  
(60 °C)  
140 °F  
(60 °C)  
140 °F  
(60 °C)  
140 °F  
(60 °C)  
Sufficient heat rejection capacity  
to limit max. fluid temperature to:  
(At max. expected ambient temperature)  
Min. cooling capacity  
3 hp  
5 hp  
7 hp  
6 hp  
at a temperature difference of  
between ambient and fluid temps  
(2.24 kW)  
40 °F  
(3.73 kW)  
40 °F  
(4.47 kW)  
40 °F  
(5.22 kW)  
40 °F  
(22 °C)  
(22 °C)  
(22 °C)  
(22 °C)  
NOTE:  
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  
25 microns  
30 gpm  
(114 lpm)  
25 microns  
30 gpm  
(114 lpm)  
25 microns  
30 gpm  
(114 lpm)  
25 microns  
30 gpm  
(114 lpm)  
Sized for flow of at least:  
(For cold temp. start-up 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  
requirements over a wide range of operating temperatures.  
*SSU = Saybolt Seconds Universal  
10 ► BR40 User Manual  
 
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  
to 100 ft/30 m.  
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.  
PRE-OPERATION PROCEDURES  
CHECK POWER SOURCE  
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 produc-  
tivity, the breaking should be done around the origi-  
nal hole.  
1. using a calibrated flowmeter and pressure gauge,  
check that the hydraulic power source develops a  
flow of 4–6 gpm/15–23 lpm at 1300 psi/90 bar.  
2. Make certain the hydraulic power source is equipped  
with a relief valve set to open at 2250 psi/155 bar  
maximum.  
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.  
INSTALL TOOL BIT  
1. Rotate the latch on the breaker foot downward  
(pointing away from the tool).  
Bites can then be gradually increased until the bro-  
ken piece becomes too large, requiring increased  
time to break off the piece.  
2. Insert the tool bit into the foot and pull the latch up to  
lock the tool bit in place.  
CONNECT HOSES  
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.  
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.  
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.  
3. observe flow indicators stamped on hose couplers  
to ensure that fluid flow is in the proper direction.  
The female coupler on the tool hose is the inlet cou-  
pler.  
Damage to the hydraulic system or breaker can result  
from use with fluid that is too viscous or thick.  
4. Move the hydraulic circuit control valve to the ON  
position to operate the tool.  
NOTE:  
If uncoupled hoses are left in the sun, pressure in-  
crease within the hoses may make them difficult to  
connect. when possible, connect the free ends of  
the hoses together.  
OPERATION PROCEDURES  
1. Observe all safety precautions.  
2. Install the appropriate tool bit for the job.  
3. Place the bit firmly on the surface to be broken.  
4. Squeeze the trigger to start the breaker. Adequate  
down pressure is very important. When the tool bit  
breaks through the obstruction or becomes bound,  
release the trigger and reposition the tool bit.  
BR40 User Manual ◄ 11  
 
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-  
nection.  
Always keep critical tool markings, such as warning  
stickers and tags legible.  
The hydraulic circuit control valve must be in the  
OFF position when coupling or uncoupling hydrau-  
lic tools. Failure to do so may result in damage to  
the quick couplers and cause overheating of the hy-  
draulic system.  
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.  
Always store the tool in a clean dry space, safe from  
damage or pilferage.  
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.  
Make sure the circuit PRESSURE hose (with male  
quick disconnect) is connected to the IN port. The  
circuit RETURN hose (with female quick disconnect)  
is connected to the opposite port. Do not reverse cir-  
cuit flow. This can cause damage to internal seals.  
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.  
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 use the tool for applications for which it was  
not intended.  
do not exceed the rated flow and pressure. See  
Specifications in this manual for correct flow rate  
and pressure rating. Rapid failure of the internal  
seals may result.  
12 ► BR40 User Manual  
 
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  
reversed at ports.  
Be sure hoses are connected to their  
proper ports.  
Mechanical failure of piston or  
automatic valve.  
Disassemble breaker and inspect for  
damaged parts.  
Tool does not hit effectively.  
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.  
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).  
Tool operates slow.  
Low gpm supply from power unit.  
High backpressure.  
Check power unit for proper flow (4–6  
gpm/15–23 lpm).  
Check hydraulic system for excessive  
backpressure (over 200 psi/14 bar).  
Couplers or hoses blocked.  
Remove restriction.  
Remove restriction.  
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.  
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  
(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.  
Replace seals.  
Fluid leakage around trigger. Valve spool seal failure.  
BR40 User Manual ◄ 13  
 
CHARGING THE ACCUMULATOR  
ACCUMULATOR TESTING  
PROCEDURE  
To check or charge the accumulator the following equip-  
ment is required:  
ACCUMULATOR CHARGING  
1. Perform Steps 1 through 4 of the accumulator test-  
ing procedure above.  
2. Connect the chuck of the charging assembly to the  
charging valve on the accumulator tester or, if pre-  
ferred, remove the tester from the charging valve  
and connect the charging assembly chuck directly  
to the charging valve.  
31254 Charge Kit: which includes the following.  
Accumulator Tester (Part Number 02835).  
Charging Assembly (P/N 15304, includes a liq-  
uid filled gauge with snub valve, hose and fit-  
tings).  
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).  
NITROGEN bottle with an 800 psi/55 bar minimum  
charge.(Not included in 31254 kit)  
NOTE:  
It may be necessary to set the gauge at 650–700  
psi/45–48 bar to overcome any pressure drop  
through the charging system.  
CAUTION  
This assembly contains nitrogen under pressure.  
4. When the accumulator is fully charged close the  
snub valve on the charging assembly hose and re-  
move the charging assembly chuck from the accu-  
mulator tester or tool charging valve.  
1. Remove the plug from the handle or handle pivot.  
2. Holding the chuck end of Accumulator Tester (P/N  
02835) turn the gauge fully counterclockwise to en-  
sure that the stem inside the chuck is completely  
retracted.  
5. If the accumulator tester has been used, be sure to  
turn the gauge-end fully counterclockwise before re-  
moving the tester from the charging valve of the tool.  
Install the valve cap.  
3. Thread the tester onto the accumulator charg-  
ing valve. Do not advance the gauge-end into the  
chuck-end. Turn as a unit. Seat the chuck on the  
accumulator charging valve and hand tighten only.  
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 procedure.  
6. Install the plug.  
14 ► BR40 User Manual  
 
CHARGING THE ACCUMULATOR  
TESTER CHARGING  
VALVE  
CW  
CHUCK  
GAUGE  
ACCUMULATOR TESTER ( P/N 02835 )  
LOCATION OF CHARGING VALVE  
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  
Gauge  
02835 TESTER  
Chuck  
TESTER CHARGING  
VALVE  
CW  
CHUCK  
GAUGE  
ACCUMULATOR TESTER ( P/N 02835 )  
LOCATION OF CHARGING VALVE  
Figure 3. Charging the Accumulator (BR40 with T-Handles)  
BR40 User Manual ◄ 15  
 
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 Pressure......................................................................................................................250 Psi/17 bar  
Couplers .........................................................................................................................................HTMA Flush Face  
(Per NFPA T3.20.15/ISO 16028)  
Connect Size & Type......................................................................................................3/8 in. Male Pipe Hose Ends  
Weight ......................................................................................................................................T-Handle 41 lbs/18 kg  
Anti-Vibration Handle 44 lbs/20 kg  
Overall Length.......................................................................................................................T-Handle 23.5 in./60 cm  
Anti-Vibration Handle 25.2 in./65 cm  
overall Width at Handles..........................................................................................................T-Handle 14 in./35 cm  
Anti-Vibration Handle 17.5 in./44.5 cm  
Max. Fluid Temperature.......................................................................................................................... 140 °F/60 °C  
System Type...........................................................................................................................Open or Closed Center  
Port Size.................................................................................................................................................SAE 8 O-ring  
HTMA Class I....................................................................................................................4–6 gpm @ 1300–2000 psi  
Guaranteed Sound Power Level (2000/14/EC)............................................................................................. 107 dBA  
Sound Pressure Level 1 meter (ISO 11203).................................................................................................... 98 dBA  
Vibration Level (ISO 8662-5)....................................................................................................T-Handle 10.0 m/sec2  
Anti-Vibration Handle 9.2 m/sec2  
ACCESSORIES  
1 in. Hex × 4-1/4 in. Shank  
Moil Point – 14 in. Long UC...............................................................................................................................07702  
Narrow Chisel Point – 14 in. Long UC...............................................................................................................07703  
3-inch Chisel – 14 in. Long UC..........................................................................................................................07704  
Clay Spade – 5-1/2 in. Blade.............................................................................................................................07705  
asphalt Wedge – 3 in. Wide ..............................................................................................................................07706  
Test Equipment  
Accumulator Charge Assembly (Includes Liquid Filled Gauge w/ Valve, Hose, & Charge Fitting)....................15304  
Accumulator Tester............................................................................................................................................02835  
Flow and Pressure Tester..................................................................................................................................04182  
Accumulator Charge Kit (Includes 02835 Tester, 15304 Charge Assembly & 372047 Charge Kit Box) ...........31254  
Service Tools  
Tamper Sleeve Tool........................................................................................................................................... 01120  
O-ring Tool Kit....................................................................................................................................................04337  
Flow Sleeve Removal Tube...............................................................................................................................04910  
Flow Sleeve Removal Tool ................................................................................................................................04919  
Accumulator Cylinder Puller ..............................................................................................................................05640  
16 ► BR40 User Manual  
 
BR40 T-HANDLE PARTS ILLUSTRATION  
BR40 User Manual ◄ 17  
 
BR40 T-HANDLE PARTS LIST  
PART  
PART  
ITEM  
NO.  
QTY  
1
2
2
1
2
1
1
1
1
1
1
1
1
1
2
1
2
4
1
1
1
1
1
4
1
1
1
2
2
1
1
2
1
1
1
1
1
1
1
1
1
1
DESCRIPTION  
ITEM  
47  
NO.  
QTY  
1
DESCRIPTION  
BaCK-uP WaSHeR  
CUP SEAL  
1
2
3
4
5
6
7
8
9
03971  
COUPLER SET  
04780  
04386  
04373  
NO ITEM  
48  
4
02900  
01652  
12832  
01605  
04058  
04077  
04057  
07699  
00293  
01362  
04056  
07493  
20499  
02494  
07483  
07492  
04374  
04371  
07479  
12833  
58601  
28409  
04605  
11588  
07485  
ROLL PIN  
49  
1
SIDE ROD  
ALTERNATE HOSE ASSY. – 12 INCH.  
ORIFICE PLUG  
50  
1
NO ITEM  
51  
04394  
04716  
04717  
04715  
04392  
04393  
LATCH*  
o-Ring (inCl W/ iTem 4)  
SPRING  
52  
1
SPRing WaSHeR*  
FOOT LATCH BOLT*  
RUBBER SLEEVE*  
SPRING*  
53  
1
VALVE SPOOL  
54  
2
BUSHING  
55  
1
BUSHING ASSY (INCL ITEMS 9–12)  
O-RING, 11/16 × 7/8 × 3/32  
O-RING, 5/16 × 7/16 × 1/16  
Rod WiPeR  
56  
1
DETENT*  
10  
11  
12  
13  
14  
15  
16  
17  
21  
22  
23  
24  
25  
26  
27  
28  
29  
31  
32  
33  
34  
35  
36  
37  
38  
39  
40  
04595  
SEAL KIT  
* Part of Breaker Foot Assembly 07489 (BR40550,  
Includes 42–48 & 51–56)  
PLUG  
CHARGE VALVE  
HANDLE GRIP  
HANDLE  
SPIROL PIN, 1/4 × 1  
LOCK NUT, 5/8-18  
TRIGGER  
ACCUMULATOR DIAPHRAGM  
PISTON  
Sound PoWeR leVel deCal  
COMPOSITE SAFETY DECAL  
PUSH PIN  
ACCUMULATOR VALVE BLOCK  
FloW SleeVe  
NO ITEM  
11206  
04381  
04379  
04378  
07480  
04571  
04382  
05152  
28374  
12835  
04383  
07477  
04374  
07445  
02022  
04387  
CIRCUIT TYPE C DECAL  
BACK-UP RING  
O-RING, 2-9/16 × 2-3/4 × 3/32  
PORTING BLOCK  
AUTOMATIC VALVE BODY  
PUSH PIN  
AUTOMATIC VALVE  
STANLEY DECAL  
MODEL NUMBER DECAL  
NAME TAG, BR40550  
FloW SleeVe TuBe  
HEX BUSHING  
41  
42  
43  
44  
45  
46  
LOCK NUT  
BREAKER FOOT  
O-RING, 2-1/4 × 2-1/2 × 1/8*  
Rod WiPeR  
18 ► BR40 User Manual  
 
BR40 PARTS  
BR40 ANTI-VIBRATION HANDLE PARTS ILLUSTRATION  
BR40 User Manual ◄ 19  
 
BR40 PARTS LIST  
BR40 ANTI-VIBRATION HANDLE PARTS LIST  
PART  
PART  
ITEM  
NO.  
QTY DESCRIPTION  
ITEM  
49  
50  
51  
52  
53  
54  
55  
56  
57  
58  
59  
60  
61  
62  
63  
64  
65  
66  
67  
68  
NO.  
QTY DESCRIPTION  
1
03971  
1
2
2
2
1
1
1
1
1
1
1
1
2
1
2
1
1
4
1
COUPLER SET  
NO ITEM  
04382  
05152  
28374  
04383  
07477  
04374  
07445  
02022  
04387  
04780  
04386  
20517  
1
1
1
1
1
1
1
1
1
1
1
4
AUTOMATIC VALVE  
2
STANLEY DECAL  
BR40 MODEL NUMBER DECAL  
FloW SleeVe TuBe  
HEX BUSHING *  
3
02900  
01652  
ROLL PIN  
4
HOSE ASSEMBLY, 12 INCH  
NO ITEM  
5
6
01605  
04058  
20515  
04057  
00293  
01362  
04056  
07493  
20499  
02494  
28369  
20500  
20511  
28494  
04374  
58526  
o-Ring (inCl WiTH iTem 4)  
SPRING  
STOP NUT *  
7
BReaKeR FooT WiTH inSeRT aSSY  
O-RING, 2-1/4 × 2-1/2 × 1/8-228 R16 *  
Rod WiPeR  
8
VALVE SPOOL  
BUSHING  
9
10  
11  
12  
13  
14  
15  
16  
17  
18  
20  
21  
22  
O-RING, 11/16 × 7/8 × 3/32  
O-RING, 5/16 × 7/16 × 1/16  
Rod WiPeR  
BaCK-uP WaSHeR  
CUP SEAL  
SIDE ROD  
PLUG  
NO ITEM  
CHARGE VALVE  
HANDLE GRIP  
HANDLE, GUARDED  
SPIROL PIN 1/4 × 1  
LEVER  
04394  
04716  
04717  
04715  
04392  
04393  
58527  
1
2
1
2
1
1
1
LATCH *  
SPRing WaSHeR *  
FOOT LATCH BOLT *  
RUBBER SLEEVE *  
SPRING *  
TOP PLATE  
DETENT *  
LOCK NUT 5/8-18  
TRIGGER LOCK (USED ON MODEL #  
ENDING IN A OR AA)  
TRIGGER (USED ON MODEL #  
ENDING IN A OR AA)  
69  
70  
66828  
07624  
1
1
TORSION SPRING (USED ON MODEL  
# ENDING IN A OR AA)  
26  
58529  
1
TRIGGER HANDLE (USED ON  
MODEL # ENDING IN A OR AA)  
ROLL PIN (USED ON MODEL #  
ENDING IN A OR AA)  
30  
31  
32  
33  
34  
35  
36  
20540  
20498  
20505  
20508  
07479  
12833  
58601  
2
2
1
2
1
1
1
SPRING  
71  
72  
71072  
02004  
1
2
CE TOOL PLATE  
DRIVE PIN  
SPRING (TRIGGER LOCK MODELS)  
HANDLE PIVOT  
PiVoT SCReW  
04595  
SEAL KIT  
ACCUMULATOR DIAPHRAGM  
PISTON  
guaRanTeed Sound PoWeR  
LEVEL (CE MODEL)  
BREAKER FOOT ASSEMBLY  
(T-HANDLE AND ANTI-VIBRATION HANDLE)  
37  
28409  
1
COMPOSITE SAFETY LABEL  
(CE MODEL)  
P/N  
SIzE  
MODEL  
38  
39  
40  
42  
43  
44  
45  
46  
47  
48  
04605  
11588  
07485  
11206  
4
1
1
1
2
2
1
1
2
PUSH PIN  
07489  
1 IN. STANDARD ROTATED  
HEX  
BR40550  
(INCL 53–59 & 62–67)  
ACCUMULATOR VALVE BLOCK  
FloW SleeVe  
07510  
1 IN. STANDARD  
BR4056801A  
(INCL 53–59 & 62–67)  
CIRCUIT C DECAL  
NO ITEM  
04381  
04379  
04378  
07480  
04571  
BACK-UP RING  
O-RING, 2-9/16 × 2-3/4 × 3/32  
PORTING BLOCK  
AUTOMATIC VALVE BODY  
PUSH PIN  
20 ► BR40 User Manual  
 
Stanley Hydraulic Tools  
3810 SE Naef Road  
Milwaukie, Oregon  
503-659-5660 / Fax 503-652-1780  
IMPORTANT  
To ll 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).  

Mitsubishi Electronics Muz Fd09na U1 User Manual
Motorola Sd4560 User Manual
Ricoh Aficio Is 2325 User Manual
Samsung Apc3240c User Manual
Sanyo Ecoi C0905dxhn8 User Manual
Trane Air Conditioner Gat2a0c60s51sa User Manual
Tripp Lite Bp48v18 User Manual
Tripp Lite Line Conditioner 230v User Manual
Xantrex Technology Dr2424 User Manual
Xerox Workcentre 35 User Manual