Stanley BR50 Hydraulic Breaker User Manual

Declaration of Conformity

This section declares that the equipment specified conforms to relevant directives and standards. Key personnel involved in the declaration include Andy Weisbeck, Engineering Manager.

Key Standards and Directives:

• ISO 11148-4:2010
• Noise Directive 2000/14/EC:2005
• Machinery Directive 2006/42/EC:2006

Measured Sound Power Level: 102 LwA (Guaranteed: 104 LwA)

Declaration made at Stanley Hydraulic Tools, Milwaukee, Oregon USA on 4-30-2012.

Safety Symbols and Precautions

Various safety symbols and signal words (DANGER, WARNING, CAUTION, NOTICE, IMPORTANT) are used throughout the manual to highlight potential hazards and critical information. Adherence to these warnings is crucial to prevent serious injury or equipment damage.

Key Safety Precautions:

• Always wear appropriate Personal Protective Equipment (PPE), including safety goggles, gloves, ear protection, head protection, and safety shoes.
• Ensure hydraulic power source is disconnected before inspecting, carrying, or cleaning the tool.
• Use only approved hoses with a minimum working pressure rating of 2500 psi / 172 bar.
• Keep all body parts away from the working tool bit.
• Never operate the tool in an explosive atmosphere.
• Ensure proper lifting techniques are used.
• Keep bystanders at a safe distance.
• Do not exceed the rated flow and pressure limits of the tool.
• Be aware of potential hazardous substances in dust generated during demolition.
• Use only non-conductive hydraulic hoses when working near electrical lines.

Hose Recommendations and Requirements

Proper hydraulic hose selection is critical for safe and efficient operation. The manual details hose types, recommendations based on flow and length, and HTMA/EHTMA requirements.

Hose Types:

• Certified Non-conductive Hose (Fiber Braid)
• Conductive Hose (Wire Braid or Fiber Braid)
• Fabric-braided Hose (not certified non-conductive)

HTMA / EHTMA Requirements:

The manual provides detailed tables outlining flow ranges, operating pressures, relief valve settings, and fluid viscosity requirements for different tool types and classifications.

Operation Procedures

Pre-Operation:

• Check Power Source: Verify that the hydraulic power source meets the specified flow (e.g., 7-9 gpm / 26-34 lpm) and pressure (e.g., 2000 psi / 140 bar) requirements and has a properly set relief valve.
• Install Tool Bit: Insert the tool bit into the breaker foot and secure it with the latch.
• Connect Hoses: Ensure couplers are clean before connecting. Connect pressure and return hoses, observing flow direction. Connect return hoses first and disconnect them last.

Operation:

• Place the tool bit firmly on the surface to be broken.
• Squeeze the trigger to start the breaker. Apply adequate down pressure.
• Release the trigger if the tool bit becomes bound or breaks through the obstruction.
• For starting, partially depress the trigger for slow-speed operation.
• Break material in small bites, gradually increasing size for optimal productivity. Avoid taking bites that are too large, which can cause the tool bit to become stuck.

Cold Weather Operation:

Preheat hydraulic fluid to at least 50°F / 10°C (400 ssu / 82 centistokes) before use in cold weather to prevent damage.

Tool Protection & Care

• Keep couplers clean and ensure the hydraulic control valve is OFF when connecting/disconnecting.
• Store the tool in a clean, dry location.
• Ensure correct hose connections (pressure to IN port, return to opposite port) to prevent damage.
• Use only recommended replacement parts.
• Do not exceed rated flow and pressure.
• Keep tool markings legible.
• Do not use a small breaker for tasks requiring a larger one.
• Keep the tool bit sharp and in good condition.
• Never operate the breaker without a tool bit or without holding it against the work surface.
• Tool repair should only be performed by authorized personnel.
• Ensure recommended relief valves are installed.
• Do not use the tool for unintended applications.

Troubleshooting

The manual provides a table to diagnose and resolve common issues:

• Tool does not run: Check power source, clear blocked couplers/hoses, verify correct hose connections, or inspect for mechanical failure.
• Tool does not hit effectively: Check power source, clear blockages, recharge accumulator, or address fluid temperature issues.
• Tool operates slow: Verify power unit flow, check for high back-pressure, clear blockages, check orifice plug, manage fluid temperature, or adjust relief valve.
• Tool gets hot: Ensure proper fluid temperature, check flow rate, and verify relief valve settings.
• Fluid leakage on tool bit: Replace lower piston seal.
• Fluid leakage around trigger: Replace valve spool seals.

Accumulator Testing and Charging

The manual details procedures for testing and charging the accumulator using specific test equipment and a nitrogen bottle. It emphasizes caution due to pressurized nitrogen.

Specifications

BR50 Hydraulic Breaker Specifications:

• Pressure Range: 1500-2000 psi / 105-140 bar
• Maximum Back Pressure: 250 Psi / 17 bar
• Flow Range (EHTMA D/HTMA Class II): 7-9 gpm / 26-34 lpm (Nominal: 8 gpm / 30 lpm)
• Flow Range (EHTMA D/HTMA Class I): 4-6 gpm / 15-22 lpm (Nominal: 5 gpm / 19 lpm)
• Hose Whips: Yes
• Connect Size & Type: 3/8 in Male Pipe Hose Ends
• Weight (T-Handle Models): 52 lbs / 24 kg
• Weight (Anti-Vib Models): 56 lbs / 25 kg
• Overall Length: 28.5 in. / 72.4 cm
• Overall Width at Handles: 17.25 in. / 44 cm
• Max. Fluid Temperature: 140°F / 60°C
• System Type: Open Center
• Port Size: SAE 8 O-ring
• HTMA/EHTMA Category: Type 1 - 2
• Nominal Pressure: 1500 psi / 103 bar
• Max Pressure: 2500 psi / 172 bar
• Max Relief Pressure: 2150 psi / 148 bar

Note: Weights, dimensions, and operating specifications are subject to change.

BR50 Sound and Vibration Declaration

Sound Levels:

• Measured A-weighted sound power level (Lwa): 102 dBA
• Guaranteed sound power level: 104 dBA
• Measured A-weighted sound pressure level (Lpa) at operator's position: 98 dBA

Vibration Levels (3-Axis):

• Measured vibration emission value: 5.9 m/sec²
• Measured vibration emission value with uncertainty: 6.4 m/sec²

Vibration Levels (Z-Axis):

• Measured vibration emission value: 2.4 m/sec²
• Measured vibration emission value with uncertainty: 4 m/sec²

Test Equipment and Accessories

The manual lists various test equipment and accessories required for maintenance and operation, including:

• Accumulator Tester (P/N 02835)
• Flow and Pressure Tester (P/N 04182)
• Accumulator Charge Assembly (P/N 15304)
• Various tool bits (Moil Point, Chisel Point, Clay Spade, Asphalt Cutter, etc.)

Parts Lists and Diagrams

Detailed parts lists and exploded view diagrams are provided for the BR50 T-Handle, BR50 Anti-Vib, and BR50 Breaker Foot assemblies, specifying part numbers (P/N) and quantities for each component.

Manufacturer Information

Stanley Hydraulic Tools
3810 SE Naef Road
Milwaukie, Oregon 97267-5698 USA
(503) 659-5660 / Fax (503) 652-1780
www.stanleyhydraulics.com