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
TOOL STICKERS & TAGS........................................................................................................................................7
FIGURE 1. TYPICAL HOSE CONNECTIONS.......................................................................................................9
TOOL PROTECTION & CARE................................................................................................................................12
FiguRe 2. CHaRging THe aCCumulaToR (BR40 WiTH anTi-ViBRaTion HandleS).............................15
FiguRe 3. CHaRging THe aCCumulaToR (BR40 WiTH T-HandleS) .......................................................15
BR40 T-HANDLE PARTS ILLUSTRATION..............................................................................................................17
BR40 T-HANDLE PARTS LIST................................................................................................................................18
BR40 ANTI-VIBRATION HANDLE PARTS ILLUSTRATION ...................................................................................19
BR40 ANTI-VIBRATION HANDLE PARTS LIST .....................................................................................................20
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).
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
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 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 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 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).
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