Page 1
BR45
HYDRAULIC
BREAKER
USER MANUAL
Safety, Operation and Maintenance
© 2014 STANLEY Black & Decker, Inc.
New Britain, CT 06053
U.S.A.
62388 9/2018 Ver. 18
Page 2
DECLARATION OF CONFORMITY
ÜBEREINSTIMMUNGS-ERKLARUNG
DECLARATION DE CONFORMITE CEE
DECLARACION DE CONFORMIDAD
DICHIARAZIONE DI CONFORMITA
______________________________________________________________________
I, the undersigned:
Ich, der Unterzeichnende:
Je soussigné:
El abajo firmante:
lo sottoscritto:
Nuerenberg, David
Surname and First names/Familiennname und Vornamen/Nom et prénom/ Nombre y apellido/Cognome e nome
hereby declare that the equipment specified hereunder:
bestätige hiermit, daß erklaren Produkt genannten Werk oder Gerät:
déclare que l’équipement visé ci-dessous:
Por la presente declaro que el equipo se especifica a continuación:
Dichiaro che le apparecchiature specificate di seguito:
1. Category:
Hydraulic Hand-Held Concrete Breaker
Kategorie:
Catégorie:
Categoria:
Categoria:
2. Make/Marke/Marque/Marca/Marca
STANLEY
3. Type/Typ/Type/Tipo/Tipo:
BR4514801, BR4516801, BR4516807, BR4516807A
BR4514801A, BR4556801, (BR45350 – For Underwater Use Only)
4. Serial number of equipment:
Seriennummer des Geräts:
Numéro de série de l’équipement:
Numero de serie del equipo:
Matricola dell´attrezzatura:
BR4514801 All
BR4514801A All
BR4516801 All
BR4516807 All
BR4516807A All
BR4556801 All
BR45350 Serial # 030612029 and above
(For Underwater Use Only)
5. Mass/Masse/Masse/Masa/Massa 23 kg
Has been manufactured in conformity with
Wurde hergestellt in Übereinstimmung mit
Est fabriqué conformément
Ha sido fabricado de acuerdo con
E’ stata costruita in conformitá con
Directive/Standards
Richtlinie/Standards
Directives/Normes
Directriz/Los Normas
Direttiva/Norme
No.
Nr
Numéro
No
n.
Approved body
Prüfung durch
Organisme agréé
Aprobado
Collaudato
EN ISO
EN ISO
EN ISO
EN ISO
Machinery Directive
28927-10
3744 (15744)
11148-4
13732-1
2006/42/EC:2006
Self
AkustikNet (Notified body ID 1585)
Bagsvard Hovedgade 141, 2880 Bagsvard, Denmark
Certificate #863/2011/002 (Verification 2015-08-04) Valid: 12/31/2018
Self
Self
Self
6. Special Provisions: None 7. Measurements: Measured Sound Power Level 105 LwA
Spezielle Bestimmungen: Messungen Guaranteed Sound Power Level 107 LwA
Dispositions particulières: Mesures Measured in accordance to Directive 2000/14/EC,
Provisiones especiales: Mediciones Annex III, Part B, No 10, 15 kg<m< 30 kg
Disposizioni speciali: Misurazioni
8. Representative in the Union: Patrick Vervier, Stanley Dubuis 17-19, rue Jules Berthonneau-BP 3406 41034 Blois Cedex, France.
Vertreter in der Union/Représentant dans l’union/Representante en la Union/Rappresentante presso l’Unione
Done at/Ort/Fait à/Dado en/Fatto a STANLEY Infrastructure, Milwaukie, Oregon USA Date/Datum/le/Fecha/Data 4-26-2018
Signature/Unterschrift/Signature/Firma/Firma
Position/Position/Fonction/Cargo/Posizione North America Quality Manager
DECLARATION OF CONFORMITY
2 ► BR45 User Manual
Page 3
TABLE OF CONTENTS
SAFETY SYMBOLS .................................................................................................................................................4
SAFETY PRECAUTIONS .......................................................................................................................................5
TOOL STICKERS & TAGS ......................................................................................................................................7
HOSE TYPES ..........................................................................................................................................................8
HOSE RECOMMENDATIONS ................................................................................................................................9
HTMA / EHTMA REQUIREMENTS ......................................................................................................................10
OPERATION .......................................................................................................................................................... 11
TOOL PROTECTION & CARE .............................................................................................................................. 13
TROUBLESHOOTING ..........................................................................................................................................14
CHARGING THE ACCUMULATOR ......................................................................................................................15
SPECIFICATIONS .................................................................................................................................................17
ACCESSORIES .....................................................................................................................................................18
BR45 T-HANDLE PARTS ILLUSTRATION ..........................................................................................................20
BR45 T-HANDLE PARTS LIST .............................................................................................................................21
BR45 ANTI-VIBRATION HANDLE PARTS ILLUSTRATION ...............................................................................22
BR45 ANTI-VIBRATION HANDLE PARTS LIST ..................................................................................................23
BREAKER FOOT ASSEMBLY 07489 ...................................................................................................................24
BREAKER FOOT ASSEMBLY 07510 ...................................................................................................................25
BREAKER FOOT ASSEMBLY 07694 ...................................................................................................................26
BREAKER FOOT ASSEMBLY 07899 ...................................................................................................................27
BREAKER FOOT ASSEMBLY 08081 ...................................................................................................................28
BREAKER FOOT ASSEMBLY 08154 ...................................................................................................................29
BREAKER FOOT ASSEMBLY 08856 ...................................................................................................................30
BREAKER FOOT ASSEMBLY 62334 ...................................................................................................................31
BREAKER FOOT ASSEMBLY 72931 ...................................................................................................................32
UNDERWATER TOOLS DEPTH GUIDELINE ..................................................................................................... 33
To ll out a product warranty validation form, and for information on your warranty,
visit www.stanleyinfrastructure.com and select the Company tab > Warranty.
Note: The warranty validation record must be submitted to validate the warranty.
SERVICING: This manual contains safety, operation and routine maintenance instructions. STANLEY Infrastructure
recommends that servicing of hydraulic tools, other than routine maintenance, must be performed by an authorized
and certied dealer. Please read the following warning.
SERIOUS INJURY OR DEATH COULD RESULT FROM THE IMPROPER REPAIR OR
SERVICE OF THIS TOOL.
REPAIRS AND / OR SERVICE TO THIS TOOL MUST ONLY BE DONE BY AN
AUTHORIZED AND CERTIFIED DEALER.
For the nearest certied dealer, call STANLEY Infrastructure at (503) 659-5660 and ask for a Customer Service Representative.
BR45 User Manual ◄ 3
Page 4
SAFETY SYMBOLS
Safety symbols and signal words, as shown below, are used to emphasize all operator, maintenance and repair
actions 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 indicates an imminently hazardous situation
which, if not avoided, will result in death or serious injury.
This safety alert and signal word indicates a potentially hazardous situation
which, if not avoided, could result in death or serious injury.
This safety alert and signal word indicates 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 avoided,
may result in property damage.
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 damage
to the equipment.
Always observe safety symbols. They are included for your safety and for the protection of the tool.
LOCAL SAFETY REGULATIONS
Enter any local safety regulations here. Keep these instructions in an area accessible to the operator and
maintenance personnel.
Tool operators and maintenance personnel must always comply with the precautions given in this manual and on
the stickers and tags attached to the tool and hose.
These precautions are given for your safety. Review them carefully before operating the tool and before performing
general maintenance or repairs.
Supervising personnel should develop additional precautions relating to the specic work area and local safety
regulations. Place the added precautions in the space provided in this manual.
The BR45 Hydraulic Breaker will provide safe and dependable service if operated in accordance with the instructions
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.
4 ► BR45 User Manual
Page 5
SAFETY PRECAUTIONS
• Operator must start in a work area without
bystanders and must assess the risk to bystanders.
• Operators and maintenance personnel shall be able
to physically handle the bulk, weight and power of
the tool.
• The operator must be familiar with all prohibited work
areas such as excessive slopes and dangerous
terrain conditions.
• Establish a training program for all operators to
ensure safe operation.
• Do not operate the tool unless thoroughly trained or
under the supervision of an instructor.
• Always wear safety equipment such as goggles,
gloves, ear protection, head protection, breathing
protection and safety shoes at all times when
operating the tool.
• Do not inspect, carry or clean the tool while the
hydraulic power source is connected. Accidental
engagement of the tool can cause serious injury.
• Supply hoses must have a minimum working
pressure rating of 2500 psi/175 bar.
• Be sure all hose connections are tight.
• The hydraulic circuit control valve must be in the
“OFF” position when coupling or uncoupling the tool.
Wipe all couplers clean before connecting. Use only
lint-free cloths. Failure to do so may result in damage
to the quick couplers and cause overheating of the
hydraulic system.
• Do not operate the tool at oil temperatures above
140 °F/60 °C. Operation at higher oil temperatures
can cause operator discomfort and may damage the
tool. Never contact the tool bit, the bit can get hot.
• When using a non-rotary percussive tool to perform
work related activities, the operator can experience
discomfort in the hands, arms, shoulders, neck or
other parts of the body.
• If you experience numbness, tingling, pain or whit-
ening of the skin in your ngers or hands, stop using
the tool. Tell your employer and consult a physician.
• Do not operate a damaged, improperly adjusted or
incompletely assembled tool.
• Do not weld, cut with an acetylene torch or hardface 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
personnel.
• Do not exceed the rated limits of the tool or use the
tool for applications beyond its design capacity.
• Inspect the tool before each use and ensure all decals are legible. Contact STANLEY if replacements
are needed.
• Always replace parts with replacement parts
recommended by STANLEY.
• Ensure work piece is securely xed. Be aware that
failure of the work piece or accessories may generate high velocity projectiles.
• Check fastener tightness often and before each use
daily.
• Never operate the tool if you cannot be sure that
underground utilities are not present, such as
electrical cables, gas pipes, etc. These can cause a
hazard if damaged with the tool.
• The tool is not insulated against coming into contact
with electric power.
• Do not wear loose tting clothing when operating
the tool.
• WARNING: Some dust created by power sanding,
sawing, grinding, drilling, and other construction
activities contains chemicals known to the State
of California to cause cancer, birth defects or
other reproductive harm. Some examples of these
chemicals are:
• Lead from lead-based paints,
• crystalline silica from bricks and cement
and other masonry products, and
• arsenic and chromium from chemicallytreated lumber.
Your risk from these exposures varies, depending
on how often you do this type of work. To reduce
your exposure to these chemicals: work in a well
ventilated area, and work with approved safety
equipment, such as those dust masks that are
specially designed to lter out microscopic particles.
Protect yourself and those around you. Research
and understand the materials you are cutting.
Follow correct safety procedures and comply with
all applicable national, state or provisional health
and safety regulations relating to them, including,
if appropriate arranging for the safe disposal of the
materials by a qualied person.
• Warning: Hydraulic uid under pressure could
cause skin injection injury. If you are injured by
hydraulic uid, get medical attention immediately.
• Keep all body parts away from the working tool.
• When handling material or the tool bit, wear your
BR45 User Manual ◄ 5
Page 6
SAFETY PRECAUTIONS
Personal Protection Equipment (PPE).
• 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.
• Never use the tool in an explosive atmospheres.
Sparks could ignite explosive gas.
• Use proper lifting techniques when handling the tool.
Get help from a co-worker and do not over-reach.
• Use proper protection from falling or ying debris
and keep bystanders at a safe distance.
• Do not exceed the rated ow and pressure. See
Specications in this manual for correct ow rate
and pressure rating. Rapid failure of the internal
seals may result.
• Do not exceed the maximum relief valve setting
stated on the tool.
6 ► BR45 User Manual
Page 7
TOOL STICKERS & TAGS
Please refer to the Parts Illustration for location of stickers.
BR45 BREAKER
74659 5-GPM Anti-Vib Name
Tag Sticker
74660 5-GPM T-Handle Name
Tag Sticker
74663 8-GPM Anti-Vib Name
Tag Sticker
74664 8-GPM T-Handle Name
Tag Sticker
74669 8-GPM T-Handle Name
Tag Sticker Under Water
These numbers
are for example
only and may
not relate to your
model of breaker,
see part numbers
below for name
tag stickers that
ts your model
breaker.
Note: The serial
number and year
of manufacture
are stamped on
the tool, near the
trigger.
Lwa
107
58601 Sound Level
Sticker (CE Only)
28409 Composite
Sticker (CE Only)
11207 Circuit Type C
Sticker (CE Only)
11208 Hex Shank
Length Sticker
28322 CE
Sticker (CE Only)
74832 STANLEY Logo 5.5” x 1.1” Black on Clear
74770 STANLEY Logo 6.5” x 1.3” Yellow on Clear
10180 Caution Sticker
STANLEY Railroad Help Desk Sticker (Not Pictured)
P/N-73680
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.
1. FAILURE TO USE HYDRAULIC HOSE LABELED AND CERTIFIED AS NON-CONDUCTIVE WHEN USING HYDRAULIC
TOOLS ON OR NEAR ELECTRICAL LINES MAY RESULT IN
DEATH OR SERIOUS INJURY.
BEFORE USING HOSE LABELED AND CERTIFIED AS NON-
CONDUCTIVE ON OR NEAR ELECTRIC LINES BE SURE THE
HOSE IS MAINTAINED AS NON-CONDUCTIVE. THE HOSE
SHOULD BE REGULARLY TESTED FOR ELECTRIC CURRENT LEAKAGE IN ACCORDANCE WITH YOUR SAFETY
DEPARTMENT INSTRUCTIONS.
2. A HYDRAULIC LEAK OR BURST MAY CAUSE OIL INJECTION INTO THE BODY OR CAUSE OTHER SEVERE
PERSONAL INJURY.
A. DO NOT EXCEED SPECIFIED FLOW AND PRESSURE
FOR THIS TOOL. EXCESS FLOW OR PRESSURE MAY
CAUSE A LEAK OR BURST.
B. DO NOT EXCEED RATED WORKING PRESSURE OF
HYDRAULIC HOSE USED WITH THIS TOOL. EXCESS
PRESSURE MAY CAUSE A LEAK OR BURST.
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.
IMPORTANT
READ OPERATION MANUAL AND
SAFETY INSTRUCTIONS FOR THIS
TOOL BEFORE USING IT.
USE ONLY PARTS AND REPAIR
PROCEDURES APPROVED BY
STANLEY AND DESCRIBED IN THE
OPERATION MANUAL.
TAG TO BE REMOVED ONLY BY
TOOL OPERATOR.
SEE OTHER SIDE
DANGERDANGER
D. DO NOT LIFT OR CARRY TOOL BY THE HOSES. DO
NOT ABUSE HOSE. DO NOT USE KINKED, TORN OR
DAMAGED HOSE.
3. MAKE SURE HYDRAULIC HOSES ARE PROPERLY CONNECTED TO THE TOOL BEFORE PRESSURING SYSTEM.
SYSTEM PRESSURE HOSE MUST ALWAYS BE CONNECTED 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.
4. DO NOT CONNECT OPEN-CENTER TOOLS TO CLOSEDCENTER HYDRAULIC SYSTEMS. THIS MAY RESULT IN
LOSS OF OTHER HYDRAULIC FUNCTIONS POWERED BY
THE SAME SYSTEM AND/OR SEVERE PERSONAL INJURY.
5. BYSTANDERS MAY BE INJURED IN YOUR WORK AREA.
KEEP BYSTANDERS CLEAR OF YOUR WORK AREA.
6. WEAR HEARING, EYE, FOOT, HAND AND HEAD PROTECTION.
7. TO AVOID PERSONAL INJURY OR EQUIPMENT DAMAGE,
ALL TOOL REPAIR MAINTENANCE AND SERVICE MUST
ONLY BE PERFORMED BY AUTHORIZED AND PROPERLY
TRAINED PERSONNEL.
IMPORTANT
READ OPERATION MANUAL AND
SAFETY INSTRUCTIONS FOR THIS
TOOL BEFORE USING IT.
USE ONLY PARTS AND REPAIR
PROCEDURES APPROVED BY
STANLEY AND DESCRIBED IN THE
OPERATION MANUAL.
TAG TO BE REMOVED ONLY BY
TOOL OPERATOR.
SEE OTHER SIDE
SAFETY TAG P/N 15875 (Shown smaller then actual size)
BR45 User Manual ◄ 7
Page 8
HOSE TYPES
The rated working pressure of the hydraulic hose must be equal to or higher than the relief valve setting on the
hydraulic system. There are three types of hydraulic hose that meet this requirement and are authorized for use with
STANLEY hydraulic tools. They are:
Certi ed non-conductive — constructed of thermoplastic or synthetic rubber inner tube, synthetic ber braid
reinforcement, and weather resistant thermoplastic or synthetic rubber cover. Hose labeled certifi ed 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
reinforcement, and weather resistant synthetic rubber cover. This hose is conductive and must never be used
near electrical conductors.
Fabric-braided (not certi ed or labeled non-conductive) — constructed of thermoplastic or synthetic rubber
inner tube, synthetic ber braid reinforcement, and weather resistant thermoplastic or synthetic rubber cover.
This hose is not certifi ed 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. 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
DANGER
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.
FOR PROPER AND SAFE OPERATION MAKE SURE THAT YOU HAVE BEEN PROPERLY
TRAINED IN CORRECT PROCEDURES REQUIRED FOR WORK ON OR AROUND
ELECTRIC LINES.
2. BEFORE USING HYDRAULIC HOSE LABELED AND CERTIFIED AS NON-CONDUCTIVE
ON OR NEAR ELECTRIC LINES. WIPE THE ENTIRE LENGTH OF THE HOSE AND FITTING
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.
DO NOT REMOVE THIS TAG
SEE OTHER SIDE
SIDE 1
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, 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.
5. CHECK ENTIRE HOSE FOR CUTS CRACKS LEAKS ABRASIONS, 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.
6. AFTER EACH USE STORE IN A CLEAN DRY AREA.
(Shown smaller than actual size)
DANGER
DANGER
SEE OTHER SIDE
SIDE 2
THE TAG SHOWN BELOW IS ATTACHED TO “CONDUCTIVE” HOSE.
DANGER
DANGER
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.
2. FOR PROPER AND SAFE OPERATION MAKE SURE THAT YOU HAVE BEEN PROPERLY
TRAINED IN CORRECT PROCEDURES REQUIRED FOR WORK ON OR AROUND ELECTRIC LINES.
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.
DO NOT REMOVE THIS TAG
SEE OTHER SIDE
SIDE 1
5. CHECK ENTIRE HOSE FOR CUTS CRACKS LEAKS ABRASIONS, 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.
6. AFTER EACH USE STORE IN A CLEAN DRY AREA.
(Shown smaller than actual size)
DANGER
SEE OTHER SIDE
SIDE 2
DO NOT REMOVE THIS TAG
DO NOT REMOVE THIS TAG
8 ► BR45 User Manual
Page 9
Min. Working Pressure
USE
Press/Return)
(
HOSE RECOMMENDATIONS
Certi ed Non-Conductive Hose - Fiber Braid - for Utility Bucket Trucks
Oil Flow Hose Lengths Inside Diameter
GPM LPM FEET METERS INCH MM PSI BAR
4-9 15-34 up to 10 up to 3 3/8 10 Both 2250 155
Conductive Hose - Wire Braid or Fiber Braid -DO NOT USE NEAR ELECTRICAL CONDUCTORS
4-6 15-23 up to 25 up to 7.5 3/8 10 Both 2500 175
4-6 15-23 26-100 7.5-30 1/2 13 Both 2500 175
5-10.5 19-40 up to 50 up to 15 1/2 13 Both 2500 175
5-10.5 19-40 51-100 15-30 5/8 16 Both 2500 175
5/8 16 Pressure 2500 175
3/4 19 Return 2500 175
5-10.5 19-40 100-300 30-90
10-13 38-49 up to 50 up to 15 5/8 16 Both 2500 175
5/8 16 Pressure 2500 175
3/4 19 Return 2500 175
10-13 38-49 51-100 15-30
3/4 19 Pressure 2500 175
1 25.4 Return 2500 175
10-13 38-49 100-200 30-60
5/8 16 Pressure 2500 175
13-16 49-60 up to 25 up to 8
3/4 19 Return 2500 175
3/4 19 Pressure 2500 175
1 25.4 Return 2500 175
13-16 49-60 26-100 8-30
PRESSURE
<<< FLOW
RETURN
FLOW >>>
Figure 1. Typical Hose Connections
Tool to Hydraulic Circuit Hose
Recommendations
The chart to the right shows recommended
minimum hose diameters for various
hose lengths based on gallons per minute
(GPM)/liters per minute (LPM). These
recommendations are intended to keep return
line pressure (back pressure) to a minimum
acceptable level to ensure maximum tool
performance.
This chart is intended to be used for hydraulic
tool applications only based on STANLEY tool
operating requirements and should not be
used for any other applications.
All hydraulic hose must have at least a
rated minimum working pressure equal to
the maximum hydraulic system relief valve
setting.
All hydraulic hose must meet or exceed
speci cations as set forth by SAE J517.
BR45 User Manual ◄ 9
Page 10
HTMA / EHTMA REQUIREMENTS
HTMA / EHTMA REQUIREMENTS
TOOL TYPE
HTMA
HYDRAULIC SYSTEM REQUIREMENTS
Flow range
Nominal operating pressure
(At the power supply outlet)
System relief valve setting
(At the power supply outlet)
Maximum back pressure
(At tool end of the return hose)
Measured at a max uid viscosity of:
(At minimum operating temperature)
Temperature: Suffi cient heat rejection capacity to limit
maximum uid temperature to:
(At maximum expected ambient temperature)
Minimum cooling capacity at a temperature di erence of
between ambient and uid temps
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 minimum full- ow ltration 25 microns 25 microns 25 microns 25 microns
Sized for ow of at least:
(For cold temp startup and maximum dirt-holding capacity)
Hydraulic uid, petroleum based (premium grade, anti-
wear, non-conductive) Viscosity (at minimum and maximum
operating temps)
Note: When choosing hydraulic uid, the expected oil temperature extremes that will be experienced in service determine the most
suitable temperature viscosity characteristics. Hydraulic uids with a viscosity index over 140 will meet the requirements over a wide
range of operating temperatures.
TYPE I TYPE II TYPE RR TYPE III
4-6 GPM
(15-23 LPM)
1500 psi
(103 bar)
2100-2250 psi
(145-155 bar)
250 psi
(17 bar)
400 ssu*
(82 centistokes)
140° F
(60° C)
3 hp
(2.24 kW)
40° F
(22° C)
30 GPM
(114 LPM)
100-400 ssu
(20-82
centistokes)
7-9 GPM
(26-34 LPM)
1500 psi
(103 bar)
2100-2250 psi
(145-155 bar)
250 psi
(17 bar)
400 ssu*
(82 centistokes)
140° F
(60° C)
5 hp
(3.73 kW)
40° F
(22° C)
30 GPM
(114 LPM)
100-400 ssu
(20-82
centistokes)
9-10.5 GPM
(34-40 LPM)
1500 psi
(103 bar)
2200-2300 psi
(152-159 bar)
250 psi
(17 bar)
400 ssu*
(82 centistokes)
140° F
(60° C)
6 hp
(5.22 kW)
40° F
(22° C)
30 GPM
(114 LPM)
100-400 ssu
(20-82
centistokes)
11-13 GPM
(42-49 LPM)
2100-2250 psi
(145-155 bar)
(82 centistokes)
100-400 ssu
centistokes)
1500 psi
(103 bar)
250 psi
(17 bar)
400 ssu*
140° F
(60° C)
7 hp
(4.47 kW)
40° F
(22° C)
30 GPM
(114 LPM)
(20-82
*SSU = Saybolt Seconds Universal
EHTMA
HYDRAULIC SYSTEM
REQUIREMENTS
Flow range
Nominal operating pressure
(At the power supply outlet)
System relief valve setting
(At the power supply outlet)
Note: These are general hydraulic system requirements. See tool speci cation page for tool speci c requirements.
10 ► BR45 User Manual
B
3.5-4.3 GPM
(13.5-16.5
LPM)
1870 psi
(129 bar)
2495 psi
(172 bar)
C
4.7-5.8 GPM
(18-22 LPM)
1500 psi
(103 bar)
2000 psi
(138 bar)
CLASSIFICATION
D
7.1-8.7 GPM
(27-33 LPM)
1500 psi
(103 bar)
2000 psi
(138 bar)
9.5-11.6 GPM
(36-44 LPM)
1500 psi
(103 bar)
2000 psi
(138 bar)
11.8-14.5 GPM
(45-55 LPM)
1500 psi
(103 bar)
2000 psi
(138 bar)
Page 11
OPERATION
The recommended hose size is .500 inch/12 mm I.D. up to 50 ft/15 m long and .625 inch/16 mm I.D. minimum up
to 100 ft/30 m.
PRE-OPERATION PROCEDURES
CHECK POWER SOURCE
1. Using a calibrated ow meter and pressure gauge, check that the hydraulic power source develops a ow of
7–9 GPM/26–34 LPM at 1500–2000 psi/105–140 bar or 5–6 GPM /18–22 LPM at 1500–2000 psi /105–140 bar.
Proper ow and pressure maintain proper tool speed.
2. Make certain the hydraulic power source
is equipped with a relief valve set to
open at 2250 psi/155 bar maximum.
INSTALL TOOL BIT - FIG. 2
1. Rotate the latch on the breaker foot
downward (pointing away from the tool).
2. Insert the tool bit into the foot and pull
the latch up to lock the tool bit in place.
Note: Never use the tool if the bit is not
locked in the tool retainer.
2
1
CONNECT HOSES
1. Wipe all hose couplers with a clean, lintfree cloth before making connections.
2. Connect the hoses from the hydraulic
power source to the tool ttings or quick
disconnects. It is a good practice to
connect return hoses rst and disconnect them last to minimize or avoid trapped pressure within the tool.
3. Observe ow indicators stamped on hose couplers to ensure that uid ow is in the proper direction. The female
coupler on the tool hose is the inlet coupler.
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 increase within the hoses may make them dicult to
connect. When possible, connect the free ends of the hoses together.
OPERATION PROCEDURES - FIG. 3
1. Observe all safety precautions.
2. Install the appropriate tool bit for the job.
3. Wrap your hands around the handles and stand in back
of the tool, using your leg against the snap-on ller for
tool stability.
Note: Hold the tool correctly and be ready to counteract
normal or sudden movements. Have both hands available.
4. Place the breaker bit on the material to be broken, at a
90° angle. Apply down pressure.
5. Flip the trigger lock (CE models only).
6. Slowly squeeze the trigger to start breaking. Squeeze
harder for fast speed operation.
7. When starting, break until the tool bit breaks through,
then reposition the bit. Do not use the tool bit as a lever
to move material.
Figure 2 - Installing the Bit
3
5
6
4
Figure 3 - Tool Use
BR45 User Manual ◄ 11
Page 12
OPERATION
Note: Never cool a hot tool bit in water. Tools can become brittle and can fail.
8. Continue breaking around the original hole, in 2 inch sized bites.
9. Release Trigger to stop the tool.
Note: If you encounter a breakdown or the tool stops for any reason, release the trigger and power down
the hydraulic power source.
COLD WEATHER OPERATION
If the breaker is to be used during cold weather, preheat the hydraulic uid at low engine speed. When using the
normally recommended uid, uid temperature should be at or above 50 °F/10 °C (400 ssu/82 centistokes) before
use.
Damage to the hydraulic system or breaker can result from use with uid that is too viscous or thick.
UNDERWATER MODEL PREVENTATIVE MAINTENANCE - FIG. 4
After each use, the movable portions of the tool that were exposed to water should be ushed with a water displacing
oil such as WD40™. Remove any remaining water and debris as follows:
1. Spray oil into the On/O valve trigger slot area.
2. Turn the tool upside down (without the tool bit) and spray oil through the drive hex and side holes in the breaker
foot assembly to displace any remaining water in the lower piston cavity.
3. Dip or spray the entire tool.
4. Cycle the tool hydraulically several times before storing away.
12 ► BR45 User Manual
Figure 4 - Underwater Maintenance
Page 13
TOOL PROTECTION & CARE
In addition to the Safety Precautions found in
this manual, observe the following for equipment
protection and care.
• Make sure all couplers are wiped clean before
connection.
• The hydraulic circuit control valve must be in
the “OFF” position when coupling or uncoupling
hydraulic tools. Failure to do so may result in damage
to the quick couplers and cause overheating of the
hydraulic system.
• Always store the tool in a clean dry space, safe from
damage or pilferage.
• Make sure the circuit PRESSURE hose (with male
quick disconnect) is connected to the “IN” port. The
circuit RETURN hose (with female quick disconnect)
is connected to the opposite port. Do not reverse
circuit ow. This can cause damage to internal seals.
• Always replace hoses, couplings and other parts
with replacement parts recommended by STANLEY.
Supply hoses must have a minimum working
pressure rating of 2500 psi/172 bar.
• Do not exceed the rated ow and pressure. See
Specications in this manual for correct ow rate
and pressure rating. Rapid failure of the internal
seals may result.
• Always keep critical tool markings, such as warning
stickers and tags legible.
• Do not force a small breaker to do the job of a large
breaker.
• Keep tool bit sharp for maximum breaker
performance. Make sure that tool bits are not
chipped or rounded on the striking end.
• Never operate a breaker without a tool bit or without
holding it against the work surface. This puts
excessive strain on the breaker foot.
• Tool repair should be performed by experienced
personnel only.
• Make certain that the recommended relief valves
are installed in the pressure side of the system.
• Do not use the tool for applications for which it was
not intended.
BR45 User Manual ◄ 13
Page 14
TROUBLESHOOTING
PROBLEM CAUSE REMEDY
Tool does not run. Power unit not functioning. Check power unit for power ow and pressure
(7–9 GPM/26–34 LPM, 1500–2000 psi/105–
140 bar or 5–6 GPM /18–22 LPM at 1500–
2000 psi /105–140 bar.
Couplers or hoses blocked. Remove restriction.
Pressure and return line hoses
reversed at ports.
Mechanical failure of piston or
automatic valve.
Tool does not hit eectively. Power unit not functioning. Check power unit for power ow and
Couplers or hoses blocked. Remove restriction.
Low accumulator charge
(pressure hose will pulse more
than normal).
Fluid too hot
(above 140 °F/60 °C).
Tool operates slow. Low GPM supply from power
unit.
High back-pressure. Check hydraulic system for excessive back-
Couplers or hoses blocked. Remove restriction.
Orice plug blocked. Remove restriction.
Fluid too hot
(above 140 °F/60 °C) or too cold
(below 60 °F/16 °C).
Relief valve set too low. Adjust relief valve to 2100–2250 psi/145–155
Tool gets hot. Hot uid going through tool. Check power unit. Be sure ow rate is not too
Fluid leakage on tool bit. Lower piston seal failure. Replace seal.
Fluid leakage around trigger. Valve spool seal failure. Replace seals.
Be sure hoses are connected to their proper
ports.
Disassemble breaker and inspect for
damaged parts.
pressure (7–9 GPM/26–34 LPM, 1500–2000
psi/105–140 bar or 5–6 GPM /18–22 LPM at
1500–2000 psi /105–140 bar. Proper ow and
pressure maintain proper tool speed.
Recharge accumulator. Replace diaphragm if
charge loss continues.
Provide cooler to maintain proper uid
temperature (130 °F/55 °C).
Check power unit for proper ow (7–9
GPM/26–34 LPM) or 5–6 GPM /18–22 LPM.
Proper ow and pressure maintain proper tool
speed.
pressure (over 200 psi/14 bar).
Check power unit for proper uid temperature.
Bypass cooler to warm the uid or provide
cooler to maintain proper temperature.
bar.
high causing part of the uid to go through the
relief valve. Provide cooler to maintain proper
uid temperature (140 °F/60 °C max).
Check the relief valve setting.
Eliminate ow control devices.
14 ► BR45 User Manual
Page 15
CHARGING THE ACCUMULATOR
ACCUMULATOR TESTING
PROCEDURE
To check or charge the accumulator the following
equipment is required.
• 31254 Charge Kit, which includes the following:
– Accumulator Tester (Part Number 02835).
– Charging Assembly (P/N 15304) (15304
includes a liquid lled gauge with snub valve,
hose and ttings).
• NITROGEN bottle with an 800 psi/55 bar minimum
charge.(Not included in 31254 kit)
This assembly contains nitrogen under pressure
Remove the plug from the handle or handle pivot.
1.
2. Holding the chuck end of Accumulator Tester (P/N
02835) turn the gauge fully counterclockwise to
ensure that the stem inside the chuck is completely
retracted.
3. Thread the tester onto the accumulator charging
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/3448 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 paragraph.
6. Install the plug.
preferred, remove the tester from the charging valve
and connect the charging assembly chuck directly to
the charging valve.
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).
Note: It may be necessary to set the gauge at 650700 psi/45-48 bar to overcome any pressure drop
through the charging system.
4. When the accumulator is fully charged close the
snub valve on the charging assembly hose and
remove the charging assembly chuck from the
accumulator tester or tool charging valve.
5. If the accumulator tester has been used, be sure to
turn the gauge-end fully counterclockwise before
removing the tester from the charging valve of the
tool. Install the valve cap.
ACCUMULATOR CHARGING
1. Perform steps 1 through 4 of the accumulator testing
procedure.
2. Connect the chuck of the charging assembly to
the charging valve on the accumulator tester or, if
BR45 User Manual ◄ 15
Page 16
GAUGE
CHUCK
TESTER CHARGING
VALVE
CW
ACCUMULATOR TESTER( P/N 02835 ) LOCATION OF CHARGINGVALVE
GAUGE
CHUCK
TESTER CHARGING
VALVE
CW
ACCUMULATOR TESTER( P/N 02835 ) LOCATION OF CHARGINGVALVE
LiquidFilled Gauge w/Snub Valve
NitrogenTank
()
Not included in Kit
Gauge
Hose
Chuck
ChargeFitting
ChargingV
alve
31254 ACCUMULATOR CHARGE KIT
Includes: Liquid Filled Gauge w/Snub Valve,
Hose, Charge Fitting, 02835 Tester, and Box
(not pictured)
02835 TESTER
Charging the Accumulator (45 with Anti-Vibration Handles)BR
Charging the Accumulator (45 with T-Handles)BR
CHARGING THE ACCUMULATOR
16 ► BR45 User Manual
Page 17
SPECIFICATIONS
Pressure Range.............................................................................................................. 1500–2000 psi/105–140 bar
Flow Range ............................................................................................................................ 7–9 GPM / 26–34 LPM
4–6 GPM /15–22 LPM
Nominal Flow .....................................................................................................8 GPM / 30 LPM or 5 GPM / 19 LPM
Maximum Back Pressure......................................................................................................................250 Psi/17 bar
Couplers ......................................................................................................................................... HTMA Flush Face
Connect Size & Type ......................................................................................................3/8 in. Male Pipe Hose Ends
Weight ....................................................................................................................................T-Handle 51 lbs / 23 kg
Anti-Vibration Handle 55 lbs / 25 kg
Overall Length .....................................................................................................................T-Handle 25.5 in. / 65 cm
Anti-Vibration Handle 28.25 in. / 72 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/EHTMA Category ..................................................................................................................................Type 2
Nominal Pressure ............................................................................................................................. 1500 psi/103 bar
Max Pressure ................................................................................................................................... 2500 psi/138 bar
Max Relief Pressure ......................................................................................................................... 2150 psi/148 bar
BR45 Sound and Vibration Declaration
Test conducted on model BR45550
Measured A-weighted sound power level, Lwa (ref. 1pW) in decibels 105 dBA
Uncertainty, Kwa, in decibels 1.7 dBA
Measured A-weighted sound pressure level, Lpa (ref. 20 µPa) at operator’s position, in decibels 98 dBA
Uncertainty, Kpa, in decibels 3 dBA
Values determined according to noise test code given in ISO 15744, using the basic standard ISO3744
Test conducted by independent notied body to comply with 2000/14/EC:2005 requirements.
NOTE: The sum of a measured noise emission value and its associated uncertainty represents an upper
boundary of the range of values which is likely to occur in measurements.
Measured vibration emission value: 3-Axis (Trigger Handle)
Measured vibration emission value: 3-Axis (Non-Trigger Handle)
Uncertainty: K 2.38 m/sec²
Values Determined according to EN ISO 28927-10
18.9 m/sec²
19.1 m/sec²
BR45 User Manual ◄ 17
Page 18
ACCESSORIES
BR45 Anti-Vibe Sound and Vibration Declaration
Test conducted on model BR4516801
Measured A-weighted sound power level, Lwa (ref. 1pW) in decibels 105 dBA
Uncertainty, Kwa, in decibels 1.7
Measured A-weighted sound pressure level, Lpa (ref. 20 µPa) at operator’s position, in decibels 98 dBA
Uncertainty, Kpa, in decibels 3 dBA
Values determined according to noise test code given in ISO 15744, using the basic standard ISO3744
Test conducted by independent notied body to comply with 2000/14/EC:2005 requirements.
NOTE: The sum of a measured noise emission value and its associated uncertainty represents an upper
boundary of the range of values which is likely to occur in measurements.
Measured vibration emission value: 3-Axis (Trigger Handle)
Measured vibration emission value: 3-Axis (Non-Trigger Handle)
Uncertainty: K 2.11 m/sec²
Values Determined according to EN ISO 28927-10
BR45 Easy-Ride Sound and Vibration Declaration
Test conducted on model BR45120E
Measured A-weighted sound power level, Lwa (ref. 1pW) in decibels 105 dBA
Uncertainty, Kwa, in decibels 1.7
Measured A-weighted sound pressure level, Lpa (ref. 20 µPa) at operator’s position, in decibels 98 dBA
Uncertainty, Kpa, in decibels 3 dBA
Values determined according to noise test code given in ISO 15744, using the basic standard ISO3744
Test conducted by independent notied body to comply with 2000/14/EC:2005 requirements.
11.4 m/sec²
12.5 m/sec²
NOTE: The sum of a measured noise emission value and its associated uncertainty represents an upper
boundary of the range of values which is likely to occur in measurements.
Measured vibration emission value: 3-Axis (Trigger Handle)
Measured vibration emission value: 3-Axis (Non-Trigger Handle)
Uncertainty: K 1.84 m/sec²
Values Determined according to EN ISO 28927-10
13.6 m/sec²
15.2 m/sec²
7/8 IN. HEX × 3-1/4 IN. SHANK
Clay Spade 16 in./40.6 cm U/C 7/8” Hex............................................................................................................02328
3 in./76 mm Wide Chisel 14 in./35.6 cm U/C 7/8” Hex.......................................................................................02330
Asphalt Cutter 5 in./12.7 cm Wide Blade × 11 in./27.9 cm U/C 7/8” Hex............................................................02341
Moil Point 18 in./45.7 cm U/C 7/8” Hex...............................................................................................................04401
Moil Point 14 in./35.6 cm U/C 7/8” Hex Heavy Duty............................................................................................04961
Rod Driver 3/4 in./19 mm Cup - 7/8” Hex............................................................................................................05255
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
18 ► BR45 User Manual
Page 19
ACCESSORIES
Asphalt Wedge – 3 in. Wide ..............................................................................................................................07706
Lag bolt Driver 1”x4-1/4” Shank 5” Clearance ................................................................................................. 208001
Lag bolt Driver 1”x4-1/4” Shank 9” Clearance ................................................................................................... 73355
Spike Driver Bit Assembly .................................................................................................................................38709
Tie Tamper Steel 5” ........................................................................................................................................... 29431
1-1/8 IN. HEX × 6 IN. SHANK
Moil Point – 14 in. Long UC ............................................................................................................................... 02333
Chisel Point – 14 in. Long UC ...........................................................................................................................03990
3-inch Chisel – 14 in. Long UC .......................................................................................................................... 02334
Clay Spade – 5-1/2 in. Blade ............................................................................................................................. 02331
Asphalt Wedge – 12 in. .....................................................................................................................................08106
Asphalt Cutter – 5 in. Wide ................................................................................................................................ 02332
Ground Rod Driver – 1 in. Rod .......................................................................................................................... 04176
1-1/4 IN. HEX × 6 IN. SHANK
Moil Point – 14 in. Long UC ............................................................................................................................... 02336
3-inch Chisel – 14 in. Long UC .......................................................................................................................... 02337
Clay Spade – 5-1/2 in. Blade ............................................................................................................................. 09262
Asphalt Cutter – 5 in. Wide ................................................................................................................................ 02335
Ground Rod Driver – 1 in. Rod .......................................................................................................................... 04367
Heavy Duty Chisel – 1 in.. .................................................................................................................................02338
Heavy Duty Moil Point – 18 in. ..........................................................................................................................04404
Clay Spade – 8 in. .............................................................................................................................................04405
Detachable Shank (Requires 17783) ................................................................................................................17782
Tamping Pad – 6 in. (Requires 17782) .............................................................................................................. 17783
UC Denotes the under collar dimension measured from bottom tip of tool to bottom surface of collar.
TEST EQUIPMENT
Accumulator Tester ............................................................................................................................................ 02835
Flow and Pressure Tester .................................................................................................................................. 04182
Accumulator Charge Assembly (Includes Liquid Filled Gauge w/ Valve, Hose, & Charge Fitting) .................... 15304
Accumulator Charge Kit (Includes 02835 Tester, 15304 Charge Assy. and 372047 Charge Kit box) ...............31254
SERVICE TOOLS
Flow Sleeve Removal Tube ...............................................................................................................................04910
Seal Kit ..............................................................................................................................................................04595
Split Ring (Auto Valve Removal) .......................................................................................................................04908
Accumulator Cylinder Puller ..............................................................................................................................05640
Accumulator Disassembly Tool .......................................................................................................................... 05508
Spacer (Flow Sleeve Installation) ...................................................................................................................... 04909
BR45 User Manual ◄ 19
Page 20
BR45 T-HANDLE PARTS ILLUSTRATION
Pictured is a BR45120
NOTE: 5-GPM Model (BR45550) has a Orice Plug P/N-12832
Installed in the lower return port of item 27 Accumulator
On-O Valve Block (Orice Plug not pictured).
20 ► BR45 User Manual
See Pages 24 through 32 for Breaker Foot
Assemblies That Apply To Your Model.
Page 21
BR45 T-HANDLE PARTS LIST
ITEM
NO.
1 01652 2 HOSE WHIP 12"
2 02494 2 HANDLE GRIP
3 02900 2 ROLL PIN 1/8 O.D. X .500 LG.
4 03972 1 COUPLER,3/8FEM.3/8NPT
5 03973 1 COUPLER,3/8MALE 3/8NPT
6 04058 1 COMPRESSION COIL SPRING
7 04077 1 VALVE SPOOL
8 04371 1 TRIGGER
9 04373 4 SIDE ROD
10 04374 4 HEX NUT
11 04378 1 PORTING BLOCK
12 04379 2 O-RING■
13 04381 2 BACK-UP RING■
14 04382 1 AUTOMATIC VALVE
15 04383 1 FLOW SLEEVE TUBE
16 04571 2 PUSH PIN
17 04605 4 PUSH PIN
18 07479 1 ACCUMULATOR DIAPHRAGM
19 07480 1 AUTOMATIC VALVE BODY
20 07481 1 PISTON
21 07483 1 HANDLE
22 07485 1 FLOW SLEEVE
23 ----- -- NO ITEM
24 07492 2 ROLL PIN
25 07493 1 O-RING PLUG MALE
26 04057 1 BUSHING
27 11588 1 ACCUMULATOR ON-OFF
28 20499 1 CHARGE VALVE
42 00293 1 O-RING■
43 01362 1 O-RING■
44 04056 1 ROD WIPER■
45 72919 2 FILLER (SNAP ON)
46 74832 2 STANLEY LOGO STICKER
PART
NO.
12833 1 PISTON (BR45550) (5-GPM
74770 2 STANLEY LOGO STICKER
QTY DESCRIPTION
FL.FACE SET 03971
FL.FACE SET 03971
MODEL ONLY)
VALVE BLOCK
(5.5” x 1.1” Black on Clear)
(6.5” x 1.3” Yellow on Clear)
ITEM
NO.
47 74664 1 NAME TAG BR45 (8-GPM)
SEAL KIT PART NUMBER 04595
■ DENOTES PART IN SEAL KIT
* DENOTES PART OF BREAKER FOOT ASSEMBLY
BUSHING ASSY 07699 (INCLUDES ITEMS 26, 42, 43,
and 44)
PART
NO.
74660 1 NAME TAG BR45 (5-GPM)
74669 1 NAME TAG BR45 (8-GPM)
QTY DESCRIPTION
T-HANDLE MODELS
T-HANDLE MODELS
T-HANDLE U/W MODEL
BR45 User Manual ◄ 21
Page 22
BR45 ANTI-VIBRATION HANDLE PARTS ILLUSTRATION
Pictured is a BR4516801
NOTE: 5-GPM Model (BR4556801) has a Orice Plug
P/N-12832 installed in the lower return port of item 25
Accumulator On-O Valve Block (Orice Plug not pictured).
22 ► BR45 User Manual
See Pages 24 through 32 for Breaker Foot
Assemblies That Apply To Your Model.
Page 23
BR45 ANTI-VIBRATION HANDLE PARTS LIST
ITEM
NO.
27* 20498 2 SPRING
27A* 20541 2 SPRING BR45158/BR45158BN
PART
NO.
1 01652 2 HOSE WHIP 12"
56725 2 HOSE ASSY 18” BR45158
66727 2 HOSE ASSY BR45158BN
2 02494 2 HANDLE GRIP
3 02900 2 ROLL PIN
4 03972 1 COUPLER,3/8FEM. 3/8NPT
5 03973 1 COUPLER,3/8MALE 3/8NPT
6 04058 1 COMPRESSION COIL SPRING
7 04374 4 HEX NUT
8 04378 1 PORTING BLOCK
9 04379 2 O-RING*
10 04381 2 BACK-UP RING*
11 04382 1 AUTOMATIC VALVE
12 04383 1 FLOW SLEEVE TUBE
13 04571 2 PUSH PIN
14 04605 4 PUSH PIN
15 07479 1 ACCUMULATOR DIAPHRAGM
16 07480 1 AUTOMATIC VALVE BODY
17 07481 1 PISTON
12833 1 PISTON (BR4556801) (5-GPM
18 07485 1 FLOW SLEEVE
19 07493 1 PLUG - BR4514801,
21 07624 1 ROLL PIN
22 07699 1 ◘ BUSHING ASSY.
23 10180 1 CAUTION N2 GAS STICKER
24 11207 1 CIRCUIT TYPE "D" STICKER
25 11588 1 ACCUMULATOR VALVE BLOCK
26 74832 2 STANLEY LOGO (5.5” x 1.1”
74770 STANLEY LOGO (6.5” x 1.3”
20540 2 SPRING BR45158/BR45158BN
QTY DESCRIPTION
FL.FACE SET 03971
FL.FACE SET 03971
MODEL ONLY)
BR4516801, BR4516807
Black on Clear)
Yellow on Clear)
ITEM
NO.
SEAL KIT PART NUMBER 04595
■ DENOTES PART IN SEAL KIT
* DENOTES PART OF BREAKER FOOT ASSEMBLY
◘ BUSHING ASSY 07699 (INCLUDES ITEMS 22, 47, 48,
and 49)
PART
NO.
28 20499 1 CHARGE VALVE
29 20500 2 ROLL PIN
30 20505 1 HANDLE PIVOT BLOCK
31 20508 2 PIVOT SCREW
32 20511 1 LEVER
33 20515 1 VALVE SPOOL
34 20517 4 SIDE ROD
35 28322 1 STICKER "CE"
36 28369 1 HANDLE (GUARDED)
37 28409 1 COMPOSITE STICKER
38 28494 1 TOP PLATE
39 58526 1 CAST TRIGGER
40 58527 1 TRIGGER LOCK
41 58529 1 TRIGGER HANDLE (WITH
42 58601 1 GUARANTEED SOUND
43 66828 1 TORSION SPRING
45 72919 2 FILLER (SNAP-ON)
46 74663 1 NAME TAG-BR45 8-GPM
74659 1 NAME TAG-BR45 5-GPM
47 00293 1 O-RING*
48 01362 1 O-RING*
49 04056 1 ROD WIPER*
52 04393 1 DETENT
QTY DESCRIPTION
TRIGGER LOCK
POWER LEVEL - 107dB
* Models BR45125S, BR45135S,
BR4513516, BR45158, BR45158BN
and BR4556801 use parts 27 and 27A.
BR45 User Manual ◄ 23
Page 24
BREAKER FOOT ASSEMBLY 07489
BREAKER FOOT ASSEMBLY (STANDARD) P/N-07489 (MODELS BR45150, BR45550, BR45158, BR45158BN)
07489 Assembly Includes Items 1 through 13 Below.
ITEM PART # QTY DESCRIPTION
1 02022 1 O-RING
2 04374 1 HEX NUT
3 04386 1 CUP SEAL
4 04387 1 ROD WIPER
5 04392 1 SPRING
6 04393 1 DETENT
7 04394 1 LATCH
8 04715 2 TAPER SLEEVE
9 04716 2 SPRING WASHER
10 04717 1 LATCH BOLT
11 04780 1 BACK UP WASHER
NOTE: IF YOU ARE REPLACING THE INSERT, BREAKER
FOOT OR HEX BUSHING YOU MUST PURCHASE A
COMPLETE BREAKER FOOT ASSEMBLY P/N-72931
13
12
5
7
12 07489 1 BREAKER FOOT - IF
ORDERING BREAKER
FOOT YOU MUST ORDER
COMPLETE FOOT ASSY
07489.
13 07489 1 HEX BUSHING 1" IF
ORDERING HEX BUSHING
YOU MUST ORDER
COMPLETE FOOT ASSY
07489.
1” HEX
6
2
8
9
1
10
3
11
4
ALIGN HEX AS SHOWN
24 ► BR45 User Manual
Page 25
BREAKER FOOT ASSEMBLY 07510
BREAKER FOOT ASSEMBLY (STANDARD) P/N-07510 (MODELS BR4516801, BR4516807, BR4516807A and
BR4556801). 07510 Assembly Includes Items 1 through 13 Below.
ITEM PART # QTY DESCRIPTION
1 02022 1 O-RING
2 04374 1 HEX NUT
3 04386 1 CUP SEAL
4 04387 1 ROD WIPER
5 04392 1 SPRING
6 04393 1 DETENT
7 04394 1 LATCH
8 04715 2 TAPER SLEEVE
9 04716 2 SPRING WASHER
10 04717 1 LATCH BOLT
NOTE: IF YOU ARE REPLACING THE INSERT, BREAKER
FOOT OR HEX BUSHING YOU MUST PURCHASE A
COMPLETE BREAKER FOOT ASSEMBLY P/N-72931
13
12
5
7
ITEM PART # QTY DESCRIPTION
11 04780 1 BACK UP WASHER
12 07510 1 BREAKER FOOT - IF
ORDERING BREAKER
FOOT YOU MUST ORDER
COMPLETE FOOT ASSY
07510.
13 07510 1 HEX BUSHING 1" - IF
ORDERING HEX BUSHING
YOU MUST ORDER
COMPLETE FOOT ASSY
07510
1” HEX
6
2
8
9
1
10
11
43
ALIGN HEX AS SHOWN
BR45 User Manual ◄ 25
Page 26
BREAKER FOOT ASSEMBLY 07694
BREAKER FOOT ASSEMBLY (STANDARD) P/N-07694 (MODEL BR4514801)
07694 Assembly Includes Items 1 through 13 Below.
ITEM PART # QTY DESCRIPTION
1 07694 1 HEX BUSHING 7/8” - IF
ORDERING HEX BUSHING
YOU MUST ORDER
COMPLETE FOOT ASSY
07694
2 02022 1 O-RING
3 04374 1 HEX NUT
4 04386 1 CUP SEAL
5 04387 1 ROD WIPER
6 04392 1 SPRING
7 04393 1 DETENT
8 04394 1 LATCH
NOTE: IF YOU ARE REPLACING THE INSERT, BREAKER
FOOT OR HEX BUSHING YOU MUST PURCHASE A
COMPLETE BREAKER FOOT ASSEMBLY P/N-72931
1
13
6
8
7
ITEM PART # QTY DESCRIPTION
9 04715 2 TAPER SLEEVE
10 04716 2 SPRING WASHER
11 04717 1 LATCH BOLT
12 04780 1 BACK UP WASHER
13 07694 1 BREAKER FOOT - IF
ORDERING BREAKER
FOOT YOU MUST ORDER
COMPLETE FOOT ASSY
07694.
7/8” HEX
9
10
3
9
10
11
2
4
12
5
ALIGN HEX AS SHOWN
26 ► BR45 User Manual
Page 27
BREAKER FOOT ASSEMBLY 07899
BREAKER FOOT ASSEMBLY (STANDARD) P/N-07899 (MODEL BR45110)
07899 Assembly Includes Items 1 through 13 Below.
ITEM PART # QTY DESCRIPTION
1 07899 1 HEX BUSHING - IF
ORDERING HEX BUSHING
YOU MUST ORDER
COMPLETE FOOT ASSY
07899
2 02022 1 O-RING
3 04374 1 HEX NUT
4 04386 1 CUP SEAL
5 04387 1 ROD WIPER
6 04392 1 SPRING
ITEM PART # QTY DESCRIPTION
7 04393 1 DETENT
8 04394 1 LATCH
NOTE: IF YOU ARE REPLACING THE INSERT, BREAKER
FOOT OR HEX BUSHING YOU MUST PURCHASE A
COMPLETE BREAKER FOOT ASSEMBLY P/N-72931
1
13
6
8
7
9 04715 2 TAPER SLEEVE
10 04716 2 SPRING WASHER
11 04717 1 LATCH BOLT
12 04780 1 BACK UP WASHER
13 07899 1 BREAKER FOOT - IF
ORDERING BREAKER
FOOT YOU MUST ORDER
COMPLETE FOOT ASSY
07899
7/8” HEX
9
10
3
9
10
11
2
4
12
5
ALIGN HEX AS SHOWN
BR45 User Manual ◄ 27
Page 28
BREAKER FOOT ASSEMBLY 08081
BREAKER FOOT ASSEMBLY (EASY-RIDE) P/N-08081 (MODELS BR45130E, BR45130EL, BR45135S and
BR4513516). 08081 Assembly Includes Items 1 through 17 Below.
ITEM PART # QTY DESCRIPTION
1 01269 2 TAPER SLEEVE
2 01744 1 SPRING
3 01837 1 LATCH
4 02022 1 O-RING
5 04386 1 CUP SEAL
6 04387 1 ROD WIPER
7 04780 1 BACK UP WASHER
8 04983 1 FOOT LATCH BOLT
9 04984 1 NYLOCK NUT
10 04985 2 SPRING WASHER
11 08081 1 HEX BUSHING 1-1/4" - IF
ORDERING HEX BUSHING
YOU MUST ORDER
COMPLETE FOOT ASSY
08081
NOTE: IF YOU ARE REPLACING THE INSERT, BREAKER
FOOT OR HEX BUSHING YOU MUST PURCHASE A
COMPLETE BREAKER FOOT ASSEMBLY P/N-72931.
11
4
14
15
ITEM PART # QTY DESCRIPTION
12 07522 1 RETAINING RING
13 08116 1 COLLAR SUPPORT ASSY.
14 08081 1 BREAKER FOOT - IF
ORDERING BREAKER
FOOT YOU MUST ORDER
COMPLETE FOOT ASSY
08081
15 08158 1 SPRING
16 08081 1 INSERT - IF ORDERING
THE INSERT YOU MUST
ORDER COMPLETE FOOT
ASSY 08081
17 08411 1 DETENT
1-1/4” HEX
10
2
3
9
1
10
1
8
5
6
7
16
28 ► BR45 User Manual
13
12
ALIGN HEX AS SHOWN
17
Page 29
BREAKER FOOT ASSEMBLY 08154
BREAKER FOOT ASSEMBLY (EASY-RIDE) P/N-08154 (MODELS BR45120E and BR45125S)
08154 Assembly Includes Items 1 through 17 Below.
ITEM PART # QTY DESCRIPTION
1 01269 2 TAPER SLEEVE
2 01744 1 SPRING
3 01837 1 LATCH
4 02022 1 O-RING
5 04386 1 CUP SEAL
6 04387 1 ROD WIPER
7 04780 1 BACK UP WASHER
8 04983 1 FOOT LATCH BOLT
9 04984 1 NYLOCK NUT
10 04985 2 SPRING WASHER
11 08154 1 HEX BUSHING 1-1/8" - IF
ORDERING HEX BUSHING
YOU MUST ORDER
COMPLETE FOOT ASSY
08154
NOTE: IF YOU ARE REPLACING THE INSERT, BREAKER
FOOT OR HEX BUSHING YOU MUST PURCHASE A
COMPLETE BREAKER FOOT ASSEMBLY P/N-72931.
11
4
14
15
12 07522 1 RETAINING RING
13 08115 1 COLLAR SUPPORT ASSY.
14 08154 1 BREAKER FOOT - IF
ORDERING BREAKER
FOOT YOU MUST ORDER
COMPLETE FOOT ASSY
08154
15 08158 1 SPRING
16 08154 1 INSERT - IF ORDERING
THE INSERT YOU MUST
ORDER COMPLETE FOOT
ASSY 08154
17 08411 1 DETENT
1-1/8” HEX
10
2
3
9
1
1
10
8
5
6
7
16
13
12
ALIGN HEX AS SHOWN
17
BR45 User Manual ◄ 29
Page 30
BREAKER FOOT ASSEMBLY 08856
BREAKER FOOT ASSEMBLY (UNDERWATER) P/N-08856 (MODELS BR45350)
08856 Assembly Includes Items 1 through 13 Below.
ITEM PART # QTY DESCRIPTION
1 02022 1 O-RING
2 04374 1 HEX NUT
3 04386 1 CUP SEAL
4 04387 1 ROD WIPER
5 04392 1 SPRING
6 04393 1 DETENT
7 04394 1 LATCH
8 04715 2 TAPER SLEEVE
9 04716 2 SPRING WASHER
10 04717 1 LATCH BOLT
NOTE: IF YOU ARE REPLACING THE INSERT, BREAKER
FOOT OR HEX BUSHING YOU MUST PURCHASE A
COMPLETE BREAKER FOOT ASSEMBLY P/N-72931
12
1
UNDERWATER BREAKER
7
ITEM PART # QTY DESCRIPTION
11 04780 1 BACK UP WASHER
12 08856 1 HEX BUSHING 1" - IF
13 08856 1 BREAKER FOOT U/W - IF
FOOT ASSY
1” HEX
2
9
ORDERING HEX BUSHING
YOU MUST ORDER
COMPLETE FOOT ASSY
08856
ORDERING BREAKER
FOOT YOU MUST ORDER
COMPLETE FOOT ASSY
08856
8
8
9
10
3
30 ► BR45 User Manual
11
4
13
ALIGN HEX AS SHOWN
5
6
Page 31
BREAKER FOOT ASSEMBLY 62334
BREAKER FOOT ASSEMBLY (STANDARD) P/N-62334 (MODELS BR45120 and BR45120D)
62334 Assembly Includes Items 1 through 14 Below.
ITEM PART # QTY DESCRIPTION
1 01269 2 TAPER SLEEVE
2 01744 1 SPRING
3 01837 1 LATCH
4 02022 1 O-RING
5 62334 1 HEX BUSHING 1-1/8" - IF
ORDERING HEX BUSHING
YOU MUST ORDER
COMPLETE FOOT ASSY
62334
6 04386 1 CUP SEAL
7 04387 1 ROD WIPER
8 04780 1 BACK UP WASHER
9 04983 1 FOOT LATCH BOLT
NOTE: IF YOU ARE REPLACING THE INSERT, BREAKER
FOOT OR HEX BUSHING YOU MUST PURCHASE A
COMPLETE BREAKER FOOT ASSEMBLY P/N-72931.
12
ITEM PART # QTY DESCRIPTION
10 04984 1 NYLOCK NUT
11 04985 2 SPRING WASHER
12 62334 1 INSERT - IF ORDERING
THE INSERT YOU MUST
ORDER COMPLETE FOOT
ASSY 62334
13 08411 1 DETENT
14 62334 1 BREAKER FOOT - IF
ORDERING BREAKER
FOOT YOU MUST ORDER
COMPLETE FOOT ASSY
62334
1-1/8” HEX
6
4
8
7
5
3
14
2
13
10
11
1
1
ALIGN HEX AS SHOWN
11
9
BR45 User Manual ◄ 31
Page 32
BREAKER FOOT ASSEMBLY 72931
BREAKER FOOT ASSEMBLY (STANDARD) P/N-72931 (MODEL BR45130)
72931 Assembly Includes Items 1 through 14 Below.
ITEM PART # QTY DESCRIPTION
1 01269 2 TAPER SLEEVE
2 01744 1 SPRING
3 01837 1 LATCH
4 02022 1 O-RING
5 04386 1 CUP SEAL
6 04387 1 ROD WIPER
7 72931 1 HEX BUSHING 1-1/4" - IF
ORDERING HEX BUSHING
YOU MUST ORDER
COMPLETE FOOT ASSY
72931
8 04780 1 BACK UP WASHER
9 04983 1 FOOT LATCH BOLT
10 04984 1 NYLOCK NUT
NOTE: IF YOU ARE REPLACING THE INSERT, BREAKER
FOOT OR HEX BUSHING YOU MUST PURCHASE A
COMPLETE BREAKER FOOT ASSEMBLY P/N-72931
12
ITEM PART # QTY DESCRIPTION
11 04985 2 SPRING WASHER
12 72931 1 INSERT - IF ORDERING THE
INSERT YOU MUST ORDER
COMPLETE FOOT ASSY
72931
13 08411 1 DETENT
14 72931 1 BREAKER FOOT - IF
ORDERING BREAKER
FOOT YOU MUST ORDER
COMPLETE FOOT ASSY
72931
1-1/4” HEX
5
4
8
6
7
3
14
2
13
10
11
11
1
1
ALIGN HEX AS SHOWN
9
32 ► BR45 User Manual
Page 33
UNDERWATER TOOLS DEPTH GUIDELINE
UNDERWATER MODELS ONLY
Do not use hydraulic tools underwater that are not
designated as an “underwater” model, or this will
result in damage to the tool.
For underwater hydraulic tools the
applications are broken down into four
quadrants depending on type of tool and
method of operation.
OPERATION OVERVIEW
PERCUSSIVE ROTATIONAL
Tools: Breakers,
Hammer Drills and
Chipping Hammers
Max Depth: 500’ -
DIVER
limitations due to
accumulator PSI
max (increase 40
PSI for every 100’)
Tools: Grinders,
Saws, Chain Saws
Max Depth: 1000’
- Reference hose
sizing guide below
The types of tools are percussive and
rotational, each with di erent characteristics
allowing for di erent depth operation. With
percussive tools, the nitrogen accumulator
PSI must counter the increase in ambient
pressure found at lower depths. Since there is
a maximum PSI for percussive tools they are
limited to certain depths. Rotational tools do
not have accumulators and thus are capable
of deeper depths.
The methods are broken into diver operated
or remote operated vehicle (ROV). ROV’s
can reach lower depths and with an onboard
hydraulic power source that is depth
compensated, can operate hydraulic tools at
depths of thousands of feet. ROV operation
is still limited to the tool, for example a
percussive tool has the same depth limitation
whether ROV or diver operated.
Tools: Breakers,
Hammer Drills and
Tools: Grinders,
Saws, Chain Saws
Chipping Hammers
Max Depth: 1000’
Max Depth: 500’ -
ROV
limitations due to
- Reference hose
sizing guide below
accumulator PSI
max (increase 40
PSI for every 100’)
RECOMMENDED HOSE DIAMETERS
DEPTH (FT) 8 GPM 12 GPM
100 5/8” 5/8”
300 3/4” 1”
600 1” 1”
1000 1” 1-1/4”
BR45 User Manual ◄ 33
Page 34
Page 35
Page 36
STANLEY Infrastructure
6430 SE Lake Road
Portland, Oregon 97222 USA
(503) 659-5660 / Fax (503) 652-1780
www.stanleyinfrastructure.com
Loading...