Stanley BR4514801 User manual

© 2014 STANLEY Black & Decker, Inc.
New Britain, CT 06053
U.S.A.
62388 9/2018 Ver. 18
BR45
HYDRAULIC
BREAKER
USER MANUAL
Safety, Operation and Maintenance

2 ► BR45 User Manual
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

BR45 User Manual ◄ 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
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 certied dealer. Please read the following warning.
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.
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 certied dealer, call STANLEY Infrastructure at [phone] and ask for a Customer Service Representative.

4 ► BR45 User Manual
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.
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.
SAFETY SYMBOLS
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 specic 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.

BR45 User Manual ◄ 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 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
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 de-
cals 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 gener-
ate 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 chemically-
treated 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 qualied 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

6 ► BR45 User Manual
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
Specications 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.

BR45 User Manual ◄ 7
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.
Please refer to the Parts Illustration for location of stickers.
28322 CE
Sticker (CE Only)
107
Lwa
58601 Sound Level
Sticker (CE Only)
28409 Composite
Sticker (CE Only)
11207 Circuit Type C
Sticker (CE Only)
11208 Hex Shank
Length Sticker
SAFETY TAG P/N 15875 (Shown smaller then actual size)
DANGERDANGER
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
1. FAILURE TO USE HYDRAULIC HOSE LABELED AND CER-
TIFIED 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 CUR-
RENT LEAKAGE IN ACCORDANCE WITH YOUR SAFETY
DEPARTMENT INSTRUCTIONS.
2. A HYDRAULIC LEAK OR BURST MAY CAUSE OIL INJEC-
TION 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
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 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.
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 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 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.
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
10180 Caution Sticker
74659 5-GPM Anti-Vib Name
Tag Sticker
74663 8-GPM Anti-Vib Name
Tag Sticker
74664 8-GPM T-Handle Name
Tag Sticker
74660 5-GPM T-Handle Name
Tag Sticker
TOOL STICKERS & TAGS
BR45 BREAKER
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.
74832 STANLEY Logo 5.5” x 1.1” Black on Clear
74770 STANLEY Logo 6.5” x 1.3” Yellow on Clear
STANLEY Railroad Help Desk Sticker (Not Pictured)
P/N-73680

8 ► BR45 User Manual
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
THE TAG SHOWN BELOW IS ATTACHED TO “CONDUCTIVE” HOSE.
(Shown smaller than actual size)
SIDE 1
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 HOSEAND 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.
SEE OTHER SIDE
SIDE 2
DO NOT REMOVE THIS TAG
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 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
DANGER
DO NOT REMOVE THIS TAG
DANGER
(Shown smaller than actual size)
SIDE 2
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.
DANGER
DO NOT REMOVE THIS TAG
DANGER
SIDE 1
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 ELEC-
TRIC 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
DANGER
SEE OTHER SIDE SEE OTHER SIDE
HOSE TYPES

BR45 User Manual ◄ 9
Oil Flow Hose Lengths Inside Diameter USE
(Press/Return)
Min. Working Pressure
GPM LPM FEET METERS INCH MM PSI BAR
Certi ed Non-Conductive Hose - Fiber Braid - for Utility Bucket Trucks
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 5-10.5 19-40 100-300 30-90 5/8 16 Pressure 2500 175
3/4 19 Return 2500 175
10-13 38-49 up to 50 up to 15 5/8 16 Both 2500 175 10-13 38-49 51-100 15-30 5/8 16 Pressure 2500 175
3/4 19 Return 2500 175
10-13 38-49 100-200 30-60 3/4 19 Pressure 2500 175
1 25.4 Return 2500 175
13-16 49-60 up to 25 up to 8
5/8 16 Pressure 2500 175 3/4 19 Return 2500 175
13-16 49-60 26-100 8-30
3/4 19 Pressure 2500 175
1 25.4 Return 2500 175
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.
PRESSURE
RETURN
<<< FLOW
FLOW >>>
HOSE RECOMMENDATIONS

10 ► BR45 User Manual
HTMA / EHTMA REQUIREMENTS
TOOL TYPE
HTMA
HYDRAULIC SYSTEM REQUIREMENTS TYPE I TYPE II TYPE RR TYPE III
Flow range 4-6 GPM
(15-23 LPM)
7-9 GPM
(26-34 LPM)
9-10.5 GPM
(34-40 LPM)
11-13 GPM
(42-49 LPM)
Nominal operating pressure
(At the power supply outlet)
1500 psi
(103 bar)
1500 psi
(103 bar)
1500 psi
(103 bar)
1500 psi
(103 bar)
System relief valve setting
(At the power supply outlet)
2100-2250 psi
(145-155 bar)
2100-2250 psi
(145-155 bar)
2200-2300 psi
(152-159 bar)
2100-2250 psi
(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  uid viscosity of:
(At minimum operating temperature)
400 ssu*
(82 centistokes)
400 ssu*
(82 centistokes)
400 ssu*
(82 centistokes)
400 ssu*
(82 centistokes)
Temperature: Suffi cient heat rejection capacity to limit
maximum  uid temperature to:
(At maximum expected ambient temperature)
140° F
(60° C)
140° F
(60° C)
140° F
(60° C)
140° F
(60° C)
Minimum cooling capacity at a temperature di󰀨 erence of
between ambient and  uid temps
3 hp
(2.24 kW)
40° F
(22° C)
5 hp
(3.73 kW)
40° F
(22° C)
6 hp
(5.22 kW)
40° F
(22° C)
7 hp
(4.47 kW)
40° F
(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 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)
30 GPM
(114 LPM)
30 GPM
(114 LPM)
30 GPM
(114 LPM)
30 GPM
(114 LPM)
Hydraulic  uid, petroleum based (premium grade, anti-
wear, non-conductive) Viscosity (at minimum and maximum
operating temps)
100-400 ssu
(20-82
centistokes)
100-400 ssu
(20-82
centistokes)
100-400 ssu
(20-82
centistokes)
100-400 ssu
(20-82
centistokes)
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.
*SSU = Saybolt Seconds Universal
CLASSIFICATION
EHTMA
HYDRAULIC SYSTEM
REQUIREMENTS BCD
Flow range
3.5-4.3 GPM
(13.5-16.5
LPM)
4.7-5.8 GPM
(18-22 LPM)
7.1-8.7 GPM
(27-33 LPM)
9.5-11.6 GPM
(36-44 LPM)
11.8-14.5 GPM
(45-55 LPM)
Nominal operating pressure
(At the power supply outlet)
1870 psi
(129 bar)
1500 psi
(103 bar)
1500 psi
(103 bar)
1500 psi
(103 bar)
1500 psi
(103 bar)
System relief valve setting
(At the power supply outlet)
2495 psi
(172 bar)
2000 psi
(138 bar)
2000 psi
(138 bar)
2000 psi
(138 bar)
2000 psi
(138 bar)
Note: These are general hydraulic system requirements. See tool speci cation page for tool speci c requirements.
HTMA / EHTMA REQUIREMENTS

BR45 User Manual ◄ 11
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.
CONNECT HOSES
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 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 di󰀩cult 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.
OPERATION
1
2
3
4
5
6
Figure 2 - Installing the Bit
Figure 3 - Tool Use

12 ► BR45 User Manual
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.
Figure 4 - Underwater Maintenance

BR45 User Manual ◄ 13
• 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
Specications in this manual for correct ow rate
and pressure rating. Rapid failure of the internal
seals may result.
In addition to the Safety Precautions found in
this manual, observe the following for equipment
protection and care.
• 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.
TOOL PROTECTION & CARE

14 ► BR45 User Manual
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.
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 e󰀨ectively. 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. Proper ow and
pressure maintain proper tool speed.
Couplers or hoses blocked. Remove restriction.
Low accumulator charge
(pressure hose will pulse more
than normal).
Recharge accumulator. Replace diaphragm if
charge loss continues.
Fluid too hot
(above 140 °F/60 °C).
Provide cooler to maintain proper uid
temperature (130 °F/55 °C).
Tool operates slow. Low GPM supply from power
unit.
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.
High back-pressure. Check hydraulic system for excessive back-
pressure (over 200 psi/14 bar).
Couplers or hoses blocked. Remove restriction.
Orice plug blocked. Remove restriction.
Fluid too hot
(above 140 °F/60 °C) or too cold
(below 60 °F/16 °C).
Check power unit for proper uid temperature.
Bypass cooler to warm the uid 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 uid going through tool. Check power unit. Be sure ow rate is not too
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.
Fluid leakage on tool bit. Lower piston seal failure. Replace seal.
Fluid leakage around trigger. Valve spool seal failure. Replace seals.
TROUBLESHOOTING

BR45 User Manual ◄ 15
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)
1.
This assembly contains nitrogen under pressure
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
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/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 paragraph.
6. Install the plug.
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
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 650-
700 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.
CHARGING THE ACCUMULATOR

16 ► BR45 User Manual
GAUGE
CHUCK
TESTER CHARGING
VALVE
CW
ACCUMULATOR TESTER( P/N 02835 ) LOCATION OF CHARGING VALVE
GAUGE
CHUCK
TESTER CHARGING
VALVE
CW
ACCUMULATOR TESTER( P/N 02835 ) LOCATION OF CHARGING VALVE
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

BR45 User Manual ◄ 17
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
SPECIFICATIONS
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 notied 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) 18.9 m/sec²
Measured vibration emission value: 3-Axis (Non-Trigger Handle) 19.1 m/sec²
Uncertainty: K 2.38 m/sec²
Values Determined according to EN ISO 28927-10

18 ► BR45 User Manual
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 notied 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) 11.4 m/sec²
Measured vibration emission value: 3-Axis (Non-Trigger Handle) 12.5 m/sec²
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 notied 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) 13.6 m/sec²
Measured vibration emission value: 3-Axis (Non-Trigger Handle) 15.2 m/sec²
Uncertainty: K 1.84 m/sec²
Values Determined according to EN ISO 28927-10
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

BR45 User Manual ◄ 19
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
ACCESSORIES

20 ► BR45 User Manual
BR45 T-HANDLE PARTS ILLUSTRATION
Pictured is a BR45120
See Pages 24 through 32 for Breaker Foot
Assemblies That Apply To Your Model.
NOTE: 5-GPM Model (BR45550) has a Orice Plug P/N-12832
Installed in the lower return port of item 27 Accumulator
On-O󰀨 Valve Block (Orice Plug not pictured).