A hydraulic breaker is a powerful tool on any job site, but like all heavy machinery, it's subject to wear and tear. Timely maintenance and proper repairs are crucial not only for extending its lifespan but also for ensuring peak performance. This blog post will walk you through some of the most common hydraulic breaker issues and provide practical tips for troubleshooting them.
Before we dive into repairs, let's briefly review how a hydraulic breaker works. It uses the hydraulic pressure from an excavator or backhoe to drive a piston up and down inside a cylinder. When the piston moves down, it strikes the chisel with great force, which in turn breaks rock or concrete. The key components in this process are the piston, oil seals, chisel, and the high- and low-pressure accumulators.
When your hydraulic breaker isn't performing as it should, there are usually some clear signs. Here are some of the most common issues and their potential solutions.
1. Low Impact Power or No Striking
This is one of the most frequent problems. If your breaker's impact force is weak or it's not striking at all, the causes could be:
Insufficient Hydraulic Oil Flow or Pressure: Check your excavator's hydraulic system to make sure the pump output meets the breaker's requirements.
Incorrect Nitrogen Pressure: The high- and low-pressure accumulators in the breaker need to be filled with the correct amount of nitrogen gas to provide a stable impact force. Pressure that's too high or too low will affect performance. Use a specialized nitrogen gauge to measure and recharge the gas.
Worn Piston or Chisel: After extended use, the gaps between the piston and the cylinder, and the chisel and the bushings, can widen. This leads to oil leakage and a drop in impact power. If the wear is severe, you'll need to replace the piston or chisel.
Damaged Oil Seals: If the oil seals on the piston are damaged, hydraulic oil will leak, causing a drop in pressure. Inspect and replace any damaged seals.
Quick Tip: If you notice a drop in impact power, the first step should always be to check and adjust the nitrogen pressure. This is the simplest and most common fix.
2. Oil Leaks
Hydraulic breaker oil leaks are not only an environmental concern but also a performance issue. Leaks usually occur at these points:
Hose Connections: Check if the hydraulic hoses connecting to the breaker are loose or if the seals are damaged.
Oil Seals: If the oil seals on the piston or cylinder are old or damaged, hydraulic oil will leak from the bottom of the breaker or the piston rod.
Accumulator Cover: Damaged accumulator seals can also cause oil leaks.
Repair Advice: Once you find the leak, tighten the connections or replace the corresponding seals. Always use OEM or high-quality seals to ensure durability.
3. Chisel Breakage or Abnormal Wear
The chisel is the part that directly contacts the material and endures immense impact. Breakage or abnormal wear is usually related to:
Improper Operation: "Blank firing"—striking without material—causes the piston to hit the bottom of the chisel directly, generating excessive force that can lead to chisel or bolt breakage. The correct way to operate is to start striking only after the breaker is in contact with the material.
Poor Chisel Quality: Using a low-quality or mismatched chisel can cause it to wear out quickly or break during use.
Worn Chisel Bushings: If the chisel bushings are worn, the chisel will wobble during operation, leading to uneven stress and accelerated wear on both the chisel and the bushings. Regularly inspect and replace worn bushings.
Preventive Measures: Train operators to avoid blank firing, and regularly inspect the condition of the chisel and bushings, replacing them as needed.
Proper maintenance is key to a long-lasting hydraulic breaker. Here are some daily and routine maintenance tips:
Daily Inspection: Before starting work, check if the chisel is in good condition, if there are any oil leaks, and if all bolts are tight.
Regular Lubrication: Use the specified grease to lubricate the contact surface between the chisel and the bushings.
Check Nitrogen Pressure: Periodically (e.g., weekly or monthly), check and adjust the nitrogen pressure in the accumulators.
Use High-Quality Hydraulic Oil: Use hydraulic oil that meets your equipment's specifications and regularly replace the oil filter to keep the hydraulic system clean.
If you're in the market for a new hydraulic breaker or need high-quality replacement parts, we highly recommend Beilite. With decades of experience in manufacturing hydraulic breakers, Beilite is a trusted name in the industry. Known for their robust design, high impact efficiency, and durability, Beilite breakers are built to handle the toughest jobs.
Beilite's website is a great resource for technical information and parts: https://www.beilite.com/en/index.html
We hope this blog post helps you better understand and maintain your hydraulic breaker. If you encounter more complex problems, it's always best to contact a professional repair technician to avoid causing further damage.