Troubleshooting a hydraulic breaker is a critical skill for anyone involved in the construction or demolition industry. As a hydraulic breaker supplier, I’ve seen firsthand the impact that a malfunctioning breaker can have on a project’s timeline and budget. In this blog post, I’ll share some of the most common issues that you might encounter with a hydraulic breaker and provide step – by – step solutions to troubleshoot them. Hydraulic Breaker
1. No Impact or Reduced Impact Force
Possible Causes
- Low Hydraulic Pressure: If the hydraulic pressure supplied to the breaker is insufficient, it won’t be able to generate the necessary force to break materials. This could be due to problems with the hydraulic pump, hoses, or valves.
- Blunt Chisel: An over – worn or damaged chisel can’t transfer the energy effectively, resulting in reduced impact force.
- Air in the Hydraulic System: Air bubbles in the hydraulic fluid can compress, absorbing some of the energy that should be used for breaking.
Troubleshooting Steps
- Check Hydraulic Pressure: Use a pressure gauge to measure the hydraulic pressure at the inlet of the breaker. Compare the reading with the manufacturer’s specifications. If the pressure is low, inspect the hydraulic pump for any signs of damage or wear. Check the hoses for leaks and the valves for proper operation. Replace any faulty components as needed.
- Inspect the Chisel: Examine the chisel for signs of excessive wear, such as a rounded tip or cracks. If the chisel is worn out, replace it with a new one. Make sure to choose the correct chisel for the type of material you’re working on.
- Bleed the Hydraulic System: To remove air from the hydraulic system, follow the manufacturer’s instructions for bleeding. This usually involves opening a bleed valve and running the hydraulic system until all the air is expelled.
2. Excessive Noise and Vibration
Possible Causes
- Loose Components: Loose bolts, nuts, or other components can cause excessive noise and vibration during the operation of the breaker.
- Incorrect Installation: If the breaker is not installed correctly on the carrier machine, it can lead to uneven stress distribution and increased noise and vibration.
- Worn – Out Internal Parts: Over time, the internal parts of the breaker, such as the piston and bushings, can wear out, causing abnormal noise and vibration.
Troubleshooting Steps
- Tighten Loose Components: Inspect all the bolts and nuts on the breaker and tighten them to the recommended torque specifications. Use a torque wrench to ensure accurate tightening.
- Check Installation: Verify that the breaker is installed correctly on the carrier machine. Make sure that the mounting brackets are properly aligned and secured. Check the hydraulic connections for proper fitting.
- Inspect Internal Parts: If the noise and vibration persist after checking the external components, it may be necessary to disassemble the breaker and inspect the internal parts. Look for signs of wear, such as scoring on the piston or excessive play in the bushings. Replace any worn – out parts.
3. Leaking Hydraulic Fluid
Possible Causes
- Damaged Seals: The seals in the hydraulic breaker can wear out or get damaged over time, leading to fluid leaks.
- Cracked Hoses or Fittings: Hoses and fittings can develop cracks or leaks due to exposure to high pressures, abrasion, or aging.
- Loose Connections: Loose hydraulic connections can also cause fluid to leak from the system.
Troubleshooting Steps
- Identify the Leak Location: Visually inspect the breaker, hoses, and fittings for signs of hydraulic fluid leakage. Look for wet spots, drips, or puddles of fluid. Once you’ve identified the leak location, mark it for further inspection.
- Replace Damaged Seals: If the leak is coming from a seal, carefully remove the old seal and replace it with a new one. Make sure to use the correct type and size of seal for your breaker model.
- Repair or Replace Cracked Hoses and Fittings: If a hose or fitting is cracked, it should be replaced immediately. When replacing a hose, make sure to choose one that is compatible with the hydraulic system’s pressure and flow requirements. Tighten all the connections securely to prevent further leaks.
4. Breaker Jams
Possible Causes
- Foreign Objects: Small rocks, debris, or other foreign objects can get stuck in the breaker’s working parts, causing it to jam.
- Incorrect Chisel Insertion: If the chisel is not inserted correctly into the breaker, it can bind and cause the breaker to jam.
- Worn – Out Components: Worn – out components, such as the chuck or retaining pins, can cause the chisel to hold incorrectly and lead to jams.
Troubleshooting Steps
- Remove Foreign Objects: Carefully inspect the breaker for any visible foreign objects. Use a small brush or compressed air to remove any debris that may be stuck in the working parts. If the object is deeply lodged, it may be necessary to disassemble the relevant parts of the breaker to remove it.
- Check Chisel Insertion: Ensure that the chisel is inserted correctly into the breaker. Make sure it is fully seated and properly aligned. Refer to the manufacturer’s instructions for the correct chisel insertion procedure.
- Inspect and Replace Worn – Out Components: Check the chuck, retaining pins, and other components for wear. If any parts are worn out, replace them with new ones.
5. Overheating
Possible Causes
- High – Load Operation: Continuous operation of the breaker under high – load conditions can cause it to overheat.
- Insufficient Hydraulic Fluid: Low levels of hydraulic fluid can lead to poor heat dissipation, resulting in overheating.
- Clogged Oil Cooler: If the oil cooler is clogged with dirt or debris, it can’t effectively cool the hydraulic fluid, causing the breaker to overheat.
Troubleshooting Steps
- Reduce Load: If the breaker is overheating due to high – load operation, reduce the load by adjusting the operating parameters or taking breaks between operations to allow the breaker to cool down.
- Check Hydraulic Fluid Level: Inspect the hydraulic fluid level in the reservoir. If the level is low, add the recommended type of hydraulic fluid to the appropriate level.
- Clean the Oil Cooler: Remove the oil cooler and clean it thoroughly to remove any dirt or debris. You can use a soft brush or compressed air to clean the fins of the cooler.
In conclusion, troubleshooting a hydraulic breaker requires a systematic approach and a good understanding of its components and operation. By being aware of the common issues and following the steps outlined above, you can effectively diagnose and resolve problems with your hydraulic breaker.
As a hydraulic breaker supplier, we offer high – quality breakers and a wide range of spare parts. Our team of experts is also available to provide technical support and advice on troubleshooting and maintenance. If you’re experiencing problems with your hydraulic breaker or are looking to purchase a new one, we encourage you to contact us for a detailed discussion. We’re committed to helping you find the best solutions for your construction and demolition needs.
Hydraulic Breaker References
- Bosch Rexroth Hydraulic Breaker Operation and Maintenance Manual
- Montabert Hydraulic Breaker Technical Documentation
Hope Precision Machinery Co., Ltd.
As one of the most professional hydraulic breaker manufacturers and suppliers in China, we also support customized service. Please feel free to buy high quality hydraulic breaker for sale here from our factory. For more information, contact us now.
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E-mail: lulu@hope-breaker.com
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