Causes and solutions for major hydraulic breaker failures

Hydraulic breakers play an important role in engineering construction. However, once a major failure occurs, it will seriously affect the construction progress and efficiency. The following is a detailed analysis of the causes of common major failures of hydraulic breakers and provides corresponding solutions.

Strike failure

Cause analysis

Hydraulic oil problem: Too high or too low viscosity of hydraulic oil will affect the working efficiency of the hydraulic system. If the viscosity of the hydraulic oil is too high, the flow resistance will increase, resulting in pressure loss, making the hammer's striking force insufficient; if the viscosity is too low, it is easy to cause leakage and also cannot provide enough power. In addition, the hydraulic oil is seriously polluted and contains impurity particles, which will aggravate the wear of hydraulic components, affect the sealing performance, and then lead to weak striking. "Hydraulic Breaker Hydraulic Oil Selection and Maintenance"

Abnormal nitrogen pressure: Nitrogen plays a role of energy storage and buffering in the work of hydraulic breakers. If the nitrogen pressure is too high, the piston return is blocked, the striking frequency is reduced and the striking force is weakened; if the nitrogen pressure is too low, the piston cannot obtain enough rebound force, which will also lead to weak striking. "Hydraulic Breaker Nitrogen Pressure Adjustment Tips"

Hydraulic pump failure: As the power source of the hydraulic system, if the internal parts of the hydraulic pump are severely worn, such as the clearance between the plunger and the cylinder body, the distribution plate, etc. is too large, the volumetric efficiency of the pump will decrease, the output flow will be insufficient, and the hammer will be unable to strike. " Hydraulic Breaker Hydraulic Pump Repair and Maintenance" emphasizes the relevant problems and treatment methods of hydraulic pumps of different brands of hydraulic breakers. ​

Solutions​

Regularly check the quality and viscosity of the hydraulic oil, select the appropriate hydraulic oil according to the requirements of the equipment manual, and replace it regularly. At the same time, install a high-quality hydraulic oil filter to prevent impurities from entering the system. ​

Use a professional nitrogen pressure gauge to accurately measure the nitrogen pressure and adjust it according to the pressure value specified by the equipment. Generally speaking, the nitrogen pressure of a new hydraulic breaker is adjusted at the factory, but it may change during use due to various reasons and needs to be checked regularly. ​

Disassemble and inspect the hydraulic pump. If it is found that the parts are severely worn, the worn parts should be replaced in time. In daily use, attention should be paid to the maintenance of the hydraulic pump, such as regularly cleaning the oil inlet filter to avoid inhaling impurities. ​

No impact failure ​

Cause analysis ​

Directional valve failure: The reversing valve controls the flow direction of the hydraulic oil. If the reversing valve core is stuck, worn, or the electromagnetic coil is damaged, the hydraulic oil will not be able to change direction normally, and the piston will not be able to reciprocate, resulting in the hammer not hitting. "Diagnosis and repair of hydraulic breaker reversing valve fault"

Piston stuck: The piston reciprocates in the cylinder. If there are too many impurities in the hydraulic oil, or the clearance between the piston and the cylinder is too small, the piston may be stuck in the cylinder. In addition, damage to the piston seal and leakage of hydraulic oil will also prevent the piston from working properly. " Hydraulic breaker piston fault handling" provides solutions for piston problems of different models of products. ​

Pipeline blockage or leakage: The pipeline of the hydraulic system is responsible for transmitting hydraulic oil. If there is a blockage in the pipeline, such as filter blockage, scaling inside the oil pipe, etc., the hydraulic oil will not flow smoothly, pressure cannot be established, and the breaker will not be able to hit. At the same time, pipeline leakage will cause the system pressure to drop, which will also cause failure. "Hydraulic Breaker Pipeline Maintenance and Troubleshooting" reflects the key role of pipelines in equipment operation and related problem handling. ​

Solution​

Disassemble the reversing valve, clean the valve core and valve seat, and check whether the electromagnetic coil is normal. If the valve core is severely worn or the electromagnetic coil is damaged, the corresponding parts need to be replaced in time. When installing the reversing valve, pay attention to the correct installation position and good sealing. ​

Take the piston out of the cylinder, clean the piston and the inside of the cylinder, and check whether the matching clearance between the piston and the cylinder meets the requirements. If the seal is damaged, replace it with a new one. At the same time, strengthen the filtration of hydraulic oil to prevent impurities from entering the system again. ​

Carry out a comprehensive inspection of the hydraulic system pipeline, clean the filter, and replace the filter element if necessary. Check whether the oil pipe is damaged or aging. If so, replace the oil pipe in time. When installing the pipeline, ensure that the connection is firm and the seal is reliable.​

Oil leakage failure​

Cause analysis​

Aging and damage of seals: During the long-term operation of hydraulic breaker, the seals will be affected by various factors such as high temperature, high pressure, wear, etc., and gradually age, deform or even damage, resulting in oil leakage. "Replacement cycle and selection of seals for hydraulic breaker"

Loose oil pipe joints: The equipment will vibrate during operation. If the fastening nut of the oil pipe joint is loose, a gap will appear on the sealing surface, causing hydraulic oil leakage. In addition, damaged or improperly installed gaskets at the joints can also cause oil leakage. "Hydraulic breaker oil pipe joint oil leakage treatment method" emphasizes the key points for solving the oil leakage problem at the joint. ​

Cylinder or valve body rupture: When the hydraulic breaker is subjected to severe impact or long-term overload operation, the cylinder or valve body may rupture, resulting in a large amount of oil leakage. This situation is more serious and requires timely repair or replacement of damaged parts. " Hydraulic breaker cylinder valve body repair" provides guidance on the repair of key components of different brands of products.​

Solution​

Check the status of the seals regularly. If the seals are found to be aged or damaged, replace them in time. Choose seals with reliable quality to ensure that they can adapt to the working environment of the hydraulic breaker. ​

Tighten the oil pipe joints and check whether the gaskets are intact. If the gaskets are damaged, replace them with new ones and tighten the fastening nuts according to the specified torque. In daily maintenance, pay attention to check whether the joints have signs of looseness. ​

If the cylinder or valve body is broken, stop using the equipment immediately and send it to a professional repair shop for repair or replacement. During the repair process, ensure that the accessories used meet the equipment requirements to ensure the quality of the repair. ​

Through the analysis of the causes of common major faults of hydraulic breaker hammers and the introduction of corresponding solutions, we hope to help users better maintain and use hydraulic breaker hammers, reduce the occurrence of faults, and improve construction efficiency. In actual operation, if you encounter complex faults, it is recommended to consult professional technicians or contact the equipment manufacturer for repair in time.

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