Hydraulic breaker weak impact (reduced striking force, slower frequency) is usually caused by issues in the hydraulic system, nitrogen pressure, mechanical wear, or improper operation.
Causes:
Excavator main pump wear resulting in reduced output flow.
Blocked hydraulic lines or excessively dirty filters.
Control valve sticking, causing incomplete oil passage opening.
Solutions:
✅ Check the hydraulic oil filter; clean or replace it.
✅ Test main pump flow (compare with rated specifications).
✅ Adjust pilot pressure (normal range: 3–4 MPa).
Causes:
Main relief valve pressure set too low or spool wear.
Hydraulic oil overheating (>80°C), causing viscosity drop.
Solutions:
✅ Check system pressure with a gauge (standard: 18–22 MPa).
✅ Clean or replace the relief valve; refill or replace hydraulic oil.
Causes:
High-pressure hoses cracked or fittings leaking.
Internal leakage in the breaker cylinder due to seal failure.
Solutions:
✅ Inspect hydraulic hoses for leakage; replace damaged parts.
✅ Test cylinder sealing (lift the chisel and check for automatic drop).
Symptoms: Slow chisel rebound, reduced impact frequency.
Standard Value: 1.2–1.6 MPa (varies by brand).
Solutions:
✅ Check nitrogen pressure with a charging gauge and refill nitrogen
(Never use compressed air!)
Symptoms: Scattered impact force, excessive chisel “bouncing.”
Solutions:
✅ Release excess nitrogen to the standard value.
Symptoms: Excessive chisel play, impact energy loss.
Solutions:
✅ Measure chisel diameter (replace if wear exceeds 5 mm).
✅ Check bushing clearance (replace if over 2 mm).
Symptoms: Abnormal noises, metal debris in hydraulic oil.
Solutions:
✅ Disassemble and inspect piston seals and cylinder wall scoring.
Symptoms: Small excavator paired with oversized breaker; sluggish machine.
Solutions:
✅ Use a breaker matched to the excavator tonnage
(refer to the machine specifications).
Symptoms: Using a flat chisel on hard rock → extremely low efficiency.
Solutions:
✅ Use a pointed chisel for hard rock; flat chisel for concrete.
Dull impact → Check nitrogen pressure & hydraulic pressure.
Metal scraping noise → Check chisel/bushing wear.
Pilot pressure: 3–4 MPa
Main system pressure: 18–22 MPa
Dark oil or metal particles → replace oil and inspect worn parts.
Daily: Check nitrogen pressure, lubricate chisel.
Weekly: Clean hydraulic filters, tighten bolts.
Monthly: Replace hydraulic oil, test sealing performance.
| Problem Type | Key Inspection Items | Solutions |
|---|---|---|
| Hydraulic System | Pressure / flow / leakage | Replace filters, adjust relief valve, repair leaks |
| Nitrogen Pressure | Accumulator pressure | Nitrogen charging or venting to standard value |
| Mechanical Wear | Chisel / bushing / piston | Replace worn parts |
| Operation Matching | Excavator & breaker compatibility | Use properly matched model |
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