Hydraulic breakers are widely used in highway, railway construction, building, mining, and other industries. Due to their harsh working environments, hydraulic breakers may encounter various faults during use, which can significantly impact the progress of engineering projects. The following provides a comprehensive analysis of common faults and corresponding solutions for hydraulic breakers.
Fault One: The Hammer Does Not Strike
Possible Causes:
- Excessively high oil temperature
- Blocked piping
- Insufficient hydraulic oil
- Inadequate oil supply
- Malfunctioning safety valve
- Abnormal nitrogen pressure
Solutions:
- Inspect the Cooling System: Ensure that the cooling system operates correctly to reduce oil temperature. If the cooling capacity is insufficient, consider adding or cleaning the cooler.
- Check the Oil Pump: Verify the condition of the oil pump and replace it if its volumetric efficiency is low.
- Clear Blockages in Pipes: Inspect and clear any blockages in the hydraulic lines to ensure smooth flow of hydraulic oil.
- Check Hydraulic Oil Level: Ensure there is enough hydraulic oil in the tank and that the oil is not contaminated.
- Adjust the Safety Valve: If the safety valve’s pressure setting is incorrect, adjust it to the proper value.
- Check Nitrogen Pressure: For breakers equipped with accumulators, verify that the nitrogen pressure is within the specified range; adjust by charging or discharging as necessary.
Fault Two: Irregular Striking of the Hydraulic Breaker
Possible Causes:
- Damage to the piston and control valve surfaces
- Piston striking without contacting the chisel (air striking)
- Sticking directional control valve
- Loose chisel
- Worn hydraulic seals
- Contaminated hydraulic oil
Solutions:
- Clean and Inspect: Disassemble the piston and control valve, carefully inspect for any damage, clean with hydraulic oil to remove burrs, and polish damaged surfaces to ensure the valve core and striking piston move freely.
- Adjust Operating Procedures: Ensure the host machine operates such that the chisel always tightly contacts the material being broken, avoiding air striking.
- Inspect the Directional Control Valve: If the directional control valve sticks, disassemble it for cleaning or replacement.
- Tighten the Chisel: Check and tighten the chisel to prevent reduced striking force due to looseness.
- Replace Seals: If hydraulic seals show significant wear, replace them promptly.
- Change Hydraulic Oil: If the hydraulic oil is contaminated, thoroughly replace it with clean oil to restore system performance.
Fault Three: Oil Leakage from the Hydraulic Breaker
Possible Causes:
- Damaged seals
- Loose pipe connections
- Poor sealing at the lower cylinder body
- Failed seals on the charging plug or check valve
- Damaged seals on the cylinder head
Solutions:
- Replace Seals: Depending on the location of the leak, replace the corresponding seals, such as those at the pipe connections, lower cylinder body, charging plug, check valve, and cylinder head.
- Tighten Pipe Connections: Inspect all pipe connections and ensure they are tightened to the specified torque to prevent leaks caused by looseness.
- Inspect Cylinder Body Seals: For issues with the lower cylinder body and other critical components, immediately replace the seal assembly if problems are found.
Fault Four: Overheating of the Hydraulic System
Possible Causes:
- Low pressure setting on the safety valve
- Insufficient cooling capacity
- Narrow hoses
- Excessive backpressure
- High viscosity of hydraulic oil
Solutions:
- Adjust the Safety Valve: Set the safety valve’s pressure to an appropriate level to maintain stable system pressure.
- Enhance Cooling Capacity: If the existing cooling system cannot meet the requirements, consider upgrading or adding additional cooling equipment.
- Replace Hoses: For hoses that are too narrow, replace them with larger diameter hoses to reduce flow resistance.
- Reduce Backpressure: Inspect sources of backpressure, such as relief valves, and adjust them appropriately to reduce backpressure.
- Select Appropriate Viscosity Hydraulic Oil: Choose a hydraulic oil with the right viscosity grade based on ambient temperature to avoid overheating due to excessively high viscosity.
Fault Five: Piston Moves but Does Not Strike
Possible Causes:
- Jammed chisel
- Increased friction between the piston and cylinder wall
- Faulty control valve
- Insufficient hydraulic oil supply
Solutions:
- Repair or Replace the Chisel: Remove the chisel and use a grinding wheel or oilstone to repair it, ensuring it moves freely within the cylinder; if severely damaged, replace the chisel.
- Inspect the Piston and Cylinder Wall: Confirm that no foreign objects or excessive wear exist between the piston and cylinder wall; clean or replace components as needed.
- Test the Control Valve: Investigate whether the control valve is faulty and repair or replace it if necessary.
- Check Hydraulic Oil Supply: Ensure an adequate supply of hydraulic oil and that the suction filter is unobstructed.
Fault Six: Severe Air Leakage
Possible Causes:
- Damaged air seals or oil seals
- Damaged valve core
- Cracks in the upper cylinder body
- Normal wear
Solutions:
- Replace Air Seals and Oil Seals: When air seals or oil seals are damaged, replace them promptly.
- Inspect the Valve Core: If the valve core is damaged, it can cause air leakage; replace the valve core.
- Repair Cracks in the Upper Cylinder Body: Address any cracks in the upper cylinder body by repairing or replacing the entire cylinder body.
- Regular Maintenance: Even without obvious fault signs, regularly inspect and maintain the breaker to prevent potential issues.
Conclusion
By providing this detailed fault analysis and solutions, users can better understand and address the problems encountered with hydraulic breakers during actual use, thereby improving equipment reliability and work efficiency. Regular maintenance and correct operating habits are also crucial for extending the service life of hydraulic breakers.
