Excavators are among the most versatile heavy machinery used in construction, demolition, and mining. One of their most powerful attachments is the hydraulic breaker, commonly known as the excavator hammer.

 

A hydraulic Breaker tool is essential for breaking through concrete, asphalt, rock, and other tough materials when using an excavator.

But how exactly does a breaker work on an excavator? Understanding the mechanics and functionality of this tool can help operators and contractors maximize efficiency, reduce maintenance costs, and ensure safe operation.

In this article, we will explore how a breaker works on an excavator, its components, operational principles, benefits, and best practices.

How Does A Breaker Work On An Excavator? Guide

Understanding Hydraulic Breakers

Hydraulic breakers are impact tools powered by the hydraulic system of an excavator. They use pressurized hydraulic fluid to drive a piston, which repeatedly strikes a chisel or moil point to break up hard materials.

The efficiency of a breaker depends on factors such as hydraulic pressure, impact energy, and frequency.

Components of a Hydraulic Breaker

A hydraulic breaker consists of several key components that work together to deliver high-impact energy. These include:

1. Housing – Protects internal components from dust, debris, and impact damage.
2. Piston – Moves back and forth to generate striking force.
3. Chisel or Moil Point – The working tool that directly impacts the material.
4. Accumulator – Stores hydraulic energy and reduces pressure fluctuations.
5. Control Valve – Regulates hydraulic flow to control impact frequency.
6. Hydraulic Hoses – Transport pressurized hydraulic fluid from the excavator to the breaker.
7. Mounting Bracket – Connects the breaker to the excavator arm.

How A Hydraulic Breaker Works on an Excavator: Step-by-Step Process

1. Hydraulic Power Activation

The excavator’s hydraulic system supplies high-pressure fluid to the breaker through dedicated hydraulic lines. This pressurized oil serves as the driving force behind the breaker’s operation.

2. Piston Movement

The hydraulic fluid enters the breaker, pushing the internal piston upwards. Once it reaches its highest point, the fluid flow rapidly shifts, forcing the piston downward with great force.

3. Impact Delivery

As the piston moves downward, it delivers a powerful strike to the attached chisel or tool bit. This high-energy impact is transferred to the material, breaking through concrete, rock, or other hard surfaces.

4. Energy Recycling

Some hydraulic breaker models incorporate nitrogen gas chambers or accumulators. These store excess energy from the piston movement and release it in the next cycle, improving efficiency and reducing fuel consumption.

5. Continuous Operation

The process repeats multiple times per second, generating rapid, successive blows. This allows the breaker to maintain consistent impact force, efficiently demolishing materials in excavation, roadwork, and construction projects.

Benefits of Using a Breaker on an Excavator

1. High Efficiency – Quickly demolishes concrete, asphalt, and rock.
2. Versatility – Used in construction, mining, and roadwork projects.
3. Precision – Targets specific areas without affecting surrounding structures.
4. Cost-Effective – Reduces labor and machine wear compared to traditional demolition methods.
5. Enhanced Safety – Keeps operators at a safe distance while breaking materials.
6. Environmentally Friendly – Reduces dust and noise pollution compared to explosives.
7. Adaptability – Can be attached to various excavator sizes.

Best Practices for Using a Hydraulic Breaker

To ensure maximum performance and longevity, follow these best practices:

• Choose the Right Breaker Size – Match the breaker’s impact energy to the material hardness.
• Check Hydraulic Pressure – Ensure the hydraulic system provides the correct pressure.
• Use the Correct Chisel Type – Select between chisel, moil, or blunt tools depending on the task.
• Avoid Dry Firing – Always have the chisel in contact with the material before activating.
• Maintain Regular Lubrication – Grease the tool to prevent excessive wear.
• Monitor Hydraulic Hoses – Inspect hoses for leaks or damage to avoid pressure loss.
• Control Overheating – Take breaks during extended use to prevent system overheating.

Common Issues and Troubleshooting hydraulic breakers

Hydraulic breakers, despite regular maintenance, may experience operational problems. Below are some common issues, their causes, and solutions to ensure optimal performance.

1. Weak Impact

   • Cause: Low hydraulic pressure due to improper settings or system inefficiencies.
   • Solution: Check the hydraulic pressure levels and adjust them according to the manufacturer’s specifications. If necessary, inspect the pump and control valves for any malfunctions that may be affecting pressure output.

2. Overheating

   • Cause: Continuous operation without sufficient cooling intervals, leading to excessive heat buildup in the hydraulic system.
   • Solution: Allow the system to cool down by taking periodic breaks during operation. Ensure proper lubrication and check for any blockages in the cooling system that might be restricting airflow or fluid circulation.

3. Oil Leaks

   • Cause: Damaged or worn-out hoses, seals, or fittings due to prolonged use, exposure to harsh conditions, or excessive pressure.
   • Solution: Inspect the hydraulic lines and seals for cracks or wear. Replace any damaged components and ensure that all fittings are properly tightened to prevent further leakage.

4. Excessive Vibration

   • Cause: Loose mounting or improper attachment of the breaker to the carrier machine, leading to unstable operation.
   • Solution: Secure the breaker properly by checking and tightening all mounting bolts and connections. Ensure that the breaker is correctly aligned with the carrier to minimize unnecessary movement and vibration.

5. Piston Sticking

   • Cause: Contaminated hydraulic fluid due to dirt, debris, or moisture entering the system, leading to restricted piston movement.
   • Solution: Drain and replace the hydraulic fluid with clean, manufacturer-recommended oil. Regularly check and clean filters to prevent contamination and ensure smooth operation.

By addressing these common issues promptly, operators can extend the lifespan of hydraulic breakers and maintain efficient performance.

How does a breaker work on an excavator?FAQs

1. How do I choose the right breaker for my excavator?

Select a breaker based on your excavator’s hydraulic flow capacity, material hardness, and project requirements. Consult the manufacturer’s specifications to ensure compatibility.

2. How often should I maintain my hydraulic breaker?

Regular maintenance should be performed daily, including greasing, checking hydraulic hoses, and inspecting for wear. More in-depth servicing should be done monthly.

3. Can I use a breaker on any type of ground?

Breakers work best on concrete, asphalt, and rock. They are less effective on loose or soft soil, as the energy dissipates rather than breaking the material.

4. What safety precautions should I take when using a breaker?

Wear protective gear, ensure proper attachment, avoid dry firing, and maintain a safe working distance. Operators should also be trained in handling hydraulic breakers.

5. Why is my breaker not hitting as hard as before?

A decrease in impact force may result from low hydraulic pressure, worn-out chisels, or a faulty accumulator. Checking these components can help restore performance.

6. Can hydraulic breakers damage the excavator?

Improper use, excessive force, or failure to maintain the breaker can lead to stress on the excavator’s arm and hydraulic system. Regular inspections help prevent damage.

7. How long does a hydraulic breaker last?

With proper maintenance, a hydraulic breaker can last thousands of hours. Its lifespan depends on usage intensity, material hardness, and maintenance frequency.

Conclusion

Hydraulic breakers are indispensable attachments for excavators, providing powerful impact force to break through tough materials efficiently. Understanding their working mechanism, components, and maintenance requirements ensures optimal performance and extended lifespan.

 

By following best practices and safety guidelines, operators can maximize productivity while reducing equipment wear.

Whether for demolition, mining, or roadwork, a well-maintained breaker enhances an excavator’s capabilities. If you’re looking to improve your construction efficiency, invest in the right hydraulic breaker and follow proper maintenance routines today!