DIY hydraulic hammer repair

It is amazing that the service life of a modern hydraulic breaker is measured in years, given that during normal operation, one part of the metal hits the other part of the metal up to 1000 times or more per minute. The very nature of this activity is destructive.

The only thing that keeps the hammer from turning into scrap metal is a good preventive maintenance plan to reduce downtime and costs. A preventative maintenance program helps you take care of the little things before they turn into big problems.

Device runtime monitoring allows scheduled maintenance at regular intervals. The industry standard is one year, which equates to approximately 2000 hours of media usage. The breaker start-up time is about 25% of the carrier's operating time. Thus, the device operates approximately 500 hours per year.

Regardless of how many routine checks you make, the operating costs of your breaker will go up. Design, material and build quality are directly related to service life. As a device wears out, it may not perform as well as it once did, leading to increased downtime and increased maintenance costs. The time will come when the hammer will need to be replaced. But this does not mean that the old instrument must be disposed of. He can serve as a donor of spare parts or can be used in not too difficult tasks.

The first step in ensuring breaker durability is proper installation and sizing. If a small hammer is used in a job that requires a much larger tool, its life will be shortened. This is due to excessive stress. You are forcing the breaker to do something it was not designed to do. A large tool can accomplish a less complex task if it makes financial sense. In this case, the operator must carefully select the size and power of the tool for a particular task.

The hydraulic systems must also be tuned according to the particular hammer being used. Hammers are designed to operate within a specific range of hydraulic pressure and flow. If the device is operated outside the factory parameters, then nothing good will happen because of this.

A common mistake is setting the flow and pressure inappropriately, or installing the unit on one machine or another without proper attention. The flow affects the speed at which the hammer works. If you exceed the speed, and the material does not collapse, you will begin to bounce. When this happens, the vibration will be transmitted to the wearer. This will lead to wear on some components as well as cracks in the boom of the carrier. This energy needs to go somewhere. It goes, practically, to destroy the hammer.

Working at low flow or pressure will also damage the tool.

Lubrication is the most important maintenance task for your breaker. The grease has two functions: it lubricates the rubbing parts and cleans debris from the bushing area. It is important to maintain the required amount. Too much grease will cause it to build up between the piston and the top of the tool. In this regard, the power of the piston impact on the working tool is lost. If there is too little lubricant, you will get excessive friction of the parts of the tool and clogging it with dust.

The grease must be able to withstand high temperature and pressure. It must contain special additives such as graphite and copper.

Manufacturers generally recommend molybdenum greases with operating temperatures above 260 ° C. Molybdenum provides additional lubrication when the petroleum components break down.

If you use a lubricant that breaks down at temperatures below 500 ° C, then after a short period of time the hammer will not have enough of it, as it will begin to split.

It is also worth paying close attention to the relubrication intervals, which can vary depending on the frequency of use of the tool. The yoke must be lubricated before starting and after every two to three parts of work.

There are visual indications that the hammer is not getting enough lubrication. Generally, if the bottom of the bushing is dry or shiny, then it's time to lubricate.

Automatic lubrication systems are capable of providing a stable supply of lubricant.

The larger the hydraulic hammer, the greater the need to equip it with an automatic lubrication system. Some particularly large models cannot be lubricated by hand with sufficient lubrication.

Tramac recommends the use of automatic hammer lubrication systems with a torque of 4000 Nm or more. For these models, a system that provides a 7mm shot of lubricant every time the hammer is in operation is well suited. For small models, 6-10 injections of grease every hour will be sufficient to maintain a sufficient level.

But automatic lubrication systems also need attention. One of the main problems with these systems is a false sense of security. It is not uncommon for a canister or cartridge to empty out during operation.

A routine inspection in addition to lubrication can help prevent damage and save on repair costs. Ignoring a proper inspection of a tool can be worth half the cost. Also, downtime of several weeks spent on repairs cannot be avoided.

Some breakers are gas hydraulic operated. These models use nitrogen gas at the rear as an airbag and to increase power. Gas and hydraulic pressures should be checked weekly. It should be remembered that the ambient temperature can affect these values.

You also need to check if the bolts are loose or broken, check the degree of wear of the bushings. If there is a play in the bushings, then this is an alarming sign.

Worn front bushings will cause misalignment between the piston and the tool. The piston can touch the inner wall of the body during operation, and therefore the piston itself and the body, which are the most expensive parts of the hammer, can be damaged.

The locking pins are also subject to wear. They must be removed and inspected every 40 hours of operation. This interval can vary up or down depending on the material from which the pins are made. The areas held by the pin should also be inspected for damage.

If you begin to notice excessive tool wear during weekly inspections, pay attention to how the hammer is used. Wear may indicate frequent idle operation of the tool. The consequences of this misuse can be very costly.

Some manufacturers, such as Furukawa, offer operators to rotate the locking pins so they wear evenly. This can double their lifespan. Slight abrasion is tolerable. But when deep scars appear, the pins need to be replaced. If this is not done in time, they can deform and it will be very difficult to remove them.

Inspection of the breaker retention system may vary depending on manufacturer and application. It needs to be checked during tool change.

Each inspection will give you the full use profile of a specific breaker. This instrument is essentially an energy transporter. A technical inspection will show how efficiently the energy is transferred and whether there has been premature wear or improper use of the tool.

It is necessary to pay attention to the specific nature of the wear. Uneven wear (on the top of the tool) indicates that the hammer is not operating at right angles to the material being destroyed.

Also pay attention to hydraulic hoses and couplings. A very common cause of hammer failure is the result of disconnecting couplings on hoses mounted on carriers. Another common cause of failure is contaminated oil in the hammer. This usually happens when the operator switches from hammer to bucket and then back to hammer. Make sure that the ends of the hoses are free of dirt.

During the operation of hydraulic breakers, various kinds of failures occur, which leads to the need to perform repair or some kind of adjustment work. The probability of failures increases if the requirements and recommendations of the operating manual are not followed. Failures can also occur depending on the design features, materials used and production technology. In the simplest cases, repairs can be carried out at the construction site, but in some cases, repairs must be performed in workshops that have the necessary technological equipment and qualified personnel.

There are cases when it is not possible to start the hydraulic hammer when it is first turned on after being attached to the excavator. First of all, you should check the correctness of the connection of the supply lines to the hydraulic hammer - "head", "drain", make sure that the hydraulic hammer is pressed against the object of work, and its tool is pushed into the axle box until it stops, check the pressure in the pressure supply line, measure the value with a hydrotester. hydraulic pump supply of the base machine. If the parameters of the pumping station of the base machine correspond to the technical characteristics of the hydraulic hammer and its connection to the hydraulic system is correct, then the new hydraulic hammer should work, since each instance of the hydraulic hammer is tested and run-in at the manufacturer's stand.

During operation of the hydraulic hammer, all its rubbing pairs are subject to wear: the tool shank - the tool bushings, the working cylinder sleeve (or the cylinder body itself), the spool - the distributor sleeve. The amount of wear of parts is strongly influenced by the cleanliness of the working fluid (oil) of the hydraulic system. When operating with clean oil, the valve parts generally operate for the entire service life of the hammer. So, for example, in our company it was necessary to repair the hydraulic breakers SP-62, produced 25 ... 30 years ago, the hydraulic valves of which did not need to be replaced with new ones.

The most responsible and expensive rubbing pair of a hydraulic hammer is the firing pin - the working cylinder sleeve, the guide bushings in which the firing pin rods move. In the manufacture of these parts, high requirements are imposed on the accuracy and cleanliness of the processing of the mating surfaces. When the striker moves, its sliding speed relative to the surfaces of the working cylinder reaches values ​​of 8 ... 9 m / s. In addition, these parts are subject to shock loads, which also have a radial component, the magnitude of which is strongly influenced by the wear of the tool-tool sleeve pair.

As a result of all the unfavorable influences on the rubbing surfaces of the striker and mating parts, gross seizures can occur, which lead to the failure of the entire hammer. If not very deep seizures are formed only on the piston part of the striker (there are no contact seals) and the mirror of the cylinder liner, then such parts can be retained during repairs.Rough risks can be removed by grinding without removing them to the full depth, after which these parts can serve for a long time. If the surfaces of the striker rods are damaged (scuffing or corrosion), then during the repair of the hydraulic hammer, the striker must be replaced with a new one, since the damaged surfaces, which are sealed by contact seals, disable these seals.

When making a new striker, it is important to observe the required gaps between the rubbing surfaces of the mating parts. In the manufacture of repair liners of the working cylinder, in addition to ensuring a high surface cleanliness, measures should be taken to reduce the coefficient of friction. A decrease in the coefficient of friction can be achieved by nitriding the surfaces, saturating the surface with molybdenum disulfite and other physicochemical treatments. As already mentioned, the load on the hammer head, interchangeable tools and tool sleeves is strongly influenced by the wear of the latter.

Repair of hydraulic breakers can be roughly divided into: routine repairs, which can often be performed on site, repairs of medium complexity and major repairs. During routine repairs, loosened threaded connections are tightened, damaged parts, some seals or individual units (hydraulic accumulators, hydraulic valves) replaced, if possible, without completely disassembling the hammer.

Before performing more complex repairs, preliminary diagnostics should be performed. The hydraulic hammer is installed on the bench, the symptoms of malfunctions are determined, the places of external oil leaks are determined, it is established whether the striker is moving, if such a phenomenon is observed. If necessary, the value of the oil pressure in the pressure supply line is measured. After that, assumptions are made about the reasons for the failure or unsatisfactory operation of the hammer. Next, the breaker is disassembled and parts are troubleshooting.

Repairs of medium complexity are carried out in a workshop. The hydraulic hammer is completely disassembled and all hydraulic seals, tool bushings and replacement tools are replaced, light scuff marks on the piston part of the striker are cleaned, and damaged parts of threaded connections are replaced. Before assembly, all parts are thoroughly washed, blown with compressed air and lubricated. Threaded connections must be tightened with a torque wrench in accordance with the recommendations of the operating manual for this hammer model.

Overhaul of the hydraulic breaker is carried out in cases where the repair of medium complexity is not sufficient to restore the breaker performance. During overhaul of a hydraulic hammer, as a rule, it becomes necessary to replace the striker, the working cylinder liner (if provided for by the design of the hydraulic hammer), guide bushings in which the striker rods move. Less often, there are cases when it is required to bore holes in the axle box, in which the tool bushings are mounted. In these cases, the outer landing diameter of the bushings is made according to the actual diameter of the axle box after its boring.

Sometimes, during a major overhaul, replacement of the cheeks is required, in which the hammer's impact block is located. If a hydraulic hammer is used for crushing oversized rocks or destroying reinforced concrete structures, then its cheeks often hit the destroyed material. The lower ends of the cheeks wear out a lot, and if there are any holes or windows in the cheeks that are stress concentrators, then cracks may appear in the cheeks during prolonged use. In some cases, it is possible to repair the cheeks by deep cutting the crack and welding it. After performing repairs of medium complexity or major overhauls, the hydraulic hammer should be tested at the stand.

Our company has extensive experience in the repair of any complexity of hydraulic hammers of various domestic and foreign models.The quality of the repair is ensured by the availability of the necessary technical equipment and qualified specialists.

During the operation of hydraulic breakers, various kinds of failures occur, which leads to the need to carry out repairs or some kind of adjustment work. The probability of failures increases if the requirements and recommendations of the operating manual of the hydraulic hammer are not followed. Failures can also occur depending on the design features, materials used and production technology. In the simplest cases, repairs can be carried out at the construction site, but in some cases, repairs must be performed in workshops that have the necessary technological equipment and qualified specialists.

There are times when it is not possible to start the hydraulic hammer when it is first turned on after being attached to the excavator. First of all, you should check the correctness of the connection of the supply lines to the hydraulic hammer - "head", "drain", make sure that the hydraulic hammer is pressed against the object of work, and its tool is pushed into the axle box until it stops, check the pressure in the pressure supply line, measure the value with a hydrotester. hydraulic pump supply of the base machine. If the parameters of the pumping station of the base machine correspond to the technical characteristics of the hydraulic hammer and its connection to the hydraulic system is correct, then the new hydraulic hammer should work, since each instance of the hydraulic hammer is tested and run-in at the manufacturer's stand.

During operation of the hydraulic hammer, all its rubbing pairs are subject to wear: the tool shank - the tool bushings, the working cylinder sleeve (or the cylinder body itself), the spool - the distributor sleeve. The amount of wear of parts is strongly influenced by the cleanliness of the working fluid (oil) of the hydraulic system. When operating with clean oil, the valve parts generally operate for the entire service life of the hammer. So, for example, in our company we had to repair the hydraulic breakers SP-62, produced 25. 30 years ago, the hydraulic valves of which did not need to be replaced with new ones.

Depending on the required minimum amount of work to restore the working capacity of the hydraulic hammer, its repair can be conditionally classified into current repairs (economy class), medium complexity and complex overhaul.

When repairing an economy class, worn and damaged parts of the hammer are replaced that do not affect the working process, that is, parts that are not related to the main parts of the hydraulic system of the hammer. These parts include interchangeable tools, tool sleeves, various pins, fasteners, fittings for connecting hoses.

During repairs of medium complexity, the hammer is diagnosed at the test bench of the hydraulic hammer and the parts are troubleshooting. At the same time, if the counter rods of the striker do not have scoring and significant wear, and there are slight scratches and risks on the piston part of the striker, as well as risks on the mirror of the working cylinder, then the scratches are cleaned and these surfaces are polished. The purpose of this operation is to remove the protrusions on the rubbing surfaces. The remaining small depressions on the working cylinder mirror and on the piston part of the striker do not have a significant effect on internal oil flows between the cylinder cavities, since these flows occur only during the striker cocking, and the remaining depressions only increase the hydraulic resistance to the flow of the working fluid. In addition, all movable and stationary seals are replaced for medium repairs.

Overhaul of a hydraulic breaker is carried out in cases where repairs of average complexity are not sufficient to restore the equipment to work. During overhaul of a hydraulic hammer, as a rule, it becomes necessary to replace the striker, the working cylinder liner (if provided for by the design of the hydraulic hammer), guide bushings in which the striker rods move.Less often, there are cases when it is required to bore holes in the axle box, in which the tool bushings are mounted. In these cases, the outer landing diameter of the bushings is made according to the actual diameter of the axle box after its boring.

Sometimes, during a major overhaul, replacement of the cheeks is required, in which the hammer's impact block is located. If a hydraulic hammer is used for crushing oversized rocks or destroying reinforced concrete structures, then its cheeks often hit the destroyed material. The lower ends of the cheeks wear out a lot, and if there are any holes or windows in the cheeks that are stress concentrators, then cracks may appear in the cheeks during prolonged use. In some cases, it is possible to repair the cheeks by deep cutting the crack and welding it.

Repairs of medium complexity and overhaul are carried out in workshops equipped with the necessary technological equipment. Before assembly, all old, new and repaired parts are washed, blown out with compressed air and lubricated. All threaded connections must be tightened with a torque wrench in accordance with the recommendations of the operating manual for the given hammer model. After the final bench tests of the hydraulic hammer, the finishing operation can be performed: priming and painting the hydraulic hammer in a special painting booth.

Excavator attachments

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Hydraulic breakers are used today in a wide variety of construction work. Installed on excavators, manipulators and other types of construction equipment of the corresponding weight, they are used for splitting and crushing concrete and reinforced concrete structures, for opening hard rocks, asphalt pavement, frozen soil. When performing such tasks, a hydraulic hammer is practically the only possible means of labor mechanization, while the efficiency and productivity of work increases significantly.

However, during prolonged or heavy use, the hammer may fail, thereby stopping all work. In some cases, repairs can be carried out on site, however, in most cases, such independent intervention in the structure of the hydraulic hammer can lead to its complete failure. And this will already entail serious expenses and monetary losses due to equipment downtime. Therefore, it is better to contact us immediately - we are ready to take on the repair of any hydraulic hammer, regardless of its model, technical features and the nature of the malfunctions. After all, thanks to impressive experience, we have brought our skills to almost perfection!

Common diseases of hydraulic hammers

These are the most common malfunctions due to the specific use of this equipment. It is for these malfunctions that we check the equipment in the first place:

• shank;
• bushings;
• the body of the working cylinder or its sleeve-striker;
• distributor sleeve;
• spool.

The reason for the failure of these parts is increased friction as a result of work. In addition, the wear of parts is accelerated due to the ingress of contaminants into the lubrication system - this is one of the most dangerous factors.Also, an increased shock load can lead to the destruction of certain elements. As a result of such influences, scuffs appear on the surface of the hydraulic breaker parts, which gradually increase and ultimately lead to a complete failure of the equipment.

How to prevent breakage?

To keep your equipment running smoothly for as long as possible, you should regularly run diagnostics. To do this, you can simply contact us - our highly qualified specialists will perform all the necessary work. For this we have all the necessary high-tech equipment, the main of which is a professional diagnostic stand. With its help, we check the condition of each element of the hydraulic breaker, each of its connections. And high-precision electronics show the most objective data - with the help of diagnostics at the stand, we can determine even a slight deviation in the operation of the equipment.

When defects are identified, then we proceed to fix them. We carry out this process in an integrated manner, without missing a single definite error. At the same time, the policy of our company is such that if it is possible to fix it, we will fix it. After all, the restoration of parts is almost always much cheaper than buying a new one. Therefore, we try to save you money and carry out the greatest possible amount of work with the existing equipment. If the purchase of a new part is inevitable, then in this case we will help you save money - with our help you can purchase quality parts without overpaying for the brand!

When the hammer is repaired, it must be refueled. For this, nitrogen is used, which must be filled under high pressure into the accumulator. The process is complicated and even dangerous, but once again our impressive experience comes to the rescue - we will refuel your repaired and rejuvenated hydraulic hammer quickly, safely and efficiently. After that, we will carry out the connection of the mechanism, its fine tuning and start-up tests.

Therefore, when contacting us for diagnostics, repair and refueling of the hydraulic hammer, you can be sure that you will receive a completely ready-to-use unit back!

You can get more detailed information by phone (351) 7-299-199 (multichannel).

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Hydraulic hammer cutaway

Technical characteristics of the hammer
DYB 50/70/100/200/300

Technical characteristics of the hammer
DYB 450/600/800/1300/1500

In conditions of long-term operation or work in difficult conditions, such as high hardness and abrasiveness of the rock in combination with low temperatures, the hammer peak breaks, deforms, or scuffs form on it.

When the working end of the lance wears out, the lance begins to slide off. Some operators try to re-sharpen the tip of the lance, but this removes the hardened surface layer and wears out the working element instantly. This method will briefly extend the operation of the equipment.

The most correct solution for the wearing out of the peak is to replace it. Therefore, when working in difficult conditions, there should always be a spare set of replacement lances.

It is also necessary to monitor the junction of the working element and the lower sleeve. When the size of the gap between the tool and the lower sleeve exceeds the allowable limit, replace the lower sleeve together with the lance.

When replacing peaks of hydraulic breakers of different types / brands, their individual characteristics should be taken into account. You can list some standard actions when replacing a peak (this instruction cannot be accepted for execution without reading the technical documents attached to a specific model of a hydraulic hammer):

1. Lay the hammer horizontally on wooden blocks or start replacing the lance without disconnecting the attachment;
2. Remove the spring pin or rubber plug, depending on the model, that cover the retaining pins in the lower housing;
3. Using a hammer and a drift, remove the retaining pin (s) from the hammer;
4. Remove the two spade wedges. Be careful, falling lances can cause injury.
5. Use an appropriate lifting tool to remove the lance from the breaker mechanism;
6. Before installing a new lance, check the condition of the lower bushing of the mechanism housing for wear, scoring, etc. Sand out any burrs or burrs on the wedges as these may make it difficult to replace the lance. Checking the condition of the wedges should be carried out every 100-150 hours of operation of the hydraulic breaker;
7. Apply a sufficient amount of grease to the bushing and lance shank;
8. Install the new lance in reverse order.

Manufacturers currently offer three main types of rush. These are "lance", "wedge" and "chisel". Each of them is designed to perform strictly regulated types of work.

The lifespan of the peak depends on the way you handle them. The lance can withstand significant vertical loads, but is not resistant to perpendicular loads. Especially the service life of working elements subject to such negative influences as crane work, inclined impact, eversion, idling, etc. is reduced. It is very important to maintain the correct working pressure in the nitrogen chamber, check and refuel in a timely manner. Work items fail for several reasons. The cause of each breakage can be determined by inspecting the damaged hammer assemblies.

NAK Machinery has all the necessary equipment for high-quality maintenance and repair of special equipment. Maintenance, repair of construction equipment, as well as a large list of works are carried out with a visit to the site to the customer, for this, mobile service complexes based on FORD cars are equipped.

The Novomax company repairs hydraulic hammers of all types and brands: MTB, KWANGLIM / HYDRARAM, ITALDEM, HANWOO, LST, JCB, KRUPP, FURUKAWA, MONTABERT, ATLAS COPCO, RAMMER, INDECO, MSB, SAGA, N.P.K., SOOSAN, SOCOMEC, STAR HAMMER.

Repair of a hydraulic breaker includes the following operations:

• Complete disassembly
• Troubleshooting
• Elimination of defects
• Replacing worn parts
• Filling with nitrogen
• Assembly
• Installation on an excavator
• Commissioning

In case of minor breakdown of the hydraulic hammer, repairs are carried out at the customer's site. The service department of the "Novomax" company will carry out all the necessary repair work as soon as possible.

Timely repair of the hydraulic breaker will allow you to avoid additional financial costs for maintenance and additional repairs.

Please contact us and we will try to help you avoid lengthy downtime of your equipment.

The jack is one of the most important tools in the arsenal, it will help everywhere: repairing a machine or equipment, carrying out a variety of construction and repair work. And if suddenly your device is out of order for some reason, you need to learn how to repair a hydraulic jack with your own hands!

A wide variety of jacks will also please, each of which has its own characteristics and distinctive features.

Like any equipment that carries huge loads, devices can often break down, and therefore you always need to know how to repair the jack yourself. To be fully armed at the time of a breakdown!

Any hydraulic jack operates on liquid, and the main elements of the jack are the body, piston and oil. If you decide to study how to carry out repairs yourself, you definitely need to know what reasons can lead to breakdowns. First of all, the structure of the device could be "attacked" by corrosion, which leads to restriction during the descent of the mechanism. Naturally, jacks often break due to too much stress, which leads to bending of the rods.

There are some other points, including the need to change the oil. However, any repair is carried out practically according to the same scheme.And the first thing you need to know is how to disassemble the device, after which you can start changing the fluid. The tool is disassembled in the following order:

• Using wrenches, unscrew the fasteners;
• Remove the fluid bleed valve and piston;
• Carrying out a competent inspection, we check the quality of the valve and all gaskets - if you notice that they have become unusable, we just change the elements of the jack;
• We clean the mechanism from debris and other foreign elements, rinse the cylinder;
• We check and change the old rubber band if necessary;
• The last step is to reassemble the tool in reverse order.

Naturally, after you assemble the jack, it should be checked for operability! If the device starts working, great, but it doesn't always work out the first time. Perhaps the oil is the problem?