Hydraulic Breaker Use on Excavators and Its Impact on Machine Longevity

[MikePhua]

The Role of Hydraulic Breakers in Demolition
Hydraulic breakers, also known as hammers, are essential tools for demolition, trenching, and concrete removal. Mounted on excavators, they deliver high-frequency percussive force through a moil point or chisel, breaking apart hard surfaces like rock, asphalt, and reinforced concrete. While highly effective, their use introduces intense vibration and hydraulic stress, raising concerns about long-term wear on the host machine.
Excavators like the 20-ton class (e.g., CAT 210, Komatsu PC200) are commonly paired with breakers weighing between 2,000 and 4,500 pounds. These setups are capable of handling large-scale demolition projects, including multi-story precast concrete structures and thick slab removal. However, improper setup or technique can accelerate wear on pins, bushings, hydraulic lines, and even the main pump.
Terminology and Component Notes
- Moil Point: The steel tool bit that delivers impact force to the material.
- Accumulator: A pressurized chamber that dampens hydraulic shock and protects the pump.
- Nitrogen Charge: Compressed nitrogen used to assist the piston return stroke and regulate impact energy.
- Backpressure: Resistance in the hydraulic return line that can damage seals and reduce breaker efficiency.
- Quick Coupler: A hydraulic connector that allows fast attachment changes, but may be vulnerable to vibration.
Machine Setup and Hydraulic Considerations
Proper hydraulic setup is critical. The breaker’s flow and pressure must match the excavator’s auxiliary circuit. Most modern machines allow flow rate adjustment via onboard displays, and some offer dedicated breaker modes that reroute return oil directly to the tank, minimizing backpressure.
Recommendations:

• Confirm one-way flow configuration for breaker use
  
• Set flow rate to match breaker specifications (e.g., 120–180 LPM for a 2,200 lb hammer)
  
• Use return-to-tank plumbing to reduce seal stress
  
• Avoid screw-type quick couplers prone to vibration failure
  
• Grease tool bushings frequently and index the tool before lubrication
  

One operator noted that improper coupler selection led to valve damage on a CAT 325FL, requiring warranty replacement. Threaded fittings with metal caps were later installed to prevent contamination and withstand vibration.
Operational Techniques and Tool Preservation
Running a breaker efficiently requires more than brute force. The moil point should be kept perpendicular to the surface, with consistent downforce. Prying with the tool is a common mistake that shortens seal life and damages the retainer wedges. Operators should avoid burying the tool too deep and retract it at the same angle to prevent binding.
Tips for longevity:

• Maintain constant contact with the work surface during impact
  
• Avoid dry firing (striking without resistance)
  
• Do not use the tool as a pry bar
  
• Store the breaker vertically when not in use
  
• Check nitrogen charge regularly and recharge as needed
  

In one demolition job involving 115,000 sq ft of concrete, a Chinese-made Mustang HM1000 breaker was used on a 210-class excavator. Despite its budget price, the hammer performed adequately, though the operator kept a second unit on standby in case of failure.
Estimating Productivity and Job Planning
Breaking speed depends on concrete thickness, reinforcement, and operator skill. For 8-inch precast slabs, a 2,200 lb hammer can reasonably achieve 800–1,200 sq ft per hour under ideal conditions. However, heavily reinforced floors with twisted rebar may require torch cutting and slower progress.
Planning considerations:

• Have spare tool points available
  
• Monitor tool wear and replace before deformation
  
• Coordinate with dump sites regarding rebar and size restrictions
  
• Factor in time for repositioning, cleanup, and equipment checks
  

One contractor reported that older school floors contained unexpected rebar types, requiring torch work and slowing progress. In such cases, burying the floor rather than hauling it off became the more economical solution.
Maintenance Intervals and Wear Management
Breaker use accelerates wear on the excavator’s hydraulic system. Manufacturers often recommend shorter intervals for oil and filter changes when hammers are used regularly.
Preventative steps:

• Change hydraulic oil every 500 hours or sooner under heavy breaker use
  
• Replace filters at 250-hour intervals
  
• Inspect hoses and fittings weekly
  
• Monitor pump performance and listen for cavitation or pressure spikes
  

Operators who neglect greasing or run low nitrogen charges risk blowing the internal membrane, leading to costly rebuilds. A well-maintained breaker can last thousands of hours, but abuse shortens its lifespan dramatically.
Conclusion
Using a hydraulic breaker on an excavator is not inherently damaging—but it demands discipline. With proper setup, thoughtful operation, and rigorous maintenance, even older machines with high hours can handle demanding demolition tasks. The breaker is a precision tool, not a blunt instrument. And when treated with respect, it turns concrete into dust without turning your machine into scrap.