Hydraulic Breakers on a Hitachi 200: Setup, Challenges, and Field Insights

[MikePhua]

Understanding Hydraulic Breakers
A hydraulic breaker (also known as a hydraulic hammer) is a powerful percussion attachment mounted on excavators like the Hitachi ZX200. It is designed for breaking through rock, concrete, and other hard materials. The system functions by converting the excavator's hydraulic pressure into repetitive high-impact blows.
This tool is indispensable in demolition, trenching, quarry work, and secondary rock breaking. When paired correctly with the host machine, it provides a cost-effective and highly efficient alternative to blasting or manual demolition.
Hydraulic Circuitry: The Lifeblood of the Breaker
To power a breaker on a Hitachi 200, the machine must be equipped with an auxiliary hydraulic circuit. Key components of this setup include:

• Hydraulic pump: Supplies the pressure and flow required by the breaker.
  
• Pilot control valves: Allow the operator to activate and regulate breaker operation.
  
• Return-to-tank (T-line): A dedicated low-pressure line allowing oil to return freely to the hydraulic tank.
  
• Flow control valves: Prevent damage by matching oil flow to the breaker’s rated capacity.
  

In older or less specialized machines, this circuit must be installed or modified, often involving custom fabrication and electrical work.
T-Line Considerations: Don’t Ignore the Return Path
A major challenge in adapting a breaker to a standard Hitachi 200 is ensuring correct return line routing. Some operators mistakenly tee the return into a high-pressure return or use a shared circuit, risking backpressure buildup that can:

• Overheat hydraulic oil
  
• Blow seals within the breaker
  
• Cause erratic hammering or reduced force
  
• Reduce overall system efficiency
  

Ideally, the breaker’s return line should be plumbed directly into the hydraulic tank with minimal resistance. If that's not possible, a low-pressure port or specially designed manifold can be used.
Case Example: Backpressure Blues
In one case, a contractor installed a mid-size breaker on a Hitachi ZX200 but failed to provide a direct tank return. Within days, the breaker lost force and began leaking oil around the tool bushing. Inspection revealed burst internal seals caused by overpressure. A $40 hose routing shortcut led to a $2,000 rebuild.
The fix? Rerouting the return to a dedicated port on the main hydraulic tank, which restored full function immediately.
Flow and Pressure: Matchmaker Rules
Each breaker model has its own hydraulic flow (L/min or GPM) and operating pressure (bar or psi) requirements. The Hitachi ZX200 can usually supply:

• Flow: ~180–200 L/min (47–53 GPM)
  
• Pressure: Up to 31 MPa (4,500 psi)
  

When selecting a breaker:

• Ensure the breaker’s maximum flow matches or slightly undercuts the excavator’s auxiliary flow.
  
• Never exceed the rated pressure, as it can crack the breaker housing or damage the carrier’s hydraulic pump.
  
• Use flow control valves if your machine supplies more than the attachment requires.
  

Mounting and Controls
Mechanically, most breakers mount using:

• Pin-on systems (direct to the boom/stick)
  
• Quick couplers for easy swap between bucket and hammer
  
• Bracket or cradle-type mounts, which reduce vibration transfer to the carrier
  

Hydraulic controls may be manual (lever or foot pedal) or integrated into the joystick, especially in newer Hitachi models.
Vibration and Isolation
Repeated breaker operation transfers high-frequency vibration into the machine structure. This can fatigue:

• Boom and stick welds
  
• Hydraulic hose joints
  
• Operator comfort systems (seats, consoles, mounts)
  

To mitigate this:

• Use urethane isolators in the breaker bracket
  
• Inspect welds for micro-cracks every 200 hours
  
• Train operators to use short bursts, not constant hammering
  

Real-World Anecdote: Rocky Lessons in Wyoming
A quarry crew in Wyoming fitted a Hitachi ZX200 with a mid-size breaker for secondary rock reduction. The terrain was harsh, with granite boulders up to 3 feet thick. Initially, they ran long, continuous hammering cycles. Within weeks, the breaker’s chisel shank was mushroomed, and one stick cylinder developed a weld crack from vibration fatigue.
After consulting with the breaker manufacturer, they adjusted their technique: shorter bursts (10–15 seconds), regular greasing of the tool shank, and added a custom polyurethane vibration pad. These changes doubled tool life and reduced operator complaints.
Greasing: The Silent Guardian
Breaker bushings face intense stress and heat. Proper greasing:

• Prevents metal-to-metal scoring
  
• Extends bushing and chisel life
  
• Reduces internal friction and noise
  

Use special breaker grease, not standard chassis grease. Breaker grease includes molybdenum disulfide and withstands the extreme temperatures and pressures at the tool interface. Automatic greasers are ideal, but manual greasing every 2 operating hours is a minimum standard.
Troubleshooting Common Breaker Issues
Some common symptoms and their possible causes:

• Breaker doesn’t fire: Check for low system pressure, faulty pilot valve, or stuck piston.
  
• Weak impact: Possible cause includes incorrect flow, backpressure, or worn internal seals.
  
• Oil leaks: Likely from a damaged diaphragm or blown seal—inspect hydraulic fittings and tool bushings.
  
• High-pitched screeching: Often caused by cavitation or dry bushings—grease or inspect hydraulic filters.
  

Final Thoughts: A Partnership of Power and Precision
Pairing a hydraulic breaker with a Hitachi 200 is a force multiplier—but only when properly installed, matched, and maintained. The breaker is not just another attachment; it is a precision tool demanding respect. Incorrect setup can cost thousands in repairs, while a properly tuned system can dramatically increase jobsite productivity.
The secret lies not in brute force, but in controlled energy—delivered, absorbed, and managed with care. With good engineering, informed choices, and attentive operation, a breaker-equipped Hitachi 200 becomes an unstoppable force against even the hardest obstacles.