Identifying and Understanding Hydraulic Hammers

[MikePhua]

Hydraulic hammers, also known as breakers, are powerful tools used in construction, demolition, and mining to break through tough materials like rock, concrete, and asphalt. They are typically mounted on excavators, skid steer loaders, or backhoes and are powered by the hydraulic systems of the host machines. Identifying a hydraulic hammer and understanding its features and components can help in choosing the right one for a project, performing maintenance, and troubleshooting common issues.
Types of Hydraulic Hammers
Hydraulic hammers come in various shapes, sizes, and power outputs. The type of hammer you choose depends on the size and strength of the material you need to break, as well as the machine’s capacity to support it. There are two primary types of hydraulic hammers:

1. Single-Impact Hydraulic Hammers:
   These hammers rely on a single impact blow to break the material. They are simple in design and relatively cost-effective. They are best for breaking through soft to medium-strength materials like concrete, asphalt, and limestone.
   
2. Double-Impact Hydraulic Hammers:
   As the name suggests, these hammers deliver a double blow to the material. This feature allows for greater force and efficiency, making them suitable for breaking tougher materials like granite and large boulders. Double-impact hammers are more expensive but often provide better performance for heavy-duty tasks.
   

Identifying Features of Hydraulic Hammers
When selecting a hydraulic hammer, it is important to identify certain features that determine its efficiency and suitability for a specific job. The key components that help with identification include:

1. Weight Class:
   Hydraulic hammers are categorized into different weight classes, which usually correspond to the weight of the hammer itself. The weight of the hammer determines the size of the material it can break and the type of machinery it can be mounted on. Hammers are often rated for use with machines in the range of 5 to 100 tons.
   
2. Hydraulic Flow Requirements:
   Each hydraulic hammer has specific hydraulic flow requirements, measured in gallons per minute (GPM). A hammer that requires a high flow rate is suitable for larger machines with more powerful hydraulic systems. A mismatch between the hydraulic flow of the host machine and the hammer can lead to inefficient operation or even damage to the equipment.
   
3. Chisels and Tools:
   The chisels, or tool bits, used in a hydraulic hammer are typically made from high-strength steel and come in various shapes and sizes. The shape of the tool determines its suitability for different applications. Common types of chisels include:
   • Moil Point: Best for general-purpose use and initial penetration into tough materials.
     
   • Chisels (Flat, Blunt): Ideal for breaking up concrete slabs or walls.
     
   • Pyramid Tools: Used for heavy-duty tasks that involve breaking through reinforced concrete or very hard rock.
     
4. Impact Energy:
   Impact energy refers to the force generated by the hydraulic hammer when it strikes the material. The higher the energy, the greater the hammer's ability to break through tough surfaces. It is often measured in joules or foot-pounds. Higher impact energy is required for tougher materials like granite or reinforced concrete.
   
5. Frequency of Impacts:
   Hydraulic hammers can deliver varying frequencies of impact. The frequency affects how fast the hammer can break material. Higher frequency hammers tend to be better for lighter, non-reinforced materials like asphalt, while lower-frequency hammers work better for heavier materials such as rock or concrete.
   

Common Brands and Models
There are several reputable brands that manufacture hydraulic hammers, and each has its own methods for identifying and categorizing its products. Some of the most well-known brands include:

1. Atlas Copco:
   Atlas Copco is a leading manufacturer of hydraulic breakers, offering a wide range of models for different types of machinery. Their models typically have a label with the model number and weight class, helping users select the correct hammer for their needs.
   
2. Epiroc:
   A global leader in hydraulic equipment, Epiroc (formerly part of Atlas Copco) produces a wide range of hydraulic breakers for various industries. Their hydraulic hammers are designed for maximum productivity and include models with advanced features like variable stroke lengths.
   
3. Soosan:
   Soosan is a popular manufacturer in Asia, known for providing durable and affordable hydraulic hammers. Their hammers are often used in demolition and mining applications. Soosan hammers also have a reputation for reliable performance in harsh conditions.
   
4. Rammer:
   Rammer is a well-known name in the construction and demolition industries. Their hydraulic breakers are widely used and known for their advanced technology, performance, and low operating costs. They have models suited for a variety of applications, from construction to mining.
   
5. Krupp:
   Krupp hammers are another option for heavy-duty tasks, known for their long-lasting performance and efficient design. They are especially effective in applications involving harder materials, like granite and basalt.
   

Troubleshooting Common Hydraulic Hammer Problems
While hydraulic hammers are designed for tough work, they are not immune to mechanical issues. Common problems include loss of impact energy, oil leaks, and poor performance. Let’s discuss how to troubleshoot some of these problems:

1. Loss of Impact Energy:
   If the hydraulic hammer has lost its ability to break through materials efficiently, it could be due to several factors:
   • Low Hydraulic Pressure: Insufficient hydraulic pressure is a common cause of low impact energy. Check the hydraulic system of the host machine to ensure it is providing the correct pressure and flow.
     
   • Worn-out Chisels: The chisel or tool bit may be worn or damaged, which can result in a loss of impact force. Replacing the chisel with a new one may resolve the issue.
     
   • Internal Damage: The piston or other internal components of the hammer may be damaged. In this case, the hammer may require disassembly and repair by a qualified technician.
     
2. Oil Leaks:
   Hydraulic oil leaks can significantly reduce the efficiency of the hammer and lead to damage. Inspect the hydraulic lines, hoses, and seals for visible cracks or wear. Tighten any loose fittings, and replace any damaged parts.
   
3. Excessive Vibration:
   Excessive vibration during operation can be caused by several factors, including:
   • Misalignment of the Hammer: Ensure the hammer is properly mounted on the machine. If it is misaligned, it can create additional vibrations that reduce its efficiency.
     
   • Damaged Components: Check the internal parts of the hammer, including the piston and cylinder, for any signs of damage. Internal damage can lead to excessive vibrations during operation.
     
4. Slow or Uneven Impacts:
   If the hammer is delivering uneven or slow impacts, it may be due to:
   • Air in the Hydraulic System: Air trapped in the hydraulic system can lead to uneven operation. Bleed the air from the system and check the fluid levels.
     
   • Valve Malfunction: The valve that controls hydraulic fluid flow may be malfunctioning, causing inconsistent performance. A technician can test and repair or replace the valve as needed.
     

Conclusion
Identifying a hydraulic hammer and understanding its various components is essential for its optimal use and longevity. Whether you are using a Wacker Neuson, Epiroc, or another brand, knowing the specifications of the hammer—such as weight class, impact energy, and hydraulic requirements—will help you choose the right model for your job. Regular maintenance and troubleshooting of hydraulic systems, tools, and components can keep your hammer in top working condition and prevent costly repairs. By adhering to the right practices, you can ensure that your hydraulic hammer remains a reliable tool for tough demolition and construction tasks.