Common Causes and Troubleshooting Guide

Common Causes and Troubleshooting Guide

When your hydraulic breaker starts working with noticeably reduced impact force or inconsistent performance, productivity on the job site suffers.

This is a common issue encountered by operators, especially in high-frequency or long-term usage.

Understanding the potential causes and how to diagnose them quickly can help minimize downtime and prevent further equipment damage.

1. Insufficient Nitrogen Pressure

Symptoms: Weak impact, reduced striking force, inconsistent blows
Cause: Nitrogen in the upper chamber of the piston plays a key role in energy storage and piston return. Low nitrogen pressure leads to poor rebound, reducing overall impact efficiency.
Solution:

Use a nitrogen charging kit and gauge to check the pressure

Refer to the breaker manual for correct pressure values

Small breakers: 12–16 bar

Medium breakers: 16–20 bar

Large breakers: 18–22 bar

Recharge nitrogen as necessary. Never use compressed air as a substitute.

2. Incorrect Hydraulic Flow or Pressure

Symptoms: Slow operation, weak or irregular striking
Cause: The breaker relies on adequate hydraulic oil flow and pressure. If either is too low, impact power drops. Excessive pressure, on the other hand, may cause seal damage.
Solution:

Check that the excavator’s hydraulic output matches the breaker’s requirements

Inspect hoses, connectors, and valves for leaks or blockages

Use a pressure gauge or consult service personnel to confirm flow and pressure are within range

3. Worn or Damaged Seals

Symptoms: Oil leakage, loss of impact power
Cause: Seals in the cylinder, piston, and nitrogen chamber wear over time, leading to internal leakage and reduced hydraulic force.
Solution:

Disassemble and inspect seals for cracks or deformation

Replace with original factory-recommended sealing kits

Ensure proper reassembly and torque application

4. Piston or Valve Malfunction

Symptoms: Unusual noises, inconsistent performance, or failure to strike
Cause: Worn pistons lose pressure efficiency, while stuck or contaminated control valves can interrupt the oil flow cycle.
Solution:

Inspect the piston and check the clearance with the cylinder

Clean or replace the valve group as needed

Check for signs of contamination in the oil system

5. Improper Operating Technique

Symptoms: Misfire, weak strikes, or rapid tool wear
Cause: Operational errors like dry-firing (striking in the air), angled blows, or insufficient downforce reduce efficiency and cause damage.
Solution:

Always apply the breaker vertically with firm pressure

Avoid striking without contact to material

Monitor operating habits and retrain personnel if necessary

Conclusion: Quick Diagnosis for Better Performance

Loss of striking power in hydraulic breakers is often due to low nitrogen pressure, hydraulic mismatches, seal wear, or improper use.

A systematic approach to troubleshooting—from checking nitrogen levels and oil pressure to inspecting internal parts and reviewing operation habits—can help restore optimal performance.

Preventive maintenance and correct tool selection are key to maximizing the lifespan and productivity of your breaker.

If issues persist, consult a certified technician or contact the manufacturer for detailed support.