Le interrupteur hydraulique, as one of the most crucial attachments of an excavator, has to operate under harsh conditions, such as in mines and construction sites, for long periods of time at high intensity.
Its internal structure is highly precise, and the working load is enormous. Without standardized maintenance and care, it not only leads to a decrease in impact force and efficiency, but also may cause damage to the core components, resulting in high maintenance costs and long-term downtime losses.
Correct usage and maintenance are the keys to unlocking the potential of the breaker and extending the equipment’s lifespan. This article will systematically elaborate on the complete maintenance specifications for METDEEM breakers from their initial installation to daily use, helping every user make good use of the breaker and maintain it properly.
First Installation: Eliminate Risks, Lay a Solid Foundation
Before installing the breaker hammer onto the excavator, there is a crucial step that is often overlooked – cleaning the debris from the hydraulic pipes.
Preventing debris from entering
Before installing the new breaker, there may be trace impurities or residues that entered the crusher pipeline of the excavator during transportation and storage. If these contaminants enter the interior of the breaker along with the hydraulic oil, they may scratch the precisely-fitting piston and cylinder, causing irreversible damage.
Operation steps
- Connect the inlet and return oil pipelines of the impactor directly with the pipe of the hammer body.
- Open the stop valve on the hydraulic pipeline.
- Step on the impact foot switch of the excavator to make the hydraulic oil circulate in the pipeline.
Flexible Tube Connection and Exhaust
After the pipeline flushing is completed, the actual connection between the breaker hammer and the excavator can be made. Connect the oil inlet (IN) of the breaker hammer to the high-pressure oil supply pipe of the excavator, and connect the oil outlet (OUT) to the return oil pipeline. Ensure that there is no reverse connection.
Exhaust operation
- After the connection is completed, place the chisel vertically on the ground.
- Activate the breaker switch by gently pressing or rapidly and intermittently stepping on it.
- Let the hydraulic oil slowly enter the interior of the breaker hammer, and expel the remaining air in the pipeline and the hammer body.
Daily Maintenance: Prevention is Key to Avoiding Problems
Fastener Inspection
The breaker hammer operates under high-frequency vibration, and there is a possibility that the connecting bolts and other fasteners of the housing may become loose.
Butter Filling
The function of butter is not only to lubricate, but also to form a protective film between the chisel and the inner and outer sleeves, significantly reducing wear.
- Frequency of addition: Add once before starting work, and then add every 2 hours of work.
- Amount of addition: The regular addition is approximately 50 milliliters.
- Special initial addition: For the newly installed breaker hammer, the internal oil passage does not have any grease yet. The initial addition requires about 100 milliliters to ensure adequate lubrication.
Replacement of Sealing Components
The sealing components are the key parts that prevent hydraulic oil from leaking and maintain the system pressure. As the usage time increases, these sealing components will naturally age and wear out.
Replacement cycle based on the diameter of the chisel
METDEEM has formulated a scientific preventive replacement cycle for sealing components based on the working conditions of different types of impact hammers:
- For chisels with a diameter of less than 100mm, it is recommended to replace them every 2500 to 3000 hours.
- For chisels with a diameter ranging from 100mm to 175mm, it is recommended to replace them every 1500 to 2000 hours.
- For chisels with a diameter of more than 175mm, it is recommended to replace them every 1000 to 1500 hours.
| Chisels Diameter（mm） | ≤ 100 | 100–175 | ≥175 |
| Suggested Replacement Cycle(hours) | every 2500 to 3000 | every 1500 to 2000 | every 1000 to 1500 |
Handling of Abnormal Situations
If oil leakage is detected during use, regardless of whether it has reached the specified duration, the machine should be stopped immediately and the seal parts replaced.
Nitrogen System Maintenance: The Core for Ensuring Stable Impact Force
The nitrogen pressure directly determines the impact efficiency of the breaker hammer. Regular inspections and standardized management are the key to ensuring the performance of the equipment.
Inspection of nitrogen in the rear cylinder block
- Check frequency: It is recommended to check once a week.
- Function: The nitrogen pressure in the rear cylinder directly affects the impact force. If the pressure is too low, the impact will be weak; if the pressure is too high, it may cause the piston to fail to return.
- Adjustment: Use a dedicated nitrogen pressure gauge and filling tools to adjust the pressure to the standard value specified for this model.
Nitrogen Check for Accumulator
Some models of the impact hammers are equipped with external accumulators, which are used to enhance the impact force and absorb hydraulic shocks.
- Check frequency: It is recommended to conduct a check once a month.
- Abnormal detection: If abnormal fluctuations in the impact frequency or increased vibration of the equipment are detected during use, the nitrogen pressure of the accumulator should be checked immediately.
Long-term Storage Nitrogen Treatment
When the breaker hammer is expected to be unused for a long period of time, the following operations must be carried out:
- Release nitrogen gas: Completely evacuate the nitrogen gas in the rear cylinder.
- Insert the piston: Use a chisel to push the piston into the middle cylinder.
- Rust prevention principle: The residual hydraulic oil inside the middle cylinder can cover the surface of the piston, isolating it from the air and effectively preventing the piston from rusting due to long-term storage.
If the nitrogen gas is not released, the piston will naturally extend outward under the spring pressure, exposing its working surface to the air, which is highly prone to rust and will seriously affect its next use.
Conclusion
The impact hammer is an extremely high-return investment tool, but this return requires proper maintenance as a prerequisite. From the initial pipeline flushing during installation to daily tightening and lubrication, from monitoring the replacement cycle of seals to regular detection of nitrogen pressure, every detail of persistence is contributing to the long-term stable operation of the equipment.
METDEEM is committed to providing high-performance impact hammer products and also hopes to help every user master scientific maintenance methods, so that the equipment can perform at its best in every operation and create greater value for you.
Contactez METDEEM today to explore more!
FAQ (questions fréquentes)
Q: Why is it necessary to use the hammer body pipe to connect and flush the pipeline before installing the new hammer?
A: The flushing is done to remove any debris that may be present in the pipeline of the excavator’s crusher, to prevent these impurities from entering the internal parts of the crusher and damaging the precision pistons and cylinder bodies.
Q: Why is it necessary to press the chisel firmly into the ground when adding butter?
A: Pressing the chisel tightly enables the dust seal to contract, opening the passage for the butter to enter the internal slide channel. At the same time, it prevents the butter from being pushed into the piston impact chamber, thus avoiding damage to the oil seal or piston sticking.
Q: Why is the replacement cycle of the sealing parts differentiated based on the diameter of the chisel?
A: The larger the diameter of the chisel, the greater the impact energy and hydraulic flow of the breaker, and the greater the pressure and wear that the sealing parts have to withstand. Therefore, the replacement cycle is shortened accordingly.
