How to Fix Unstable Hydraulic Breaker Operation – Complete Troubleshooting Guide

A hydraulic breaker (hammer) that operates unstably can lead to inefficient demolition, excessive wear, and even equipment failure. Common symptoms include irregular impacts, loss of power, or excessive vibrations.

This guide explains the main causes of unstable breaker performance and provides step-by-step solutions to restore optimal function.

!!!WARNING:When disassembling the hydraulic breaker, be sure to release the gas in the nitrogen chamber first!

8 Causes of Unstable Hydraulic Breaker Operation & Fixes

1. Excessive Nitrogen Gas Pressure

·        Problem: Too much nitrogen pressure (above 14-16 bar / 200-230 psi) reduces impact efficiency.

·        Solution:

.        Check with a nitrogen pressure gauge.

.        Release excess gas using a charging kit.

.        Refill to recommended pressure (varies by model).

2. Low Hydraulic System Pressure

·        Problem: Inadequate oil pressure (below 100-150 bar / 1,450-2,175 psi) weakens strikes.

·        Solution:

.        Adjust the main relief valve (consult manual for specs).

.        Check for pump wear or leaks.

3. Damaged Tool (Chisel) or Bushing

·        Problem: Worn or bent chisel, front bushing, or retaining pins cause misalignment.

·        Solution:

.        Inspect for cracks or deformation.

.        Repair with a grinder or replace if necessary.

.        Ensure proper lubrication (grease every 2 hours).

4. Piston, Cylinder, or Valve Damage

·        Problem: Scratched piston, worn seals, or stuck control valves disrupt hydraulic flow.

·        Solution:

.        Disassemble and polish piston/cylinder with fine sandpaper (if minor damage).

.        Replace seals and damaged valves.

5. High Return Line Backpressure

·        Problem: Clogged filters or restricted hoses increase backpressure (> 5 bar / 72 psi).

·        Solution:

.        Clean or replace hydraulic filters.

.        Check for kinked or undersized hoses.

6. Overheated Hydraulic Oil

·        Problem: Oil temps > 80°C (176°F) reduce viscosity and efficiency.

·        Solution:

.        Clean oil cooler and check fan operation.

.        Use high-quality hydraulic oil (ISO VG 46 or VG 68).

7. Incorrect Relief Valve Setting

·        Problem: Low relief pressure causes weak impacts.

·        Solution:

.        Adjust to manufacturer’s specs (typically 150-200 bar / 2,175-2,900 psi).

8. Low Hydraulic Oil Level

·        Problem: Insufficient oil leads to cavitation and erratic operation.

·        Solution:

.       Top up to recommended level (check sight glass).

Preventive Maintenance Tips

✅ Daily: Check oil levels, grease the tool bushing.
✅ Weekly: Inspect hoses, fittings, and nitrogen pressure.
✅ Monthly: Test hydraulic pressure and clean coolers.

When to Call a Professional

·        If internal components (piston, valve) are severely damaged.

·        If hydraulic leaks persist after repairs.

·        If the breaker still vibrates excessively after troubleshooting.

Most unstable breaker issues stem from nitrogen pressure, hydraulic settings, or worn parts. Regular maintenance and proper adjustments can extend the hammer’s lifespan and improve performance.

Need OEM replacement parts or expert service? Contact us today!