How to Specify a Hydraulic Breaker | Construction Equipment

Hydraulic breakers are becoming smarter and heading to a breakout future. The Infrastructure Investment and Jobs Act (IIJA) should bring plenty of work for hammers as they chip through structurally deficient old bridges, bust away outdated pavement, and clear out the old for new construction. Maximizing breaker productivity for these projects starts with proper pairing of the hammer, carrier, and application.

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Matching the right hydraulic breaker to a job is a balancing act of considerations. The core machine considerations for matching a breaker to its carrier are the machine’s operating weight, its hydraulic flow characteristics—operating pressure, hydraulic flow rate, auxiliary flow rate—its overall lift capacity, and the geometry of the carrier’s boom design, all of which contribute to operating stability.  

How to match a breaker to its carrier

Breaker manufacturers and OEM compatibility charts provide a range of mechanical and operating requirements proven to pair specific sized carriers efficiently with various breakers. These listings are a good starting point and provide a proven foundation on which to add other considerations such as the job’s material type, time constraints, and the contractor’s budget.

“Correctly matching the breaker to the available carrier is crucial to optimize efficiency as well as protect the contractor’s equipment,” says Joe Tedesco, president of Gorilla Hammers/Tech Hydraulics. Tedesco says selecting the right hammer for a job begins with the carrier’s size and its oil output.

“The key to fitting the right hammer to the machine is a test with a flow meter to make sure the hydraulic flow pressure matches the capabilities of the hammers,” says Tedesco.

“To maximize the life and efficiency of a hydraulic hammer while putting as little strain on the hydraulic system as possible, the carrier must be set up to deliver oil to the hydraulic breaker at the correct volume, pressure, and relief without exceeding the backpressure limitations of the hammer.

“Too much oil or pressure will cause the hammer to overspeed, which reduces seal life and can damage internal components,” he says. “Improperly set relief or excessive backpressure can cause the breaker to overheat and transfer heat to the carrier’s hydraulic system. Too little oil flow reduces the breaker’s impact power. Additionally, too little oil flow won’t provide the necessary lubricating film between internal moving parts and lead to damage.”

According to Joel Escalante, senior product specialist, Doosan Infracore North America, “The proper rule of thumb for excavator/breaker matching is to ensure one pump flow. For instance, if the maximum flow on an excavator is 2 x 50 gpm = total of 100 gpm, the maximum flow requirement by the breaker should not exceed 50 gpm. In other words, if the flow required is 60 gpm, you must use a bigger excavator or reduce the size of the breaker.”

“Most carriers have adjustable hydraulic systems to perform this fine-tuning,” Tedesco says, “but a qualified hydraulic technician with the proper flow meter to measure all of the hydraulic values simultaneously throughout the operating range is the only way to optimize your hydraulic breaker’s performance and protect your carrier.”

How weight affects breaker performance 

Stability is critical for safe and efficient breaker performance. The balance between the carrier’s and hammer’s weights, along with the lift capacity and length of the arm, need to match to avoid a damage to the breaker or the carrier.

 “If the carrier is equipped with a quick-hitch mounting bracket, consult the operating manual of the quick-hitch bracket before you attempt to mount the product,” says Todd Cannegieter, product manager for Volvo Construction Equipment. “Faulty bracket geometry may lead to contact and cause expensive damage to the boom cylinders.”

Not only does the machine need to be able to move and position the breaker, but it is also important that it can handle the forces from the breaker.

“Your carrier has to be heavy enough to safely carry the hammer at all angles and extensions of the boom and stick without tipping the carrier or causing too much diving when the hydraulic hammer breaks through the material being demolished,” Tedesco says. “The carrier also must be large enough to withstand the recoil that all hydraulic hammers transfer back to the carrier while operating. Too much recoil can loosen the hammer’s supply pipes and clamps and can affect the carrier’s weldments.”

More than productivity is directly affected by the breaker’s size—and as tempting as it might be to select the biggest, baddest breaker available—assuming the “big job, bigger tool” mindset can lead to less efficiency and possible damage to the carrier.

A hammer that is too heavy for the carrier’s lift and stability limits severely weakens the operator’s ability to lift the hammer efficiently and move across the material being broken. This is especially important when breaking hard, rounded, and unevenly shaped rock where the operator must move frequently to find fissures, weak spots, and striking points. An oversized breaker transmits energy in two directions: both toward the material and resonating through the carrier. This produces wasted energy and can also damage the carrier. An excessively heavy bracket may increase the weight of the attachment more than the lifting capacity of the carrier allows, says Cannegieter.

On the other hand, a hydraulic breaker should not be too small for the carrier. Each carrier exerts down-pressure on the hydraulic hammer as it is planted on the material to be broken. If the hammer is too small, excessive down-pressure will cause the frame to twist, damage mounting adapters and produce weldment cracks, according to Tech Hydraulics.

How to pick the right breaker

Matching the tool to the application also depends on the type of rock and how the rock breaks. Additionally, material hardness (its Geological Strength Index), material size, production requirements, and duration of the project determine the pairing. If the work involves large and hard material, high production requirements, and a project that will last for several months, experts recommend using the largest attachments appropriate for the available carrier size.

“Every contractor has a breaker in his fleet,” Aaron Scarfia, Komatsu’s manager of North America attachment division, says. The type of hammer the fleet manager keeps on hand depends on the kind of work his firm does regularly: concrete demolition, boulder busting, trenching, etc.

“For constant full impact, when you just need to hit hard with every stroke the same force and frequency to break up hard rock, gas fired breakers such as Komatsu’s G-series are very productive,” Scarfia says. “Seventy-five percent of gas-fired hydraulic breaker energy is produced by nitrogen and the remaining energy is hydraulic. The nitrogen is contained in a pressurized vessel and produces identical force for each strike.” Komatsu says that because gas breakers have fewer moving parts, they deliver maximum reliability.

The addition of Komatsu’s “smart” 100-precent hydraulic V-series multiple speed variable breakers are adding even finer breaker control.

“Even before the operator can feel the rock break, the multiple speed breakers can detect and automatically shift to select the best piston stroke length and speed,” Scarfia says. “Because the V-series breakers are not dependent on the operator’s observations and reactions, the opportunities for blank firing are significantly lessened. That decreased blank firing, along with full upper and lower suspensions to dampen the impact of the breaker, protects the excavator boom and arm, and adds years to the breaker’s service life.”

Escalante says the operator must follow the proper recommendations in the breaker and machine’s manuals.

“Breaker point types vary upon application and provided the right point is used, we strongly recommend avoiding activating the breaker for long stretches of time,” he says. “If the material does not break within 15 to 20 seconds, reposition the tool and try again. If the breaker is activated for a full minute, the high idle period should be one minute before resuming operation.”

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Foot-pound ratings and classes are reported in ranges, not hard numbers, so matching brand breakers to its brand family carrier presumes the pairing is optimal. In the case of Komatsu, Scarfia says the company tested its full line of breakers with the company’s complete machine line up for years before releasing the new breaker line. The same can be said about coupler compatibility.

According to Cannegieter, making sure the mounting adaptor design tightly corresponds with the attachment ensures safe operation and helps avoid structural issues. Although an OEM can be a one-stop-shop for the complete package (machine plus breaker), Cannegieter says a third-party vendor may be able to support its breaker better or react quicker than an OEM.

Whether the equipment maker or attachment maker provide the breaker, the correct balance between carrier and tool ensures maximum strike efficiency for the project.

Excavator jack hammers are indispensable tools for heavy industries. They provide the power and efficiency needed to tackle some of the toughest jobs. This powerful attachment, also known as a hydraulic hammer, excavator breaker hammer or hydraulic breaker, is designed to break through concrete, rock, and other hard materials, making them essential for construction, demolition, and mining projects. Hammer attachments are one of the most versatile and popular tools for backhoe loaders, skid steer loaders and excavators on the job site.

In heavy machinery, excavator jack hammer attachments stand out due to their ability to transform an excavator or mini excavator into a versatile tool capable of performing a wide range of tasks. Hydraulic hammers are designed to be mounted on various carriers, including different types of excavators and machinery, ensuring compatibility and flexibility for diverse job requirements. Their significance lies in their ability to efficiently and effectively break down solid materials, a critical part of various industrial jobs. Whether constructing a new building, demolishing an old structure, or extracting rocks from a quarry or minerals from the earth, the proper excavator jack hammer can significantly enhance productivity and safety.

The market offers a variety of excavator jack hammers, each designed to meet specific needs, excavator type (including mini excavator, skid steer and backhoe loaders) and challenges matching hydraulic capacity. Excavator breaker and excavator breaker hammer attachments are also available as versatile options for mini excavators, suitable for applications such as concrete breaking, rock chipping, and post driving. Choosing the compatible, correct tool diameter for the energy class and operating weight of your excavators will ensure optimal performance, safety, and efficiency. Factors such as the nature of the material to be broken, the working environment, and the specific requirements of the task at hand all play a role in determining the most suitable type of jack hammer. Having the right equipment is crucial for achieving desirable results and maximizing uptime on tough job sites. Please note that the availability of certain models or types may be subject to availability, which could affect purchasing decisions or project planning.

This blog will focus on the top five types of excavator jack hammer attachments, highlighting their features, applications, and real-world examples to help you make an informed decision. By understanding each type’s distinct advantages and ideal use cases, you can select the best tool to meet your project’s demands, making short work of difficult jobs and ensuring you can support your your crew no matter the project.

Introduction to Excavator Jack Hammers

Excavator jack hammers have become essential attachments for excavators and skid steer loaders on modern construction sites. Originally introduced over sixty years ago, with the first serially manufactured rock breaker—the Krupp HM 400—making its debut in , these tools have revolutionized the way operators tackle tough materials. Today’s hydraulic breakers are engineered to efficiently break through concrete, rock, and asphalt, making them indispensable for demolition, deconstruction, primary and secondary rock breaking, trenching, foundation work, and asphalt cutting.

The evolution of hydraulic hammers has brought about a range of advanced features designed to enhance both operator comfort and equipment longevity. Modern models may include self-lubricating systems, sound and vibration damped systems, automatic rock hardness adjusting systems, energy recovery, and solid body concepts. These innovations not only improve performance and efficiency but also help reduce wear and tear on both the breaker and the carrier machine. Whether mounted on a skid steer or a full-size excavator, these hammers deliver the power and versatility needed to handle a wide range of jobs, from breaking up old pavement to excavating rock in challenging environments. As a result, hydraulic breakers remain a cornerstone of efficient, high-performance equipment fleets across the construction and demolition industries.

Underwater Breakers

Overview

Underwater breakers are specially designed to operate in submerged conditions and are compatible with various machinery, including backhoe loaders. They are modified to prevent water ingress and maintain functionality underwater, making them essential for marine construction and underwater demolition projects.

Key Features

• Waterproof Design: These breakers are built to withstand underwater conditions, ensuring reliable performance. The waterproof construction prevents water damage, allowing the breaker to operate effectively in submerged environments.
• Durability: They are made from materials that resist corrosion and other damage caused by prolonged exposure to water. The durable design ensures long-lasting performance, even in harsh underwater conditions.

Applications

• Marine Construction: Underwater breakers are essential for building and maintaining marine structures. They can efficiently break through submerged concrete and rock, facilitating construction and maintenance projects in aquatic environments.
• Underwater Demolition: They demolish submerged structures or clear underwater obstacles. The breakers provide the power to remove underwater obstructions, enabling safe and efficient demolition.
• Dredging: These breakers assist in breaking up hard materials during dredging operations. They enhance the effectiveness of dredging equipment, allowing for the removal of rigid underwater materials.

Example

In underwater pipeline maintenance, an excavator with an underwater hammer attachment breaks up rock formations obstructing the pipeline. This application highlights the breaker’s capability to perform in challenging underwater environments, ensuring the smooth operation of underwater construction and maintenance tasks.

Vibratory Breakers

Overview

Vibratory breakers utilize vibration to break materials, making them practical for breaking large volumes of concrete or asphalt. The vibration technology enhances the breaker’s efficiency, allowing it to handle extensive demolition tasks easily.

Key Features

• Vibration Technology: These breakers use vibration to efficiently break through rigid materials, reducing the effort required. The vibration helps to loosen and fracture the material, making it easier to break.
• High Efficiency: They are capable of handling large-scale demolition projects with ease. The efficient design allows for quick and effective breaking of large volumes of material, improving productivity.

Applications

• Road Construction: Vibratory breakers are commonly used to break up old road surfaces during road construction projects. They facilitate the removal of asphalt and concrete, preparing the site for new construction.
• Large-Scale Demolition: They are ideal for demolishing large structures quickly and efficiently. The powerful vibration technology makes them suitable for extensive demolition tasks, reducing the time and effort required.

Example

During a highway expansion project, an excavator with a vibratory hammer attachment breaks up the existing asphalt. This example demonstrates the breaker’s efficiency in handling extensive demolition tasks, ensuring the quick and effective preparation of the site for new construction.

Safety Precautions and Operating Guidelines

Operating a hydraulic breaker or excavator jack hammer safely is crucial for achieving maximum efficiency and protecting both the operator and the equipment. Before starting any job, it’s essential to consult the equipment manual or specification sheet to ensure the breaker and chisel are properly matched to your mini excavator or excavator’s rating. Using the right equipment for the job not only enhances performance but also reduces the risk of damage or accidents.

When attaching a breaker to your machine, always verify that your excavator or mini excavator meets the necessary operating capacity and specifications for the chosen attachment. Never use a breaker hammer in water unless it is specifically equipped with a water seal kit, as improper use can lead to equipment failure or safety hazards. Regular maintenance checks are vital—inspect the attachment for signs of wear, ensure all bolts and pins are secure, and confirm that hydraulic connections are leak-free.

Operators should also be mindful of the vibration and sound produced during operation. Prolonged exposure can impact both comfort and safety, so it’s important to use appropriate personal protective equipment and take regular breaks as needed. By following these safety precautions and operating guidelines, you can ensure your hydraulic breaker delivers reliable performance and efficiency on every job.

Hydraulic Breaker Maintenance

Keeping your hydraulic breakers in top condition is key to ensuring maximum efficiency and extending the life of your equipment. Regular maintenance not only helps maintain the powerful force needed for tough jobs but also reduces the risk of unexpected downtime. Many modern hydraulic breakers are designed with easy maintenance in mind, featuring quick change systems that allow for fast replacement of wear parts and accessories, minimizing service interruptions.

To get the best performance from your breaker, always follow the manufacturer’s maintenance guidelines. This includes routine lubrication, inspecting hoses for leaks or damage, and replacing worn pins and bushings as needed. Proper storage and careful handling of both the breaker and its accessories can prevent unnecessary wear and help maintain durability. Regularly checking the hammer’s components ensures that any potential issues are caught early, keeping your equipment running efficiently and safely. By prioritizing maintenance, you’ll ensure your hydraulic breaker continues to deliver the reliable, efficient performance you need on every job site.

Environmental and Regulatory Considerations

When using hydraulic breakers and excavator jack hammers, it’s important to be aware of the environmental and regulatory requirements that may apply to your job site. These powerful hammers can generate significant vibration, noise, and dust, which can impact the surrounding environment and nearby communities. Operators must ensure their equipment is used efficiently and in compliance with all local regulations, especially in sensitive areas such as quarries, mines, or locations with fragile ecosystems.

In addition to managing noise and vibration, it’s crucial to take precautions to avoid damaging underground utilities, pavements, or nearby buildings. This may involve conducting site surveys, using protective barriers, or adjusting work schedules to minimize disruption. By staying informed about the regulations that govern the use of hydraulic breakers and adopting best practices for environmental stewardship, operators can ensure their work is both efficient and responsible, helping to protect the environment and maintain a positive reputation within the industry.

Innovations and Technological Advancements

The hydraulic breaker industry continues to evolve, with manufacturers introducing a range of innovations and technological advancements to meet the demands of modern construction and demolition. Today’s hydraulic breakers are built with new materials and designs that enhance durability, reduce maintenance, and improve overall efficiency. Features such as automatic rock hardness adjusting systems, energy recovery, and solid body concepts help optimize performance and extend the life of both the breaker and the carrier machine.

Advancements in hydraulic capacity matching systems ensure that breakers are perfectly suited to the excavators or skid steers they’re mounted on, maximizing power and efficiency for every job. The development of more compact and powerful breakers has also expanded the range of suitable applications, making it easier to equip smaller machines with high-performance attachments. As technology continues to advance, operators can expect even more efficient, durable, and environmentally friendly hydraulic breakers that deliver superior results while reducing the need for frequent maintenance. These innovations are helping to set new standards for performance, operator comfort, and environmental responsibility across the industry.

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