Pressure loss, also known as leakage, is a common fault in hydraulic breakers. Once pressure loss occurs, the system pressure cannot be established, leading to environmental pollution, increased downtime, reduced productivity, increased production costs, and potentially unpredictable serious consequences. Therefore, controlling leakage in hydraulic breakers is crucial.
- Classification of Leaks: Leaks in hydraulic breakers are mainly classified into fixed seal leaks and moving seal leaks. Fixed seal leaks primarily occur at the piston ring and cylinder block seals, cylinder block and nitrogen chamber seals, valve sleeve and valve body seals, valve cover and valve body seals, valve body and cylinder block seals, and pipe joint connections. Moving seal leaks primarily occur at the cylinder block and piston front end, piston rear end, piston ring area, valve core and valve sleeve area, etc. Leaks can also be classified by the direction of oil leakage: external leakage and internal leakage. External leakage refers to hydraulic oil leaking from the system into the environment, while internal leakage refers to hydraulic oil leaking from the high-pressure side to the low-pressure side within the system due to pressure differences between the high and low pressure sides or seal failure. 2. Causes of Leakage
2.1 Design Factors
(1) Selection of Seals.
The reliability of a hydraulic breaker largely depends on the design of the seals and the selection of the seals. Inappropriate selection of the sealing structure or non-compliant seal selection, failure to consider the compatibility of hydraulic oil with the sealing material, load conditions, ultimate pressure, operating speed, and changes in ambient temperature, can all directly or indirectly cause hydraulic system leakage to varying degrees. Furthermore, since the operating environment of a hydraulic breaker contains dust and impurities, appropriate dustproof seals must be selected in the design to prevent dust and other contaminants from entering the system, contaminating the oil, damaging the seal, and thus causing leakage.
2.2 Manufacturing and Assembly Factors
(1) Manufacturing Factors.
All hydraulic components and sealing parts of a hydraulic breaker have strict requirements regarding dimensional tolerances, surface treatment, surface roughness, and geometric tolerances. If these tolerances are exceeded during manufacturing—for example, in the cylinder and piston diameter, sealing groove depth or width, or the size of the hole for the sealing ring—or due to machining problems such as out-of-roundness, burrs, pits, or chrome plating peeling—the sealing parts will deform, scratch, become crushed, or fail to seal properly, thus losing their sealing function and creating inherent leakage points that will lead to leakage after assembly or during use.
(2) Assembly Factors.
Rough handling should be avoided during the assembly of a hydraulic breaker. Excessive force will deform the parts. Before assembly, the parts should be carefully inspected. During assembly, the parts should be lightly pressed in with a small amount of hydraulic oil. Diesel oil should be used for cleaning, especially for rubber components such as sealing rings, dust rings, and O-rings. Using gasoline for cleaning can easily cause them to age, lose their original elasticity, and reduce their sealing function. The ATB hydraulic breaker core uses Korean technology and precision assembly, and the seals are also imported directly from Japan. If operated strictly according to the usage procedures, its service life will be significantly longer than that of other hydraulic breakers.
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