How do you apply it? Use an automatic greaser (if available) and set it to apply grease only when the breaker is operating. If the automatic greaser runs while the breaker tool has dropped down, grease will be deposited on the top of the tool. The next time you use the breaker, the grease (now trapped between the top of the breaker tool and the bottom of the strike piston) will be forced through the lower piston seals and damage them. If applying lubricant manually, the tool must be pushed upward into the breaker before greasing. This is easy to do by lowering the breaker vertically and pressing the tool against the ground.

The bottom line: using the proper amount of high-quality grease and putting it on in the correct manner will greatly reduce the friction wear on the tool and tool bushings.

3) When is it time to inspect?

The Fault: Tool tops not checked regularly lead to more damage overall.

The Fix: The top of the tool takes a tremendous beating from the strike piston. Eventually, the tool top’s surface will mushroom just like the top of a mechanic’s cold chisel or punch. It is important that the mushrooming areas be filed off before they become so large that they break off. Broken pieces of the tool can get trapped between the tool and the strike piston, resulting in piston damage. Also, be sure to check for damage on the areas of the tool that strike the tool retainers. Any mushrooming or other faults must be filed off regularly.

An important reminder: different types of breaker applications will result in more or less tool damage. Inspect and service the tool once a week until experience teaches you how long your service intervals can be.

4) When do I replace the bushings?

The Fault: Wear limits on bushings are routinely misjudged, resulting in piston damage and shortened lifespan on other parts.

The Fix: All breaker tool bushings have a specified inner-diameter wear limit. When this limit is reached, most bushings appear to have plenty of material left to wear off and are usually not replaced as recommended. But the key is to remember that the wear limit is not based on how much material is left, but on the possible angle of engagement between the tool and strike piston. The lower bushing will be the first to wear out. If it is allowed to wear past the limit, the tool can be at such an angle to the piston that the piston only hits the tool on the edge of the strike surface. Continuing to operate the breaker in this way will damage the strike piston. In addition, wear on the upper bushing is accelerated when the lower bushing is worn out. You can extend the lifespan of the upper bushing by replacing the lower bushing when the wear limit is reached.

Why risk down time, lost job opportunities, and uncontrolled spending to replace worn equipment? Spend a little time and money on the simple fundamentals and the results can pay off for a long time to come.

To view this article in the Aggregates Manager Digital Edition, which includes photos and illustrations, go to http://www.digitalmagazinetechnology.com/a/?KEY=aggregatesmanager-10-06june#page=25.