Aftermarket Product

Komatsu Hydraulic Breaker

JTHB series

Structure &
Function

Structure

Aftermarket Product

Function

Aftermarket Product

high pressure oil

14-18MPa (JTHB210-3)
Low pressure oil
(return)
Nitrogen gas
1.1MPa (JTHB210-3)

Based upon Pascals law

Pressure = Force / Surface

Or Force => Pressure * Surface
3

Working principle - strokes

Aftermarket Product

high pressure oil

14-18MPa (JTHB210-3)
Low pressure oil
(return)
Nitrogen gas
1.1MPa (JTHB210-3)

Working principle - strokes

Aftermarket Product

high pressure oil

14-18MPa (JTHB210-3)
Low pressure oil
(return)
Nitrogen gas
1.1MPa (JTHB210-3)

Working principle - strokes

Aftermarket Product

high pressure oil

14-18MPa (JTHB210-3)
Low pressure oil
(return)
Nitrogen gas
1.1MPa (JTHB210-3)

Working principle - strokes

Aftermarket Product

high pressure oil

14-18MPa (JTHB210-3)
Low pressure oil
(return)
Nitrogen gas
1.1MPa (JTHB210-3)

Working principle - strokes

Aftermarket Product

high pressure oil

14-18MPa (JTHB210-3)
Low pressure oil
(return)
Nitrogen gas
1.1MPa (JTHB210-3)

Working principle - strokes

Aftermarket Product

high pressure oil

14-18MPa (JTHB210-3)
Low pressure oil
(return)
Nitrogen gas
1.1MPa (JTHB210-3)

Working principle - strokes

Aftermarket Product

high pressure oil

14-18MPa (JTHB210-3)
Low pressure oil
(return)
Nitrogen gas
1.1MPa (JTHB210-3)

10

Working principle - strokes

Aftermarket Product

high pressure oil

14-18MPa (JTHB210-3)
Low pressure oil
(return)
Nitrogen gas
1.1MPa (JTHB210-3)

11

Working principle - strokes

Aftermarket Product

high pressure oil

14-18MPa (JTHB210-3)
Low pressure oil
(return)
Nitrogen gas
1.1MPa (JTHB210-3)

12

Working principle - strokes

Aftermarket Product

high pressure oil

14-18MPa (JTHB210-3)
Low pressure oil
(return)
Nitrogen gas
1.1MPa (JTHB210-3)

13

Working principle - strokes

Aftermarket Product

high pressure oil

14-18MPa (JTHB210-3)
Low pressure oil
(return)
Nitrogen gas
1.1MPa (JTHB210-3)

14

Working principle - strokes

Aftermarket Product

high pressure oil

14-18MPa (JTHB210-3)
Low pressure oil
(return)
Nitrogen gas
1.1MPa (JTHB210-3)

Based upon Pascals law

Pressure = Force / Surface

Or Force => Pressure * Surface
15

Aftermarket Product

Komatsu Hydraulic Breaker

JTHB series

Installation

16

Main hydraulic circuit on Breaker-mode

Flow quantity 550L/min
Filtration particle size 20m

Aftermarket Product
Flow qty 16L/min
Filtration 6m

R Pump

Hydraulic
oil filter

F Pump

Hydraulic
oil

C
/
V

BREAKE
R

Breaker
Additional
Return Filter

Flow quantity 200L/min

Filtration particle size 6m
17

Hydraulic piping & Electric circuit

Aftermarket Product

18

Main hydraulic circuit on Breaker-mode

Aftermarket Product

19

Delivery Service

Aftermarket Product

Checking Accumulators

Low pressure line accumulator is necessary

Pulsation pressure may cause breakage of aluminum oil
cooler
Komatsu piping has it
High Pressure line accumulator is NOT necessary
JTHB breaker has not high pulsation pressure.
No Accumulator
(High Pressure)
Accumulator
(Low Pressure)

20

Reinforcement

Aftermarket Product

Reinforcement of work equipment of PC200-8

Refer Parts Service News reinforce work equipment by PSN:BT06005.

21

Delivery Service

Aftermarket Product

Check Nitrogen gas pressure

Check gas pressure using specified gas gauge

Standard 1.1MPa (11kg/cm2)(JTHB210-3)

Adjust the pressure by gas N2 gas charging tool

22

Aftermarket Product

Special Tool

Gas checking and charging tool for Box bracket

1

Description

Reference

Gas tool Assy

BTA01016040
Charging socket

Comment

Charging socket
9/16-18 UNF

Box bracket

23

Delivery Service

Aftermarket Product

Check Safety valve pressure (ex. PC200-8)

two stage safety valve 305/250kg/cm2 for ATT valve

Cracking pressure is 205kg/cm2
Sales code 4PJ34C-A, Parts ref. 723-90-76300
Checking method
Monitoring : B mode relief pressureR pump: 01101)
Attachment pedal pushing to forward : 230kg/cm2
Punch mark on the safety valve
mark PK 723-90-76300 (305/250kg/cm2)

24

Delivery Service

Aftermarket Product

Check Oil flow quantity of excavator

(ex. PC200-8)
Specification Oil flow160200 L/min
Checking method
1. By Monitor (ex. After PC200-7)
set 180 L/min

2. By Flow meter (ex. Before PC200-6)

Measure PQ by flow meter
Set flow 160-200L/min on 1418MPa
Adjust by Fuel dial, Pedal position,

25

Aftermarket Product

PC200-M0

03 With / Without
Attachment
07 Default

With Attachment

F6
Set Flow quantity

26

PQ measurement

Aftermarket Product

How to Measure P Q by flow meter

27

Aftermarket Product

Komatsu Hydraulic Breaker

JTHB series

Maintenance

28

Aftermarket Product

Delivery Service

Hydraulic oil

Recommend HO46-HM
The oil is strong for oil
temperature change

Breaker
ratio

100%

50
%

25
%

Bucket

Eco White
element
(after
PC200-7)

Paper
element
(before
PC200-6)

Hydraulic Oil

1000

600

Oil filter element

250

150

Element for breaker

250

250

Hydraulic Oil

1500

900

Oil filter element

250

150

Element for breaker

250

250

Hydraulic Oil

2000

1200

Oil filter element

500

200

Element for breaker

500

500

Hydraulic Oil

5000

2000

Oil filter element

1000

500

No

No

Item

Element for breaker

29

Hydraulic oil HO46

Aftermarket Product

Aftermarket Product

Greasing Chisel

Greasing every 2 hours

GOOD

END

BAD
31

Grease

Aftermarket Product

Do not use Molybdenum content grease.

It will lead the hydraulic components failure of the excavator.

32

grease
HYPERWHITE GREASE

Aftermarket Product

Periodical maintenance

Aftermarket Product

34

Aftermarket Product

Special Tool

Hydraulic Breaker Special Tools

Description

Reference

Comment

Flow meter

790-303-1003

PQ checking

Helisert insert tool

Local Purchasing

Breaker Stand

Local making

Standing breaker
for repairing

Bush tool

Local making

For pressing the

bushing

(Refer to Shop manual)

(Refer to Shop manual)

4
35

Aftermarket Product

Repair / Overhaul

Chisel bush removing (press fitted)

1.By Hydraulic Press
100ton Press
(over JTHB120-3)

2. Gas cutting

60ton Press
(under JTHB60-3)

36

Aftermarket Product

Komatsu Hydraulic Breaker

JTHB series

Operation

37

Aftermarket Product

Test run

Carry out test run in cases below:

- New Hydraulic breaker installed onto the excavator
- Reconnect hydraulic hoses after storage or repair

Before

After

38

Test run

Aftermarket Product

Process (2) & (3) must be performed

as shown in Fig. 2 where the breaker is
lifted up and held straight up.
When performing process (2) & (3)
make sure the breaker does not impact
by adjusting the operating pedal
accordingly.

39

Park position

Aftermarket Product

keep breaker on vertical position after operation

To oil leakage from piston seal

40

Storage
STORAGE FOR ONE MONTH

Aftermarket Product

STORAGE FOR MORE THAN ONE MONTH

41

Operation Hydraulic breaker

Aftermarket Product

Refer Operation & Maintenance Manual

42

Aftermarket Product

Komatsu Hydraulic Breaker

JTHB series

Service
Operation

43

Summary

Warranty
Delivery Service
Periodical Visit

Aftermarket Product

Service Manual
TSI / Claim
Damaged Parts

Contact
Repair / Overhaul
Special Tool
Parts

44

Aftermarket Product

Warranty

Warranty period

12 month after delivery

Parts Not Covered par

warranty

1.
2.
3.
4.
5.
6.
7.

Consumable, Tools
Chisel
Chisel bushing
Chisel holder bushing
Retainer pin
Retainer stopper
Retainer stopper plug
Retainer pin plug
Seals
Bolt and Nuts
Hoses

4
6
5
7

1
2

TSI, Claim

Aftermarket Product

Caution for making TSI and Claim application

1 Model Type is JTHB

correctJTHB210-3 10017

IncorrectPC200-8

2 SMR is Breaker equipped hours

Machine SMR Breaker installed SMR)
3 Mention excavator information.
Machine type, SMR, piping type.
(in Description Column
46

Aftermarket Product

Repair

Standard Rate for Hydraulic Breaker

Specified Component codes and Rate.

Component
Work Code
Code
7GG0
7GN0
7GH0
7GH8
7GJ1
7GJ2
7GK0
7GK0
7GK1
7GK2
7GK3
7GK4
7GK5
7GK5
7GK6
7GK7
7GL0
7GL0
7GL4
7GL5
7GL6
7GM1
7GM3
7GM4

B5
B5
B5
B5
B5
B5
D3
B5
B5
B5
FU
B5
D3
B5
B5
B4
D3
B5
B5
B5
B4
B4
B5
B5

Component
HYD.BREAKER
HYD.BREAKER
HYD.BREAKER
HYD.BREAKER
HYD.BREAKER
HYD.BREAKER
HYD.BREAKER
HYD.BREAKER
HYD.BREAKER
HYD.BREAKER
HYD.BREAKER
HYD.BREAKER
HYD.BREAKER
HYD.BREAKER
HYD.BREAKER
HYD.BREAKER
HYD.BREAKER
HYD.BREAKER
HYD.BREAKER
HYD.BREAKER
HYD.BREAKER
HYD.BREAKER
HYD.BREAKER
HYD.BREAKER

ASSY
CHISEL ASSY
BRACKET ASSY
BRACKET BOLT,NUT
HOSE
HOSE ADAPTER
CYLINDER ASSY
CYLINDER ASSY
CYLINDER COVER
SIDE BOLT, NUT
GAS VALVE
PACKING BUSH
PISTON
PISTON
PISTON GAS SEAL
PISTON OIL SEAL
CONTROL VALVE ASSY
CONTROL VALVE ASSY
VALVE CAP
VALVE HELISERT
VALVE SEAL
CHISEL HOLDER HELISERT
CHISEL BUSH
CHISEL HOLDER BUSH

Work
Remove Install
Remove Install
Remove Install
Remove Install
Remove Install
Remove Install
Glinding
Remove Install
Remove Install
Remove Install
Charging
Remove Install
Glinding
Remove Install
Remove Install
Replace
Glinding
Remove Install
Remove Install
Remove Install
Replace
Replace
Remove Install
Remove Install

JTHB210-3
1.0
0.5
1.4
1.4
0.8
0.2
0.2
1.4
0.6
0.9
0.2
0.3
1.1
0.3
0.2
0.2
0.7
0.3
0.4
0.2
0.2
0.3
2.4
2.3

47

Aftermarket Product

Service Manuals

Uploaded on K-source
It will be on PUBLIST in mid 2013.

Manual

Reference

Operation and
Maintenance

PEN00651-01

Parts Book

FEN02448-02

Shop Manual

SEN06343-00

48

Spare Parts

Aftermarket Product

JTHB breaker parts numbers are

BTxxxxxxxxxx
Parts ordering is same as normal
operation PWINS.

49

Periodical Visit

Aftermarket Product

Service Report

Fill the Hydraulic Breaker Service Report

Register into EQP Care
Register equipped machine data also
(Machine type, SMR, Piping)

50