Aftermarket Product

Komatsu Hydraulic Breaker

JTHB series

Structure &
Function

1
 Aftermarket Product
Structure
 Aftermarket Product
Function
high pressure oil
14-18MPa (JTHB210-3)

Low pressure oil

(return)

Nitrogen gas
1.1MPa (JTHB210-3)

Based upon Pascal’s law… Pressure = Force / Surface

Or Force => Pressure * Surface
3
 Aftermarket Product
Working principle - strokes
high pressure oil
14-18MPa (JTHB210-3)

Low pressure oil

(return)

Nitrogen gas
1.1MPa (JTHB210-3)

4
 Aftermarket Product
Working principle - strokes
high pressure oil
14-18MPa (JTHB210-3)

Low pressure oil

(return)

Nitrogen gas
1.1MPa (JTHB210-3)

5
 Aftermarket Product
Working principle - strokes
high pressure oil
14-18MPa (JTHB210-3)

Low pressure oil

(return)

Nitrogen gas
1.1MPa (JTHB210-3)

6
 Aftermarket Product
Working principle - strokes
high pressure oil
14-18MPa (JTHB210-3)

Low pressure oil

(return)

Nitrogen gas
1.1MPa (JTHB210-3)

7
 Aftermarket Product
Working principle - strokes
high pressure oil
14-18MPa (JTHB210-3)

Low pressure oil

(return)

Nitrogen gas
1.1MPa (JTHB210-3)

8
 Aftermarket Product
Working principle - strokes
high pressure oil
14-18MPa (JTHB210-3)

Low pressure oil

(return)

Nitrogen gas
1.1MPa (JTHB210-3)

9
 Aftermarket Product
Working principle - strokes
high pressure oil
14-18MPa (JTHB210-3)

Low pressure oil

(return)

Nitrogen gas
1.1MPa (JTHB210-3)

10
 Aftermarket Product
Working principle - strokes
high pressure oil
14-18MPa (JTHB210-3)

Low pressure oil

(return)

Nitrogen gas
1.1MPa (JTHB210-3)

11
 Aftermarket Product
Working principle - strokes
high pressure oil
14-18MPa (JTHB210-3)

Low pressure oil

(return)

Nitrogen gas
1.1MPa (JTHB210-3)

12
 Aftermarket Product
Working principle - strokes
high pressure oil
14-18MPa (JTHB210-3)

Low pressure oil

(return)

Nitrogen gas
1.1MPa (JTHB210-3)

13
 Aftermarket Product
Working principle - strokes
high pressure oil
14-18MPa (JTHB210-3)

Low pressure oil

(return)

Nitrogen gas
1.1MPa (JTHB210-3)

14
 Aftermarket Product
Working principle - strokes
high pressure oil
14-18MPa (JTHB210-3)

Low pressure oil

(return)

Nitrogen gas
1.1MPa (JTHB210-3)

Based upon Pascal’s law… Pressure = Force / Surface

Or Force => Pressure * Surface
15
 Aftermarket Product

Komatsu Hydraulic Breaker

JTHB series

Installation

16
Main hydraulic circuit on Breaker-mode Aftermarket Product

Flow quantity ： 550L/min Flow qty ： 16L/min

Filtration ： 6μm
Filtration particle size： 20μm

R Pump
Hydraulic
oil filter F Pump
Hydraulic
oil

C
BREAKE
/
R V

Breaker
Additional
Return Filter

Flow quantity ： 200L/min

Filtration particle size ： 6μm

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)

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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
Special Tool Aftermarket Product

• Gas checking and charging tool for Box bracket

Description Reference Comment
1 Gas tool Assy BTA01016040 Charging socket
Charging socket
9/16-18 UNF
1

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 pressure（R 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 flow：160～200 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 14-
18MPa
（Adjust by Fuel dial, Pedal position,）

25
PC200-８M0 Aftermarket Product

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

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 Aftermarket Product

Komatsu Hydraulic Breaker

JTHB series

Maintenance

28
 Delivery Service Aftermarket Product

 Hydraulic oil
Eco White Paper
 Recommend HO46-HM Breaker element element
Item
The oil is strong for oil ratio (after
PC200-7)
(before
PC200-6)
temperature change
Hydraulic Oil 1000 600
Oil filter element
100% 250 150
Element for breaker 250 250
Hydraulic Oil 1500 900
50 Oil filter element 250 150
%
Element for breaker 250 250
Hydraulic Oil 2000 1200
25 Oil filter element 500 200
%
Element for breaker 500 500
Hydraulic Oil 5000 2000
Oil filter element
Bucket 1000 500
Element for breaker No No

29
Hydraulic oil HO46 Aftermarket Product
Greasing Chisel Aftermarket Product

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 Aftermarket Product

HYPERWHITE GREASE
Periodical maintenance Aftermarket Product

34
Special Tool Aftermarket Product

 Hydraulic Breaker Special Tools

Description Reference Comment 1
1 Flow meter 790-303-1003 PQ checking

2 Helisert insert tool Local Purchasing

3 Breaker Stand Local making Standing breaker

(Refer to Shop manual) for repairing
4 Bush tool Local making For pressing the 2
(Refer to Shop manual) bushing

4
35
Repair / Overhaul Aftermarket Product

 Chisel bush removing (press fitted)

2. Gas cutting
1.By Hydraulic Press

100ton Press 60ton Press

(over JTHB120-3) (under JTHB60-3)

プレスでブッシュを押し出し

36
 Aftermarket Product

Komatsu Hydraulic Breaker

JTHB series

Operation

37
Test run Aftermarket Product

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 Aftermarket Product

STORAGE FOR ONE MONTH 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 Aftermarket Product

 Warranty  Service Manual

 TSI / Claim
 Delivery Service  Damaged Parts
 Periodical Visit

 Contact
 Repair / Overhaul
 Special Tool
 Parts

44
Warranty Aftermarket Product

Warranty period
 12 month after delivery

 Parts Not Covered par

warranty

 Consumable, Tools
1. Chisel 4
2. Chisel bushing 6
3. Chisel holder bushing 5
4. Retainer pin
7
5. Retainer stopper
6. Retainer stopper plug
7. Retainer pin plug
3
Seals 1
Bolt and Nuts
Hoses 2
TSI, Claim Aftermarket Product

 Caution for making TSI and Claim application

＊1： Model Type is JTHB

（correct）JTHB210-3 ＃10017
（Incorrect）PC200-8

＊2： SMR is Breaker equipped hours

（Machine SMR – Breaker installed SMR)

＊3： Mention excavator information.

Machine type, SMR, piping type.
(in Description Column）

46
Repair Aftermarket Product

 Standard Rate for Hydraulic Breaker

 Specified Component codes and Rate.
Component
Work Code Component Work JTHB210-3
Code
7GG0 B5 HYD.BREAKER ASSY Remove Install 1.0
7GN0 B5 HYD.BREAKER CHISEL ASSY Remove Install 0.5
7GH0 B5 HYD.BREAKER BRACKET ASSY Remove Install 1.4
7GH8 B5 HYD.BREAKER BRACKET BOLT,NUT Remove Install 1.4
7GJ1 B5 HYD.BREAKER HOSE Remove Install 0.8
7GJ2 B5 HYD.BREAKER HOSE ADAPTER Remove Install 0.2
7GK0 D3 HYD.BREAKER CYLINDER ASSY Glinding 0.2
7GK0 B5 HYD.BREAKER CYLINDER ASSY Remove Install 1.4
7GK1 B5 HYD.BREAKER CYLINDER COVER Remove Install 0.6
7GK2 B5 HYD.BREAKER SIDE BOLT, NUT Remove Install 0.9
7GK3 FU HYD.BREAKER GAS VALVE Charging 0.2
7GK4 B5 HYD.BREAKER PACKING BUSH Remove Install 0.3
7GK5 D3 HYD.BREAKER PISTON Glinding 1.1
7GK5 B5 HYD.BREAKER PISTON Remove Install 0.3
7GK6 B5 HYD.BREAKER PISTON GAS SEAL Remove Install 0.2
7GK7 B4 HYD.BREAKER PISTON OIL SEAL Replace 0.2
7GL0 D3 HYD.BREAKER CONTROL VALVE ASSY Glinding 0.7
7GL0 B5 HYD.BREAKER CONTROL VALVE ASSY Remove Install 0.3
7GL4 B5 HYD.BREAKER VALVE CAP Remove Install 0.4
7GL5 B5 HYD.BREAKER VALVE HELISERT Remove Install 0.2
7GL6 B4 HYD.BREAKER VALVE SEAL Replace 0.2
7GM1 B4 HYD.BREAKER CHISEL HOLDER HELISERT Replace 0.3
7GM3 B5 HYD.BREAKER CHISEL BUSH Remove Install 2.4
7GM4 B5 HYD.BREAKER CHISEL HOLDER BUSH Remove Install 2.3

47
Service Manuals Aftermarket Product

 Uploaded on K-source Manual Reference

Operation and PEN00651-01

It will be on PUBLIST in mid 2013. Maintenance
Parts Book FEN02448-02

Shop Manual SEN06343-00

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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