JTHB Shop Manual Sen06343-00

SEN06343-00
Shop Manual
Hydraulic Breakers Serial numbers

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This shop manual is for Hydraulic Breakers.

For excavators, please refer to their shop manual.
.
Shop Manual
00 Index and foreword

Index、safety
Index 00-1
Foreword, safety and general information 00-2
00-1
Foreword, safety and general information
Important safety notice

Appropriate servicing and repair are extremely important to ensure safe operation of the machine. The shop manual
describes the effective and safe servicing and repair methods recommended by Komatsu. Some of these methods
require the use of the special tools designed by Komatsu for the specific purpose.
The symbol mark is used for such matters that require special cautions during the work. The work indicated by
the caution mark should be performed according to the instructions with special attention to the cautions. Should
hazardous situation occur or be anticipated during such work, be sure to keep safe first and take every necessary
measure.
1. General precautions 7) If welding repairs is required, always have a

trained and experienced welder with good
Inappropriate handling causes an extreme danger. knowledge of welding perform the work. When
Read and understand what is described in performing welding work, always wear welding
the operation and maintenance manual before gloves, apron, shielding goggles, cap, etc.
operating the machine. Read and understand what
is described in this manual before starting the work. 8) Before starting work, warm up your body
thoroughly to start work under good condition.
1) Before performing any greasing or repairs,
read all the safety labels stuck to the machine. 9) Avoid continuing work for long hours and take
For the locations of the safety labels and detailed rests with proper intervals to keep your body
explanation of precautions, see the operation in good condition. Take a rest in a specified
and maintenance manual. safeplace.
2) Locate a place in the repair workshop to keep

Safety points
the tools and removed parts. Always keep the 1 Good arrangement
tools and parts in their correct places. Always 2 Correct work clothes
keep the work area clean and make sure that 3 Observance of work standard
there is no dirt, water or oil on the floor. Smoke
only in the areas provided for smoking. Never 4 Practice of making and checking signals
smoke while working. 5 Prohibition of operation and handling by
unlicensed workers
3) When performing any work, always wear the 6 Safety check before starting work
safety shoes and helmet. Do not wear loose work Wearing protective goggles
7 (for cleaning or grinding work)
cloths, or clothes with buttons missing.
1. Always wear the protective eyeglasses 8 Wearing shielding goggles and protectors
(for welding work)
when hitting parts with a hammer.
9 Good physical condition and preparation
2. Always wear the protective eyeglasses
Precautions against work which you are not
when grinding parts with a grinder, etc. 10 used to or you are used to too much
4) When performing any work with two or more

workers, always agree on the working procedure
2. Preparation
before starting. While working, always keep 1) Before adding oil or making any repairs, place
conversations of the work between your fellow the machine on a firm and level ground, and
workers and your self on any step of the work. apply the parking brake and chock the wheels
During the work, hang the warning tag of or tracks to prevent the machine from moving.
"UNDER WORKING" in the operator's
compartment. 2) Before starting work, lower the work equipment
(blade, ripper, bucket, etc.) to the ground. If it
5) Only qualified workers must perform the work is not possible to lower the equipment to
and operation which require license or the ground, insert the lock pin or use blocks to
qualification. prevent the work equipment from falling. And
be sure to lock all the work equipment control
6) Keep the tools in good condition. And learn the levers and hang a warning tag on them.
correct way to use the tools, and use the proper
ones among them. Before starting the work, 3) When performing the disassembling or assembling
thoroughly check the tools, forklift truck, service work, support the machine securely with blocks,
car, etc. jacks, or stands before starting the work.
00-2
4) Remove all of mud and oil from the steps or 7) When removing the part which is under internal
other places used to get on and off the machine pressure or reaction force of the spring, always
completely. Always use the handrails, ladders leave two bolts in diagonal positions.
of steps when getting on or off the machine. Loosen those two bolts gradually and alternately
Never jump on or off the machine. When the and release the pressure, then, remove the part.
scaffold is not provided, use steps or stepladder
to secure your footing. 8) When removing the part, be careful not to break
or damage the electrical wiring. The damaged
wiring may cause electrical fires.
3. Precautions during work
9) When removing piping, prevent the fuel or oil from
1) For the machine equipped with the battery
spilling out. If any fuel or oil drips onto the floor,
disconnect switch, check that the system
wipe it off immediately. Fuel or oil on the floor
operating lamp is turned off before starting
can cause you to slip and can even cause fires
the work. Then, turn the battery disconnect
switch to the OFF position and remove the
10) As a general rule, do not use gasoline to wash
switch key. For the machine not equipped
parts. Do not use gasoline to clean the electrical
with the battery disconnect switch, remove
parts, in particular.
the cable from the battery before starting the
work. Be sure to remove the negative end of
11) Reinstall the parts removed to their original places.
the battery cable first.
Replace the damaged parts and the parts which
must not be used with new ones. When installing
2) Release the remaining pressure in the circuits
the hoses and wiring harnesses, be careful that
completely before the work when the parts in
they are not damaged by contacting with other
the circuits of oil, fuel, coolant and air are
parts when the machine is operated.
disconnected or removed. When the cap of
the oil filter, drain plug or oil pressure pickup
12) When connecting the high pressure hoses and
plug is removed, loose them slowly to prevent
tubes, make sure that they are not twisted.
the oil from spurting out.
The damaged high pressure hoses and tubes
are very dangerous when they are installed.
3) When removing or installing the checking plug
So, be extremely careful when connecting the
orthe piping in the fuel circuit, wait 30 seconds
high pressure pipings. In addition, check that
or longer after the engine is shut down and
their connections are correct.
start the work after the remaining pressure is
released from the fuel circuit.
13) When assembling or installing the parts, be
sure to tighten the bolts to the specified torque.
4) Immediately after the engine is shut down,
When installing the protective parts such as
the coolant and oil in the circuits are hot. Be
guards, or the parts which vibrate violently or
careful not to get scalded by the hot coolant
rotate at high speeds, be sure to check that
and oil. Start the work after checking that the
they are installed correctly.
coolant and oil are cooled down sufficiently.
14) When aligning two holes, never insert your
5) Start the work after the engine is shut down.
fingers or hand into the holes. Align the holes
Be sure to shut down the engine when working
with care so that your fingers are not caught
on or around the rotating parts in particular.
in the hole.
When checking the machine without shutting
down the engine (measuring oil pressure,
15) When measuring hydraulic pressure, check
engine speed, oil or coolant temperature),
that the measuring tools are correctly installed.
take extreme care not to get caught in the
rotating parts or the working equipment.
16) Pay attention to safety when removing and
installing the tracks of the track type machines.
6) The hoist or crane must be used to sling the
When removing the track, it separates suddenly.
components weighing 25 kg or heavier. Check
The workers should not stand at either end of
the slings (wire rope, nylon sling, chain and
the track.
hook) for damage before the work. Use the
slings with ample capacity and install them to
17) If the engine is operated for a long time in a
the proper places. Operate the hoist or crane
closed place which is not ventilated well, you
slowly to prevent the component from hitting
may suffer from gas poisoning. Accordingly,
any other part. Do not work with any part still
open the windows and doors to ventilate the
raised by the hoist or crane.
place well.
00-3
4. Precautions for slinging work and making signals

1) Only one appointed worker must make signals
and co-worker must communicate with each
other frequently.
The appointed signaler must make specified
signals clearly at the place where the signaler
is well seen from the operator's seat and where
the signaler can see the working condition
easily. The signaler must always stand in front
Load capacity
of the load and guide the operator safely.
・Do not stand under the load.

・Do not step on the load.
Habging angle (deg)
2） Check the slings before starting sling work.
3） Keep putting on the gloves during sling work. 9) When installing wire ropes to an angular load,
(Put on the leather gloves, if available.) apply pads to protect the wire ropes.
If the load is slippery, apply proper material to
4） Measure the weight of the load by the eye prevent the wire rope from slipping.
and check its center of gravity.
10）Use the specified eye bolts and fix wire ropes,
5） Use the proper sling according to the weight chains, etc. to them with shackles, etc.
of the load and method of slinging. If too thick
wire ropes are used to sling a light load, the 11）Apply wire ropes to the middle portion of the
load may slip and fall. hook.
6） Do not sling a load with one wire rope only. ・Slinging near the tip of the hook may cause
If do so, the load may rotate or the sling gets the rope to slip off the hook during hoisting.
loose and the sling may slip off. Install two or The hook has the maximum strength at the
more wire ropes symmetrically. middle part.
Slinging with one rope may cause turning
of the load during hoisting, untwisting of
the rope, or slipping of the rope from its
original slinging position on the load,
which can result in a dangerous accident.
7） Hanging angle must be 60 degrees or smaller

as a rule.
8） When hanging a heavy load (25kg or heavier),

the hanging angle of the rope must be narrower
than that of the hook.
12) Do not use twisted or kinked wire ropes.
★ When slinging a load with two ropes or
more, the larger the hanging angle is, the 13) When slinging up a load, observe the following.
larger the tension of each rope. ・ Wind up the rope slowly until the wire rope
The figure bellow shows the variation of tensions. When putting your hands on the
allowable load in kN {kg} when hoisting is wire ropes, do not grasp them but press
made with two ropes, each of which is them down from above. If you grasp them,
allowed to sling up to 9.8 kN {1000kg} a your fingers may be caught.
load vertically, at various hanging angles.
When the two ropes sling a load vertically, ・ After the wire ropes are stretched, stop the
up to 19.6 kN {2000 kg} of total weight can crane and check the condition of the slung
be suspended. This weight is reduced to load, wire ropes, and pads.
9.8 kN {1000 kg} when the two ropes make
a hanging angle of 120 degrees. If the two ・ If the load is unstable or the wire rope or
ropes sling a 19.6 kN {2000 kg} load at a chains are twisted, lower the load and lift it
hanging angle of 150 degrees, each rope up again.
is subjected to a force as large as 39.2 kN
{4000 kg}. ・ Do not lift up the load at an angle.
00-4
14）When lowering a load, pay attention to the 9) Consider the travel route in advance and lift up
following. a load to a safe height.
・ When lifting down a load, stop it temporarily
at 30 cm above the floor, and then lower it 10) Place the control switch in a position where it
slowly. will not be an obstacle to work and passage.
・ Check that the load is stable, and then 11) After operating the hoist, do not swing the
remove the sling. control switch.
・ Remove kinks and dirt from the wire ropes 12) Remember the position of the main switch so
and chains used for the sling work, and that you can turn off the power immediately in
put them in the specified place. an emergency.
13) Shut down the main switch when the hoist

5. Precautions for using stops because of a blackout. When turning on
a switch which is turned OFF by the ground
mobile crane fault circuit interrupter for electric shock
prevention, check that the devices related to
Read the Operation and Maintenance Manual that switch are not in operating condition.
of the crane carefully in advance and operate
the crane safely. 14) If you find an obstacle around the hoist,
stop the operation.
15) After finishing the work, stop the hoist at

6. Precautions for using the specified position and raise the hook to at
overhead traveling crane least two meters above the floor. Do not leave
the sling attached to the hook.
The hoist or crane must be used to sling

the components weighing 25 kg or heavier.
A part weighing 25 kg or heavier in
7. Selecting wire ropes
"disassembly and assembly" section is 1) Select adequate ropes depending on the weight
indicated with the symbol of . of the parts to be hoisted, referring to the table
below
1) Before starting work, check the wire ropes,
brake, clutch, controller, rails, over winding Wire ropes
prevention device, ground fault circuit (standard "Z" twist ropes without galvanizing)
interrupter for electric shock prevention, crane (JIS G3525, Type 6X37-A)
collision prevention device, and energizing Nominal
Allowable load
warning lamp, and check the following safety diameter of rope
items. mm kN ton
2) Observe the signals for sling work. 10 8.8 0.9

12 12.7 1.3
3) Operate the hoist at a safe place. 14 17.3 1.7
16 22.6 2.3
4) Be sure to check the directions of the direction
indication plate (north, south, east and west) 18 28.6 2.9
and the operating button. 20 35.3 3.6
25 55.3 5.6
5) Do not sling a load at an angle. Do not move
the crane while the slung load is swinging. 30 79.6 8.1
40 141.6 14.4
6) Do not raise or lower a load while the crane is
50 221.6 22.6
moving longitudinally or laterally.
60 318.3 32.4
7) Do not drag a sling.
The allowable load is calculated as one sixth
8) When lifting up a load, stop it just after it leaves of the breaking load of the rope to be used
the ground and check safety, and then lift it up. (safety coefficient: 6).
00-5
Handling of hydraulic equipment

With the increase in pressure and precision of the hydraulic components, the most common cause of a failure is
dirt (foreign material) in the hydraulic circuit. Therefore, the special care must be taken when adding hydraulic oil,
or when disassembling or assembling the hydraulic components.
1. Be careful of working
environment
Avoid adding hydraulic oil, replacing filters, or
repairing the machine in rain or high winds, or at
places where there is a lot of dust.
2. Disassembly and
maintenance work in the field
When disassembly or maintenance work of the
hydraulic is performed in the field, there is danger
of dust entering the components. It is also difficult
to check the performance of the components after
repairs, so it is desirable to use the component
exchange service. The disassembly and assembly
of the hydraulic components must be performed in
the specially arranged dustproof workshop and t
he performance test of the components must be
performed with the special testing equipment.
3. Sealing openings
Plug the pipes and the openings of the components
which are removed with the caps, tapes, vinyl bags,
etc. to prevent foreign material from entering.
Never leave the openings of the pipes and hoses
without being covered or plugged with cloth as
foreign material may enter them or environment
may be polluted by the oil leaked. Do not discard
the waste oil somewhere or other. Hand it over to
your customer for disposal, or dispose it by yourself.
4. Preventing intrusion of foreign materials during

refilling operations.
Care must be taken when adding hydraulic oil so that foreign material does not enter. Keep the oil filler port
and the area around it, oil supply pump and oil container clean. If an oil cleaning device is used, it is possible
to remove the dirt that is collected during storage. It is a surer means.
5. Replacing hydraulic oil while its temperature is high

When the hydraulic oil is warm, it flows easily. In addition, sludge can also be drained from the circuit together
with the oil. So, it is better to change the hydraulic oil while it is warm. When changing the hydraulic oil, the old
oil must be drained as much as possible. (Drain the oil not only from the hydraulic tank, but also from the filter
housing and the drain plug hole in the circuit.) If the old oil is left in the system, the contaminant and sludge in
the oil mix with the new oil and shorten the life of the new hydraulic oil.
00-6
6. Flushing operations
After disassembling the equipment or when
changing the hydraulic oil with new one, flush the
system to remove the contaminant and sludge Flushing oil
left in the hydraulic circuit as well as the oil which
includes them. Normally, flushing is performed
twice. Primary flushing is performed by use of the
flushing oil and the secondary flushing is
performed by use of the specified hydraulic oil.
7. Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when the machine is in
operation, perform oil cleaning to remove the
sludge or contaminant in the hydraulic oil circuit.
The oil cleaning equipment can remove the ultra
fine (approximately 3 μm) particles that the filter
built in the hydraulic equipment can not remove.
So, it is an extremely effective device.
00-7
Shop Manual
01 Summary
Specifications
Specifications Dimensions 01-2
Specifications 01-3
01-1
01 Summary
Dimensions
c b
d
a
20-3 30-3 40-3 60-3

Model Type JTHB Unit 08-3 10-3 50-3
(20S-3) (30S-3) (40S-3) (60S-3)
1009 1161 1236 1595
a Length (Incl. Chisel) mm 896 960 1435
(1154) (1324) (1402) (1657)
255 240 275 404
b Width mm 223 222 330
(246) (265) (336) (417)
565 620 730 870
c Height mm 431 445 770
(625) (735) (806) (955)
500 630 681 825
d length (bracket only) mm 455 475 740
(823) (950) (1013) (1151)
120-3 210-3
Model Type JTHB Unit 160-3 350-3 450-3
(120S-3) (210S-3)
1939 2344
a Length (Incl. Chisel) mm 2150 2778 2886
(1989) (2469)
486 525
b Width mm 546 611 738
(480) (553)
1095 1395
c Height mm 1346 1780 1792
(1129) (1385)
1172 1630
d length (bracket only) mm 1247 1765 1818
(1391) (1916)
* (a) state the length of the chisel is pushed to full Length
01-2
01 Summary
Specifications
20-3 30-3 40-3 60-3
Model Type JTHB 08-3 10-3 50-3
(20S-3) (30S-3) (40S-3) (60S-3)
　 Side Mount
Bracket kg 56 75 95 165 220 295 400
Working weight
Top Mount
kg 75 100 140 210 255 315 -
Bracket(2PC)
Top Mount
kg 90 120 165 255 320 385 570
Box Bracket
Side Mount
kg - - 155 240 290 - 395
Silenced Bracket
Oil flow ℓ/min 18〜25 20〜30 20〜35 25〜45 30〜55 35〜60 40〜70
Operating pressure MPa 6〜13 7〜14 8〜15 10〜15 10〜16 10〜16 10〜16
Impact rate bpm 930〜1300 700〜1200 600〜1150 550〜1000 580〜1060 550〜1000 600〜1050
φ 95
Chisel diameter mm φ 40 φ 45 φ 50 φ 58 φ 64 φ 75
(φ 75)
42.6
Chisel weight kg 4.0 5.5 7.4 11.9 15.2 23.2
(23.2)
3/4
Hose size inch 3/8 1/2 1/2 1/2 1/2 1/2
(3/4)
Gas pressure MPa 0.8 0.8 0.8 0.8 0.8 0.8 1
6〜11
Base machine Ton 0.7〜1.5 1〜2 1.5〜2.5 2.4〜4 3〜4.5 3.8〜6
(5.5〜8)
PC30MR PC55MR PC60/88
Excavator model PC10MR PC18MR PC20MR PC45MR /56/
PC35MR WB9X /78US
Safety valve
MPa
(Komatsu Excavator)
01-3
01 Summary
120-3 210-3
Model Type JTHB 160-3 350-3 450-3
(120S-3) (210S-3)
　 Side Mount
Bracket kg 820 1010 1710 2500 3100
Working weight
Top Mount
kg 950 1240 2000 2700 3600
Box Bracket
Side Mount
kg 950 - 1850 - -
Silenced Bracket
Oil flow ℓ/min 80〜120 100〜140 160〜200 180〜230 240〜300
Operating pressure MPa 14〜18 12〜17 14〜18 13〜18 14〜18
Impact rate bpm 450〜720 430〜600 490〜630 380〜450 370〜470
Chisel diameter mm φ 105 φ 115 φ 135 φ 146 φ 160
Chisel weight kg 63.5 91.5 133 185 236
Hose size inch 3/4 3/4 1” 1” 1”-1/4
Gas pressure MPa 1.1 0.8 1.1 0.8 0.8
Base machine Ton 8〜14 14〜20 18〜25 27〜40 38〜50
PC128US/ PC160/180
Excavator model PC200/270 PC300系 PC400系
138US/100/120 /PW200
Safety valve
MPa 25
(Komatsu Excavator)
01-4
Shop Manual
10 Structures, Operation and

Maintenance
Structures of the Hydraulic Breaker 10-2

Principle Function 10-6
10-1
10 Structures, Operation and Maintenance
Structures of the Hydraulic Breaker

ＪＴＨＢ０８-３～５０-３ Molding in a control valve
Side Bolt
Side bolt Nut Gas Valve
Cylinder Cover
Gas seal
Control Valve Cap
Oil seal
Control Valve
Slide ring
Hose Adapter
Packing bushing
Cylinder
Piston
Air Port for Air Supply

Oil seal
(JTHB40-3 (40S-3), 50-3)
Dust seal
Chisel holder bushing Chisel holder
Retainer Pin
Grease Nipple
Retainer Pin Stopper Pin
Chisel Bushing
Chisel
10-2
ＪＴＨＢ０８-３～５０-３
Gas Valve
Hose Adapter OUT

Hose Adapter IN
Air port for air Supply

(JTHB20-3 (20S-3), 30-3 (30S-3),
40-3 (40S-3), 50-3 )
Grease Nipple
10-3
ＪＴＨＢ６０-３～４５０-３
Side Bolt
Gas seal
Side bolt Nut
Gas Valve Oil seal
Cylinder Cover Slide ring
Hose Adapter Packing bushing
Control Valve Box

Piston
Cylinder
Control Valve
Oil seal
Control Valve Cap

Dust seal
Air Cap Chisel holder

(Over JTHB120-3)
Chisel holder bushing
Retainer Pin
Stopper Pin
Retainer Pin
Grease Nipple
Chisel Bushing
Chisel
ＪＴＨＢ６０-３～１２０-３ＪＴＨＢ１６０-３～４５０-３
10-4
.
ＪＴＨＢ６０-３～４５０-３
Gas Valve
Hose Adapter IN
Hose Adapter OUT
Air port for air Supply
Grease Nipple
ＪＴＨＢ６０-３～１２０-３ＪＴＨＢ１６０-３～４５０-３
10-5
PRINCIPLE FUNCTION
ＪＴＨＢ０８-３～５０-３
(1) Upward movement (2) Reversing (3) Downward movement (4) Impact
(1) Upward movement

Oil flows into chambers 1 and 9: the control valve is pressed in the downward direction.
The piston moves in the upward direction toward the cushion chamber 5.
Oil in the opposite chamber 4 is discharged through chamber 6 and 7.
(2) Reversing direction

When the lower flange fills with oil, it reaches camber 2. At this point both chamber 8 and 9 exert the
same pressure on the flange but the control valve moves in the upward direction due to the area
difference between the flanges.
(3) Downward movement

When the control valve rises and reaches chamber 9, the flow moves through chamber 6 then 4.
Due to the difference in area between the piston flange and the force from the cushion chamber 5
pressure, the piston accelerates downwards.
(4) Impact
The piston hits the chisel. At this point the mid-section of the piston reaches chamber 2 and as a result
chamber 8 releases the pressure through chamber 2 and 3.
When chamber 8 is empty, as chamber 9 is constantly pressurized, the valve moves in the downward
direction.
Repetition of the cycle mentioned above results in continuous blows.
10-6
.
ＪＴＨＢ６０-３～４５０-３
(1) Upward movement (2) Reversing (3) Downward movement (4) Impact
(1) Upward movement

Oil flows into chambers 1 and 8: the control valve is pressed in the downward direction.
The piston moves in the upward direction toward the cushion chamber 5.
Oil in the opposite chamber 4 is discharged through the control valve into chamber 7.
(2) Reversing direction

When the lower flange fills with oil, it reaches camber 2. At this point both chamber 6 and 8 exert the
same pressure on the flange but the control valve moves in the upward direction due to the area
difference between the flanges.
(3) Downward movement

When the control valve rises and reaches chamber 8, the flow moves through control valve and
reaches chamber 4.
Due to the difference in area between the piston flange and the force from the cushion chamber
pressure, the piston accelerates downwards.
(4) Impact
The piston hits the chisel. At this point the mid-section of the piston reaches chamber 2 and as a result
chamber 6 releases the pressure through chamber 2 and 3.
When chamber 6 is empty, as chamber 8 is constantly pressurized, the valve moves in the downward
direction.
Repetition of the cycle mentioned above results in continuous blows.
10-7
Shop Manual
30 Testing and Adjustment

Inspection, Adjustment
Circuit diagram 30-2
Delivery Inspection and Adjustment When It Is Delivered 30-3
Piping - PC200 30-3
See Also: Old Models' or Other Companies' Piping 30-6
　　　　Mount the Hydraulic Breaker onto the Excavator 30-6
　　　　P-Q Measurement 30-6
　　　　The Purpose of P-Q Measurement 30-6
　　　　How to Measure the P-Q 30-6
　　　　How to Set the Hydraulic Breaker Relief Valve 30-10
　　　　How to Set the Hydraulic Breaker Throttle Position 30-12
Test Run 30-13
30-1
30 Testing and, Adjustment
Circuit
Example) PC200-8 KOMATSU Piping
Hydraulic circuit Electric circuit

It connects by
this news.
Main valve
Attachment Yes/No
ATT circuit Setting Monitor
switching valve
service
Bucket ATT + Boom up

Self-pressure It connects by
Left travel reducing valve this news. Modulating flow
(F pump Monitor
Boom pressure
Turning
Pilot
Right travel filter Right service valve Modulating
Arm flow Monitor
Pressure
sensor
Pressure
sensor Additional
filter for
breaker
Controller
Monitor
Example) The old model and the other company (Non genuine piping)
Foot pedal
Accumulator
Operation valve Piping
Stop valve
Pump Adapter
Relief valve
Breaker
Cooler Stop valve

Tank Secondary relief valve
Extension filter
30-2
.
Delivery Inspection and Adjustment

1. KOMATSU Piping
(PC200-8)
1) Check the pressure of the nitrogen
gas in the breaker.
◆ Check the pressure with the nitrogen gas
gauge.
・Standard value 1.1MPa (11kg/cm2)
(JTHB210-3)
◆ If the pressure is not enough, adjust it to the

accurate amount with a nitrogen-gas filler.
2) Check the pressure of the safety valve relief.

◆ Specifications.
・2-stage safety valve relief should be used for the check.
・723-90-76300 for retro-fit.
4PJ34C-A for new excavator ordering.
◆ How to Check
・Monitor Check : Relief pressure on B mode.(R Pump pressure:01101)
Pressure while the attachment pedal is pressed forward. 230kg/cm2
・Valve Check : Check the mark on the top of the safety valve.
Mark : “PK” 723-90-76300 (305/250kg/cm2)
“PG” 723-90-76100 (305/210kg/cm2)
30-3
.
Service mode change

Operator usual work screen Service member work screen item 03 Attachment Yes / No
06 Initial value setting
Select "Yes"
It switches to user mode from service mode.
3) Check the set pressure and the flow of

the safety valve.
Flow Check
　　　◆ Specifications
　　　　・Standard Flow : 160 ~ 200 L/min
　　　◆ How to Check
　　　　① Set up the monitor (example: PC200-7 later)
User Mode
　⇩
Set up the Breaker / attachment
　⇩
Set up Flow
　⇩
Set up Flow on 180 L/min
* Set value of the monitor may be differed with
real How by the condition of the excavator.
Because the set value is calculated data.
* Refer to the shop manual for details.
30-4
4) Bleed the air in the circuit, and carry out test run.
B mode condition R Pump

Hydraulic
oil filter F Pump
Hydraulic oil
Operation valve
Breaker
The extension
filter for
breaker
30-5
Reference : The old model and the other company (Non genuine)
Reference : The old model and the other company

(Non genuine)
Mounting the Hydraulic Breaker onto the Excavator
Before operating, warm up both the excavator and the hydraulic breaker.
That will remove the air pockets in the hydraulic circuit.
1) Measuring Pressure (P) and Flow (Q)

Measuring P – Q means measuring the relationship between Flow x Pressure
P : Pressure
Q : Quantity
2) Purpose of P & Q measurment

① Before mounting the Hydraulic Breaker onto the excavator, first check the flow and pressure to confirm
that the pump performance will meet the requirements for the Hydraulic Breaker. Also, check any failure
in the pump performance for the excavator. In these cases the P x Q should be measured and evaluated.
② In order to set the relief valve of the Hydraulic Breaker.
③ In order to set the throttle position of the Hydraulic Breaker.
3) How to Measure P - Q
① Prepare two hydraulic hoses that meet to excavator. Attach these hoses to the IN and OUT ports of the
Flow meter. (If the hose adapter does not fit, use an adapter to make the adjustments for proper fitting.)
Now proceed to open the flow meter handle.
OUT Side
Open the handle
IN Side
* Make sure foreign particles do not enter.
30-6
Reference : The old model and the other company
② After confirming that the Stop valve at the end of the arm of the excavator is “ Closed”, connect the hoses
from the flow meter to the excavator. (Make sure the IN & OUT hoses are connected correctly)
Close the stop valve
Valve “Closed”
Flow of oil
OUT Side
IN Side
③ After everything is connected, make sure all connections are secure tighten. Then OPEN the stop valves.
Open the Stop valve. Valve “Open”
30-7
④ Start up the engine of the Hydraulic excavator, place the throttle lever or dial to the MAX.position and Press
down on the operating pedal. The value indicated on the pressure gauge is the backpressure of the piping
(resistance).
Relief valve for Hydraulic breaker.
Operating Pedal for Breaker
ＯＵＴ
ＩＮ Open handle fully
Pressure gauge
Flow & Temp.Gauge
Power switch and Flow/temp.

gauge change over switch
P - Q Measurement chart
Backpressure (MPa) (Pressure gauge reading when handle is open fully)
P ５７.５１０１１１２１３１４１５１６１７１８１９２０２１
Q
Indicate the flow reading when the handle is open fully.
30-8
⑤ With the throttle fully opened and the pedal in the ON position, adjust the handle of the flow meter so that
the pressure and flow meet the pressure indicated on the P - Q chart. When the handle is fully closed (The
flow meter will show “ 0 ”) the reading of the pressure gauge will be the relief valve pressure for the
hydraulic breaker. This procedure should be performed by two people signaling each other.
P – Q Measurement chart (Sample chart)

(Example) When Mounting a JTHB210-3
JTHB210-3 Specifications are Pressure 14 – 18 (MPa), Flow 160 – 200 (L/min.)
Throttle position for the breaker; Pressure 18 (MPa) at Flow 180 (L/min.)
Excavator A; Measurement data

P （MPa） 5 7.5 10 11 12 13 14 15 16 17 18
Q (l/min.) 185 175 148 71 0
Excavator B; Measurement data

P （MPa） 5 7.5 10 11 12 13 14 15 16 17 18 19 20 21
Q (l/min.) 167 161 158 156 146
Excavator C; Measurement data

P （MPa） 0 5 7.5 10 11 12 13 14 15 16 17 18 19 20 21
Q (l/min.) 245 243 240 236 232 228 226 223 220 217 212 208 186 81 0
Excavator A → The relief valve’s setting presure is too low. Increase the relief valve setting. After the
adjustments have been made, re-measure the P - Q. If the flow can be obtained,
the breaker can be mounted to this machine.
Excavator B → Flow is low. The breaker can be operated at the lower specification level but the impact
energy may lack in performance.
Excavator C → Flow is too much. Adjust the throttle lever to the hydraulic breaker position.
30-9
4) How to set the Hydraulic Breaker Relief Valve

Proceed as followings when setting the hydraulic excavator relief valve for hydraulic breaker.
① Refer to “How to measure the P – Q” Following points ①～③.
② Start up the engine, place the throttle lever or dial to the MAX. position and Press down on the operating
pedal. The pressure indicated on the pressure gauge is the backpressure of the piping (resistance).
Relief valve
Boom
Press the pedal
Open handle fully

at first.
Pressure gauge
③ At this point, close the handle completely. The reading on the pressure gauge is the relief pressure at this
time. (The flow gauge will show “ 0 ” (L/min.) )
Close the handle
Current relief valve pressure
30-10
④ Set the relief valve of the hydraulic breaker based on the operating pressure.
Relief valve
Relief valve
Boom Boom
Turning the handle IN will Loosen the lock nut

increase the relief pressure and adjust by using
(Loosening will reduce the a Hex wrench
pressure) (After adjusting tighten
the lock nut)
Lock Nut
Handle
30-11
5) How to set Throttle Position for

Hydraulic breaker Handle
(Example) For setting a JTHB210-3
Set the throttle lever of the hydraulic breaker as
followings;
① Press the hydraulic breaker pedal and turn

the flow meter handle until the Pressure meter
reaches about 14 to 18 (MPa)
Flow meter
② When the pressure gauge reaches 14 to 18

(MPa), stop turning the handle and adjust
the excavator throttle down until it reaches
By turning the handle, make sure the pressure
160 to 200 (l/min.). Reducing the throttle, the
gauge shows 18(MPa)
pressure will also decrease. As a result, it will
be necessary to adjust the flow meter to 160
~ 200 (l/min.) and 14 ~ 18 (MPa) pressure.
This can be performed by adjusting the handle
on the flow meter and the throttle lever of
the excavator.
P (MPa) 2 5 7.5 10 11 12 13 14 15 16 17 18 19 20 21
Q (l/min.) （１６０〜２００）
③ When the throttle position is determined,

please the decal below to that location.
30-12
TEST RUN
Carry out test run in cases below:
- New Hydraulic breaker installed onto the excavator
- Reconnect hydraulic hoses after long time storage
- After repairing or overhauling the hydraulic breaker
① Fill up the hydraulic oil up to full level (boom position is bottom)
② For air bleeding and filling up, circulate slowly the hydraulic oil
(Engine low idle, operate breaker pedal on half position 5 to 6 times.)
③ Check looseness of the bolts and nuts on bracket and bare breaker
④ Check abnormal noise, vibration, oil leakage
⑤ Check piping bolt, nuts and hoses looseness and oil leakage
⑥ Check hydraulic hose excessive swing or interfere.
CAUTION
- If the hydraulic breaker hose is disconnected or connected, it is necessary to release all air from
the hydraulic breaker oil circuit. If the breaker is suddenly operated in this condition, the oil film
will be lost and will lead to seizure causing damage to the breaker.
- Control a foot pedal and slowly supply hydraulic oil to the hydraulic breaker till you feel the rise of
a piston. Slowly close the foot pedal before impact of piston.
- Make sure the processes of air removal (2) to preparation time (5) are performed.
- The operating time from removing the air to the preparation time is shown in the chart below.
(1) Excavator (2) Air removal (3) Seal recovery time (4) Preparation (5) Preparation
time time time
New unit
More than More than
After the hose has 5 min. 10 min. Less than 50% At 70% Throttle
been removed Throttle 10min. 20 min.
After the breaker More than More than

has been repaired 10 min. 15 min.
IMPORTANT
- 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.
30-13
P-Q check sheet
Date : / /
User Name : Inspector Name：
Breaker Model Type : JTHB Breaker Serial Number：
Machine Model Type : Machine SMR： hours
Piping Type :
* Check Procedure
A. In case of machine has B-mode and oil flow setting
1 Set B-mode on machine
2 Check relief pressure MPa (ex：PC200-8 R pump pressure by monitoring：01101）
3 Check oil flow quantity L/min (ex：PC200-8 setting flow rate by monitor）
B. In case of machine does NOT have B-mode and oil flow setting
Set flow mater at the end of attachment piping
1 Set machine setting for breaker using
2 Check relief pressure MPa
3 Check PQ on rated condition
P(MPa) 50 75 100 110 120 130 140 150 160
Q(L/min)
P(MPa) 170 180 190 200 210 220 230 240 250 260
Q(L/min)
4 Adjust fuel dial and/or reliaf valve to adapt appropriate PQ for the breaker.
* oil temperature should be 40-60℃
30-14
Shop Manual
40 Troubleshooting
Troubleshooting Check Sheet 40-3

Troubleshooting Guide 40-4
40-1
40 Troubleshooting Guide
FOREWORD
In order to operate the JTHB Breaker at its specified performance level and to prolong the life of the breaker,
the following preconditions must be met.
1. Based on the Operating Manual, proper inspection and operating methods must be used.
2. Clean hydraulic oil must be supplied.
3. Based on the Operating Manual, proper inspection and operating methods must be used.
Based on the above 3 points, when a problem is received from a customer, it can be solved promptly and efficiently.
The following information is a guide to solve some of the problems which may occur during the operation of the breaker.
40-2
HYDRAULIC BREAKER TROUBLESHOOTING CHECK SHEET

Date
Company Name Model JTHB Maker’s name
Name Ser.No. Model
Customer Name Delivery date Ser.No.
Hour Meter hr.
* Inspection points A - R
Does not From the beginning （Ｆ、Ｈ、Ｊ、Ｒ、Ａ８、Ａ７）

work
After some rest Breaker

Does not After a while
operates
impact
About Hrs later （Ｆ、Ａ４、Ａ５）
Does not operate after rest

（Ｆ、Ｈ、Ｊ、Ａ８、Ａ４、Ａ７） Measure
P-Q
（Ｆ、Ｈ、Ｊ、Ｒ、Ａ８、Ａ５、Ｄ３、
From the start
Ａ７）
Blows are Inspect
erratic P-Q
After a while After some rest Breaker
operates Based on
About Hrs later （Ｆ、Ａ４、Ａ５） the chart
Does not operate after rest
（Ｆ、Ｈ、Ｊ、Ａ８、Ａ４、Ｄ３、Ａ７）
Compared to energy
when it was purchased
About % power （Ｉ、Ｊ）
Compared to energy
of a competition’s No problem
Impact About % power （Ｅ、Ｄ）
Energy
is weak Has problem
Breaker
Model: （Ａ３、Ｃ）
Excavator:
Model: Excavator
Manufacturer
（Ａ１、Ａ２）
Decreases BPM when （Ｆ）
operating the Boom,
Lacks Arm on the excavator
BPM
Lacks BPM even during From the beginning

other operations （Ｅ、Ｆ、Ｈ、Ｊ、Ｒ、Ａ８、Ａ７）
After some usage Will operate after rest

（Ｆ、Ａ４、Ａ５）
No difference after rest
（Ｆ、Ｈ、Ｊ、Ａ８、４、７）
Breaks; Inspect based on “Claim judgment chart”

Chisel
Wear is quick; Inspect based on “Chisel wear conditions”
40-3
Troubleshooting
Hydraulic Breaker RELATED
　 Failure Phenomenon Presumed Cause Action Item
Lack of P - Q Inspect and measure Ａ
Clog in piping or pump problems Measure, Inspect, Repair Ｃ
Seizure within the breaker Repair, Replace parts Ｄ

Does not impact or
1
Stop impacting
Cylinder cover filled with hyd. oil Replace seals Ｅ
Lack of hyd. oil in tank (system) Inspect, Refill
Stop valve is not turned ON Open stop valve
Lack of P - Q Measure and Inspect. Ａ

The breaker stops
Impacting after 30 - 90 min.
2 Clog in piping or Pump problems Measure, Inspect, Repair Ｃ
of operation or the breaker
starts to blow erratically
Nitrogen gas pressure is too high Adjust Ｆ
Hyd.oil in the cylinder cover Change seals Ｇ

3 Erratic blows
A large amount of grease has entered Remove grease,
Ｈ
the impact chamber instruct method for greasing
Lacks P x Q Measure Ａ
4 Lacks BPM Chisel not pushed in far enough Inspect Ｂ
Nitrogen gas pressure is too high Adjust Ｆ
Reduction in Nitrogen gas pressure Inspect, Re-fill Ｉ
Chisel not pushed in far enough Inspect Ｂ

5 Impact energy is low
Lack of (P – Q) Measure Ａ
Chisel broken inside the chisel holder Change chisel, Inspect piston. Ｊ
a) From IN,
Loose hose adapter, O-ring damage Re-tighten, replace O-ring Ｋ
OUT port area
Oil leakage
b) From chisel and Chisel

Wear or damage of the oil seal Replace seal(s) Ｌ
bushing
6
c) From cylinder cover Loose side bolt nut Retighten, or Replace
and cylinder Damage of O-ring or back up ring the O-ring or the back up ring.
40-4
PARTS RELATED
Failure Phenomenon Presumed Cause Action Item
Due to operating the Breaker used in prying
1 Breakage of chisel or applying a bending action to the chisel.
Also wear of arm, link and pin parts Repair, Replace
Impacting the breaker in the same place

2 Melting chisel
for a long time
Breakage of the tip portion Full power usage from the beginning of Operate the breaker slowly
3
of the chisel. the operation for about 30 min.
Unable to assemble Deformation of the Retainer pin or the
4 Inspection, repair or replace Ｏ
the Retainer pin chisel
Looseness between the Loose the bracket bolt(s) Re-tighten

5 Bracket and the body of Ｐ
the breaker Wear of the bracket Repair
Excessive wear of the Not enough grease. Operating the Instruct based on the
6
chisel bushing. breaker with bending or prying action. operation manual
EXCAVATOR OR PIPING RELATED

　 Failure Phenomenon Presumed Cause Action Item
After installation of the piping,
1
the excavator does not move Difference in the Relief valve set pressures
straight forward.
Problems in the cooling mechanism of
the excavator.
2
The hydraulic oil temperature
Problem with pump
increases rapidly.
Clog pipin Ｃ
Excessive wear in the width of the arm and

3 Difficulty in pin pointing
link. Also, wear of the pins and bushing.
the demolition material
Wear of the bracket.
Water is entering the system.
Deterioration of the hydraulic

4 Lack of engine output
oil
The engine performance has declined.
5 Engine RPM reduces quickly. The hydraulic oil temp.is too low.
40-5
ITEM list
ITEM DESCRIPTION MEASURES
Lack of P (Pressure) x Q (Flow)
Measure (To be performed by the Service dealer)
1. Reduction in pump performance
* Occurs with used machines which have gear pumps.
2. Reduction in engine performance Measure (the Same as the above)
3. Poor setting of the relief valve or foreign Disassemble and inspect.

matter has entered into the relief valve If damaged or broken, it must be replaced or cleaned.
4. Lack of the Hydraulic oil Add hydraulic oil
Ａ 5. Deterioration of the hydraulic oil Change the hydraulic oil
6. Wear of control valve causes to Replace the control valve part.

Oil leakage. * Occurs when the Hydraulic breaker is used often.
Back pressure will increase. Check starting from the pump side.
7. Clogged the breaker piping
* Refer to Item C for the filter and the check valve.
8. Lack of stroke of the change valve Adjust to the appropriate stroke length
9. Poor throttle position setting Reset the throttle position of the breaker
Due to the lack of pressing the chisel into the breaker,

the appropriate power will not transmit to the chisel.
Ｂ Lack of pressing the chisel ↓
If the chisel is pressed into the breaker correctly,
the breaker will operate normally.
The return filter is clogged (Filter located in the tank)
(Replace every 100 hours of operation)
Clog piping
Check to make sure that no foreign items are caught
inside the check valve.
Friction of the piping is large Piping size and Hose are thin
Back pressure with no load. Estimation of normal levels.
(Measured at the breaker)
Piping size Flow Back Pressure
inch l/min. MPa
20 ＜1.5
1/2 30 ＜2.0
50 ＜3.0
Ｃ 70 ＜3.5
80 ＜1.5
3/4 100 ＜2.0
150 ＜3.0
200 ＜4.5
200 ＜2.0
1 220 ＜2.5
250 ＜3.0
250 ＜2.0
1-1/4 300 ＜2.5
350 ＜3.0
40-6

Seizure within the Hydraulic Breaker
Seizure problems in control valve area or piston. Control
1. Lack of flushing and hammering after valve seizure normally occurs after the breaker starts up.
installation of the piping Then the piston may develop seizure disassemble and
repair. Re-flush and perform hammering (More than 30 min.)
2. When changing the bucket to the breaker, Occurs when the bucket is changed frequently.
Ｄ foreign material enters into the breaker When changing attachments, be careful not to let foreign
through the hose adapters. material enter into the breaker.
When the chisel impact area is slanted and the piston hits it,
3. When the chisel bushing wears seizure may occur with the piston. Or when the impact area
excessively. of the chisel gets damaged, the retainer pin may be broken.
* Change the chisel bushing immediately.
Control valve, Piston and Cylinder seizure repair
1) For light scratches use an oil stone (whetstone) or water paper for the repair
2) For deep scratches on the lower section of the piston (Area where seals move), since the seals move in
the area, piston must be replaced
Piston cannot move
Ｅ Hydraulic oil fills up in the cylinder cover This is caused by the wear between the oil and gas seals.
The seals should be replaced.
The operating pressure increases, and the relief valve will
be operated. Flow will be reduced and the operating
Ｆ Nitrogen gas pressure is too high
temperature will increase
* The excavator pump performance may also reduce the gas pressure.
When wear between the oil seal and the Gas seal occurs,
Hydraulic oil will enter the cylinder cover slowly.
↓
The volume of gas may also decrease, so the ration of the gas
Ｇ Hydraulic oil enters into the cylinder cover compression will increase, and the operating pressure will increase.
↓
The relief valve is actuated, the flow will reduce,
and the temperature of the oil will increase.
Then the breaker may operate erratically.
When the piston moves up, the operating pressure will increase,
the relief valve will actuate, and the flow will decrease.
* When removing the grease from the impact chamber, first
Much Grease enters the impact chamber of
Ｈ the chisel holder
remove the gas from the cylinder, push the piston from the
low point to the cylinder cover, and remove the grease from
the Impact chamber. When greasing, stand the breaker up
and press the chisel into the breaker. Then grease.
40-7

Reduction in piston speed during the descent
(Reduction in impact energy)
I Reduction in Nitrogen gas pressure ↓
Re-charge Nitrogen gas
* If Nitrogen gas cannot be re-charged, replace the gas seal.
The accurate impact energy does not transmit to the tip of
J Breakage of the Chisel in the chisel holder the chisel and the BPM decrease.
That may also cause retainer pin breakage
“ Oil leakage ” means the hydraulic oil leaks outside of the
breaker continuously for several hours. “ Oil ooze ” is that
hydraulic oil is noticed after disassembly/assembly of the
K Oil leakage breaker within about 200 hours. The areas where you may
notice this oil is around the mating areas, bolts and washers.
Or before the oil gets dried, dust may stick on the area, and
can not be cleaned, or dried. In this case, this is not abnormal.
When Hydraulic oil is flowing out all around the chisel
diameter, this is abnormal.
* The oil seal should be replaced. If seizure has developed
Oil leakage from between the chisel and on the piston, it must be repaired.
Ｌ
the chisel bushing If the seizure is deep in the lower area of the piston, the
piston should be replaced.
* If a standard breaker is used underwater, the oil seal will
get damaged and may develop seizure marks.
Breakage straight across
Ｍ Chisel breakage Breakage with a step
* Do not put a bending force onto the chisel.

Impact energy transfers heat energy at the tip of the chisel.
The tip will get heated and will begin to be melted.
Ｎ Chisel tip melting
* For hard and tough rocks, do not operate the breaker at
the same spot for more than 30 seconds
The retainer pin gets deformed inside the chisel holder.
In this case, the chisel may also get deformed.
Ｏ Difficulty in assembling the Retainer pins
↓
Repair or replace.
Loosening will cause for more loosening. Re-tighten the bolts
Ｐ Loosening of the Bracket as soon as possible. When the bracket or bracket bushing
has worn excessively, repair or replace the part.
40-8
.

Increase in hydraulic oil Occurs with gear-type pumps which
temperature due to wear within have worn excessively.
Ｑ the pump The oil does not work and leaks, it
changes to heat and increases the oil
temperature.
Occurs in winter when the outside

Ｒ Hydraulic oil temperature is temp. is low.
too low. Warm up the machine so that the
hydraulic oil goes up over 40°C.
40-9
Shop Manual
50 Disassembly/ Assembly
Hydraulic Breaker
Hydraulic Breaker Disassembly/ Assembly Tools 50-3
Clean the Breaker and the Bracket 50-6
Disassembly of the Bracket 50-6
　　　Side Mount Bracket 50-6
　　　2 PC Top Mount Bracket 50-7
　　　Top Box Bracket 50-8
　　　Assembly/ Disassembly Chart for the Bracket 50-10
Disassembly of the Hydraulic Breaker 50-12
　　　Work Table and Set up of the Breaker 50-12
　　　Side Bolt Nut/ Cylinder Cover 50-15
　　　Piston 50-15
　　　Control Valve 50-16
　　　Cylinder 50-18
　　　Side Bolt Nut 50-18
　　　Hose Adapter 50-19
　　　Remove the Seals 50-19
　　　Assembly/ Disassembly Chart for the Hydraulic Breaker 50-21
JTHB Torque Chart 50-24
Inspect and Repair the Hydraulic Breaker 50-25
　　　Seals 50-25
　　　Chisel Bushing 50-25
　　　　　　How to Change the Chisel Bushing 50-26
　　　Chisel Holder Bushing 50-28
　　　　　　How to Change the Chisel Holder Bushing 50-28
　　　Control Valve/ Control Valve Box 50-30
　　　Retainer Pin 50-33
50-1
Shop Manual
Assembly of the Hydraulic Breaker 50-34
　　　Chisel Holder Bushing, Chisel Bushing 50-34
　　　　　　Chisel Holder Bushing 50-35
　　　　　　Chisel Bushing 50-36
　　　Chisel Holder Bushing 50-38
　　　　　　How to Insert the Helisert 50-39
　　　Side Bolt 50-43
　　　　　　How to Insert the Helisert to the Control Valve 50-44
　　　　　　Cylinder Seal 50-48
　　　Packing Bushing 50-50
　　　Control Valve 50-53
　　　Control Valve Box 50-54
　　　Filling the Breaker with Hydraulic Oil 50-55
　　　Cylinder Cover/ Side Bolt Nut 50-56
　　　　　　How to Use the Power Wrench 50-56
　　　　　　See Also: Alternative Method of Tightening the Side Bolt Nuts 50-58
without a Torque Wrench
　　　Hose Adapter 50-60
　　　Check & Recharge the Cushion Chamber with Nitrogen Gas 50-61
Special Work 50-62
　　　How to Change the Broken Side Bolt 50-62
50-2
Hydraulic Breaker Disassembly / Assembly Tools

Sym No. Description Note
1 Power Wrench Side bolt nut
2 Impact Wrench Bracket bolt nut etc.
3 Torque Wrench
4 Air Grinder
5 Air Drill
6 Grinding Wheel with Spindle
7 Flap Wheel with Spindle Piston, cylinder, valve etc
8 Wire Brush Cylinder cover etc
9 Flex hone Cylinder, control valve box
10 Emery paper (Abrasive paper) #400, #800
11 Oil stone (Whetstone) #400, #800
12 Hex Socket for Impact Wrench 1/2Hex, 3/4Hex, 1”Hex
13 Ratchet Wrench 1/2Hex, 3/4Hex, 1”Hex
14 Extension bar 1/2Hex, 3/4Hex
15 Spanner
16 Impact Spanner Refer to nut size
17 MoS2-grease (Anti-seize agent) To apply to threads
18 Hydraulic Oil For piston and valve assembly
19 Lubricating agent For seal assembly
20 Anti-corrosive spray
21 Loctite #242, #410
22 Helisert Insertion tool Chisel holder, cylinder
23 Tag removal tool
24 Eye bolt M8, M12, M16, M20, M24, M30
25 Seal Tape Plug
１２３４
50-3
５６７８９
１０１１１２１３１４
１５１６２０２１
２２２３２４２５
50-4
Top Mount Box Bracket
Description Part Code Qt Remark

11 Gas gauge kit A01016040 1 Charging socket 9/16-18 UNF male
50-5
1. Clean the Breaker and the Bracket

To prevent any material from entering the breaker, before replacing parts or overhauling, the breaker
removes all dirt and foreign material from the breaker and bracket.
2. Disassembly of the Bracket

1）Side Mount Bracket
① Remove the bracket pins and bracket bushings. At this time, remove the chisel from the breaker.
② If there are hoses in the bracket, loosen and remove the hoses on the swivel side.
③ With the bracket plate of the bracket bolt nut facing up, loosen the bracket bolt nut and remove them.
④ Fit the “Eyebolt” onto the top of the plate and lift the plate straight up.
⑤ Remove the breaker body like the above.
⑥When assembling, perform this procedure in the opposite direction.
But when the breaker is assembled into the bracket, make sure the bracket key plates fit the breaker
key slot properly.
Bracket bolt nut

Bracket ring
Eyebol Washer
Bracket
Key slot
Bracket bushing Hyd.Hose
(Within the bracket)
Bracket bolt
Bracket pin
* Depending on the model, some changes may occur.
50-6
2）PC Top Mount Bracket

① Remove the bracket pin and bracket bushing. At this time, remove the chisel from the breaker.
② Loosen the bolt of bracket (B) and remove it.
Bracket ring Bracket (B)
Bracket bushing
Bracket pin
③ With the bracket plate of the bracket bolt nut, loosen the bracket bolt nuts and remove them.
④ Fit the “Eyebolt” onto the top of the plate and lift up the plate straight up.
⑤ Remove the breaker body like as the above.
⑥ When assembling, perform this procedure in the opposite direction. But when the breaker is assembled
into the bracket, make sure the bracket key plates fit the breaker key slot properly.
Bracket bolt nut

Eyebolt
Washer
Key slot
Bracket
Bracket bolt
50-7
3）Top Box Bracket

① Remove the bracket pins and the bracket bushings. At this time remove the retainer pin and the chisel
from the breaker.
② Loosen the hex bolt and nut, and remove the bracket (B), the top rubber plate and the cover plate.
cover plate
Bracket (A)
Top rubber plate
Bracket (B)
Bracket pin
Bracketring
Bracket bushing
③ Loosen the hard lock nut and remove the

guide plate and the guide spacer.
Remove the hydraulic hose and fit the hose
plug to prevent any material from entering
the breaker. Guide plate
Guide spacer
Hard lock nut
④ Assemble the “Eyebolt” and pull out the

breaker by using a wire rope.
Eyebolt
50-8
⑤ Pull out the side spacer.
Side spacer
⑥ Pull out the chisel holder spacer.
Chisel holder spacer
⑦ Pull out the back spacer.
Back spacer
⑧ Pull out the under spacer A & B.
Under spacer A
Under spacer B
⑨ When assembling, perform this procedure in the opposite direction.

But please assemble the chisel holder spacer after assembling the side spacer.
(Assembly procedure of the spacer is ⑧, ⑦, ⑤, ⑥ )
50-9
4）Assembly / Disassembly chart for the Bracket

20-3 30-3 40-3
Model JTHB 08-3 10-3 50-3 60S-3 60-3
(20S-3) (30S-3) (40S-3)
Width across flats (mm) 24 27 30 30 32 36 41 46
① Bracket bolt/nut Bolt size (mm) (M16) (M18) (M20) (M20) (M22) (M24) (M27) (M30)
Tightening torque (N・m) 176 255 343 343 412 588 882 980
② 2PC bracket bolt/nut Bolt size (mm) (M16) (M16) (M16) (M16) (M16) (M16) (M20) (M20)
Top Box bracket bolt/nut Bolt size (mm) (M16) (M16) (M16) (M16) (M16) (M16) (M20) (M20)
③ Hyd. hose IN/OUT Bolt size G3/8 G1/2 G1/2 G1/2 G1/2 G1/2 G1/2 G3/4
④ Guide bolt/nut Bolt size (mm) (M12) (M16) (M16) (M16) (M16) (M16) (M16) (M20)
Width across flats (mm) - - - - - - - 17
⑤ Gas valve cover plate Bolt size (mm) - - - - - - - (M10)
Tightening torque (N・m) - - - - - - - 44
⑥ Control valve plate Bolt size (mm) (M10) (M10) (M12) (M12) (M12) (M12) (M12) (M16)
⑦ Eyebolt for Top/Side brackt Bolt size (mm) M8 M8 M8 M12 M12 M12 M12 M12
Eyebolt for Silenced bracket Bolt size (mm) M10 M10 M12 M12 M12 M12 M12 M16
⑧ Eyebolt for cylinder cover Bolt size (mm) M8 M8 M8 M12 M12 M12 M12 M12
⑨ Eyebolt for chisel holder Bolt size (mm) - - - M12 M12 M12 M12 M12
⑩ Eyebolt for cylinder Bolt size (mm) M8 M8 M8 M12 M12 M12 M12 M12
②
② ①
⑥
⑦
⑦
50-10
Model JTHB 120-3 160-3 210-3 350-3 450-3

(120S-3) (210S-3)
Width across flats (mm) 55 55 60 75 75
① Bracket bolt/nut Bolt size (mm) (M36) (M36) (M48) (M48) (M48)
Tightening torque (N・m) 1372 1372 2744 2744 2744
② 2PC bracket bolt/nut Bolt size (mm) (M20) (M20) (M24) (M30) (M39)
Top Box bracket bolt/nut Bolt size (mm) (M20) (M20) (M24) (M30) (M39)
③ Hyd. hose IN/OUT Bolt size G3/4 G3/4 G1. G1. G1-1/4
④ Guide bolt/nut Bolt size (mm) (M20) (M20) (M24) (M30) (M30)
⑤ Gas valve cover plate Bolt size (mm) (M12) (M12) (M12) (M12) (M12)
⑥ Control valve plate Bolt size (mm) (M16) (M16) (M16) (M20) (M20)
⑦ Eyebolt for Top/Side brackt Bolt size (mm) M20 M20 M20 M24 M30
Eyebolt for Silenced bracket Bolt size (mm) (Hook) (Hook) (Hook) (Hook) (Hook)
⑧ Eyebolt for cylinder cover Bolt size (mm) M20 M20 M20 M24 M30
⑨ Eyebolt for chisel holder Bolt size (mm) M20 M20 M20 M24 M30
⑩ Eyebolt for cylinder Bolt size (mm) (M20) M20 M20 M24 M30
⑤
①
⑦
⑥
50-11
3. Disassembly of the Hydraulic Breaker

* Mark suit cylinder cover, cylinder and Chisel holder
Cylinder cover
Cylinder
Chisel holder
1) Work table and set up the Breaker
Breaker stand
Make sure the pivot is

welded securely and
is not removed.
Breaker
locater
50-12
Reference chart of pivot size

20-3 30-3 40-3 50-3 a
Model　JTHB 08-3 10-3
(20S-3) (30S-3) (40S-3) 60S-3
a (mm) φ 35 φ 40 φ 45 φ 55 φ 60 φ 70
b (mm) 100 125 145 180 200 200
120-3 210-3
Model　JTHB 60-3 160-3 350-3 450-3
(120S-3) (210S-3) b
a (mm) φ 90 φ 110 φ 110 φ 130 φ 140 φ 155
b (mm) 225 280 280 350 350 420
Reference chart of the hole size
20-3 30-3 40-3

Model　JTHB 08-3 10-3 50-3
(20S-3) (30S-3) (40S-3)
a (mm) 90 105 120 140 150 160
b (mm) 105 115 120 140 150 160
Depth (mm) 220 230 240 280 320 350
120-3 210-3
Model　JTHB 60S-3 60-3 160-3 350-3 450-3
(120S-3) (210S-3)
a (mm) 165 180 230 240 270 300 330
b (mm) 165 180 230 240 270 300 330
Depth (mm) 350 380 500 500 640 670 780
50-13
① Remove the gas valve plug from the gas

valve on the cylinder cover of the breaker.
Driver
② Using a tool such as a screwdriver, push Gas valve body
the valve in and completely remove all of
the gas from the cushion chamber. Gas valve
③ Before removing the side bolt nut, first

loosen the bolts on the control valve box.
Control valve box
Loosen the bolts
④ Fix the hydraulic breaker, loosen the side
bolt nut about 2-3mm from the fastening
surface.
Loosen about 2 – 3mm
⑤ Fit the “Eyebolt”onto the cylinder cover and
lift the breaker up. Lower the breaker onto
a breaker stand or a breaker locater so
that the breaker does not fall over.
50-14
2) Side Bolt Nut / Cylinder Cover

Remove the side bolt nut and the ring, lift the cylinder cover up. At this time, reconfirm that the
gas in the cushion chamber is completely removed. If gas remains in the cushion chamber, the
cylinder cover may pop up and that can be dangerous. ( CAUTION ; Take special care with the
O-ring and the back up ring on the side of cylinder and cylinder cover.)
Side bolt nut
Eyebolt Side bolt ring
Cylinder cover
O-ring and back up ring

Side bolt
CAUTION; When removing the side bolt ring, be careful not to damage the side bolt threads.
3) Piston
Fit an “Eyebolt” to the piston and lift it straight up. Then the packing bushing will also be
removed with the piston. Remove the packing bushing from the piston by using a rubber hammer.
Eyebolt
Eyebolt
Piston
Piston
Packing bushing
Packing bushing
Valve cap
CAUTION;
CAUTION; Oil may come out
Oil may come out from these parts.
from these parts.
ＪＴＨＢ０８-３～５０-３ＪＴＨＢ６０-３～４５０-３
50-15
4) Control Valve
① Fit the cylinder so that it does not move. ① Loosen the bolts on the Control valve box.
Assemble an “Eyebolt”to the valve cap and Screw tow of them into the tap hole of the
lift it straight up. Control valve box. During this procedure
do not remove the bottom two bolts.
(This is to prevent the control valve from falling.)
Eyebolt
Valve cap
O-ring,
Back up ring
Tap Hole
ＪＴＨＢ０８-３～５０-３
ＪＴＨＢ６０-３～４５０-３
② Put a sling or a safety power rope onto the

Hex bolts and lift the Control valve box off
by using a crane or hoist.
Hoist
Belt sling
Do not use an Impact wrench during

loosing the bolts. (The Helisert may
come out from the cylinder.)
ＪＴＨＢ６０-３～４５０-３
50-16
③ Fix the control valve box by a vice. Loosen

the hex bolt on the valve cap. Then using
a removal tap, screw the removal bolt in
and remove the valve cap.
O-ring, Back up ring
Removal tap
Remove Evenly
Control valve cap
ＪＴＨＢ６０-３～４５０-３
After removing the valve cap, the control valve can be seen. If seizure or pickup has not developed,
the control valve can be moved from the control valve box by hand. If seizure or pickup has developed,
using the valve hole or the groove, pull the valve out from the control valve box.
Control valve
Control valve
ＪＴＨＢ０８-３～５０-３ＪＴＨＢ６０-３～４５０-３
50-17
5) Cylinder
Assemble “Eyebolts”to the cylinder and lift them up.
Eyebolt
Eyebolt
Cylinder
Cylinder
ＪＴＨＢ０８-３～５０-３ＪＴＨＢ６０-３～４５０-３
6) Side Bolt
After removing the cylinder, fix the chisel holder so that it does not move. Loosen the Side
bolt by turning the spanner at the root of the side section.
Hex area
Spanner section
Spanner section
Spanner section
Ｏ-ring Ｏ-ring
ＪＴＨＢ０８-３～５０-３ＪＴＨＢ６０-３～４５０-３
* When re-using a side bolt, be careful not to damage the spanner and thread areas.
50-18
7) Hose Adapter
Disassemble the hose adapters with an Impact wrench.
(Make sure the O-ring and hose adapters are not damaged or deformed. Check any scratches or
damage. If damaged replace the O-ring and the Hose adapter. That may cause oil leakage.)
Hose adapter
Hose adapter
ＪＴＨＢ０８-３～５０-３ＪＴＨＢ６０-３～４５０-３
8) Removal of the Seals

By using a screw driver, remove the seals in the bottom of the cylinder and the seals in the packing
bushing. These seals are the oil seal, dust seal, slide ring, O-ring and gas seal. Once the seals have
been removed, they cannot be re-used. Always replace it with new ones.
① Insert tip of the awl under the seal
② Lift after inserting the driver
50-19
③ Insert the driver
④ Remove the seal
50-20
9) Assembly / Disassembly chart for the Hydraulic Breaker

20-3 30-3 40-3
Model JTHB 08-3 10-3 (20S-3) (30S-3) (40S-3) 50-3
① Eyebolt for cylinder cover Bolt size (mm) M8 M8 M8 M12 M12 M12
Width across flats (mm) 24 27 32 32 32 36
② Side bolt nut
Tightening torque (N・m) 216 294 441 441 539 637
Width across flats (mm) - - - - - -
③ Control valve box bolt
Tightening torque (N・m) - - - - - -
④ Eyebolt for valve cap Bolt size (mm) M8 M8 M8 M8 M8 M12
⑤ Eyebolt for piston Bolt size (mm) M8 M8 M8 M12 M12 M12
⑥ Eyebolt for cylinder Bolt size (mm) - M8 M8 M8 M8 M12
⑦ Eyebolt for chisel holder Bolt size (mm) - - - (M12) (M12) M12
Width across flats (mm) 11/13 11/17 11/19 11/19 13/19 17/21
⑧ Side bolt Top / Bottom
⑨ Gas valve plug
⑩ Gas valve body
⑪ Hose adapter
① ② ① ⑤ ④
⑨ ⑥
⑩
⑪
50-21
Model JTHB 60S-3 60-3 120-3

(120S-3)
① Eyebolt for cylinder cover Bolt size (mm) M12 M12 M20
Width across flats (mm) 41 41 55
② Side bolt nut
Tightening torque (N・m) 980 980 1960
④ Eyebolt for valve cap Bolt size (mm) M8 x 30 M8 x 30 M8 x 30
⑤ Eyebolt for piston Bolt size (mm) M12 M12 M20
⑥ Eyebolt for cylinder Bolt size (mm) M12 M12 M12
⑦ Eyebolt for chisel holder Bolt size (mm) M12 M12 M12
Width across flats (mm) 17/24 17/24 27/30
⑨ Gas valve plug
⑩ Gas valve body
⑪ Hose adapter
① ① ⑤
②
⑥
⑨
⑩
④
⑦
50-22
Model JTHB 210-3

160-3 (210S-3) 350-3 450-3
① Eyebolt for cylinder cover Bolt size (mm) M20 M20 M24 M30
Width across flats (mm) 55 70 80 80
② Side bolt nut
Tightening torque (N・m) 1960 2254 3528 3528
④ Eyebolt for valve cap Bolt size (mm) M10 x 40 M10 x 40 M12 x 50 M16 x 60
⑤ Eyebolt for piston Bolt size (mm) M20 M20 M24 M30
⑥ Eyebolt for cylinder Bolt size (mm) M12 M12 M16 M16
⑦ Eyebolt for chisel holder Bolt size (mm) M12 M16 M16 M16
Width across flats (mm) 27/30 32/36 36/46 36/46
⑨ Gas valve plug
⑩ Gas valve body
⑪ Hose adapter
① ① ⑤
②
⑥
⑨
⑩
④
⑦
50-23
4. JTHB plugs torque chart

CAUTION; If the breaker is normal condition,
do not disassemble the choke plug.
Tightening torque N·m
① Plug PT1/8 ２０
② Plug PT1/4 ４９
③ Plug PT3/8 １１８
④ Plug PT1/2 ２４５
⑤ Plug PT3/4 ４４１
⑥ Plug PT1” ５８８
⑦ Plug PT1-1/4 ７３５
20-3 30-3 40-3 120-3

Model JTHB 08-3 10-3 (20S-3) (30S-3) (40S-3) 50-3 60S-3 60-3 (120S-3)
Choke plug torque
(N・m) 69 69 69 69 69 108 196 196 196
① ① ① ① ① ① ① ④ ①
③ ④ ② ② ② ② ② ⑥ ④
Plug ④ ⑤ ③ ④ ④ ④ ④
⑤ ⑤ ⑤ ⑥ ⑥
⑥
210-3
Model JTHB 160-3 (210S-3) 350-3 450-3
Choke plug torque
(N・m) 294 294 294 392
① ① ② ②
② ② ④ ④
Plug ④ ④
Choke plug
Choke plug
Cylinder Control valve box
ＪＴＨＢ０８-３～５０-３ＪＴＨＢ６０-３～４５０-３
50-24
5. Inspecti and Repair the Hydraulic Breaker

1) Seals
With the seals assembled in the breaker, check wear, deformation and scratches.
Even small scratches may cause oil leakage from the breaker.
When the breaker is disassembled and operated more than 600 hours, all seals should be changed.
Crack Tear
O-ring
New
Wear, deformation
Dirt or foreign material
Oil Seal Crack
Crack
New
Gnaw
2) Chisel Bushing
Inspect the clearance between the chisel (New) and the chisel bushing.
If the clearance expands more than the maximum width shown in the chart below, the Chisel bushing
should be replaced.
Model JTHB 08-3 〜 60S-3 60-3

Wear Width (mm) 4 6
Model JTHB 120-3, 160-3 210-3(210S-3)

Wear Width (mm) 7 8 Wear Width
Model JTHB 350-3 〜 450-3

Wear Width (mm) 10
Clearance
Chisel
50-25
1］How to change the Chisel Bushing

① Remove the stopper plugs and the stopper pins.
Stopper pin
Stopper plug
② Place the chisel bushing removal jig (A) in the correct position. Then position removal jig (B)
Set the Removal bar

in place
Bushing
Place Bushing Removal jig (A) Removal jig (B)
on top of the Chisel bushing
Chisel Bushing
so that it does not fall.
Dimensions required for the Chisel Bushing removal jigs & the steel bar.
20-3 30-3 40-3 50-3
Model JTHB 08-3 10-3 (20S-3) (30S-3) (40S-3) 60S-3
O.D (mm) - φ55 φ60 φ70 φ75 φ90
Chisel Bushing
Width (mm) - 30 40 50 50 60
Removal Jig (A)
Thickness(mm) - 16 16 20 25 25
Chisel Bushing O.D (mm) φ140 φ140 φ160 φ200 φ200 φ220
Removal Jig (B) I.D (mm) φ80 φ80 φ88 φ96 φ108 φ118
Length (mm) 90 90 100 120 120 130
Chisel Bushing O.D (mm) φ25 φ30 φ36 φ46 φ50 φ55
Removal Bar Length (mm) As required
50-26
Dimensions required for the Chisel Bushing

removal jigs & the steel bar.
Model JTHB 60-3 120-3 (120S-3)
160-3
O.D (mm) φ 110 φ 130
Chisel Bushing
Width (mm) 70 90
Removal Jig (A)
Thickness (mm) 30 40
Chisel Bushing O.D (mm) φ 250 φ 300
Removal Jig (B) I.D (mm) φ 138 φ 185
Length (mm) 150 200
Chisel Bushing O.D (mm) φ 65 φ 90
Model JTHB 210-3

350-3 450-3
(210S-3)
O.D (mm) φ 150 φ 160 φ 180
Chisel Bushing
Width (mm) 100 110 110
Removal Jig (A)
Thickness (mm) 45 50 50
Chisel Bushing O.D (mm) φ 350 φ 350 φ 400
Removal Jig (B) I.D (mm) φ 210 φ 210 φ 270
Length (mm) 220 220 250
Chisel Bushing O.D (mm) φ 110 φ 120 φ 120
③ Push the removal bar down and this will remove

the bushing.
(Force of 100 t is needed for JTHB210-3)
CAUTION; During the press operation,

the operating load is very high.
Proceed carefully.
50-27
3) Chisel Holder Bushing

Confirm that the wear of the chisel holder
bushing is within the width shown in the chart
below. If the wear exceeds the limits, the chisel
holder bushing should be replaced.
Model JTHB 08-3 ~ 30-3 40-3 ~ 60S-3

Wear Width (mm) 1.5 2
Model JTHB 60-3 120-3, 160-3

Wear Width (mm) 2.5 3.5
Wear width
Model JTHB 210-3 350-3 ~ 450-3
Wear Width(mm) 4 5
1］How to change the Chisel Holder

Bushing Stopper Pin
① Remove the stopper pins and stopper plugs.
Stopper Plug
② Choose the correct size of the removal tool and push it into the chisel. Then weld the removal tool,
and place the steel bar as the following shown below.
Chisel holder Set the removal bar.

bushing
Insert the removal tool as shown in the diagram above and weld.
50-28
① Remove the chisel holder bushing by

using a press machine.
CAUTION ; During the press

operation, the operating load is
very high. Proceed carefully.
Also, always remove the chisel
bushing first before removing
the chisel holder bushing.
Dimensions required for the Chisel Holder Bushing bar

and its tool
20-3 30-3 40-3
Model JTHB 08-3 10-3 (20S-3) (30S-3) (40S-3) 50-3
Diameter for holder bushing removal bar (mm) － φ 40 φ 46 φ 46 φ 50 φ 65
Diameter for holder bushing removal tool (mm) (φ 40) φ 45 φ 50 φ 55 φ 60 φ 75
Length as required
120-3
Model JTHB 60S-3 60-3 (120S-3) 160-3
Diameter for holder bushing removal bar (mm) φ 65 φ 65 φ 90 φ 103
Diameter for holder bushing removal tool (mm) φ 75 φ 90 φ 110 φ 110
Length as required
210-3
Model JTHB (210S-3) 350-3 450-3
Diameter for holder bushing removal bar (mm) φ 118 φ 133 φ 138
Diameter for holder bushing removal tool (mm) φ 130 φ 140 φ 160
Length as required
50-29
4) Control Valve / Control Valve Box

Inspect the control valve for seizure or pick up marks. If the seizure marks are small, use a fine oil stone
(a whetstone) or water paper (#400 - #800) to repair the markings.
If seizure has developed on the control valve or the control valve box, repair properly. When repairing
the valve box with a flex-hone, operate about 10 secs. Do not operate more than 10 secs. (Also, use the
correct diameter flex-hone as shown in the chart below.)
Repair direction × Repair direction ○
ＪＴＨＢ０８-３～５０-３ＪＴＨＢ６０-３～４５０-３
If the seizure marks are deep and extensive, the control valve and control valve box should be replaced.
ＪＴＨＢ０８-３～５０-３ＪＴＨＢ６０-３～４５０-３
BREAKER Appropriate dia meter of Flex-hone

Model Flex-Hone (mm)
JTHB08-3 φ24～φ27
JTHB10-3 φ30～φ33
JTHB20-3（20S-3) φ33～φ36
JTHB30-3（30S-3）
Marked with black color
JTHB40-3（40S-3）
JTHB50-3 φ38～φ43
JTHB60S-3 #120 AO (aluminum oxide)
JTHB60-3 (Particle size & Material)
φ48～φ52
JTHB120-3（120S-3）
JTHB160-3 * When performing the flex-hone operation, always
φ58～φ61
JTHB210-3（210S-3） use grinding fluid.
JTHB350-3 φ72～φ78 When the grinding balls wear on the flex-hone and
JTHB450-3 φ82～φ89 the fiber thread appears, replace to a new one.
50-30
5) Piston
Periodically inspect the amount of deformation
Marginal wear volume

of the impact area of the piston. If the amount of
the wear at the impact area exceeds the limits
shown in the chart, the piston must be replaced.
* If the piston wears beyond the limits shown in

the chart Area A will swell and that may cause Ａ
difficulty to remove the piston from the cylinder.
The piston should be replaced before that
occurs.
Model JTHB 08-3 ~ 60S-3 60-3 120-3 (120S-3), 160-3 210-3(210S-3) 350-3 ~ 450-3
Wear (mm) 1.5 1.5 2 4 5
Inspect the piston for seizure marks or pickup. If seizure marks on the large diameter are small, use a fine oil
stone (a whetstone), paper, or flap wheel with spindle (#400 - #800) to repair the marks. If the seizure develops
where burrs are visible, use the corner of the oil stone or grinding wheel to clean the burrs out.
Repair direction × Repair direction ○
Oil groove area
50-31
5) Cylinder
Also repair the seizure on the cylinder with
flex-hone. Do not grind inside of the cylinder
with flex-hone more than 10 secs.
(Make sure the size of the Flex-hone is the ② ①
appropriate size to repair.)
BREAKER FLEX-HONE Appropriate

Model Size (mm)
① φ43～φ48
JTHB08-3
② φ38～φ43
① φ53～φ58
JTHB10-3
② φ48～φ52
① φ62～φ65
JTHB20-3(20S-3)
② φ58～φ61
②
JTHB30-3(30S-3) ① φ72～φ78 ①
JTHB40-3(40S-3) ② φ66～φ71
JTHB50-3 ① φ76～φ83
JTHB60S-3 ② φ72～φ78
① φ89～φ95 Flex-hone
JTHB60-3
② φ82～φ89
① φ110～φ116
JTHB120-3(120S-3)
② φ110～φ116
① φ130～φ140
JTHB160-3
② φ120～φ130 Marked with black color
① φ130～φ140
JTHB210-3(210S-3)
② φ130～φ140
#120 AO (aluminum oxide)
① φ160～φ170 (Particle size & Material)
JTHB350-3
② φ140～φ160
① φ180～φ190 * When performing the flex-hone operation, always
JTHB450-3
② φ160～φ170 use grinding fluid. When the grinding balls wear on
the flex-hone and the fiber thread appears, replace
to a new one.
50-32
7) Retainer Pin
Remove the retainer pin and check for any abnormalities.
Retainer Pin
Retainer Pin
Retainer Pin plug

Retainer Pin plug
ＪＴＨＢ０８-３～１２０-３ＪＴＨＢ１６０-３～４５０-３
If the retainer pins have swelled, that may cause retainer pin breakage. In this case, remove the swelling
by using a grinder immediately. If swelling occurs on the area where the retainer pin attaches the chisel,
repair these area by using a grinder.
ＪＴＨＢ０８-３～１２０-３ＪＴＨＢ１６０-３～４５０-３
* For lasting the retainer pin for a long time, after rocks or demolition materials are broken, release your
foot from the pedal as early as possible to reduce the amount of blank blows. Also, a retainer pin wears
in diameter more than 2mm, the retainer pin should be replaced to new one. Not replacing the retainer
pin will cause breakage of the retainer pin and that may be dangerous.
50-33
6. Assembly of the Hydraulic Breaker

1) Chisel Holder Bushing / Chisel Bushing
① With a gas burner, warm up the surface of the chisel holder for about 30 minutes.
(The temperature of the chisel holder should be about 200°C and check it with the thermometer.)
Warm the surface of the chisel holder using a gas burner.

(Do not heat one section only)
② With Dry ice blocks, cool the chisel holder bushing and chisel bushing for about 6-8 hours.
(To about -50°C ~ -60°C )
Chisel bushing Chisel Holder bushing
Dry ice
Make sure the lid is closed properly
Effective cooling
container needed
* When removing these parts, make sure proper gloves are used.
(Do not handle with bare hands.)）
50-34
1］Chisel Holder Bushing

① Drop the chisel holder bushing into the chisel holder. Before assembling the holder bushing, mark the
position where it will be assembled to assemble it at the proper place.
② Assemble two stopper pin removal bars at the same time. The pin which has been assembled more
deeply should be moved back and forth for positioning.
③ The chisel holder bushing will rotate inside, and the pin will be assembled to the deeper position.
(The position should be set at this time)
④ Remove the stopper pin removal bar and hammer the stopper pin into its position.
⑤ Assemble the other stopper pin to its deeper position.
* The chisel holder has been heated. Be careful not to burn yourself.
Align it so that the stopper pin can be assembled
Mark the position on the chisel holder and on the chisel holder bushing so
that it is aligned properly.
Move-
ment Set
properly
Chisel holder Stopper pin removal bar The stopper pin should be hammered into place
① ②③ ④ ⑤
50-35
2］Chisel Bushing (JTHB08-3 ~ 210-3)

① Drop the chisel bushing into the chisel holder.
② Assemble two stopper pin removal bars at the same time. (The position should be set at this time)
③ Remove the stopper pin removal bar and hammer the stopper pin into its position.
④ Assemble the other stopper pin to its deeper position.
Chisel holder Stopper pin removal bar Stopper pin

(Use a hammer to assemble
in place)
① ② ③ ④
50-36
3］Chisel Bushing (JTHB350-3 ~ 450-3)

① Drop the chisel bushing into the chisel holder. Before assembling the chisel bushing, mark the position
where it will be assembled to assemble it at the proper place.
② Assemble two stopper pin removal bars at the same time. The pin which has been assembled should
be moved back and forth for positioning.
③ Remove the stopper pin removal bar and hammer the stopper pin into its position.
④ Assemble the other stopper pin to its deeper position.
Align it so that the stopper pin can be assembled
Mark the position on the chisel holder and on the chisel holder bushing so that
it is aligned properly.
Move-
ment
Set
properly
Chisel holder Stopper pin removal bar Stopper pin (Use a hammer to assemble in place)
① ②③ ④ ⑤
50-37
1) Chisel Holder Bushing

① After making sure the chisel hold gets the room temperature, apply “Loctite #410” to the stopper plug and
hammer the part into the place.
② Apply “Loctite #242” to the Grease Nipple thread section and assemble it into the place.
③ Assemble the Air cap spring Urethane ball as the diagram shown below, then apply seal tape to the thread
section of the Air cap thread and assemble.
④ Assemble the hex plug with O-ring and the GM plug. The tightening torque chart is shown below.
Torque N·m
① Grease Nipple PT1/8 ２０
② Grease Nipple PT1/4 ３９
③ Air Cap PT3/8 １９６
④ Hex Plug withO-ring PT1/2 ３９
⑤ GM Plug PT1/8 ２０
⑥ GM Plug PT1/4 ４９
Air Cap (Apply Seal tape to threads)
Urethane ball
Air Cap spring
③
Hex plug withO-ring
(Apply Loctite #242)
④
Stopper Plug
(Apply Loctite ＃410)
① ①
Grease nipple
GM Plug (Apply seal
(Apply Loctite #242) ④
tape to the threads)
②
Stopper Plug
(Apply Loctite ＃410)
① ①
50-38
1］How to insert the Helisert

Make sure the Chisel Holder gets cool to room temp.
TAG REMOVAL TOOL

HANDLE
HELISERT (E-SERT)
SLEEVE
MANDREL
TAG
① From the sleeve window, set the tip of the

Mandrel into the tag. Turn the handle
HANDLE
facing up.
MANDREL
SLEEVE
Helisert
② Turn the Helisert into the sleeve so that it

stops 1-2 threads before reaching the
sleeve.
Helisert
(Set with the tag)
50-39
③ Hold it lightly with the left hand.
Place the jig straight

on the hole.
④ Do not press the tag. (pulling up action is

needed)
Place the thread on the top of the hole
and turn the handle clock wise.
⑤ When the helisert is assembled

completely in the chisel holder, turn
the sleeve counter clock wise and
remove the sleeve from the Helisert.
Sleeve
50-40
⑥ Push in any remains on the helisert with

the front tip of the Mandrel.
MANDREL
⑦ With the front tip of the Mandrel, put the

helisert into the hole by one thread.
MANDREL
⑧ Place the front tip of the Tag removal

tool into the tag, and push it with a HAMMER
hammer.
TAG REMOVAL
TOOL
CAUTION; When turning the handle, always turn in the right direction (Clock-wise).
Turning in the left hand direction will make the tag broken, and will not be able to assemble
the helisert.
50-41
Helisert Thread Sizes

20-3(20S-3) 40-3
Model JTHB 08-3 10-3 30-3(30S-3) (40S-3) 50-3
Helisert M16 M18 M20 M22 M24
Chisel Holder (Side bolt area)
Insertion Tool P=1.5 P=1.5 P=1.5 P=1.5 P=2
60S-3 120-3 210-3

Model JTHB 60-3 160-3 (210S-3) 350-3 450-3
Helisert M27 M36 M42 M52 M52
Chisel Holder (Side bolt area)
Insertion Tool P=2 P=3 P=3 P=3 P=3
50-42
3) Side Bolt
Apply anti-seize lubricant (MoS2-grease) or equivalent Brands to the thread area of the side bolt.
Assemble the side bolt into the chisel holder with the specified torque.
(Refer to “Assembly / disassembly chart for the Hydraulic Breaker” which indicates the torque settings.)
Apply a small amount of grease to the rod area of the side bolt and rubber area.
This will allow easier assembly of the cylinder.
Side bolt (Apply MoS2-grease)
Torque wrench
Make sure the Heliserts

are assembled properly
50-43
4) Cylinder
Proceed directions shown below to assemble the Heliserts into the Cylinder.
① From the sleeve window, set the tip of the

Mandrel into the tag. Turn the handle
facing up. Handle
Mandrel
Sleeve
Helisert
② Turn the Helisert into the sleeve so that

it stops 1-2 threads before reaching the
sleeve. Helisert
(Set with the tag)
③ Hold it lightly with the left hand.

Please the jig straight
on the hole.
50-44
④ Do not press the tag. (pulling up action is

needed)
Place the thread on the top of the hole and
turn the handle clock wise.
⑤ When the helisert is assembled completely

in the cylinder, turn the sleeve counter
clock wise and remove the sleeve from the
helisert.
Sleeve
⑥ Push in any remains on the helisert with

the front tip of the Mandrel.
Mandrel
50-45
⑦ With the front tip of the Mandrel, put the

helisert into the hole by one thread.
Mandrel
⑧ Place the front tip of the Tag removal tool

into the tag, and push it with a hammer.
Hammer
Tag remove tool
CAUTION; When turning the handle, always turn in the right direction (Clock-wise).
Turning in the left hand direction will make the tag broken, and will not be able to assemble
the helisert.
50-46
Helisert Thread Sizes

60-3
Model JTHB 60S-3
120-3(120S-3)
Helisert Chisel Holder M16 3/4-16
Insertion Tool (Control valve box area) P=1.5 UNF
160-3
Model JTHB 350-3 450-3
210-3(210S-3)
Helisert Chisel Holder M24 M30 M33
Insertion Tool (Control valve box area) P=2 P=2 P=3
* Helisert is not used on the breakers from JTHB08-3 to 50-3.
Reasons for the Helisert to come out

① Bolts were attempted to be removed when the breaker is still hot.
② Bolts were not washed properly or anti-seize lubricant was not applied to the thread.
③ When removing the bolt, even though the bolt was difficult to remove, it was forcefully removed.
Countermeasures
① Before loosening the bolts, make sure the breaker has cooled off before starting.
② Bolts should be washed before assembly and always apply an anti-seize (MoS2-grease) to the threads
before assembly.
③ If the bolt becomes hard to remove, do not remove forcefully, Put the spanner on the bolt and attempt to
remove when hammering the head of the bolt.
When assembling or removing bolts, proceed as stated above.
50-47
1］Cylinder Seal
After the Helisert has been assembled, Apply lubricant to the seal grooves evenly.
Apply lubricant to the seals. Before assembling the seals, check the direction referring to the parts list.
* Before assembling the seals, make sure all of the seals are clean and free of foreign items.
Assemble the cylinder onto the chisel holder. (Before the assembly, re-confirm the seal direction)
At this time, press down until the cylinder reaches the surface of the chisel holder.
Buffer ring Cylinder
Oil Seal
Cylinder Dust seal

Oil Seal
ＪＴＨＢ１２０-３ , １６０-３
Cylinder
Buffer ring
Dust seal
Buffer ring
ＪＴＨＢ０８-３～６０-３
X seal
Dust seal
ＪＴＨＢ２１０-３～４５０-３
Cylinder
Cylinder
Chisel Holder
Chisel Holder
Make sure
the O-ring
is assembled
Make sure the O-ring is
correctly
assembled correctly
ＪＴＨＢ０８-３～５０-３ＪＴＨＢ６０-３～４５０-３
50-48
* For the JTHB20-3 ~ 160 make sure

the O-ring (hardness-Hs90) is in
place before putting in the piston.
5) Piston
Apply Hydraulic oil to the piston and assemble the piston into the cylinder.
Eyebolt
Eyebolt
Apply Hyd. Oil
ＪＴＨＢ０８-３～５０-３ＪＴＨＢ６０-３～４５０-３
50-49
6) Packing Bushing
With a rubber hammer, or a Packing bushing
assembly jig & a hammer, assemble the Packing
bushing straight into the Cylinder. (Before
assembling the packing bushing into cylinder,
check the seal direction) Please refer to the
Parts Manual for the seal direction.
GAS Seal
GAS Side (up) GAS Side (down)
Gas seal
O - ring
O - ring
O - ring Gas seal
Oil seal
Step seal
O - ring
Slide ring S
O - ring (Hs90)
SEAL DIRECTION
O - ring (Hs90) SEAL DIRECTION
ＪＴＨＢ０８-３～１０-３ＪＴＨＢ２０-３～４０-３
Gas seal Gas seal
O - ring
O - ring
Oil seal Oil seal
O - ring
Slide ring S Slide ring S
O - ring
SEAL O - ring (Hs90)

O - ring (Hs90) SEAL DIRECTION DIRECTION
ＪＴＨＢ５０-３～１６０-３ＪＴＨＢ２１０-３～４５０-３
50-50
Packing bushing Packing bushing

Assembly jig Assembly jig
ＪＴＨＢ０８-３～６０-３ＪＴＨＢ６０-３～４５０-３
50-51
Dimensions required for the Pucking Bushing

Assembly Jig
20-3 30-3 40-3 50-3
Model JTHB 08-3 10-3 (40S-3) 60S-3
(20S-3) (30S-3)
Packing O.D (mm) 55 φ 65 φ 75 φ 85 φ 85 φ 95
Bushing I.D (mm) φ 48 φ 58 φ 66 φ 76 φ 76 φ 85
Assembly Jig I.D Depth / Height of jig (mm) 20/70 20/75
15/55 20/60 20/60 20/70
120-3 210-3
Model JTHB 60-3 (120S-3) 160-3 (210S-3) 350-3 450-3
Packing O.D (mm) φ 110 φ 140 φ 150 φ 170 φ 190 φ 200

Bushing I.D (mm) φ 95 φ 120 φ 133 φ 145 φ 165 φ 180
Assembly Jig I.D Depth / Height of jig (mm)
20/50 25/55 25/55 25/55 30/60 30/60
Fit the “Eyebolts” into 2 places out side of

hammering area.
O.D. O.D.
Put on handle
Hight of jig
Hight of jig
Depth
Depth
I.D.
I.D.
I.D. I.D.
ＪＴＨＢ０８-３～６０Ｓ-３ＪＴＨＢ６０-３～４５０-３
50-52
7) Control Valve〔ＪＴＨＢ０８-３～５０-３〕〔ＪＴＨＢ６０Ｓ-３～４５０-３〕

① The valves have to assemble to the cylinder ① The valves have to assemble to the cylinder
in order of size as the diagram shown below. in order of size as the diagram shown below.
Apply hyd. oil to valve Medium dia. Medium dia.

Apply hyd. oil to valve
Large dia. Large dia.
Small dia.
Small dia.
② Apply fresh hydraulic oil to the valve cap ② Apply fresh hydraulic oil to the valve cap
O-ring groove, the O-ring, and the back up O-ring groove, the O-ring, and the back up
ring. Then, assemble these parts into the ring. Then, assemble these parts into the
cylinder. The assembly needs light press, so valve box. The assembly needs light press.
assemble the part with a rubber hammer and Please make the 4-bolts tightened into the
assemble the part straight into the bore. valve box evenly.
(Not uneven)
Valve cap
O-ring Tighten the bolts down in diagonal sequence.

Back up ring
③ Put the valve box into a vice. Tighten the 4-
* When assembling the valve cap, make sure the O-ring bolts to the correct torque value in a diagonal
and back up ring are not damaged or cut. sequence referring to the torque chart on
Assembly / Disassembly chart for the
How to assemble the back up ring; Hydraulic Breaker)
(Bias-cut and spiral cut)
(Bias cut)
When assembled as shown above, the diameter may

larger and lead to damage or over riding of the ring.
④ After tighten the bolts to the proper torque

level, using your finger check to make sure
As a result, before assembly make the ring smaller as that the control valve moves freely. (Make
shown above and this will prevent the ring from over sure dirt or other foreign matter does not
riding. enter the valve inside.)
50-53
8) Control Valve Box〔ＪＴＨＢ６０Ｓ-３～４５０-３〕

Assemble the Control valve box onto the cylinder
and tighten the bolts according to torque chart. Make sure the O-ring and the back up ring are
(Refer to Assembly / Disassembly chart for the assembled into the Control valve box properly.
Hydraulic Breaker section.)
O - ring
Back up ring
50-54
9) Filling the Breaker with Hydraulic Oil

After assembling the Packing bushing, in order
to protect the seals, apply the hydraulic oil
into the cylinder as the drawing shown.
Don’ t forget to
assemble the O-ring
and the back up ring.
Packing Bushing
a:
Piston Cylinder
Recommended amount of Hydraulic Oil for assembly

20-3 (20S-3)
Model JTHB 08-3 10-3 30-3 (30S-3) 50-3 60S-3
40-3 (40S-3)
a) Top of cylinder to oil level (mm) 5 5 5 5 5
Oil volume (cc) 20 25 30 60 65
Model JTHB 120-3

60-3 (120S-3) 160-3
a) Top of cylinder to oil level (mm) 5 10 10
Oil volume (cc) 70 150 180
210-3
Model JTHB (210S-3) 350-3 450-3
a) Top of cylinder to oil level (mm) 10 10 10
Oil volume (cc) 270 320 350
50-55
10) Cylinder Cover / Side Bolt Nut

① Assemble the cylinder cover onto the breaker and assemble the side bolt rings.
② Apply anti-seize lubricant (MoS2-grease) to the side bolt threads and tighten the side bolt nuts with
the specified torque. The torque chart is on the page “Assembly / Disassembly chart for the Hydraulic
Breaker.”
Side bolt ring Side bolt nut

(If it is worn or deformed,
change this part to a new one) Make sure anti-seize lubricant is not applied to
the bottom of the nut.
(If the lubricant is applied, please remove)
Make sure O-ring is assembled on the cylinder

cover.
Align the 4 surfaces of the cylinder cover and

the cylinder properly before tighten the bolts.
1］How to use the Power Wrench

Move the Change Dial to the
① Tighten the side bolt nut with an impact
Change Dial “ Tighten R” position
wrench. (Do not use a power wrench.)
② Put the reaction bar on the left side of the
nut, which will be tightened. Adjust the
“ Change dial ” to the “ Tighten R” position.
Position
the reaction bar
to the left side
of the nut.
③ Each breaker bolt has a specific tightening Tightening Torque N·m

torque (Output torque). (Output Torque)
Calculate the required torque valves of the
torque wrench, which is assembled to the
Power wrench (Input torque).
There are 2 ways to calculate the torque ①
values. The first way is to use the chart
shown on the Power Wrench. ②
Torque setting for Torque

wrench (Input Torque) N·m
50-56
The second way is to use the following formula;

Out put torque ＝ Input torque x Magnification of the wrench from this formula
Input torque ＝ Output torque ÷ Magnification of the wrench
T = W ÷ 13.6
At this point T : The torque value of the torque wrench (Input torque)
W : The tightening torque value of the bolt (Output torque)
13.6 : Magnification of the Power wrench
(It will vary depending on the power wrench model)
EX) When the JTHB210-3 side bolt nut is tightened
According to “Assembly / Disassembly chart of the Hydraulic Breaker”,
its torque is 2254 (N・m)
Ｔ＝２２５４ ÷ １３．６≒１６６（Ｎ・ｍ）
Thus, the torque value will be 166 (N・m)
④ Put the torque wrench onto the Power wrench

and turn in the right hand direction (Clockwise).
Power wrench
⑤ When the set torque value is reached, the
torque wrench will make a “click” sound. After
this sound, turn slightly clockwise and “hold”
in its position, then switch the “change dial”
on the power wrench to the “ Loosen L” setting.
This will free the reaction power to the torque
wrench. When the reaction is released,
keep holding the torque wrench.
The torque wrench may swing around quickly Torque wrench
and may result in injury. Also, during this
operation, do not position yourself in the
moving diameter of the torque wrench.
Position the “change dial”

to “ Loosen L”
When changing the Change dial

to “ Loosen L”, do not let go of
the torque wrench.
⑥ Place the trench on the nuts in a diagonal,

and tighten them in the same way.
CAUTION; THE POWER WRENCH IS

A PRECISION TOOL, MAKE SURE
THE “CHANGE DIAL SWITCH” IS
CORRECTLY PUT INTO THE “R” & “L”
POSITION.
50-57
Width across flats Tightening Toruque

Model Rotating angle
(mm) (N･m)
JTHB08-3 ２４２１６２７０°
JTHB10-3 ２７２９４２７０°
JTHB20-3(20S-3)
３２４４１３００°
JTHB30-3(30S-3)
JTHB40-3(40S-3) ３２５３９３３０°
JTHB50-3 ３６６３７１５０°
JTHB60S-3 ４１９８０２７０°
JTHB60-3 ４１９８０２４０°
JTHB120-3(120S-3) ５５１９６０１８０°
JTHB160-3 ５５１９６０２１０°
JTHB210-3(210S-3) ７０２２５４２１０°
JTHB350-3 ８０３５２８２７０°
JTHB450-3 ８０３５２８２７０°
The angles shown below are measured after each nut are tightened to the cylinder cover with a spanner
See Also : Alternative Method of Tightening

The Side Bolt Nuts
① Put the side bolt rings into the side bolts.

Side bolt
② Apply the grease spray to the thread area of
the side bolts.
③ With a socket and ratchet wrench or a spanner,

tighten the side bolt nuts. Then make sure Side bolt ring
the side bolt nuts are firm enough seated in
the cylinder cover.
Grease spray
Cylinder cover
Spanner
Ratchet wrench
50-58
④ With a marker, put a mark on the cylinder

cover and the side bolt nuts like marks Start angle point
shown on the picture. (Mark 2 place ; start
and specifiedroating angle points)
⑤ With a power wrench and a ratchet wrench

or an impact spanner, rotate the nut to the
specified rotating angle.
Specified rotating angle point
Ratchet wrench
Impact spanner
Power wrench
２７０°
⑥ Tighten the side bolt nuts in the following

sequence ( A –B – C – D ).
Make sure the 4 side bolt nuts are
tightened equally.
A C
D B
50-59
11) Hose Adapter

Assemble the hose adapters. The “IN” side has the throttle, and the “OUT” adapter doesn’t have the
throttle. Please assemble correctly. (Refer to the torque chart.)
IN side OUT side

IN side
OUT side
ＪＴＨＢ０８-３～５０-３ＪＴＨＢ６０-３～４５０-３
IN side OUT side
Throttle is located in the

On the “IN” side is
inside diameter.
a Cut mark. No throttle
O - ring
* The cylinder has “P” & “T” marks on the side of the part.
The IN side adapter shows “P” and the
OUT side adapter shows “T”.
50-60
12) Check & Recharge the Cushion Chamber with Nitrogen Gas
① Remove the gas valve plug.
Plug
② Fill it with the gas by the gas fill tool.

(Insert the gas slightly to reach the
recommended level, +0.1 MPa.)
③ Check the gas pressure by the measuring

gauge as shown. (refer to the chart shown
below)
③ Assemble the gas valve plug to 12 (N·m)

torque.
Standard value of nitrogen gas pressur

Model 08-3 ~
ambient temp. 60S-3
JTHB 50-3
Nitrogen 45℃ 0.9 1.1
gas 20℃ 0.8 1.0
（MPa） -10℃ 0.7 0.9
Model ambient temp.60-3 ~ 210-3 350-3 ~
JTHB 160-3 (210S-3) 450-3
Nitrogen 45℃ 0.9 1.2 0.9
gas 20℃ 0.8 1.1 0.8
（MPa） -10℃ 0.7 1.0 0.7
* Do not use any other gas except Nitrogen.
50-61
7. Special Work
1) How to change the broken Side Bolt
① Place the nut on the top of the broken side bolt horizontally. (The size of nuts depends on the model.)
② Weld the Side bolt to the inside of the nut.
③ After the weld gets cool off, loosen the broken

side bolt and remove it from the breaker.
50-62
④ Apply anti-seized grease (MoS2-grease) to

the thread area of the new side bolt and
tighten the bolt with the specified torque.
⑤ Assemble the side bolt ring. Side bolt ring
Apply grease
⑥ Tighten the side bolt nut to the correct torque

value by power wrench.
CAUTION ; Please note, changing only one side bolt may result in breakage of the others in a short
period of time. It is recommended to change all 4 side bolts although only one bolt is broken.
Check the torque levels periodically after changing all side bolts.
50-63
Komatsu Hydraulic Breaker JTHB08-3, 10-3, 20-3, 20S-3, 30-3, 30S-3, 40-3, 40S-3, 50-3, 60-3,
60S-3, 120-3, 120S-3, 160-3, 210-3, 210S-3, 350-3, 450-3
SEN06343-00
issued on 3 April 2013
2013 KOMATSU
All Rights Reserved
Printed in Japan

JTHB Shop Manual Sen06343-00

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JTHB Shop Manual Sen06343-00

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SEN06343-00

Hydraulic Breakers Serial numbers

This shop manual is for Hydraulic Breakers.

00 Index and foreword

Foreword, safety and general information

Important safety notice

1. General precautions 7) If welding repairs is required, always have a

2) Locate a place in the repair workshop to keep

4) When performing any work with two or more

4. Precautions for slinging work and making signals

・Do not stand under the load.

7） Hanging angle must be 60 degrees or smaller

8） When hanging a heavy load (25kg or heavier),

13) Shut down the main switch when the hoist

15) After finishing the work, stop the hoist at

The hoist or crane must be used to sling

2) Observe the signals for sling work. 10 8.8 0.9

Handling of hydraulic equipment

4. Preventing intrusion of foreign materials during

5. Replacing hydraulic oil while its temperature is high

20-3 30-3 40-3 60-3

* (a) state the length of the chisel is pushed to full Length

Gas pressure MPa 0.8 0.8 0.8 0.8 0.8 0.8 1

Oil flow ℓ/min 80〜120 100〜140 160〜200 180〜230 240〜300

Operating pressure MPa 14〜18 12〜17 14〜18 13〜18 14〜18

Impact rate bpm 450〜720 430〜600 490〜630 380〜450 370〜470

Chisel diameter mm φ 105 φ 115 φ 135 φ 146 φ 160

Chisel weight kg 63.5 91.5 133 185 236

Hose size inch 3/4 3/4 1” 1” 1”-1/4

Gas pressure MPa 1.1 0.8 1.1 0.8 0.8

Base machine Ton 8〜14 14〜20 18〜25 27〜40 38〜50

10 Structures, Operation and

Structures of the Hydraulic Breaker 10-2

Structures of the Hydraulic Breaker

Side bolt Nut Gas Valve

Air Port for Air Supply

Chisel holder bushing Chisel holder

Hose Adapter OUT

Air port for air Supply

Gas Valve Oil seal

Cylinder Cover Slide ring

Hose Adapter Packing bushing

Control Valve Box

Control Valve Cap

Air Cap Chisel holder

ＪＴＨＢ６０-３ ～ １ ２ ０-３ ＪＴＨＢ１６０-３ ～ ４ ５ ０-３

10 Structures, Operation and Maintenance

Hose Adapter OUT

Air port for air Supply

ＪＴＨＢ６０-３ ～ １ ２ ０-３ ＪＴＨＢ１６０-３ ～ ４ ５ ０-３

(1) Upward movement

(2) Reversing direction

(3) Downward movement

Repetition of the cycle mentioned above results in continuous blows.

10 Structures, Operation and Maintenance

(1) Upward movement

(2) Reversing direction

(3) Downward movement

Repetition of the cycle mentioned above results in continuous blows.

30 Testing and Adjustment

Hydraulic circuit Electric circuit

Bucket ATT + Boom up

Cooler Stop valve

ＪＴＨＢ６０-３～１２０-３ＪＴＨＢ１６０-３～４５０-３

ＪＴＨＢ６０-３～１２０-３ＪＴＨＢ１６０-３～４５０-３