PEN00651-01 JTHB Hydraulic Breaker Operation and Maintenance Manual

PEN00651-01
KOMATSU HYDRAULIC BREAKER

Model Serial No.
JTHB 08-3 10 0 01~
JTHB 10-3 10 0 01~
JTHB 20-3 10 0 01~
JTHB 30-3 10 0 01~
JTHB 40-3 10 0 01~
JTHB 50-3 10 0 01~
JTHB 60-3 10 0 01~
JTHB 120-3 10 0 01~
JTHB 160-3 10 0 01~
JTHB 210-3 10 0 01~
JTHB 350-3 10 0 01~
JTHB 450-3 10 0 01~
This manual describes only the Hydraulic Breaker. Therefore please refer to this manual and the
applicable machine Operation & Maintenance Manual for hydraulic breaker operation.
WARNING
Unsafe Use of this machine may cause serious injury or
Death, Operators and maintenance personnel must read
this manual before operating or maintaining this machine.
This manual should be kept near the machine for
reference and periodically reviewed by personnel who will
come into contact with it.
NOTICE
Komatsu has Operation & Maintenance Manuals
written in some other languages. if a foreign language
manual is necessary, contact your local distributor for
availability.
FOREWORD
1―1
BEFORE READING THIS MANUAL FOREWORD
BEFORE READING THIS MANUAL

This manual gives details of the operation and methods of inspection and maintenance for this Hydraulic Breaker
that must be obeyed in order to use the hydraulic breaker safely. Most accidents are caused by the failure to
follow fundamental safety rules for the operation and maintenance of machines.
Read, understand and follow all precautions and warnings in this manual and on the machine before performing
operation and maintenance. Failure to do so may result in serious injury or death.
Komatsu cannot predict every circumstance that might involve a potential hazard when the machine is used.
Therefore, the safety messages in the machine manual and this manual and on the machine may not include
all possible safety precautions. If you carry out any operation, inspection, or maintenance under conditions
that are not described in the machine manual and this manual, understand that it is your responsibility to take
the necessary precautions to ensure safety. In no event should you or others engage in the prohibited uses or
actions described in the machine manual and this manual. If the machine is operated wrongly when carrying out
inspection and maintenance, there is danger that it may lead to serious injury or death. If you sell or hire out the
Hydraulic Breaker, be sure to give this manual to the new owner together with the Hydraulic Breaker. Always
keep the machine manual and this manual in the location shown in the machine manual or near the machine so
that all relevant personnel can read it any time.
*The machine: the machine on which this Hydraulic Breaker to be installed such as excavator or loader
If this manual is lost or damaged, contact your distributor immediately to arrange for its replacement. To ensure
that the correct manual is sent, check the serial number of the machine/this Hydraulic Breaker and inform your
Komatsu distributor.
This manual uses the international units (SI) for units of measurement. For reference, units that have been used
in the past are given in (). (For example: ① → (1))
The explanations, values, and illustrations in this manual have been prepared based on the latest
information available as of the date of its publication. Continuing improvements in the design of this
Hydraulic Breaker may lead to additional changes that are not reflected in this manual. Consult Komatsu
or your Komatsu distributor for the latest available information concerning your machine or with
questions regarding information contained in this manual.
• The numbers in circles in the illustrations correspond to the numbers in () in the text.
Komatsu delivers this Hydraulic Breaker that comply with all applicable regulations and standards of the country
to which it has been shipped. If this Hydraulic Breaker has been purchased in another country, it may lack
certain safety devices and specifications that are necessary for use in your country. If there is any question about
whether your product complies with the applicable standards and regulations of your country, consult Komatsu or
your Komatsu distributor before operating the machine.
1―2
FOREWORD BEFORE READING THIS MANUAL
IMPORTANT SAFETY INFORMATION

To enable you to use the Hydraulic Breaker safely, and to prevent injury to operators, service personnel or
bystanders, the precautions and warning included in the machine manual and this manual and the safety signs
attached to the machine and this Hydraulic Breaker must always be followed.
To identify important safety messages in the manual and on the machine labels, the following signal words are
used.
The “Safety Alert Symbol” identifies important safety messages on machines, in manuals, and elsewhere. When
you see this symbol, be alert to the risk of personal injury or death. Follow the instructions in the safety message.
This signal word indicates an imminently hazardous situation which, if not avoided, will
DANGER result in death or serious injury.
This signal word indicates a potentially hazardous situation which, if not avoided, could
WARNING result in death or serious injury.
This signal word indicates a potentially hazardous situation exists which, if not avoided,
CAUTION may result in minor or moderate injury.
The following signal words are used to alert you to information that must be followed to avoid damage to the
machine.
This precaution is given where the machine may be damaged or the service life reduced
NOTICE if the precaution is not followed.
REMARKS This word is used for information that is useful to know.
INTENDED USE
USE OF the Hydraulic Breaker (Applying Works)
This Komatsu Hydraulic Breaker is designed to be used mainly for the following work:
- Demolition of Concrete and secondary breaking

- Demolition of Asphalt and secondary breaking
- Demolition of Rock
- Secondary demolition of Rock
- Quarry application
- Demolition of Buildings
- Road Construction
Please consult with Komatsu Dealers in case of tunnel work or under water work.
1―3
BEFORE READING THIS MANUAL FOREWORD
PRODUCT INFORMATION
When requesting service or ordering replacement parts, please inform your Komatsu distributor of the following
items.
LOCATION OF SERIAL NUMBER ON THE HYDRAULIC BREAKER

Product's Name plate is located at the side of Bracket
PRODUCT IDENTIFICATION NUMBER(PIN)MACHINE SERIAL NO. PLATE

On the bottom right of the operator's cab
The design of the nameplate ditters according to the territory
SERVICE METER LOCATION

On top of the machine monitor
1―4
FOREWORD CONTENTS
CONTENTS
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
BEFORE READING THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
SAFETY LABELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
BEFORE READING THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
GENERAL PRECAUTIONS FOR SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
PRECAUTION FOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
LIFTING BREAKER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
PIPING FOR THE HYDRAULIC BREAKER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
GREASE AND OIL RECOMMENDATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
HYDRAULIC OIL TEMPERATURE AND CONTAMINATION CONTROL . . . . . . . . . . 3-10
INSTALLATION OF THE HYDRAULIC BREAKER ON TO THE EXCAVATOR . . . . . 3-11
INSTALLATION OF THE CHISEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
REPLACEMENT OF CHISEL (1) REMOVING THE CHISEL . . . . . . . . . . . . . . . . . . . 3-14
REPLACEMENT OF CHISEL (2) INSERTING THE CHISEL . . . . . . . . . . . . . . . . . . . 3-16
LUBRICATION OF CHISEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
INSPECTION PRIOR TO OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
TEST RUN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
OPERATION OF HYDRAULIC BREAKER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
PRECAUTIONS DURING OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
DISMANTLING THE BREAKER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
STORAGE OF THE BREAKER (1) STORAGE FOR ONE MONTH . . . . . . . . . . . . . 3-28
STORAGE OF THE BREAKER (2) STORAGE FOR MORE THAN ONE MONTH . . 3-29
MAINTENANCE AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

TIGHTENING TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
CHECK BEFORE STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
MAINTENANCE AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
PERIODIC MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
SAFETY CRITICAL PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
OIL FILTER ELEMENTS AND HYDRAULIC OIL REPLACEMENT . . . . . . . . . . . . . . 4-22
HYDRAULIC OIL / OIL FILTER ELEMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
NITROGEN GAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
TROUBLE SHOOTING GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

OIL LEAKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
GAS LEAKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
POOR OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
ACCESSORY TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
1―5
SAFETY
WARNING
Please read and make sure that you fully understand the precautions
described in this manual and the safety labels on the machine. When
operating or servicing the machine, always follow these precautions
strictly.
2ー1
SAFETY LABELS SAFETY
SAFETY LABELS
The following safety labels are used on this attachment.
• Make sure that you fully understand the location and content of each safety label, together with the means of
avoiding the danger shown.
• To ensure that the contents of safety labels can be read properly, be sure that they are in the correct place and
always keep them clean. When cleaning the labels, do not use organic solvents or gasoline.
They may cause the labels to peel off.
• If the labels are damaged, lost, or cannot be read properly, contact your Komatsu distributor immediately
regarding their replacement. For details concerning the part numbers for the labels, see this manual or the
actual label.
• There are also other labels on the attachment addition to the safety labels. Handle those labels in the same way.
2ー2
SAFETY SAFETY LABELS
POSITION FOR HYDRAULIC BREAKER SAFETY LABEL

2PC Top Type Bracket
JTHB08-3 〜 50-3 JTHB60-3 〜 120-3
Box Type Bracke

JTHB08-3 〜 50-3 JTHB60-3 〜 450-3
SAFETY LABELS
(1) Caution for operation, inspection and Warning!
maintenance
(BT137317190) JTHB08-3 〜 50-3
(BT137317195) JTHB60-3 〜 450-3
Read manual before operation,

maintenance, disassembly,
assembly and transportation.
2ー3
SAFETY LABELS SAFETY
(2) Caution for high-temperature

Sign indicates a burn hazard from
hydraulic oil and chisel
touching heated parts, such as
(BT137317192) JTHB08-3 〜 50-3
hose, chisel during or right after
(BT137317197) JTHB60-3 〜 450-3
operation.
Never touch when hot.
(3) Caution for frying objects

Sign indicates an impact hazard
(BT137317193) JTHB08-3 〜 50-3
from flying objects.
(BT137317198) JTHB60-3 〜 450-3
Keep away from machine when it

is operating.
(4) Prohibited to lift a load with a

Sign indicates hazard of a falling
hydraulic breaker
load.
(BT137317194) JTHB08-3 〜 50-3
(BT137317199) JTHB60-3 〜 450-3
Never lift a load with hydraulic

breaker.
2ー4
SAFETY SAFETY LABELS
Caution for High Pressure GAS
(5) Caution for N2 gas in the hydraulic Sign indicates an explosion

breaker hazard.
(BT137317191) JTHB08-3 〜 50-3 Never drill, cut with gas, hit or
(BT137317196) JTHB60-3 〜 450-3 disassemble. Also, keep open
flame away.
2ー5
BEFORE READING THIS MANUAL SAFETY
GENERAL PRECAUTION FOR SAFETY
WARNING
When operating the hydraulic breaker, read the
instruction manual for the hydraulic excavator and
obey the safety requirements.
WARNING
• Only trained and authorized personnel can operate and maintain the machine and the Hydraulic Breaker.
• Follow all safety rules, precautions and instructions when operating or performing maintenance on the
machine and Hydraulic Breaker.
• Do not operate and repair the machine and Hydraulic Breaker when you are under the influence of alcohol or
medication.
• When working with another operator or with a person on worksite traffic duty, be sure that all personnel
understand all hand signals that are to be used.
2ー6
SAFETY SAFETY INFORMATION
WORKING WEAR AND PERSONAL PROTECTIVE ITEMS

• Do not wear loose clothing and accessories. There is a hazard that they may catch on control levers or other
protruding parts.
• If you have long hair and it hangs out from your hard hat,
there is a hazard that it may get caught up in the machine
and the Hydraulic Breaker, so tie your hair up and be careful
not to let it get caught.
• Always wear a hardhat and safety shoes. If the nature of the
work requires it, wear safety glasses, mask, gloves, earplugs,
and safety belt when operating or maintaining the machine
and the Hydraulic Breaker.
• Check that all protective equipment functions properly before
using it.
FALLING OBJECTS, FLYING OBJECTS AND INTRUDING

OBJECTS PREVENTION
On jobsites where there is a hazard that falling objects, flying
objects, or intruding objects may hit or enter the operator's cab,
consider the operating conditions and install the necessary
guards to protect the operator.
When carrying out demolition or breaker operations, install a
front guard and use a laminated coating sheet on the front
glass.
• When working in mines or quarries where there is a hazard
of falling rock, install FOPS (Falling Objects Protective
Structure) and a front guard, and use a laminated coating
sheet on the front glass.
• When carrying out the above operations, always close the
front window. In addition, always ensure that by standers are
a safe distance away and are not in hazard from falling or
flying objects.
• The above recommendations assume that the conditions
are for standard operations, but it may be necessary to add
additional guards according to the operating conditions on the
jobsite.
Always contact your Komatsu distributor for advice.
2ー7
GENERAL PRECAUTIONS FOR SAFETY SAFETY
PROTECTION AGAINST FALLING OR FLYING OBJECTS

• When operating a hydraulic breaker, install a front guard on the windscreen. Also place a laminate coating sheet
over the windscreen.
• For work in mines, tunnel or other places where there is a danger of falling rocks, fit a FOPS (falling object
protective structure). Also place a laminate coating sheet over the windscreen.
• When operating a hydraulic breaker, make sure that you close the front window.
• During operation, make sure all personnel are out of range of materials which may fly up.
TOP GUARD
FOPS (FALLING OBJECTS
PROTECTION STRUCTURE)
FRONT GUARD
LAMINATE COATING SHEET

FOPS
CHECKS FOR HYDRAULIC PIPING

• When piping, a cap of the hose and an adapter should be always cleaned. Take off mud and sand if found.
Dust and foreign material in the pipes may cause a serious problem to the hydraulic breaker, hydraulic
component of the machine and hydraulic equipment. These pipes should be cleaned up to keep a good
operation.
• After finishing the piping, confirm no leakage of oil and no interference.
• For details of the removal or installation operation, please consult with your Komatsu distributor.
DO NOT DISASSEMBLE
• The hydraulic breaker contains a high volume of pressurized nitrogen gas. It can therefore be dangerous if the
breaker is not dismantled correctly. As a result, if the breaker needs service, please contact Komatsu or an
authorized distributor/ service depot.
2ー8
SAFETY GENERAL PRECAUTIONS FOR SAFETY
UNAUTHORIZED MODIFICATION
• Non-approved modifications can cause injury and damage.
• Consult your Komatsu dealer for advice before making any modifications. Komatsu will not accept responsibility
for any injury or damage caused by any unauthorized modifications.
WARNING – HIGH TEMPERATURE OIL

Do not remove the hydraulic hose immediately after stopping the hydraulic breaker. The oil reaches a very high
temperature during operation and may possibly cause burns. Remove hose only when the temperature has
dropped.
WARNING – HIGH PRESSURE OIL

The oil pressure in the hydraulic circuit remains high immediately after the hydraulic breaker has been stopped.
The oil may spurt out from the hose cap when the hose is removed. Remove the hose only after switching off the
engine of the excavator and releasing the pressure in the hydraulic hose.
WARNING - HIGH PRESSURE GAS

The high pressure nitrogen gas is charged in the hydraulic breaker. It may cause injury if disassembly process is
mistaken. Contact Komatsu distributor in case of trouble.
USE SUITABLE TOOLS

It is very dangerous to use worn and broken tools and to misuse tools. Use the proper tools for maintenance.
POSITION THE HYDRAULIC BREAKER

Position the hydraulic breaker in a stable and flat place so as to prevent it from over turning.
2ー9
SAFETY INFORMATION SAFETY
Safety operation
WARNING
When working on embankments or near excavated
ditches, there is a hazard that the weight and
vibration of the machine will cause the soil to
collapse. Before starting operations, take steps to
ensure that the ground is safe and to prevent the
machine from rolling over or falling.
WARNING
When working on the structure, it may happen
collapse of floor. Check the strengthen of floor
before operation.
Reinforce the floor if it's necessary.
WARNING
Do not raise up too high.
It may cause damage of excavator or falling
accident when excavator becomes unbalance after
breaking an object.
WARNING
Do not lift materials with the breaker.
This may cause damage to the breaker and
breaker bracket and is a dangerous maneuver.
2 ー 10
SAFETY SAFETY INFORMATION
IF ABNORMALITIES ARE FOUND

• If you find any abnormality in the machine during operation or maintenance (noise, vibration, smell, incorrect
gauges, smoke, oil leakage, etc., or any abnormal display onth e warning devices or monitor), report to the
person in charge and have the necessary action taken. Do not operate the machine until the abnormality has
been corrected.
DISTANCE TO HIGH VOLTAGE CABLES

Do not travel or operate the machine near electric cables.
There is a hazard of electric shock, which may cause serious
injury or property damage. On jobsites where the machine may
go close to electric cables, always do as follows.
• Before starting work near electric cables, inform the local
power company of the work to be performed, and ask them to
take the necessary action.
• Even going close to high-voltage cables can cause electric

shock, which may cause serious burns or even death. Always Voltage of Cables Safety Distance
maintain a safe distance (see the table on the right) between 100 V - 200 V Over 2 m (7 ft)
themachine and the electric cable. Check with the local power
6,600 V Over 2 m (7 ft)
company about safe operating procedure before starting
operations. 22,000 V Over 3 m (10 ft)
• To prepare for any possible emergencies, wear rubber shoes
66,000 V Over 4 m (14 ft)
and gloves. Lay a rubber sheet on top of the seat, and be
careful not to touch the chassis with any exposed part of your 154,000 V Over 5 m (17 ft)
body.
187,000 V Over 6 m (20 ft)
• Use a signalman to give warning if the machine approaches
too close to the electric cables. 275,000 V Over 7 m (23 ft)
• When carrying out operations near high voltage cables, do 500,000 V Over 11 m (36 ft)
not let anyone near the machine.
• If the machine should come too close or touch the electric cable, to prevent electric shock, the operator should
not leave the operator's compartment until it has been confirmed that the electricity has been shut off.Also, do
not let anyone near the machine.
2 ー 11
SAFETY INFORMATION SAFETY
SAFETY AT JOBSITE
Before starting operations, thoroughly check the area for any unusual conditions that could be dangerous.
• When carrying out operations near combustible materials such as thatched roofs, dry leaves or dry grass,
thereis a hazard of fire, so be careful when operating.
• Check the terrain and condition of the ground at the worksite, and determine the safest method of operation.
Donot operate where there is a hazard of landslides or falling rocks.
• If water lines, gas lines, or high-voltage electrical lines may beburied
under the worksite, contact each utility and identify their locations.
Be careful not to sever or damage any of these lines.
• Take action to prevent unauthorized people from approaching the
jobsite.
When working on public roads, position flagmen and erectbarriers
to ensure the safety of passing traffic and pedestrians.
• When traveling or operating in shallow water or on soft ground,
check the shape and condition of the bedrock, and the depth and
speed of flow of the water before starting operations.
FIRE PREVENTION AND EXPLOSION PREVENTION

• Fire caused by fuel or oil
Fuel, oil, antifreeze, and window washer liquid are particularly
flammable and can be hazardous. To prevent fire, always observe
the following:
• Do not smoke or use any flame near fuel or oil.
• Stop the engine before refueling.
• Do not leave the machine while adding fuel or oil.
• Tighten all fuel and oil caps securely.
• Do not spill fuel on overheated surfaces or on parts of the
electrical system.
• Use well-ventilated areas for adding or storing oil and fuel.
• Keep oil and fuel in the determined place and do not allow
unauthorized persons to enter.
• After adding fuel or oil, wipe up any spilled fuel or oil.
• When carrying out grinding or welding work on the chassis, move
any flammable materials to a safe place before starting.
• When washing parts with oil, use a non-flammable oil. Diesel oil
and gasoline may catch fire, so do not use them.
• Put greasy rags and other flammable materials into a safe container to maintain safety at the work place.
• Do not weld or use a cutting torch to cut any pipes or tubes that contain flammable liquids.
• Fire caused by accumulation of flammable material.
Remove any dry leaves, chips, pieces of paper, dust, or any other flammable materials accumulated or affixed
around the engine, exhaust manifold, muffler, or battery, or inside the undercovers.
2 ー 12
SAFETY PRECAUTION FOR MAINTENANCE
NOISE
When carrying out maintenance of the breaker and you are exposed to noise for long periods of time, wear ear
covers or ear plugs while working.
If the noise from the machine is too loud, it may cause temporary or permanent hearing problems.
PRECAUTION FOR MAINTENANCE

CAUTION
The hydraulic breaker is an attachment for the hydraulic excavator. Before maintaining the hydraulic breaker,
read and understand the manual for the hydraulic excavator.
Always wear protection such as hard hat, safety glasses, safety shoes and mask, and gloves. When tightening
the bolt and nut by an impact spanner, debris of metal may fly out or be scattered. It may cause serious injury
for eyes.
When you leave an abnormal on the hydraulic breaker, it may cause serious injury. Repair immediately when
an abnormal is found.
• Carry out a flat and solid ground surface.

• When the operation is carried out by two or more workers, choose the leader and follow leaders instructions.
• A crane should be used for handling heavy material (over 25 kg)
When using a crane, make sure that the material is well balanced.
Do not work on materials that are being lifted. Put them on a worktable.
• When assembling and disassembling the hydraulic breaker, make sure that the breaker is balanced.
• Never remain under material which is being lifted by crane.
• Keep away from material.
CAUTION
Do not carry out when the hydraulic oil temperature is
high. After operating the breaker many parts are still hot.
If the hose is removed immediately, it may cause serious
burn injury.
2 ー 13
PRECAUTION FOR MAINTENANCE SAFETY
CAUTION
Before starting maintenance, stop the hydraulic excavator engine and release the internal pressure. Do not
remove the hydraulic hose immediately after stopping the breaker. The high pressure oil may splash.
Use appropriate tools for maintenance. It may cause serious accident when using damaged tool, or using
improperly method a tool.
Put stable position and condition when the hydraulic breaker is removed.
Do not touch the chisel right after operating the hydraulic breaker. The chisel becomes hot during operation. It
may cause burn injury.
When removing or inserting pins, be extremely careful not to get your fingers caught. Never insert your fingers
into the pin holes when aligning the holes. It may cause serious finger injury.
Use only nitrogen gas for the breaker. The explosion accident will be caused when another type of gas is
charged into the hydraulic breaker.
When filling nitrogen gas, the chisel may suddenly come out. Therefore, keep away from the chisel when
refilling with nitrogen gas
2 ー 14
SAFETY LIFTING BREAKER
TRANSPORTATION
When transporting the breaker, observe all related laws and regulations, and be careful to assure safety.
TRANSPORTATION PROCEDURE
Select the method of transportation to match the weight and dimensions given in "SPECIFICATIONS.
LIFTING BREAKER
CAUTION
• The operator carrying out the lifting operation using a crane must be a properly qualified crane operator.
• Never raise the breaker with any worker on it.
• Always make sure that the wire rope is of ample strength for the weight of this breaker.
• When lifting, keep the breaker horizontal.
• Never enter the area under or around a raised machine.
• Never try to lift the breaker in any posture other than the posture given in the procedure below or using lifting
equipment other than in the procedure below. There is a hazard that the breaker may lose its balance.
2 ー 15
OPERATION
3ー1
SPECIFICATIONS OPERATION
SPECIFICATIONS
20-3 30-3 40-3 60-3
MODEL JTHB 08-3 10-3 50-3
(20S-3) (30S-3) (40S-3) (60S-3)
Side Mount
kg 56 75 95 165 220 295 400
Bracket
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
φ95
Chisel diameter mm φ40 φ45 φ50 φ58 φ64 φ75
(φ75)
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)
0.8
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)
PC55MR
PC30MR PC60/88
Excavator model PC10MR PC18MR PC20MR PC45MR /56/
PC35MR /78US
WB9X
3ー2
OPERATION SPECIFICATIONS
120-3 210-3
MODEL JTHB 160-3 350-3 450-3
(120S-3) (210S-3)
Side Mount
kg 820 1010 1710 2500 3100
Bracket
Working Weight
Top Mount
kg 950 1240 1830 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 φ105 φ115 φ135 φ146 φ160
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 PC200
Excavator model 138US/100 PC300 PC400
/PW200 /PC270
/120
3ー3
STRUCTURE OPERATION
STRUCTURE
JTHB08-3, 10-3, 20-3 (20S-3), 30-3 (30S-3), 40-3 (40S-3), 50-3
(01) Side Bolt (13) Piston

(02) Side bolt Nut (14) Oil seal
(03) Gas Valve (15) Dust seal
(04) Cylinder Cover (16) Air Port for Air Supply
(05) Control Valve Cap (JTHB20-3(20S-3),30-3(30S-3),40-3(40S-3),50-3)
(06) Control Valve (17) Chisel holder
(07) Hose Adapter (18) Retainer Pin
(08) Cylinder (19) Retainer Pin Stopper Pin
(09) Gas seal (20) Grease Nipple
(10) Oil seal (21) Chisel holder bushing
(11) Slide ring (22) Chisel Bushing
(12) Packing bushing (23) Chisel
3ー4
OPERATION STRUCTURE
JTHB08-3, 10-3, 20-3 (20S-3), 30-3 (30S-3), 40-3 (40S-3), 50-3
(01) Gas Valve

(02) Hose Adapter IN
(03) Hose Adapter OUT
(04) Auto Lubrication Port
(JTHB20-3(20S-3),30-3(30S-3),40-3(40S-3),50-3)
(05) Air port for air Supply
(JTHB20-3(20S-3),30-3(30S-3),40-3(40S-3),50-3)
(06) Grease Nipple
3ー5
STRUCTURE OPERATION
JTHB60-3 (60S-3) 120-3(120S-3), 160-3, 210-3 (210S-3), 350-3, 450-3
(01) Side Bolt (13) Packing bushing

(02) Side bolt Nut (14) Piston
(03) Gas Valve (15) Oil seal
(04) Cylinder Cover (16) Dust seal
(05) Hose Adapter (17) Chisel holder
(06) Control Valve Box (18) Air Cap(Over JTHB120-3)
(07) Control Valve (19) Chisel holder bushing
(08) Control Valve Cap (20) Retainer Pin
(09) Cylinder (21) Retainer Pin Stopper Pin
(10) Gas seal (22) Grease Nipple
(11) Oil seal (23) Chisel Bushing
(12) Slide ring (24) Chisel
3ー6
OPERATION STRUCTURE
JTHB60-3 (60S-3) 120-3(120S-3),160-3, 210-3 (210S-3), 350-3, 450-3

6
6

(01) Gas Valve

(02) Hose Adapter IN (P)
(03) Hose Adapter OUT (T)
(04) Auto Lubrication Port (L)
(05) Low Pressure Port (R)
(06) Air port for air Supply (A)
(07) Grease Nipple (G)
(08) High Pressure Port(H)
3ー7
PIPING FOR THE HYDRAULIC BREAKER OPERATION
PIPING FOR THE HYDRAULIC BREAKER

In order to install the hydraulic breaker, piping for the hydraulic breaker is required as shown in the diagram
below.
Check whether piping for the hydraulic breaker is installed.
If piping for the hydraulic breaker is not installed, consult with our Distributor.
NOTICE: In line accumulator is required in the return line to protect hydraulic system.
(1) Stop valve (4) Lock pin

(2) Selector valve (5) Breaker circuit additional oil filter
(3) Attachment control pedal (6) Accumulator
Stop Valve
This valve (1) stops the flow of the hydraulic oil.
(a) FREE: Hydraulic oil flows.
(b) LOCK: Hydraulic oil stops.
When removing or installing attachments, set this valve to
the LOCK position.
3ー8
OPERATION GREASE AND OIL RECOMMENDATION
GREASE RECOMMENDATION
Use Komatsu genuine grease in the Recommended oil list in the operation and maintenance manual of
excavator.
Hyper White grease is recommended for the hydraulic breaker because of high antifriction and high heat resistant.
Hyper White grease (G2-TE) has a high performance.

When it is necessary to improve the lubricating ability of the grease in order to prevent squeaking of pins and
bushings, the use of G2-TE is recommended.
CAUTION
Do not use Molybdenum content grease. It will lead the hydraulic components failure of the excavator.
HYDRAULIC OIL RECOMMENDATION

CAUTION
Use Komatsu genuine oil in the Recommended oil list in the operation and maintenance manual of excavator.
HO46-HM is recommended for the Komatsu Hydraulic breaker.
Komatsu genuine oils are adjusted to maintain the reliability and durability of Komatsu construction equipment
and components.
In order to keep your machine in the best conditioner for long periods of time, it is essential to follow the
instructions in this Operation and Maintenance Manual.
3ー9
HYDRAULIC OIL TEMPERATURE
AND CONTAMINATION CONTROL OPERATION
HYDRAULIC OIL TEMPERATURE CONTROL

CAUTION
Carry out warm-up!

• Do not operate immediately after starting engine. Carry out warm-up operation.
• During 5 minutes, operate slowly the boom and arm until the hydraulic oil temperature monitor displays the
correct temperature.
Operate the breaker in the temperature range from

40 to 60 degree Celsius
If the hydraulic oil temperature becomes over 80 degree Celsius, the oil becomes low viscosity. And then it
influents the performance of hydraulic breaker, shorten the seal life and deterioration of oil. When the breaker
is operated in warm ambient temperature condition, the oil control is very important.
HYDRAULIC OIL CONTAMINATION CONTROL

CAUTION
If the hydraulic oil is contaminated, it causes operating failures not only the breaker but also the excavator. It
leads damages of internal parts. So the oil contamination control is very important.
Replace the hydraulic oil within the change interval. Clean the insides of hydraulic tank, cylinders and piping
when replacing the oil. Also check the oil condition when changing the filter elements.
3 ー 10
INSTALLATION OF THE HYDRAULIC BREAKER
OPERATION ON TO THE EXCAVATOR
INSTALLATION OF THE HYDRAULIC BREAKER ONTO THE EXCAVATOR

CAUTION
• When hammering the pin, metal chips fly off and may enter your eye causing serious injury.
Always wear a hard hat, protective goggles, safety boots, mask, gloves and other protective equipment
during operation.
• Work should be performed in a stable and flat area.
• Read the manual for the hydraulic excavator carefully and remove the attachment, which is installed on the
excavator.
CAUTION
Make sure sand or dust do not get onto the pin or bushing. If this occurs wipe it clean.
CAUTION
When alining the pin, do not put your finger or hand into the pin hole. The arm or hydraulic breaker can move
and this may lead to loosing your finger or hand.
1. Lay the hydraulic breaker in a stable and flat

area.
2. Fit the bracket bushing (1) to the inside of the

bracket.
3. Position the arm in the hole (a), then places

the link in the hole (b).
Apply grease to the bracket pins (2) and
insert them into the holes.
4. Fit the bracket rings (3), bracket ring bolts (4)

and bracket ring nuts (5) to hold the pins and
apply grease to the pin.
3 ー 11
INSTALLATION OF THE HYDRAULIC BREAKER
ON TO THE EXCAVATOR OPERATION
5. Extend the arm and boom and prepare for installation.
CAUTION
Make sure dirt or dust do not get in contact with the end
of the hose fittings and the arm (C). If dirt or dust enters
the hydraulic hoses this will contaminate the hydraulic
oil and may damage the hydraulic breaker or excavator.
6. Attach the hydraulic hose (6) to the piping on the arm of
the breaker.
CAUTION
After removing the hose plugs, make sure dirt or dust
do not get on the plugs and store them in the toolbox.
7. Open the stop valve (D).
CAUTION
Check interference and twisting the hoses. It may cause
bursting of hydraulic hose.
'
3 ー 12
OPERATION INSTALLATION OF THE CHISEL
INSTALLATION OF THE CHISEL

1. Lay the hydraulic breaker on the ground.
WANING
Use a crane (A) when installing the chisel for sizes
above JTHB60-3.
2. Apply grease to the inside of the chisel bushing (1) and
the chisel (2), and insert the chisel into the chisel holder.
3. Insert the retainer pins (3).
4. Insert the retainer pin stopper pin (4) and retainer pin
stopper plug (5) using the hammer and the chisel pin
detacher (B).
CAUTION
Make sure the retainer pin stopper plug (5) is inserted
deep into its position.
3 ー 13
REPLACEMENT OF CHISEL (1) REMOVING THE CHISEL OPERATION
REPLACEMENT OF CHISEL
WARNING
When hammering the pin, always wear protective goggles, hard hat, gloves, mask and safety boots due to
the possibility that metal chips will fly off and may enter your eye causing serious injury.
WARNING
A crane should be used for handling heavy material.
• Assembly and disassembly work should be performed in a flat area.
• A signal must be decided in advance for the work if more than two people are involved.
• Make sure that a crane is used for lifting if the material weight exceeds 25 kg.
• When dismantling heavy parts, support the part as it is removed.
• Do not work on materials that are being lifted by one means or another: put them on a work table.
When assembling and disassembling the hydraulic breaker, make sure that the breaker is well balanced.
• Never remain under the chisel which is being lifted by a crane.
Keep away from the chisel which is being lifted.
IMPORTANT
A license is required to operate a crane. Do not operate the crane without a license.
(1) REMOVING THE CHISEL

(1) Press the chisel into the hydraulic breaker using the
excavator.
During this process, make sure the area is flat and
safe.
(2) Using the hammer and chisel pin detacher, remove the
retainer pin stopper plug and retainer pin stopper pin.
For JTHB08-3, 20-3, 30-3,40-3, a spring pin is used
and they do not use a retainer pin stopper plug and
retainer pin stopper pin.)
3 ー 14
OPERATION REPLACEMENT OF CHISEL (1) REMOVING THE CHISEL
(3) From the opposite side of the retainer pin plug using
the hammer and the chisel pin detacher, remove the
retainer pin plug.
(4) Although the retainer pin possibly comes out at this

moment, put it back into the chisel holder to prevent the
chisel from falling out.
(5) Place the breaker in a horizontal position, and lay it

down on wooden blocks.
Stop the excavator engine.
(6) Place the retainer pin up from bottom using the chisel
pin detacher.
JTHB120-3,160-3,210-3,350-3 have M8 tapped holes
and the JTHB450-3 have M12 tapped holes on their
end faces. Using removal bolt, which is included in the
accessory tools, screw the bolt into the retainer pin to
pull it out.)
(7) Remove the chisel from the chisel holder.

NOTE: Use a crane when removing the chisel for size
above JTHB60-3.
3 ー 15
REPLACEMENT OF CHISEL (2) INSERTING THE CHISEL OPERATION
(2) INSERTING THE CHISEL

(1) Place the breaker on the ground and stop the engine of
the excavator.
(2) Apply a sufficient amount of grease to the chisel and

insert the chisel into the chisel holder.
NOTE: Use a crane when installing the chisel for sizes
above JTHB60.
(3) Fit the retainer pins.
(4) Insert the retainer pin stopper pin and retainer pin
stopper plug using the hammer.
(5) Assemble the retainer pin plugs using the hammer.
3 ー 16
OPERATION LUBRICATION OF CHISEL
LUBRICATION OF CHISEL
WANING
When greasing, make sure the chisel (1) is firmly pressed into the chisel holder and do not apply the grease
excessively. Otherwise, the grease will go into the top of the chisel, which could damage the dust and oil seal
installed at the lower cylinder due to its pressurization.
This would lead not only a cause for malfunction of the breaker but also contaminate the hydraulic oil and
deteriorate the pump performance.
3 ー 17
OPERATION
Apply grease to the grease nipple on the chisel holder by using a grease gun every two hours.
Number of times to
MODEL push the grease gun
(gram)
JTHB08-3
JTHB10-3 2 3 (2g 3g)
JTHB20-3 (20S-3)
JTHB30-3 (30S-3)
4 5 (4g 5g)
JTHB40-3 (40S-3)
JTHB50-3
JTHB60S-3 5 6 (5g 6g)
JTHB60-3
JTHB120-3 (120S-3)
6 7 (6g 7g)
JTHB160-3
JTHB210-3 (210S-3) 7 8 (7g 8g)
JTHB350-3 9 10 (9g 10g)
JTHB450-3 10 11 (10g 11g)
NOTICE
• Make sure the chisel is completely in contact with the piston and in the deep back position before greasing,
otherwise, grease will stay between the chisel and the piston and it could cause damage to the hammer.
• Before greasing, place chisel of the hydraulic breaker on the ground, lower the boom of the excavator and press
the chisel into the chisel holder.
Position of grease nipple

CAUTION JTHB120-3 (120S-3)
other model
JTHB210-3 (210S-3)
Do Not Use Molybdenum Content Grease.
It May Lead Excavator Pump And Other Components Failure.
3 ー 18
OPERATION INSPECTION PRIOR TO OPERATION
INSPECTION PRIOR TO OPERATION

The hydraulic breaker is an attachment to the hydraulic excavator. Read the instruction manual for the hydraulic
excavator carefully and carry out an inspection prior to operation. Also carry out the inspection and lubrication of
the hydraulic breaker.
CAUTION
Lack of inspection before operation causes damage and poor operation of the hydraulic breaker.
3 ー 19
TEST RUN OPERATION
TEST RUN
CAUTION
Carry out warm-up!

• Do not operate immediately after starting engine. Carry out warm-up operation.
WARNING
• When operating the hydraulic breaker, ensure to use the piping for the hydraulic breaker.
• If there is a ”Hydraulic Breaker Mode” on the excavator, change to the mode.
• If a piping of the excavator is set up for the hydraulic crusher, 1) the excessive hydraulic oil might be supplied
to the hydraulic breaker. 2) Wrong pedaling creates the high pressure to the low pressure piping of the
hydraulic breaker. In both cases, it could cause damage to the hydraulic breaker.
CAUTION
• After installing the hydraulic breaker to the hydraulic base
machine, always perform a test run.
• Especially when storing the breaker as shown in Fig.1, a
test run be performed to prevent seizure and oil leakage.
3 ー 20
OPERATION TEST RUN
• 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.
NOTICE
Do not maintain 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.
(2) Air removal (3) Seal recovery (4) Preparation (5) Preparation
(1) Excavator
time time time time
New unit
After the hose
More than 5 min. More than 10 min.
has been
Less than 50% At 70% Throttle
removed
Throttle 10min. 20 min.
After the
breaker has More than 10 min. More than 15 min.
been repaired
CAUTION
• 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.
3 ー 21
OPERATION OF HYDRAULIC BREAKER OPERATION
OPERATION OF HYDRAULIC BREAKER

CAUTION
• When operating the hydraulic breaker, ensure to use the piping for the hydraulic breaker.
• If there is a ”Hydraulic Breaker Mode” on the excavator, change to the mode.
• If a piping of the excavator is set up for the hydraulic crusher, 1) the excessive hydraulic oil might be supplied
to the hydraulic breaker. 2) Wrong pedaling creates the high pressure to the low pressure piping of the
hydraulic breaker. In both cases, it could cause damage to the hydraulic breaker.
• The hydraulic breaker is an attachment to the hydraulic excavator. Follow the instruction manual for the
hydraulic excavator when starting the machine.
• Set up the excavator to operate the hydraulic breaker. If there is a ”Hydraulic Breaker Mode” on the excavator,
change to the mode. Position the throttle of the excavator (engine RPM) at the mark for the hydraulic breaker.
Then, follow the excavator manual for operation.
OPERATION OF HYDRAULIC BREAKER

• Place the breaker against the object at a 90-degree angle.
CAUTION
When the angle is not 90 degree, the breaker will be
slipped. It cause the chisel breakage, seizure of bush.
Choose stable surface to beating. Avoid any excessive
force.
CAUTION
Ensure that the front part of the excavator is not raised
too high.
After the material is broken, take caution since the
balance of the excavator will become unstable.
• When operating the breaker, raise the chisel against the

object and the front portion of the excavator about 5 cm
from the ground.
CAUTION
When pushing force is not enough, it will lead shock on
the breaker and the excavator. And then it leads failures
on them.
3 ー 22
OPERATION OPERATION OF HYDRAULIC BREAKER
• When breaking up an object, which is large and hard, start,

where the rock can be easily broken.
• After striking against the same point continuously for 1

minute without the rock breaking, change to another area of
the rock.
CAUTION
When pushing force is not enough, it will lead shock on the
breaker and the excavator. And then it leads failures on
them.
• When the breaker is set to demolish an object, always set the

breaker 90 degrees to the object you are demolishing.
• During impact, prevent blank blows by using the breaker

properly.
Stop the pedal immediately when the object is broken.
• As soon as the material has broken, immediately remove

your foot from the operating pedal to stop striking the
material.
3 ー 23
PRECAUTIONS DURING OPERATION OPERATION
PRECAUTIONS DURING OPERATION

Do not use the breaker in the following manner since this will reduce the life of the breaker and may result in
reduced safety.
CAUTION
Do not operate the breaker when the cylinder on the
excavator is fully extended ( stroke-end). It is essential
to have about 5 cm of stroke in the cylinder.
Ignoring this instruction will lead to the hydraulic cylinder
being damaged.
CAUTION
Do not jiggle the chisel when it has been hammered into
the material.
This will lead to side bolt or chisel breaking or premature
wearing of the chisel bushing.
CAUTION
Make sure that you do not hit the boom with the chisel
during operation.
CAUTION
Avoid hitting the material abruptly with the chisel.
This can cause damage to the breaker, bracket, boom
and swing parts on the excavator.
3 ー 24
OPERATION PRECAUTIONS DURING OPERATION
CAUTION
Do not use the breaker to move material.
This can cause damage to the breaker, breaker bracket,
excavator boom, arm and swing parts.
CAUTION
Do not use traveling for moving the material such as
large rock.
CAUTION
Do not lift materials with the breaker.
This will cause damage to the breaker and breaker
bracket and is a dangerous maneuver.
CAUTION
When the hydraulic hose is excessively swinging, stop
operation. And then request for checking to Komatsu
distributor.
CAUTION
Do not operate the breaker under water. Do not put any
part of the breaker into water except for the chisel.
This may cause damage to the hyd. breaker and
excavator.
3 ー 25
DISMANTLING THE BREAKER OPERATION
DISMANTLING THE BREAKER

WARNING
When hitting a pin with a hammer, always wear safety goggles, hard hat, heavy-duty gloves, mask and safety
boots due to the possibility of bits of material flying off which could enter your eyes and cause serious injury.
WARNING
A crane should be used for handling heavy material.
• Assembly and disassembly work should be performed in a flat area.
• A signal must be decided in advance for the work if more than two people are involved.
• Make sure that a crane is used for lifting if the material weight exceeds 25 kg.
• When dismantling heavy parts, support the part as it is removed.
• Do not work on materials that are being lifted by one means or another: put them on a work table.
• When assembling and disassembling the hydraulic breaker, make sure that the breaker is well balanced.
• Never remain under th e chisel which is being lifted by a crane.
• Keep away from the chis el which is being lifted.
IMPORTANT
A license is required to operate a crane. Do not operate the crane without a license.
WARNING
When removing the hyd. hose, do not remove it imme diately after stopping the breaker. The hydraulic oil
will still be hot and may cause burns. Remove the hose after the hydraulic oil has had time to cool. Do not
remove the hydraulic hose immediately after stopping the breaker as on removing the hose, high pressure oil
may squirt out. Stop the engine of the excavator and remove the excess pressure in the line before removing
the hose.
3 ー 26
OPERATION DISMANTLING THE BREAKER
(1) Place the breaker near the ground and locate the top
of the arm where the stop valve can be reached.
(2) Stop the excavator engine and remove the excess

pressure in the hose.
(3) Turn the stop valve to the off position.
(4) Remove the hydraulic hose from the stop valve.
(5) Do not allow any foreign matter to enter the hose and
hose adapter.
(6) Start the excavator engine.
(7) Operate the excavator and place the hydraulic breaker

in a flat and stable place.
(8) Remove the bolt and nut from the bracket pin.
(9) Remove the 2 bracket pins.
(10) Lift the arm and remove the hydraulic breaker from the
excavator.
CAUTION
Do not touch the chisel right after operating the hydraulic breaker.
The chisel becomes very hot during operation and you may get burnt.
3 ー 27
STORAGE OF THE BREAKER (1)
STORAGE FOR ONE MONTH OPERATION
STORAGE OF THE BREAKER

When the hydraulic breaker is not being used for a long period of
time, proceed as follows:
CAUTION
When washing the breaker by high pressure water, make
sure that the water do not into chisel holder and air cap. The
penetrated water can be accumulated into inside of the breaker,
and then it causes rusts inside of the breaker.
(1) STORAGE FOR ONE MONTH

1. Place the breaker on 2 pieces of wood (A).
NOTE: Lay the breaker down so that the cylinder side is

higher than the chisel holder side.
2. Apply grease to the retainer-pin holes.
3. Remove the hex plug (1) from the chisel holder.

Spray anti-rust spray (B) onto the piston area and replace
the hex plug (1) in the chisel holder.
4. Place a canvas cover (C) over the breaker for storage.
3 ー 28
OPERATION STORAGE FOR MORE THAN ONE MONTH
(2) BREAKER STORAGE FOR MORE THAN ONE MONTH

1. Place the breaker on 2 pieces of wood (A).
Lay the breaker down so that the cylinder side is higher
than the chisel holder side.
WARNING
Use a crane (B) when removing the chisel (1) for sizes
above JTHB60.
2. Remove the chisel (1) from the breaker.
3. Remove the nitrogen gas from the cylinder cover

through the gas valve (2).
4. Loosen the hose plug (3) on the hose.

5. From the chisel holder end insert a rod (C) into the
piston and hit the rod lightly with a hammer to push it up
into the piston.
NOTE: During this procedure release any excess
nitrogen gas from the cushion chamber.
6. Mount the hose plug (3) to hose joint.
WARNING
Use a crane (B) when installing the chisel (1) for sizes
above JTHB60.
7. Apply a sufficient amount of grease to the chisel (1) and

inside of the chisel bushing (4), and insert the chisel into
the chisel holder (5).
3 ー 29
STORAGE FOR MORE THAN ONE MONTH OPERATION
8. Apply grease to the retainer-pin holes.
9. Fit the retainer pins (6).
10. Insert the retainer pin stopper pin (7) and retainer pin
stopper plug (8) using the hammer and the chisel pin
detacher (C).
CAUTION
Make sure the retainer pin stopper plug (8) is inserted
deep into its position.
11. Assemble the retainer pin plugs (9) using the hammer.
12. Use canvas sheet (D) to cover the breaker.
CAUTION
After a long period of storage, replace the gas when
using the breaker again.
3 ー 30
MAINTENANCE
AND
INSPECTION
4―1
MAINTENANCE AND INSPECTION MAINTENANCE
MAINTENANCE AND INSPECTION

WARNING
The JTHB hydraulic breaker is an attachment for a hydraulically operated excavator. All maintenance and
service personnel should carefully read the instruction manual for the hydraulically operated excavator before
carrying out maintenance and inspection of the JTHB hydraulic breaker.
WARNING
The metal chips produced when hitting a pin into a hole using a hammer may fly off and enter your eye
resulting in serious injury. Always wear a hard hat, protective goggles, safety boots, mask, gloves and other
protective equipment during operation.
4―2
MAINTENANCE TIGHTENING TORQUE SPECIFICATIONS
TIGHTENING TORQUE SPECIFICATIONS BARE BREAKER

JTHB08-3, 10-3, 20-3(20S-3), 30-3(30S-3), 40-3(40S-3), 50-3
Torque : N·m(kg·m)
20-3 30-3 40-3
MODEL JTHB 08-3 10-3 50-3
(20S-3) (30S-3) (40S-3)
HEX SIZE
24 27 32 32 32 36
(01) Side bolt nut (mm)
216 (22) 294 (30) 441 (45) 441 (45) 539 (55) 637 (65)
Torque
HEX SIZE
27 32 32 32 32 32
(02) Hose adapter (mm)
245 (25) 441 (45) 441 (45) 441 (45) 441 (45) 441 (45)
Torque
HEX SIZE
22 22 22 22 22 22
(03) Gas valve body (mm)
83 (8.5) 83 (8.5) 83 (8.5) 83 (8.5) 83 (8.5) 83 (8.5)
Torque
HEX SIZE
13 13 13 13 13 13
(04) Gas valve plug (mm)
12 (1.2) 12 (1.2) 12 (1.2) 12 (1.2) 12 (1.2) 12 (1.2)
Torque
4―3
TIGHTENING TORQUE SPECIFICATIONS MAINTENANCE

JTHB60-3(60S-3) JTHB120-3(120S-3)
120-3
MODEL JTHB 60S-3 60-3
(120S-3)
HEX SIZE(mm) 41 41 55
(01) Side bolt nut
Torque 980 (100) 980 (100) 1960 (200)
(02) Control valve box bolt
Torque 274 (28) 441 (45) 245 (25)
(03) Control valve cap bolt
Torque 274 (28) 441 (45) 245 (25)
(04) Hose adapter
Torque 441 (45) 539 (55) 441 (45)
(05) Gas valve body
Torque 83 (8.5) 83 (8.5) 83 (8.5)
(06) Gas valve plug
Torque 12 (1.2) 12 (1.2) 12 (1.2)
4―4

JTHB160-3, 210-3(210S-3), 350-3, 450-3
210-3
MODEL JTHB 160-3 350-3 450-3
(210S-3)
HEX SIZE
55 70 80 80
(01) Side bolt nut (mm)
1960 (200) 2254 (230) 3528 (360) 3528 (360)
Torque
HEX SIZE
32 32 41 46
(02) Control valve box bolt (mm)
735 (75) 735 (75) 882 (90) 1274 (130)
Torque
HEX SIZE
32 32 41 46
(03) Control valve cap bolt (mm)
735 (75) 735 (75) 882 (90) 1274 (130)
Torque
HEX SIZE
41 50 50 60
(04) Hose adapter (mm)
539 (55) 588 (60) 588 (60) 637 (65)
Torque
HEX SIZE
22 22 22 22
(05) Gas valve body (mm)
83 (8.5) 83 (8.5) 83 (8.5) 83 (8.5)
Torque
HEX SIZE
13 13 13 13
(06) Gas valve plug (mm)
12 (1.2) 12 (1.2) 12 (1.2) 12 (1.2)
Torque
4―5
TIGHTENING TORQUE SPECIFICATIONS

SIDE MOUNT BRACKET
JTHB08-3, 10-3, 20-3, 30-3, 40-3, 50-3
MODEL JTHB 08-3 10-3 20-3 30-3 40-3 50-3
HEX SIZE(mm) 24 27 27 27 27 27
(01) Hydraulic hose Torque 59~98 84~132 84~132 84~132 84~132 84~132
(6.0~10.0) (8.5~13.5) (8.5~13.5) (8.5~13.5) (8.5~13.5) (8.5~13.5)
HEX SIZE(mm) 24 27 30 30 32 36
(02) Bracket bolt nut
Torque 176 (18) 255 (26) 343 (35) 343 (35) 412 (42) 588 (60)
4―6

SIDE MOUNT BRACKET
JTHB60-3, 120-3, 160-3
MODEL JTHB 60-3 120-3 160-3
(01) Hydraulic hose Torque 128~186 128~186 128~186
(13.0~19.0) (13.0~19.0) (13.0~19.0)
(02) Port joint bolt nut Torque 108 (11) 245 (25) 108 (11)
Lock Nut - 100(11) -
HEX SIZE(mm) 19 19
(03) Bracket pin bolt / nut -
Torque 76 (8) 76 (8)
HEX SIZE(mm) 46 55
Torque 980 (100) 1372 (140)
4―7

SIDE MOUNT BRACKET
JTHB210-3, 350-3, 450-3
MODEL JTHB 210-3 350-3 450-3
(01) Hydraulic hose Torque 177~245 177~245 197~294
(18.0~25.0) (18.0~25.0) (20.0~30.0)
(02) Port joint bolt nut Torque 490 (50) 490 (50) 490 (50)
Lock Nut 200(20) 200(20) 200(20)
(03) Bracket pin bolt / nut
Torque 176 (18) 343 (35) 588 (60)
Torque 3400 (340) 4200 (428) 4200 (428)
4―8

TOP MOUNT BRACKET
JTHB08-3, 10-3, 20-3, 30-3, 40-3, 50-3
MODEL JTHB 08-3 10-3 20-3 30-3 40-3 50-3
HEX SIZE(mm) 24 27 27 27 27 27
(6.0~10.0) (8.5~13.5) (8.5~13.5) (8.5~13.5) (8.5~13.5) (8.5~13.5)
HEX SIZE(mm) 24 24 24 24 24 24
(02) High tension
Torque 190 (20) 190 (20) 190 (20) 190 (20) 190 (20) 190 (20)
bolt nut
Lock Nut - - - - - -
HEX SIZE(mm) 24 27 30 30 32 36
Torque 176 (18) 255(26) 343 (35) 343 (35) 412 (42) 588 (60)
4―9

TOP MOUNT BOX BRACKET
JTHB08-3, 10-3, 20-3, 30-3, 40-3, 50-3
MODEL JTHB 08-3 10-3 20-3 30-3 40-3 50-3
HEX SIZE(mm) 24 27 27 27 27 27
(6.0~10.0) (8.5~13.5) (8.5~13.5) (8.5~13.5) (8.5~13.5) (8.5~13.5)
(02) High tension HEX SIZE(mm) 24 24 24 24 24 24

bolt nut Torque 190 (20) 190 (20) 190 (20) 190 (20) 190 (20) 190 (20)
(03) High tension HEX SIZE(mm) 17 17 19 19 19 19

bolt nut Torque 44 (4.5) 44 (4.5) 76 (8) 76 (8) 76 (8) 76 (8)
HEX SIZE(mm) 19 24 24 24 24 24
(04) Guide bolt / Nut
Torque 76(8) 190 (20) 190 (20) 190 (20) 190 (20) 190 (20)
4―10

JTHB60-3, 120-3
MODEL JTHB 60-3 120-3
HEX SIZE(mm) 36 36
(01) Hydraulic hose Torque 128~186 128~186
(13.0~19.0) (13.0~19.0)
HEX SIZE(mm) 30 36
(02) High tension
Torque 370 (38) 650 (66)
bolt nut
Lock Nut - 300 (31)
(03) Bracket pin HEX SIZE(mm) 19

-
bolt / nut Torque 76 (8)
(04) High tension HEX SIZE(mm) 24

-
bolt nut Torque 190 (20)
(05) High tension HEX SIZE(mm) 17

-
bolt nut Torque 44 (4.5)
HEX SIZE(mm) 30 36
(06) Guide bolt / Nut Torque 370 (38) 650 (67)
Lock Nut - 300 (31)
4―11

JTHB160-3, 210-3, 350-3, 450-3
MODEL JTHB 160-3 210-3 350-3 450-3
HEX SIZE(mm) 36 41 41 50
(01) Hydraulic hose Torque 128~186 177~245 177~245 197~294
(13.0~19.0) (18.0~25.0) (18.0~25.0) (20.0~30.0)
HEX SIZE(mm) 30 36 46 60
(02) High tension
Torque 370 (38) 650 (66) 1260 (128) 2900 (295)
bolt nut
Lock Nut - 300 (31) - -
(03) Bracket pin HEX SIZE(mm) 19 24 30 36

bolt / nut Torque 76 (8) 176 (18) 343 (35) 588 (60)
(04) High tension HEX SIZE(mm) 24 24 30 30

bolt nut Torque 190 (20) 190 (20) 370 (38) 370 (38)
(05) High tension HEX SIZE(mm) 19 19 19 19

bolt nut Torque 76 (8) 76 (8) 76 (8) 76 (8)
HEX SIZE(mm) 30 36 46 46
(06) Guide bolt / Nut Torque 370 (38) 650 (67) 1260 (128) 1260 (128)
Lock Nut - 300 (31) - -
4―12
MAINTENANCE CHECK BEFORE STARTING
CHECK BEFORE STARTING

SIDE MOUNT BRACKET
Inspection Item Substance Action Period
(01) Side bolt nut Looseness Retightening Daily
(02) Control valve box bolt Looseness Retightening Daily
(03) Control valve cap bolt Looseness Retightening Daily
(04) Hose adapter Looseness Retightening Daily
(05) Hydraulic hose Looseness, damage, Oil leakage Retightening, Replace Daily
(06) Gas valve body and plug Looseness Retightening Daily
(07) High tension bolt nut Looseness, damage Retightening, Replace Daily
(08) Port joint bolt nut Looseness Retightening Daily
(09) Bracket pin bolt nut Looseness Retightening Daily
(10) Bracket bolt nut Looseness, damage Retightening, Replace Daily
(13) Guide bolt / nut abrasion, damage Repair, Replace Daily
(14) Chisel, Chisel bush abrasion, damage Replace Daily
(15) Bracket abrasion, damage, Crack Repair, Replace Daily
Hydraulic oil Level, Deterioration, Contamination Add, Replace Daily
4―13
CHECK BEFORE STARTING MAINTENANCE
TOP MOUNT BRACKET TOP MOUNT BOX BRACKET
Inspection Item Substance Action Period
(01) Side bolt nut Looseness Retightening Daily
(02) Control valve box bolt Looseness Retightening Daily
(03) Control valve cap bolt Looseness Retightening Daily
(04) Hose adapter Looseness Retightening Daily
(05) Hydraulic hose Looseness, damage, Oil leakage Retightening Daily
(06) Gas valve body and plug Looseness Retightening Daily
(07) High tension bolt nut Looseness, damage Retightening, Replace Daily
(08) Bracket pin bolt nut Looseness Retightening Daily
(09) Bracket bolt nut Looseness, damage Retightening, Replace Daily
(10) Guide bolt / nut abrasion, damage Repair, Replace Daily
(11) Chisel, Chisel bush abrasion, damage Replace Daily
(12) Bracket abrasion, damage, Crack Repair, Replace Daily
Hydraulic oil Level, Deterioration, Contamination Add, Replace Daily
4―14
MAINTENANCE MAINTENANCE AND INSPECTION
RETAINER PINS INSPECTON AND LIMIT

Inspect the retainer pins every day.
CAUTION
It is essential to change the Retainer Pin if the values are less than the serviceability limit shown in the table.
If is breaks, this will lead to damage of the hydraulic breaker and is dangerous.
1. Repair the excess bulge build-up from around the retainer pin.
2. Insert the retainer pin into the retainer pin holes.

The retainer pins have 4 surfaces that can be used so that the
wear is equally distributed.
4―15
MAINTENANCE AND INSPECTION MAINTENANCE
INSPECTION OF RETAINER PINS

Inspect the retainer pins every day.
JTHB08-3, 10-3,20-3(20S-3),30-3(30S-3),40-3
NOTE: M
easure at contact area on
chisel
Model JTHB 08-3 10-3 20-3(20S-3) 30-3(30S-3) 40-3(40S-3)
Brand-new O.D A(mm) φ16 φ18 φ20 φ24 φ26
Service ability limit O.D A(mm) φ14.5 φ16.5 φ18 φ22 φ24
JTHB50-3, 60S-3, 60-3
NOTE: M
easure at contact area
(Middle Dia.) with chisel.
Model JTHB 50-3 60S-3 60-3
Brand-new O.D A(mm) φ29.5 φ29.5 φ31.5
Service ability limit O.D A(mm) φ27.5 φ27.5 φ29.5
JTHB160-3, 210-3, 350-3, 450-3
NOTE: M
easure at contact area with chisel.
REMARK
It is essential to change the retainer pin if the
values are less than the service ability limit shown
in the table below.
120-3 210-3
Model JTHB 160-3 350-3 450-3
(120S-3) (210S-3)
Brand-new length AxB(mm) 35x70 35x70 40x80 50x160-3 55x110
Service ability limit lenght AxB(mm) 32x67 32x67 37x77 47x97 51x106
4―16
INSPECTION OF CHISEL
BUSHING WEAR
Inspect the wear of the chisel bushing every day.
1. Lay the hydraulic breaker on the ground horizontally.
2. Insert brand new chisel (1).
3. M
easure the clearance (C) between the chisel bushing (2)
and chisel (1); check whether the clearance (C) is within the
permitted values shown in the table below.
4. It is essential to change the chisel bushing if the clearance is

not within the permitted values shown in the table below.
As regards to changing the chisel bushing, please contact
Komatsu's Distributor.
20-3 30-3 40-3

Model JTHB 08-3 10-3 50-3
(20S-3) (30S-3) (40S-3)
Wear width C (mm) 4 4 4 4 4 4
120-3 210-3
Model JTHB 60S-3 60-3 160-3 350-3 450-3
(120S-3) (210S-3)
Wear width C (mm) 4 6 7 7 8 10 10
5. It is essential to change the chisel bushing if the ID is beyond the

permitted values shown in the table below.
NOTE: Measure I.D at 10 mm depth from the edge.
Measure I.D at 10 mm
depth from the edge.
20-3 30-3 40-3

Model JTHB 08-3 10-3 50-3
(20S-3) (30S-3) (40S-3)
Brand-new I.D A (mm) φ40 φ45 φ50.3 φ58 φ64 φ75
Service ability limit I.D. (mm) φ44 φ49 φ54.3 φ62 φ68 φ79
120-3 210-3
Model JTHB 60S-3 60-3 160-3 350-3 450-3
(120S-3) (210S-3)
Brand-new I.D A (mm) φ75 φ95 φ105 φ115 φ135 φ146 φ160
Service ability limit I.D. (mm) φ79 φ101 φ112 φ122 φ143 φ156 φ170
4―17
MAINTENANCE
INSPECTION OF CHISEL WEAR

Inspect the wear of the chisel every day.
1) SIDE MOUNTED TYPE BRACKET

TOP MOUNTED TYPE BRACKET
Press the chisel into the hydraulic breaker before
measuring
Model JTHB 08-3 10-3 20-3 30-3 40-3 50-3

Brand-new length A (mm) 285 290 295 346 360 490
Service ability limit length B (mm) 180 180 200 220 240 250
Model JTHB 60-3 120-3 160-3 210-3 350-3 450-3

2) BOX TYPE BRACKET

Press the chisel into the hydraulic breaker before
measuring
Model JTHB 08-3 10-3 20-3 30-3 40-3 50-3

Model JTHB 60-3 120-3 160-3 210-3 350-3 450-3

4―18
INSPECTION OF CHISEL HOLDER BUSHING WEAR

Contact your Komatsu distributor for inspection
Inspect the wear of the chisel holder bushing every 600hrs.
1. R
emove the chisel Inspection table for wear
measurement of the chisel holder bushing.
2. It is essential to change the chisel holder bushing if the

I. D. is not within the permitted values shown in the
table below.
As regards to changing the chisel holder bushing, Measure I.D at the back center.
please contact Komatsu's Distributor.
20-3 30-3 40-3

Model JTHB 08-3 10-3 50-3
(20S-3) (30S-3) (40S-3)
Brand-new I.D A (mm) φ40 (*) φ45 φ50.3 φ58 φ64 φ75
Service ability limit I.D (mm) φ41.5 (*) φ46.5 φ51.8 φ59.5 φ66 φ77
120-3 210-3
Model JTHB 60S-3 60-3 160-3 350-3 450-3
(120S-3) (210S-3)
Brand-new I.D A (mm) φ75 φ95 φ105 φ115 φ135 φ146 φ160
Service ability limit I.D (mm) φ77 φ97.5 φ108.5 φ118.5 φ139 φ151 φ165
(*) As for the JTHB08, this number would be the measurance of the CHISEL HOLDER.
NOTICE
• I n below case, make sure to change the chisel
holder bushing, even if the value of I.D is within the
serviceability limit.
• The wear on the chisel holder bushing is application
dependent.
As a general rule, the chisel holder bushing is
replaced every second time the chisel bushing is
replaced.
WEAR OF THE SHOULDER PART OF THE CHISEL HOLDER BUSHING

20-3 30-3 40-3
Model JTHB 08-3 10-3 50-3
(20S-3) (30S-3) (40S-3)
Brand-new lenght A (mm) 135 (*) 160 175 218 238 250
Service ability limit lenght B (mm) 138 (*) 163 178 221 241 253
120-3 210-3
Model JTHB 60S-3 60-3 160-3 350-3 450-3
(120S-3) (210S-3)
Brand-new lenght A (mm) 250 280 330 360 457 468 535
Service ability limit lenght B (mm) 253 283 333 363 460 471 538
(*) As for the JTHB08, this number would be the measurance of the CHISEL HOLDER.
4―19
PERIODIC MAINTENANCE MAINTENANCE
PERIODIC MAINTENANCE
It’s necessary to inspect parts periodically. Please inspect parts according to period specified as under table.
Please repair immediately when you find damage.
Inspection Items Substance Action Interval
N2 gas pressure Gas pressure Recharge 100hr
Hydrulic oil Replace

Refer oil and
Hydraulic oil filter element Replace filter element
pages 4-23
Additional filter element for breaker Replace
Periodical overhaul
Inspection Items Substance Action Interval
Gas seal Replace 600hr
Oil seal Replace 600hr
Dust seal Replace 600hr
Buffer ring Replace 600hr
O-ring Replace 600hr
Chisel holder bushing Wear, damage Replace 600hr
Piston Seizure, wear, damage Repair, Replace 600hr
Control valve Seizure, damage Repair, Replace 600hr
Packing bush Seizure, damage Repair 600hr
Every 2 years
or 4000hours,
Breaker hydraulic hoses Replace
whichever
comes sooner
4―20
MAINTENANCE SAFETY CRITICAL PARTS
SAFETY CRITICAL PARTS

For using the machine safely for an extended period of time, you must periodically replace the safety critical and
fire prevention-related parts.
Material quality of these parts can change as time passes and they are likely to wear out or deteriorate. However,
it is difficult to determine the extent of wear or deterioration at the time of periodic maintenance. Hence, it is
required to replace them with new ones regardless of their condition after a certain period of usage. This is
important to ensure that these parts maintain their full performance at all times.
Furthermore, should anything abnormal be found on any of these parts, replace it with a new one even if the
periodic replacement time for the part has not yet arrived.
If any of the hose clamps show deterioration like deformation or cracking, replace the clamps at the same time as
the hoses.
Also perform the following checks with hydraulic hoses which need to be replaced periodically. Tighten all loose
clamps and replace defective hoses, as required.
When replacing hoses, always replace O-rings, gaskets, and other such parts at the same time.
Have your Komatsu distributor replace the critical parts.
4―21
OIL FILTER ELEMENTS AND HYDRAULIC OIL
REPLACEMENT MAINTENANCE
OIL FILTER ELEMENTS AND HYDRAULIC OIL

REPLACEMENT
WARNING
• The parts and oil are at high temperature immediately after the engine is stopped, and may cause burns.
Wait for the temperature to go down before starting the work.
• When removing the oil filler cap, turn it slowly to release the internal pressure, then remove it.
• Use komatsu genuine oil and filter elements

• Do not mix different type of oil. Change all quantity of oil when changing oil type. (small quantity in the tube does
not cause problem)
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC OIL

• Oil is used in the engine and hydraulic equipment under extremely severe conditions (high temperature, high
pressure), and deteriorates with use.
Always use oil that matches the grade and maximum and minimum ambient temperatures recommended in the
Operation and Maintenance Manual. Even if the oil is not dirty, always change the oil at the specified interval.
• Oil corresponds to blood in the human body, always be careful when handling it to prevent any impurities (water,
metal particles, dirt, etc.) from getting in.
The majority of problems with the machine are caused by the entry of such impurities.
Take particular care not to let any impurities get in when storing or adding oil.
• Never mix oils of different grades or brands.
• Always add the specified amount of oil.
Having too much oil or too little oil are both causes of problems.
• If the oil in the work equipment is not clear, there is probably water or air getting into the circuit. In such cases,
please contact your Komatsu distributor.
• When changing the oil, always replace the related filters at the same time.
• We recommend you have an analysis made of the oil periodically to check the condition of the machine. For
those who wish to use this service, please contact your Komatsu distributor.
• When using commercially available oil, it may be necessary to reduce the oil change interval.
We recommend that you use the Komatsu oil clinic to carry out a detailed checks of the characteristics of the
oil.
4―22
MAINTENANCE HYDRAULIC OIL / OIL FILTER ELEMENTS
HYDRAULIC OIL / OIL FILTER ELEMENTS

WARNING
Various parts will be very hot after operation of the engine. Do not change the filter element immediately.
Change the element after the hydraulic oil and various parts have cooled off.
If the machine is equipped with a hydraulic breaker, the hydraulic oil will deteriorate much faster than during
normal bucket operations.
It must be changed by shorter period than normal operation (with bucket), otherwise you may have big problem in
hydraulic components.
• Replace Hydraulic oil and Element in accordance with the table below:
Breaker
Eco White element Paper element
operation Item
(after PC200-7) (before PC200-6)
ratio
Hydraulic oil 1000 600

100% Hydraulic oil filter element 250 100
Additional filter element for breaker 250 250
Bucket Hydraulic oil filter element 1000 500
Additional filter element for breaker Unnecessary Unnecessary
Remark:
Breaker operation ratio 100% means the machine equipped the hydraulic breaker all time.
Breaker operation ratio 50% means the machine equipped the breaker a half of operation.
(ex. Other 50% is bucket equipped)
4―23
NITROGEN GAS MAINTENANCE
NITROGEN GAS
WARNING
Do not use any other gas except nitrogen.
WARNING
When filling nitrogen gas, the chisel may suddenly come out. Therefore, keep away from the chisel when
refilling with nitrogen gas.
Nitrogen gas is contained inside the cylinder cover of the hydraulic breaker.The impact force will decrease if the
gas pressure reduces. Check the gas pressure after every 100 hours of operation. If the gas pressure is low, fill
the cushion chamber with nitrogen gas according to the following procedures.
CHECKING THE GAS PRESSURE

1. Place the hydr aulic breaker ab out 30 ~50 cm from the ground in
a horizontal position and place wooden block underneath of the
breaker.
2. Remove the gas valve plug (1) from the cylinder cover (2).
3. Insert a pressure gauge (A) into the valve and measure the
nitrogen gas pressure.
4―24
MAINTENANCE NITROGEN GAS
NITROGEN GAS CHARGING PRESSURE IN A CORRELATION

WITH ATMOSPHERIC TEMPERATURE
Y = Nitrogen gas pressure
X = Atmospheric temperature
a = JTHB120-3 and 210-3
b = Other JTHB breakers
REFILLING THE NITROGEN GAS

1. Fit a pressure regulator (1) and hose (2) onto the nitrogen gas
cylinder (3).
2. Fit a filling adapter (4) to the end of the hose and insert the
adapter into the gas valve.
3. Open the regulator valve (1) of the nitrogen gas cylinder (3).
4. Turn the handle of the pressure regulator while reading
thepressure gauge of the regulator. Fill with nitrogen gas up to
the pressure shown in the table.
4―25
NITROGEN GAS MAINTENANCE
5. Stop turning the handle after the gas pressure reaches the
correct value shown in the table and keep it there for about 10
seconds.
6. Close the regulator valve (1) of the nitrogen gas cylinder (3).
7. Remove the adapter inserted in the gas valve.
8. Insert a pressure gauge (5) into the gas valve and check the gas
pressure.
9. Adjust the gas pressure down to the correct value using the
nitrogen gas pressure gauge if the gas pressure value is higher
than the correct value shown in the table.
10. Fit the plug (6) onto the gas valve and tighten it to the prescribed
torque value.
11. Remove the hose (2) and the pressure regulator (1) attached to
the nitrogen gas cylinder (3) and store them in the tool box.
Parts for measuring the nitrogen gas pressure and for gas filling are available from Komatsu's Distributor.
4―26
TROUBLE SHOOTING GUIDE
5ー1
OIL LEAKAGE TROUBLE SHOOTING GUIDE
TROUBLE SHOOTING GUIDE

(1) OIL LEAKAGE
By referring to the following chart, when oil leakage occurs, investigate the cause and repair accordingly. After
fitting the hydraulic breaker on the excavator, sometimes you may see oil ooze from the breaker. This is grease,
which is used in assembly and may continue for up to 5 hours, but will stop eventually. But please note, oil
coming from section A (See sketch) between the chisel and chisel bushing, this oil is for lubrication purposes and
is normal.
5ー2
TROUBLE SHOOTING GUIDE OIL LEAKAGE
JTHB08-3, 10-3, 20-3 (20S-3), 30-3 (30S-3), 40-3 (40S-3), 50-3
Oil leakage from Cause Action
Between the chisel and

A Wear or damage of oil seal (Replace)
chisel bushing
Wearing of O-ring or back up ring. (Replace)

Between the cylinder
B
cover and cylinder. Retighten the side bolt nut to
Loosing of the side bolt nut
the specified torque.
Wearing of O-ring. (Replace)

Between the cylinder and
C
the choke plug Retighten the choke to the
Loosening of the choke plug.
specified torque.

D
hose adapter Retighten the hose adapter to
Loosening of hose adapter
• ():Always contact your Komatsu distributor when dealing with these items.
• In cases of problem or causes which are not listed above, contact your Komatsu distributor for repairs.
5ー3
OIL LEAKAGE TROUBLE SHOOTING GUIDE
JTHB60S-3, 60-3, 120-3 (120S-3), 160-3

JTHB210-3 (210S-3), 350-3, 450-3
Oil leakage from Cause Action
Between the chisel and

A Wear or damage of oil seal (Replace)
chisel bushing

Between the cylinder
B
cover and cylinder. Retighten the side bolt nut to
Loosing of the side bolt nut

C
the control valve box Loosing of the bolts on the control Retighten the bolts to the
valve box specified torque.
Between the control valve Wearing of O-ring or back up ring. (Replace)

D box and the control valve
Loosing of the bolts on the control Retighten the bolts to the
cap
valve cap specified torque.

E
hose adapter Retighten the hose adapter to
Loosening of hose adapter
5ー4
TROUBLE SHOOTING GUIDE GAS LEAKAGE
(2) GAS LEAKAGE

It is abnormal for the nitrogen gas to leak more than 0.3MPa per 100 hours. Check the areas as shown in the
chart for repairs.
NOTE: In this case it is necessary to disassemble the hydraulic breaker in order to perform repairs.
Please contact Komatsu’s Distributor.
JTHB08-3, 10-3, 20-3 (20S-3), 30-3 (30S-3), 40-3 (40S-3), 50-3
*
+
JTHB60S-3, 60-3, 120-3 (120S-3), 160-3

JTHB210-3 (210S-3), 350-3, 450-3
Sym Area of gas leakage Cause Countermeasure
F Gas leakage from Gas valve plug. Wear or damage of O-ring. (Replace)
G Gas leakage from Gas valve body. Damage of the gas valve piston. (Replace gas valve)
Gas leakage from between the

H Wear or damage of O-ring. (Replace)
cylinder and the cylinder cover.
Wear or damage of the O-ring (Replace)
Wear or damage of the gas seal. (Replace)

If gas leakage cannot be
I
found from the above areas. Wear or damage of the O-ring. (Replace)
Seizure of piston and packing bushing. (Replace or repair)
5ー5
POOR OPERATION TROUBLE SHOOTING GUIDE
(3) POOR OPERATION OF BREAKER

Phenomenon Cause Action
Temperature of the hydraulic oil is too low Warm up the hydraulic excavator
Stop valve is closed Open the stop valve
Inversion the hose In and Out Set correct direction
The pedal stopper is not Breaker position. Set the pedal on Breaker position
Does not Impact
The nitrogen gas pressure in the cushion (Adjust nitrogen gas to the correct
chamber is out of spec pressure)
Oil pressure is too low (Adjust oil pressure)
Oil flow is out of specification (Adjust oil pressure)
Lack of down force on the chisel Raise the excavator front 5cm
Operation mode is not Breaker (B) mode Set to Breaker (B) mode
Erratic Blows
(At the beginning breaker The nitrogen gas pressure in the cushion (Adjust nitrogen gas to the correct
operates normally, but chamber is out of spec pressure)
later blows are erratic)
Lack of Power
Lack of hydraulic oil Add hydraulic oil
Lack of Engine power Adjust fuel dial
Back pressure is too high because of

(repair clogging)
clogging inside piping
Lack of Blows
5ー6
ACCESSORY TOOLS
6―1
ACCESSORY TOOLS
ACCESSORY TOOLS
No Model JTHB 08-3 10-3 20-3
Description Size Part Code Qt Size Part Code Qt Size Part Code Qt
1 Spanner 22mm BT134005122 1 27mm BT134005127 1 27mm BT134005127 1
2 Spanner 24mm BT134005124 1 32mm BT134005132 1 (30mm) BT134005130 (1)
3 Spanner 27mm BT134005127 1 - 32mm BT134005132 1
4 Impact Spanner - - -
5 Monkey Wrench 200mm BT134006200 1 200mm BT134006200 1 200mm BT134006200 1
6 Hammer #1 BT133906001 1 #1 BT133906001 1 #1 BT133906001 1
7 Hexagon Wrench 8mm BT134001008 1 8mm BT134001008 1 8mm BT134001008 1
8 Eyebolt M8 BT131601008 2 M8 BT131601008 2 M8 BT131601008 2
9 Eyebolt - - -
10 Hex Bolt - - -
11 Chisel pin remover 7mm BT415057820 1 7mm BT415105820 1 9.5mm BT415111820 1
12 Retainer pin - - -
Stopper plug
13 Charging Adapter BTA01016040 1 BTA01016040 1 BTA01016040 1

KIT
14 Seal Tape BT137509001 1 BT137509001 1 BT137509001 1
15 Tool Box BT137507350 1 BT137507350 1 BT137507350 1
＊1 Tools in the parentheses are not supplied for Box Type Bracket.
＊2 Tools in the □ are only for Box Type Bracket.
6―2
ACCESSORY TOOLS
No Model JTHB 30-3 40-3 50-3

Description Size Part Code Qt Size Part Code Qt Size Part Code Qt
1 Spanner 27mm BT134005127 1 27mm BT134005127 1 27mm BT134005127 1
2 Spanner (30mm) BT134005130 (1) 32mm BT134005132 1 32mm BT134005132 1
3 Spanner 32mm BT134005132 1 - 36mm BT134005136 1
4 Impact Spanner - - -
5 Monkey Wrench 200mm BT134006200 1 200mm BT134006200 1 200mm BT134006200 1
6 Hammer #1 BT133906001 1 #1 BT133906001 1 #1 BT133906001 1
7 Hexagon Wrench 8mm BT134001008 1 8mm BT134001008 1 10mm BT134001010 1
8 Eyebolt M12 BT131601012 2 M12 BT131601012 2 M12 BT131601012 2
9 Eyebolt M8 BT131601008 1 M8 BT131601008 1 -
10 Hex Bolt - - -
11 Chisel pin remover 9.5mm BT415111820 1 9.5mm BT415111820 1 9.5mm BT415118820 1
12 Retainer pin - - BT136402012 1

Stopper plug
13 Charging Adapter BTA01016040 1 BTA01016040 1 BTA01016040 1

KIT
14 Seal Tape BT137509001 1 BT137509001 1 BT137509001 1
15 Tool Box BT137507350 1 BT137507350 1 BT137507350 1
6―3
ACCESSORY TOOLS
No Model JTHB 60-3 120-3

Description Size Part Code Qt Size Part Code Qt
1 Spanner 36mm BT134005136 1 19mm BT134005119 1
3 Spanner - 41mm BT134005141 1
4 Impact Spanner 41mm BT134010041 1 55mm BT134010055 1
5 Impact Spanner (46mm) BT134010046 (1) -
6 Ring Spanner 27mm BT134011027 1 27mm BT134011027 1
7 Monkey Wrench 200mm BT134006200 1 250mm BT134006250 1
8 Hammer #1 BT133906001 1 #2 BT133906002 1
9 Hexagon Wrench - -
10 Eyebolt M12 BT131601012 2 M20 BT131601020 2
11 Hex Bolt M8 BT131608340 2 M8 BT131608350 2
12 Chisel pin remover 9.5mm BT415118820 1 15.8mm BT415131820 1
13 Retainer pin BT136402012 1 BT136402011 1

Stopper plug
14 Charging Adapter BTA01016040 1 BTA01016040 1

KIT
15 Seal Tape BT137509001 1 BT137509001 1
16 Foundation Bolt - -
17 Tool Box BT137507350 1 BT137507531 1
6―4
ACCESSORY TOOLS

1 HEX Wrench 22mm BT134001022 1
3 Spanner 30mm BT134005130 1
4 Ring Spanner 32mm BT134011032 1 32mm BT134011032 1
5 Spanner 36mm BT134005136 1
6 Spanner
8 Spanner 46mm BT134005146 1
10 Impact Spanner - 70mm BT134010070 1
11 Impact Spanner 55mm BT134010055 1 75mm BT134010075 (1)
12 Socket - -
14 Hammer #2 BT133906002 1 #2 BT133906002 1
15 Eyebolt M20 BT131601020 2 M20 BT131601020 2
16 Hex Bolt M10 BT131610350 2 M10 BT131610350 2

Stopper plug

KIT
20 Seal Tape BT137509001 1 BT137509001 1
21 Foundation Bolt M8-150 BT133109008 1 M8-150 BT133109008 1
22 Tool Box BT137507531 1 BT137507531 1
6―5
ACCESSORY TOOLS

4 Impact Spanner (75mm) BT134010075 (1) (75mm) BT134010075 (1)
5 Impact Spanner 80mm BT134010080 1 80mm BT134010080 1
6 Ring Spanner - 46mm BT134011046 1
7 Socket 41mm BT134008041 1 -
9 Hammer #2 BT133906002 1 #2 BT133906002 1
10 Eyebolt M24 BT131601024 2 M30 BT131601030 2
11 Hex Bolt M12 BT131612350 2 M16 BT131616370 2

Stopper plug

KIT
15 Seal Tape BT137509001 1 BT137509001 1
16 Foundation Bolt M8-150 BT133109008 1 M12-150 BT133109012 1
17 Tool Box BT137507531 1 BT137507531 1
6―6
Komatsu Hydraulic Breaker J THB08-3, 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
PEN00651-01
issued on 5 April 2013
2012 KOMATSU
All Rights Reserved
Printed in Japan
YOUR HYDRAULIC BREAKER SERIAL NUMBER AND DISTRIBUTOR
User Name
Distributor Name
Address
Tel number
Hydraulic Breaker JTHB -
Serial Number
Delivery Date / /
Excavator
Model / Type / Serial
Excavator
SMR at Delivery
Hydraulic Filter □ Eco White element □ Paper element

Element Type (ex: after PC200-7) (ex: before PC200-6)

PEN00651-01 JTHB Hydraulic Breaker Operation and Maintenance Manual

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PEN00651-01

KOMATSU HYDRAULIC BREAKER

BEFORE READING THIS MANUAL

IMPORTANT SAFETY INFORMATION

REMARKS This word is used for information that is useful to know.

- Demolition of Concrete and secondary breaking

LOCATION OF SERIAL NUMBER ON THE HYDRAULIC BREAKER

PRODUCT IDENTIFICATION NUMBER(PIN)MACHINE SERIAL NO. PLATE

SERVICE METER LOCATION

MAINTENANCE AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

TROUBLE SHOOTING GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

ACCESSORY TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

POSITION FOR HYDRAULIC BREAKER SAFETY LABEL

Box Type Bracke

Read manual before operation,

(2) Caution for high-temperature

Never touch when hot.

(3) Caution for frying objects

Keep away from machine when it

(4) Prohibited to lift a load with a

Never lift a load with hydraulic

Caution for High Pressure GAS

(5) Caution for N2 gas in the hydraulic Sign indicates an explosion

GENERAL PRECAUTION FOR SAFETY

WORKING WEAR AND PERSONAL PROTECTIVE ITEMS

FALLING OBJECTS, FLYING OBJECTS AND INTRUDING

PROTECTION AGAINST FALLING OR FLYING OBJECTS

LAMINATE COATING SHEET

CHECKS FOR HYDRAULIC PIPING

WARNING – HIGH TEMPERATURE OIL

WARNING – HIGH PRESSURE OIL

WARNING - HIGH PRESSURE GAS

USE SUITABLE TOOLS

POSITION THE HYDRAULIC BREAKER

IF ABNORMALITIES ARE FOUND

DISTANCE TO HIGH VOLTAGE CABLES

• Even going close to high-voltage cables can cause electric

FIRE PREVENTION AND EXPLOSION PREVENTION

PRECAUTION FOR MAINTENANCE

• Carry out a flat and solid ground surface.

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 φ105 φ115 φ135 φ146 φ160

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

(01) Side Bolt (13) Piston

JTHB08-3, 10-3, 20-3 (20S-3), 30-3 (30S-3), 40-3 (40S-3), 50-3

(01) Gas Valve

JTHB60-3 (60S-3) 120-3(120S-3), 160-3, 210-3 (210S-3), 350-3, 450-3

(01) Side Bolt (13) Packing bushing

JTHB60-3 (60S-3) 120-3(120S-3),160-3, 210-3 (210S-3), 350-3, 450-3

(01) Gas Valve

PIPING FOR THE HYDRAULIC BREAKER

(1) Stop valve (4) Lock pin

Hyper White grease (G2-TE) has a high performance.

HYDRAULIC OIL RECOMMENDATION

HYDRAULIC OIL TEMPERATURE CONTROL

Carry out warm-up!

Operate the breaker in the temperature range from

HYDRAULIC OIL CONTAMINATION CONTROL

INSTALLATION OF THE HYDRAULIC BREAKER ONTO THE EXCAVATOR