Breaker_KOM_.pdf

Aftermarket Product

Komatsu Hydraulic Breaker JTHB series

Structure & Function

1

Structure

Aftermarket Product

Function

Aftermarket Product

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

Based upon Pascal’s law…

Pressure = Force / Surface Or Force => Pressure * Surface 3

Working principle - strokes

Aftermarket Product

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

4

Working principle - strokes

Aftermarket Product

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

5

Working principle - strokes

Aftermarket Product

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

6

Working principle - strokes

Aftermarket Product

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

7

Working principle - strokes

Aftermarket Product

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

8

Working principle - strokes

Aftermarket Product

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

9

Working principle - strokes

Aftermarket Product

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

10

Working principle - strokes

Aftermarket Product

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

11

Working principle - strokes

Aftermarket Product

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

12

Working principle - strokes

Aftermarket Product

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

13

Working principle - strokes

Aftermarket Product

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

14

Working principle - strokes

Aftermarket Product

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

Based upon Pascal’s law…

Pressure = Force / Surface Or Force => Pressure * Surface 15

Aftermarket Product

Komatsu Hydraulic Breaker JTHB series

Installation

16

Main hydraulic circuit on Breaker-mode Flow quantity ： 550L/min Filtration particle size： 20μm

Aftermarket Product Flow qty ： 16L/min Filtration ： 6μm

R Pump

Hydraulic oil filter

F Pump

Hydraulic oil

C / V

BREAKE R

Breaker Additional Return Filter

Flow quantity ： 200L/min Filtration particle size ： 6μm 17

Hydraulic piping & Electric circuit

Aftermarket Product

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Main hydraulic circuit on Breaker-mode

Aftermarket Product

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Delivery Service

Aftermarket Product

 Checking Accumulators

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

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Reinforcement

Aftermarket Product

 Reinforcement of work equipment of PC200-8

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

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Delivery Service

Aftermarket Product

 Check Nitrogen gas pressure

 Check gas pressure using specified gas gauge  Standard 1.1MPa (11kg/cm2)(JTHB210-3)

 Adjust the pressure by gas N2 gas charging tool

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Aftermarket Product

Special Tool

• Gas checking and charging tool for Box bracket 1

Description

Reference

Gas tool Assy

BTA01016040 Charging socket

Comment

Charging socket 9/16-18 UNF

1

Box bracket

23

Delivery Service

Aftermarket Product

 Check Safety valve pressure (ex. PC200-8)

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

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Delivery Service

Aftermarket Product

 Check Oil flow quantity of excavator (ex. PC200-8)  Specification Oil flow：160～200 L/min  Checking method 1. By Monitor (ex. After PC200-7) set 180 L/min

2. By Flow meter (ex. Before PC200-6) Measure PQ by flow meter ⇒ Set flow 160-200L/min on 1418MPa （Adjust by Fuel dial, Pedal position,）

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Aftermarket Product

PC200-８M0

03 With / Without Attachment 07 Default

With Attachment

F6 Set Flow quantity

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PQ measurement

Aftermarket Product

How to Measure P – Q by flow meter

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Aftermarket Product

Komatsu Hydraulic Breaker JTHB series

Maintenance

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Aftermarket Product

Delivery Service

 Hydraulic oil

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

Breaker ratio

100%

50 %

25 %

Bucket

Eco White element (after PC200-7)

Paper element (before PC200-6)

Hydraulic Oil

1000

600

Oil filter element

250

150

Element for breaker

250

250

Hydraulic Oil

1500

900

Oil filter element

250

150

Element for breaker

250

250

Hydraulic Oil

2000

1200

Oil filter element

500

200

Element for breaker

500

500

Hydraulic Oil

5000

2000

Oil filter element

1000

500

No

No

Item

Element for breaker

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Hydraulic oil HO46

Aftermarket Product

Aftermarket Product

Greasing Chisel

Greasing every 2 hours

GOOD

END

BAD 31

Grease

Aftermarket Product

Do not use Molybdenum content grease. It will lead the hydraulic components failure of the excavator.

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grease HYPERWHITE GREASE

Aftermarket Product

Periodical maintenance

Aftermarket Product

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Aftermarket Product

Special Tool

 Hydraulic Breaker Special Tools Description

Reference

Comment

1

Flow meter

790-303-1003

PQ checking

2

Helisert insert tool

Local Purchasing

3

Breaker Stand

Local making

Standing breaker for repairing

4

Bush tool

Local making

For pressing the bushing

(Refer to Shop manual) (Refer to Shop manual)

1

2

3

4 35

Aftermarket Product

Repair / Overhaul

 Chisel bush removing (press fitted) 1.By Hydraulic Press 100ton Press (over JTHB120-3)

2. Gas cutting

60ton Press (under JTHB60-3)

プレスでブッシュを押し出し

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Aftermarket Product

Komatsu Hydraulic Breaker JTHB series

Operation

37

Aftermarket Product

Test run

Carry out test run in cases below: - New Hydraulic breaker installed onto the excavator - Reconnect hydraulic hoses after storage or repair

Before

After

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Test run

Aftermarket Product

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

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Park position

Aftermarket Product

• keep breaker on vertical position after operation To oil leakage from piston seal

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Storage STORAGE FOR ONE MONTH

Aftermarket Product

STORAGE FOR MORE THAN ONE MONTH

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Operation Hydraulic breaker

Aftermarket Product

• Refer Operation & Maintenance Manual

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Aftermarket Product

Komatsu Hydraulic Breaker JTHB series

Service Operation

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Summary

 Warranty  Delivery Service  Periodical Visit

Aftermarket Product

 Service Manual  TSI / Claim  Damaged Parts

 Contact  Repair / Overhaul  Special Tool  Parts

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Aftermarket Product

Warranty

Warranty period

 12 month after delivery

 Parts Not Covered par warranty  1. 2. 3. 4. 5. 6. 7.

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

4 6 5 7

3

1 2

TSI, Claim

Aftermarket Product

 Caution for making TSI and Claim application

＊1： Model Type is JTHB

（correct）JTHB210-3 ＃10017

（Incorrect）PC200-8

＊2： SMR is Breaker equipped hours （Machine SMR – Breaker installed SMR) ＊3： Mention excavator information. Machine type, SMR, piping type. (in Description Column） 46

Aftermarket Product

Repair

 Standard Rate for Hydraulic Breaker  Specified Component codes and Rate.

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

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

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

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

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

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

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Aftermarket Product

Service Manuals

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

Manual

Reference

Operation and Maintenance

PEN00651-01

Parts Book

FEN02448-02

Shop Manual

SEN06343-00

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Spare Parts

Aftermarket Product

JTHB breaker parts numbers are BTxxxxxxxxxx Parts ordering is same as normal operation PWINS.

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Periodical Visit

Aftermarket Product

 Service Report

 Fill the Hydraulic Breaker Service Report  Register into EQP Care Register equipped machine data also (Machine type, SMR, Piping)

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