o Foreword

We appreciate your purchasing JISUNG hydraulic breaker.

This man ual exp lains the corree! handing methods , inspection, repair, operation, assembly and

disassembly in order to use your hydraulic breaker safely and efficiently.

Also, this manual fully i/lustrates all information you need lo achieve the best performance and minimize

down time of your hydraulic breaker.

Before using this hydraulic breaker, be sure lo read and fu/ly understand this manual.

If you do not follow this manual, a serious accident can be occurred.

AWARNING
The operator should read and fully understand this manual before installing, repalrlng or
operatlng this hydraulic breaker.
Thls manual should be kept near the hydraulic breaker, and those who use or manage the
hydraulic breaker should read It periodlcally.
When this hydraulic breaker Is transferred, this manual must be attached to the hydraullc
breaker.
If this hydraulic breaker is used carelessly, a serious accident can occur sueh as seriously
Injure or kili a persono
If thls manualls lost or damaged, please contact to our dealer In your terrltory or
JISUNG HEAVY INDUSTRIES CO., LTD.

CD .JISUNG
HEAVY INCUSTRIES ce ., L1'O .
 o Foreword
o Contents
1. Safety Information - - ------------------------------------------------------ -- 3-4

2. Specification ---------------------------------------------- 5

3. Structure and Working principie ------------------------------------------ 6 - 13

4. Installation and Removal ---------------------------------------------------- 14 - 18

4-1. Fundamental circuits
4-2. General view
4-3. Installation
4-4. Removal

5. Maintenance --------- ------------ -- -- -------------------- - ------------------- 19 - 38

5-1. Serial numbering system
5-2. Safety label
5-3. Moving and Iifting
5-4. Maintenance intervals
5-5_Hydraulic oil
5-6. Greasing
5-7. Inspection and charging of nitrogen gas
5-7-1 . Back head
5-7-2. Accumulator

5-8. Pressure setting

5-9. Seal inspection

5-10. Wear inspection

5-11 . Through bolt inspection

5-12. Torque table

5-13. Storage

6. Operation ~ ---------- ------ ---- - --- --- -- - - -- ------------------------ ------------- 39 - 44

6-1 . Tool installation
6-2. Salety operation
6-3. Function 01adjuster
6-3-1_ Cylinder adjuster

6-3-2. Valve adjuster

7. Trouble shooting ---- ------------------------------------- 4546

8. Service tools ----------------- -.------------------------------ -- ------ 47 - 49

8-1 . Standard too 1
8-2. Nitrogen gas charging kit

9. Tool selection ------------------------------------------------------------- ------ 50 - 55

9-1. Tool selection
9-2. Tool claim judgement

.JISUNG

HEAVV jNOU~IES ca . l TO .
1. Safety Information
Before operation
Many accident are caused by disregarding the basic rule of installation , operation and repair, or by

neglecting the inspection before operating.

Before operating or repairing this hydraulic breaker, be sure to read and fully understand the

preventive methods and warn ings described on the hydraulic breaker or in this manual.

Satety labels and messages are classifi ed as below so that the user may understand the warnings

on the hydraulic breaker or in th is manual.

Indicates an seriously dangerous sltuatlon which, 11 not avoided, will result In death or
serious injury.
This slgnalls to be IImlted to the most extreme sltuation.

Indicates a potentially dangerous sltuation which, 11 not avoided, could result in death or
serious injury.

Indicates a potentially dangerous situation whlch,lf not avoided, may result In minor Injury.

Slgns used to Indlcate a statement 01 company policy dlrectly or Indlrectly related to

the personnel safety or property protection.

Speclfied works
This hydraulic breaker can be used tor breaking, demolishing and drilling in mines, stone breaking or
building engineering work.

Do not use thls hydraullc breaker tor other works except the speclfled works.
Wear the protective tools for safety
Wear the clothes your body not to be caught by the projection of the base machine or
the any lever or pulled by the machine .
. Wear the helmet, safety shoes, earplug, etc. If necessary, wear a dustproof mask,
protective glasses and gloves.

- Usually clean the machine and keep a clear environment tor working .

.JISUNG
HEA\fY INCUBT'RJES CC ., LTlJ .
 Keep the cautions and take a preventive measure for safety.

Observance of safety rules in work place

- Observe all the rules, cautions and procedures lor safety when the hydraulic breaker is operated or

repaired,

- Fulfill the work according to the signals already decided when cooperative work or

work by guide is done,

Inspection for safety devices

- When the work is stopped or finished , be sure to set the safety lock of operation switch for the
hydraulic breaker,
- When the operator gets out from the base machine, be sure to put the hydraulic breaker on the ground and
stop the engine of base machine,

Be careful from the hydraulic oil pressure

- Before disconnecting or connecting hydraulic hoses, stop the engine of base machine, close stop valves
"IN" and "OUT' connection, then operate the control level to relea se pressure trapped in the hoses and
wait ten(10) minutes.

Safety from flying chips of rock during hydraullc breaker operation

- Protect yourself and your neighborhood against fl ying chips of rock.

Do not operate the hydraulic breaker or base machine if someone is too close .

- Keep the base machine's cab doors and windows closed during operation.

Window bars are recommended to protect the windows from flying chips of rock ,

.JISUNG
HEAVY INDUSTRIES CC" L.TtI.
 ~
g
(!J ~
2. Speciffcation
Z~
J~
UJ
- q
~
,~
Weight 72 150 I 220
Length mm 1,135 1,262
1,34~1,200 1,600 1,860 I 2,101 2,326 2,604 2,691
D
----!--
Required Oil Flow I/min 15-25 20-30
25-40 t 40"'70 30-45 40- 80 1 45-85 80-110 90- 120 100-150

I- - - + -
Working Pressure kg/cnf 80-110 80-110
90-120 110"'140 95-130 .130-150 130-150 I 150-170
150-170 160- 180

Tool Diameter
Impact Energy

mm
jou l
-
40
200
45

290

53
320

I
r
60

110"'1 o
68
690- r 900

75
h 85
-+----t-~-----+I-
1,300 I 2,100
I 100

4.00~4,80~
125 135

800-140 O 700-1200 600-1100

500- 900 500-900 I 400-80~00-800 I 350-700
350-650 350-600

Ji
Impact Rate bpm
Hose Diameter inch 1/2 1/2 1/2 1/2 1/2 I 1/2 3/4 3/4
I

Carrier Weight ton 0.8-2.5 1.2-3.0 2,5-4.5 3.0'" 5 4.0-7.0 I 7-10. ~7-14.0 11-16.0 15-18 18-21

- -
0)
Weight
Length

kg
mm

1,780
2,828

2,100
3,055

2,700
3,255
2,995
3,395

4,100
3,709
1,230
2,031
t 1,740
2,327 2,500 2,740
Required Oil Flow I I/min I 120-150 140-190 170-240
190-250
210-290
90-120
130-150 150-190 190-250

Working Pressure I kg/cnr I 160-180 160-180 I 160-180

160-180
160-180
160-180
160-180 160-180 160-180

Tool Diameter mm 140

150 ~ 155

165
175 120 135 150 160

Impact Energy jou l 5,200 7,000 7,500 9,000 14,500 3,200 4,500 7,000 10,000
Impact Rate bpm 350-500
300-450 300-450
250-400 200- 350 350-650 400-500 300-450 250-400

Hose Diameter inch 3/4

,
Carrier Weight ton 18-26 25- 30 28-35
30-45
l 40-55
1 13-18 L 18-26
J 27-35 I 35-50

 3. Structure and Working principie

Model : JSB10 / JSB20 / JSB30 / JSB35/ JSB40 / JSB43/ JSB45/ JSB50 / JSB60 /
JSB70 / JSB81/ JSB100 / JSB121/ JSB130 / JSB151
(lnward valve type)

Back head

1) Cyllnder
This contains the moving pistan which strikes the tool. The seals tor both ends of the piston are also
located in the cylinder. The seals for the upper end of Ihe piston are located in a removable seal
retainer while the seals tor the lower end ot the piston are located in proves machined directly into
the cylinder.

2) Plston
The piston transfers impact power to the tool] generated by hydraulic power.

.J.SUNG

HEAVY INDUEiTRliiS ce .. LTD,

3) Seal retainer
The seal retainer has 011 seals to seal Nitrogen(N2) gas in back head , and to prevent hydraulic oilleakage .

4) Valve
The valve controls reciprocates piston action with hydraulic fluid distribution.

5) Front head assembly

This retains the tool, using the tool pins.

By removing these pins, the tool can be changed.

6) Inner bush
This guides the tool, inner bush limits the uppermost position of the tooL

It is consumable parts, which shoul d be checked for wear limits. If needed, they should be replaced .

7) Tool
This transfers piston impact power to the objects.

We recommend that various tool shapes according to working circumstan ce.

8)Pin-tool
This is installed on the front head, and prevents the tool Irom coming off.

9) Back head assembly

This contai ns the cushion chamber charged with nitrogen(N2) gas that compresses during upward
strokes of the piston , and serves to provide maximum absorption 01 piston recoil, efficiency storing this
energy for the next blow.

10) Through bolts

These are used to assemble the Iront head, th e cylinder and the back head. They have to be

constantly tightened to specified torque. Inspect the bolts for loosening, and re-tighten them weekly.

o
.JISUNG
HEAVY INDUSTRIES ce " LoTO.
 1) Set Up
The relation between the area (A 1) affecting the
pressure from the upper chamber of th e piston
and the (A2) affecting the pressure from the
C2
lower chamber of th e piston s A 1 > A2 and high A3

A4 ~~P-'tY A1
pressure always applies to A2 . When A 1 change
O UT ~
from high to low press ure or vice versa, Piston 83
C1 reciprocates . Inside of back head is change
I N~
with the high pressure gas and gas energy
sto red in the up stroke of the C1 effectively acts
A2
on Ihe piston C1 during the impact.

2) Piston Conversion
When piston C1 reaches l op dead center, high
pressure oH from valve high-pressure port B3
applies lo upper chamber of the piston A 1 to
change the piston stroke from upstroke to impact.
At this time the relation between the area(A3)
affecting the pressure from valve high pressure
changes and the area(A4) of the valve change
chamber is A4>A3 . The high pressure always
applies to A4 and valve C2 remains in the upper
posilion .
e2
A3

B4

85
OUT4 A1
3) Valve Conversion
83 B1
When cylinder low pressure port 81 is connected
IN~
to cylinder change port 82 , the pressure in valve
change port 84 lowers . As force acting port C2 is 82

Ihe only pressure in valve high pressure chamber

A3, valve C2 starts lowering. During the valve
lowering stroke , valve high pressure port 83 is
closed and valve low pressure port 85 is apened
lo the lower the pressure in the upper chamber of
the piston A 1.

.JISUNG

HEAVV tNDUB'TRIE!i CQ . LTD .

4) Impact
When pistan C1 reaches impact point, kinetic
energy obtained by pistan C1 during the impact
stroke is transmitted to the tool for the impact
energy required to hydraulic breaker . At this
time, as high pressure applies only to Ihe lower
chamber of the pistan A2, pistan C1 starts
reversing. Further, as high pressure applies only
to the valve high pressure chamber A3, valve C2
is remaining in the lower position. A2

5) Piston Raise
When cylinder change port 82 is connected lo
cylinder lower pressure port 81 , high pressure ol
applies to low pressure outlet Port valve C2 time Al

valve low pressure port A 1 this time valve low

pressure port 85 is closed and valve high
pressure 83 is opened the upper chamber 01 the Bl

B2

piston A1 to rise the pressure in the lower

chamber of the piston A 1. A2

A1: Piston upper chamber 81 : Cylinder low pressure port C1 : Pistan

A2.: Piston lower chamber 82: Cylinder conversion part C2: Valve
A3: Valve high pressure chamber 83: Valve high pressure port
A4: Valve conversion chamber 64: Valve converson port
85: Valve low pressure port

 Model : JSB18G I JSB20G I JSB30G I JSB40G I JSB50G

(Outward valve type)

Frontcover

Tool

Front head

1) Cyllnder assembly
This contains the moving piston which strikes the tool. The seals for both ends of the pisto n are also
located in the cylinder, The seals for the upper end of the piston are located in a removable seal
retainer while the seals for the lower end of the piston are located in proves machined directly into the
cylinder,

2) Plston
The piston transfers impact power to the tool, generated by hydraulic power,

.JISUNB
HEAVV INDUSTRI'EB ca., LTC .
3) Seal retainer
The seal retainer has oil seals to seal Nitrogen(N2) gas in back head , and lo prevenl hydraulic oil leakage.

4) Valve housing
Th is guides Ihe main valve movement

5) Valve
The valve controls reciprocates pistan action with hydraulic fluid distribution.

6) Valve adjuster
When the base machine supplies insufficiently hyd. oil to hydraulic breaker, Ihis valve adjuster can obtain the rated
working pressure by reducing number of blows, and in the reverse, when excessive oil flow from base
machine, the increasing number of blows, by this valve adjuster can keep the rated working pressure.

7) Cylinder adjuster
Turn the setting screw clockwise lo decrease blows rale of hydraulic breaker, counterclockwise
to increase blows rate 01 hydraulic breaker.

8) Accumulatorassembly
The accumulator is a gas charged storage device designed to hold a reserve quantity of hydraulic fluid
under pressu re.
In a hydraulic circuit, minar variations or lags in pump outpul that might otherwise cause unsteady ar
irregular operation are made up from the supply of pressurized oi l in the accumulator.
Accumulators are solidly conslructed to resisl high operating pressure .

9) Front head assembly

This retains the tool, using the tool pins.
By removing these pins, the tool can be changed.

10) Inner bush

This guides the tool, inner bush limits the upper positi on of the tool.
It is consumable parts, which should be checked lor wear limits. If needed, they should be replaced.

11) Tool
This transfers pisto n impact power to the objects.
We recommend that various 1001 shapes according lo working circumstance.

12) Pln-tool
This is installed on the front head, and prevents the tool from coming off.

13) Back head assembly

This contains the cushion chamber charged with nitrogen(N2) gas Ihat compresses during upward
strokes of the pistan, and serves to provide maximum absorption of piston recoil, efficiency storing this
energy for the next blow.

14) Through bolts

These are used to assemble the front head, the cylinder and the back head. They have to be
constantly tightened to specified torque. Inspect the bolts far loosening, and re-tighten them weekly.

 1) Set Up

Chambers C3, C2 always maintain low pressure ,

Because they are connected to the output line .

Chambers V3 , V1 , C1 and accumulator always

C4
maintain high pressure, because they are

connected to the input line.

Chamber V2 pressure is changed to low pressure

e3
or high pressure depending on pistan position.

/
V2 '
/
F===
/ el
VI

2) Plston Raise
Oil enlers to "IN" port, and begins to
accumulale force to raise pistan; hydraulic force
is applied on A 1 of pistan lower flan ge, and
Piston Raise
piston begins to rai se.
When the piston begins to raise , oil !rom C4
chamber returns to the output line through the
contro l valve .

V3

C3

3) Valve Raise
e2
When pistan raises to around upper limits, A 1 of V2

pistan lower flange reaches chamber C2, and the el

Vl
back head nitrogen(N2) gas is compressed.
Al this time, oil from chamber C2 goes to
chamber V2 .
A3 area is larger than A4 area, but applied
pressure 01 area A3 is Ihe same as applied
pressure of A4.
Therefore, Ihe valve begins to raise, because of
Valve Raise
the area difference between A4 and A3 .

@
..JISUNB
HEAVV INDUSTRies ce., LTD.
4) Pistan Deseent
When the valve reaches the upper limits,
chamber C4 becomes high pressure area,
because oil from the working pump goes to C4

chamber C2 through the control valve holes.

A2 area is larger than A1 area, but pressure
CJ
applied to A4 area is the same as the pressure
applied to A1.
Therefore, the piston begins to descend, because
of the area difference between A2 and A1. lo,
C2

At this time, piston descent speed is accelerated

by compressed nitrogen(N2) gas pressure and
piston weight.

Plston Deseent

5) Impaet
Chamber V2 is changed in low pressure as
C4
chamber C2 s connected with C3 du ri ng pisten V3

descent. But V3 is always high pressure.

Therefore, the valve begins to descend.
C3

r~~~ C;rL-f-':';:J-- ! - C2
6) Contlnuous Strlke V2 .

After the pisten strikes the tool, the status of all I

-,
circuits are changed to "Piston Raising". CI

The pisto n begins to raise via status flowing into

"IN" port, and the cycle is repeated again.

Impact

.JISUNG
HEAVY INOUSTRIE:& CO., LoTO .
 4. Installation and Removal

4-1. Fundamental circuit

When piping the hydraulic lines on base machine, it is important to know the fundamental ci rcuit to
which the piping belongs. Then the piping can be connected correctly, properly and quickly.

Stop val ve
out
- in

Aelief valve

Hydraulic breaker

,
M. C.V ,
I
------ -.j
ro -
o

Hyd,tank
(Fig.4-1)

Fig.4-1 is shown the cne of simplest hydraulic circuit in case 01 installation a sarvice port into the
main control valva of basa machine .

11 the plping method is dlfferent with Fig.4-1 , consult us or attachment manufacturer.

@
.JISUNG
HEAVY INOUS11=tIES CO. , LTD,
4-2. General view

Check the piping lines for correctness of such as pressure, flows or pressure los8,
if the hydraulic pipe once are installed in the base machine
A pressure control valve has to be installed, if there is no pressure control valve on the
main control valve of base machine.

Standard view of installation is as shown in Fig. 4-2

Hydraulic breaker

Hydraulic breaker control valve -i~~~~~~~~f~~__.,""",-,

~ Input Line (Pressure Line)

I
r...-_ _... Output Line (Return Line)

(Fig.4-2)

.JISUNG
HEAVY INDUSTRIES ce., L.TO.
 4-3. Installation

Never insert your hand or fingers into the pin hole

While aligning the arm hole, or moving the bucket, make sure that there are no person
in the vlclnity of arm or bucket 01 base machine.
It is dangerous to move the base machine suddenly durlng In5tallatioo.
Wear the safety shoes to protect feet.

Be careful so that dust may not enter the hydraulic breaker and base machlne.
Install or remove the hydraulic breaker on horizontal ground without mud or dust.

1) Sel Ihe hydraulic breaker on horizontal ground.

2) Remove the bucket lro m the base machine after disassembling Ihe two pins .

11 the bucket cylinder is retracted,

the installation will be easier.

3) Move the base machine in Ihe vicinity

01 hydraulic breaker, and align the pin hole 01 arm with
the pin hole of hydraulic breaker, and Ihen, insert the pins .
4) After the arm pin is inserted , lift Ihe boom, resert the
hydraulic breaker on the wood blocks like as 4-3-3.
Extend Ihe bucket cylinder, lit jt to the bucket
link's hole and insert Ihe pins.
5) Insta/I the stop rings, align he bol! holes
and insert the bolls. Mulually lock double nut.

If the stop rings are secured with one nut only,

(4-3-2)

the service life of the boh may be shortened or

the bolt may be loosened out very quickly.

6) Stop the engine 01 the base machine,

turn off the main switch and discharge the air
pressure in the hydraulic oil tank.
7) Remove the union caps from Ihe hydraulic breaker
pipe 01 !he arm end, and connect the hoses after
disassembling the hose plug.

... ISUNG
HEAVY INOUSTRIES ca., lTO.
 NOTICE

Do not allow the oil to drop onto the ground.

Store the removed union cap and hose plug
in the tool box.
When installing or removing the oil hose and
union cap. clean them fully to prevent the dust
and mud from entering the hydraulic breaker
or the base machine. (4-3-4)

8) Connect the hoses to stop valves at both sides 01 arm o

9) Turn on the engine 01 the base machine, left the boom,
operate the bucket cylinder and check the hose 01
hydraulic breaker is connected correctly.
10) Starts warm up the base machine .
HYD' Hose SPEC
Lenglh Working Burst
MODEL Hose Dia. Pressure Pressure
(mm) (Bar) (Bar) (4-3-5)

JSB10, 20, 30, 35, 40, 43 1/'1' 1500 140 1100

JSB45,50 I 3/4' 2000 170 1100
JSB60,70, 81 , 20G 1" 2300 180 1100
JSB30G 1" 2500 180 1100
JSB 100, 121. 130. 151, 40G 1t" 2500 180 1300

Warm Up the base machine by Idllng tor

5 minutes after startlng the engine.
Move the boom and arm for approx.
5 minutes after warm up operation to rise the
hydraulic oil temperature of base machine.

11) Tum the stop valves lo "ON" position.

The tool may come out under 011 pressure In the pipe line. Do nol stand near of hydraullc breaker.

 4-4. Removal

Personal injury can result from dropping pins during removal.

ON OfF

Wear safety shoes to protect feet.

1) Set the hydraulic breake r on clean and

horizontal ground.
Lock the packing brake of base machine.

2) Stop the engine.

3) Tum stop valve to "OFF" postion.

4) Disconnect hoses from stop valves. Ensure

no leakage occurs from hoses and stop valves.

5) Apply union cap and plug to hose ends fittings

to prevent
(4-4-2)

6) Remove pins fixing fasteners.

7) Remove pins.

S} When pins have been withdrawn, move

operating joystick slightly, to take weight off
remaining link pino

9) Lift arm away from hydraulic breaker so that

hydraufic breaker can be carried away, or (4-4-3)

another attachment mounted on base machine.

Cover the hydraullc breaker already

removed with sheet, and then store It in
doors.

@
..ISUNG
HEAVY INClUBTRIEB CC., LTD.
5. Maintenance

5-1. Serial numbering system

The unit serial number is stamped on the bracket left side by steel name plate (PIno. JSB-80003)
It is very important for management of repairing or spare parts ordering.

Structure of serial number is following :

JAOBXX , where
J : Manufacturer (JISUNG HEAVY INDUSTRIES eo., LTD)
A : Hydraulic breaker model (Refer to below table)
O : Year
B : Month (JAN : A, FEB : B, MAR : e, ............. DEe : L)

XX : Lot Number

MODEL eODE of Hyd' Breaker

JSB 10 A JSB 81 K I
JSB 20 B JSB 100 L
JSB 30 C JSB 121 M
JSB 35 D JSB 130 N
JSB 40 E JSB 151 o
JSB 43 F JSB 18G P
JSB 45 G JSB 20G Q
JSB 50 H JSB 30G R
JSB 60 I JSB 40G S
JSB 70 J JSB 50G T

Example : JN4F17
This is the Hydraulic Breaker model JSB20G of the 17th lot, which is made on June,
2004 by the manufacture, JISUNG HEAVY INDUSTRIES Co., LTD.

o ( o O (E O O ( O

.JISUNG .JISUNG JISUNG

MOOeI JSB Model JSB40 MOOeI JSB20G
Senal Number Serial Number Serial N...,-,ber
Manulacluring Dale Manuiac1urlng Dale MarUacturing Dale
Workr1g Weighl kg 'AQrl<'ng 'Mighl 250 kg I'\brkJng We1gll1 1,740 kg
~ng Pressure bar Ope<aling Pressure 130"'150 bar Operatlr Pressure 230-250 bar
ReQUII'ed 01 Row I../rnn Reqvlred 01 Row 40"-70 I../min Requ:red 0 11 Row 120-180 1../lT'it1

..JISUNCJ
IilAV 'I" INOlJS"fFItBa. ca ., LoTO
" ~2~~~",'! ca., un " ~~~u~~ ca. LTO.

1.1J-l .tlaechang-ri~ Hw~--cit)o 143-1, ~IJ--fI PaItarr-m'(eOR ....as=o.;~II,. l tt3- 1. ~1l~HW4ISfilOr!g-o

G~~I("45-914l 6_",",,1"""") G~-do~ ('4HiC)
O
O IEl : +82-31- J52-S455 O O TB.. : +82-31- 352-8455 O O l El : +82-:n- 352-8455
 A DANGER

PASSED
Q.e

KE EP AWAY!

1) (Pino. JSB-80001) 2) Flying debris warning label

(pino. JSB- 80002)

rJ

~
>
WARNING
DISCHARGE
PR IORTO
DISASSEMBlY

3) High noise level warning label 4) Discharge warning label

(Pino. JSB-80004) lar back head(P/no. JSB-80005)

.. --""""'

GREASING

5) Greasing label 6) Accumulator serial no. label
(Pino . JSB- 80006) (Pino. JSB-80007)

A CAUTION
A CAUTION
~UR~
-PlfESSURIZED VE$$EL
ACCUMULATOR IS NOT CHARGED
use ONlV NfTROOEH
-DISCI-lAR.GE PfUOR 1'0 ~SASSEW..Y USE NITROGEN ONLY
- SYSTEl.t CONTAINS ACCUW.tJLATOR
-DEPRESSURIZE SVSTEM 9ERIAr ....IITEHANCE

7) Accumulator high pressure 8) Accumulator not charged warning label

warning label(P/no. JSB-80008) (pino. JSB-80009)

A CAUTION
BAC K HEAD IS NOT CHARGED
USE NITROGEN ONLY

9) Back head not charged warning label 10) Consult manual warning label
(Pino. JSB-80010) (PIno. JSB-80011)

.JISUNG
H~VY INOUSTRIES CO' 1 LTn.
53. Moving and lifting

Always use eye-bolts when lifting & moving the hydraulic breaker, after fasten up to bracket.

Fasten the ropes to the shackles(four pieces) and lift the hydraulic breaker up.

Remove the eye-bolts befo re hydraulic breaker operation.

Eye bolt size Wire Rope

MODEL
(mm) Size(mm)
JSB10, 20, 30, 35,40,43 M12 <1>6

JSB 45, 50, 60, 70 M16 <1>8

JSB 81, 18G, 20G, 30G M24 <1>16

JSB 100, 121, 130, 151, 400, 50G M30 <1>20

..JISUNG
HEAVY INDUSTR leB ce . LTD.
 5-4. Maintenance intervals

Before hydraulic breaker operation, be sure to check the following points.

Every 3 hours
- App ly the grease in front head.

- Check hydraulic oil temperature, piping and hose connections, and working condition .

- Check tightness of fasteners .

Every 10 Hours, or Daily

- If rough skin on the tool and tool pins have been found , it must be removed.

- Check the nitrogen gas pressure in back head.

- Retighten the bracket bo lts.

Every 50 Hours, or Weekly

- Check the clearance between 1001 and front cover.

- Check hydraulic hoses.

- Retighten the through bolts .

Every 1000 hours, or Slx(6) Months

- Factory inspection by authorized serviee personnel recommended.

- AII hydraulic pipe and hose connections .

- Hose interference from carrier movement.

- Conditions of oil filler, accumulator diaphragm, through bolts and tool pins.

Every 2000 hours, or Annually

AII hydraulic pipe and hose connections.

- Hose interference with excavator boom.

- Conditions of oi! filter, accumulator diaphragm and through bolts.

- AII seals.

- Conditions 01 piston , tront cover, inner bush .

..ISUNG
HEAVV INDUSTRIES C C o, l.TO.
5-5. Hydraulic oil

Recommended hydraulic oil

Normally, any hydraulic oil originally intended for base machine can be used in the hydraulic breaker.
However oil viscosity must be checked timely, beca use the oi l may be heated much more in the
hydraulic breaker works than in normal excavator works.
When hydraulic breaker is used continuously, the oil temperature normalizes at certain levels,
depending on conditions and carrier.

At such temperatures, hydraulic oil viscosity shoul d be 20-40 cST.

Usually, the hydraulic oil temperature 01 hydraulic breaker and base machine
must be controlled between 40'C and 60'C .
When you have operated the hydraulic breaker while the 011 temperature exceeds 80'C ,
you must check the seals.

..

l Maker
Esso
ISO VG 68
Nuto H68
HydrauUc aH
.
I ISO VG 46
Univis N 46
_._ ' ~ . ~ -

Shell Tellus oil68 Tellus oil46

-
Mobile DTE16 DTE15
Gulf Harmony 68 Harmony 46

For hat weather use For cold weather use

I

.JISUNG
HEAVV INDusmlEU ce . LTO.
 Replacement of hydraulic 011 & oil filter
Contamination of hydraulic oil may result in part damage, not only in hydraulic breaker, but also in
earrier main eomponents. We recommend hydraulic oil and oil filters replacement as shown in
the following table, which is based on 100% hydraulic breaker operation .

First 250 hours

Hydraulc oi l Every 600 hours
Based on 100% hydraulie breaker operation
First 50 hours
Oil filters
Every 100 hours

Hydraullc 011 vlscoslty

Hydraulic breaker must not ba started if hydraulie oi! viseosity exeeeds 1000 eST, nor oparated when
hydraulic oil viseosity falls 15 eSTo

011 vlscoslty too hlgh

-Start up difficulty
-Operation stiffness
-Irregular hydraulic breakar impact
-Danger of eavitation in pumps and hydraulic breaker
-Valve stieking
-If the filter is very eontaminated, hydraulie components could be damaged, due to open bypass valve

Oil vlscoslty too low

-Efficieney losses from internal leakage

-Damage to seals, o-rings

-Aceelerated wearing of parts, beeause of decreased lubrieation efficiency

Coollng
Maximum permitted hydraulie oi! temperature range in continuous hydraulie breaker use is 50-80'C

(120-17S'F), depending on viseosity of oil in the system.

Therefore, a reliable hydraulie oil thermometer is necessary.

If there is no thermometer on the earrier, one must be installed. Hydraulic oil temperature depends

on ambient conditions, earrer cooling system effieieney, and on hydraulie breaker use.

When hydraulic breaker is used eontinuously, it is neeessary to have a cooling system with extra

cooling eapaeity, as compared with normal excavation work.

Hydraullc oil temperature

The normal temperature of hydraulie oi! operating is -20'C"'80'C (- 4'F"'175'F)

If the temperature is lower than -20'C (-4 'F), the hydraulic oi! have to be preheated before operation,

in order to avoid breakage of the accumulator diaphragm.

To preheat hydraulie oil, operate the base maehine(without running hydraulie breaker), until oil

temperature rises specified temperature range.

During operation, oil will remain warm.

If hydraulie oil temperature exeeeds speeified limits, please stop equipment and don' t restart

operation until oil has cooled to speeified operating temperature range .

.JISUNG
HEAVY rNDUSTAIES ce., LTC .
5-6. Greasing

Insufficient greasing may cause abnormal wear of front cover and tool, and tool breakage.

Apply grease to grease nipple on fron t head every 3 hours .

Adapt grease interval and amounts to tool wear rates and working conditions.

Tool shank must be welllubricated before installed

in front head.
Greaslng label(P/no. FB-80006)

GRE ASING

While greasing, hydraulic breaker must be upright

agalnst the tool, to ensure that grease wlll penetrate
between tool and inner bush.

Recommended lubricant greases (NIGI No.2)

I Maker Grease

Esso Beacon Q2

Shen RetinaxAM

Mobile Mobile Grease special

 5-7. Inspection and charging of Nitrogen(N2) gas

5-7-1. Back head

Do not stand in front 01 the tool whle nitrogen gas is charged in back head.
The nitrogen gas in back head must be discharged completely when a Ihrough bolt is
replaced or a main body is disassembled.

Use nitrogen gas only.

The temperature 01 the hydraulic breaker mal n body must normal when inspection or
charging 01 nitrogen gas in back head.

Handle

Handle

Prassure gauge

~-
Charging valva o N2 cylinder
~dluster

0- rin9

./
"
(Flg.5-7-1)

...ISUNG
tfEAVV rNDUST'RIES ca" LTC.
(1 ) Conn ect gas hose to N2 gas cylinder.
(2) Tu rn the handle of charging gauge counterclockwise befo re install the charging gauge .
(3) Install charging gauge to charging valve.
(Make sure Ihat O-rings are installed on ch arging gauge .)
(4) Connect olher end of gas hose to charg ing gauge .
(5) Slowly turn the handle of chargin g gauge clockwise to sel charging pressure and turn
handle of N2 gas cylinder clockwise.
(6) Turn the handle of charging gauge counterclockwise , and than tu rn the handle of N2 gas
cylinder counterclockwise lo close .

For N2 gas sealing pressure, reter to Fig. 5-7-2

(7) Close the cap of charging gauge after gas hose is relieve fro m charging gauge .
(8) Recheck charging pressure in back head as turning Ihe handle 01 charging gauge clockwise .

When nitrogen gas is charged in back head completely by following procedures (1) through (8),
dlsconnect charging gauge from charging valve of back head after tum the handle of charging
gauge counterclockwise. But, if need to adjust the pressure of charging gas in back head by
following procedures (9) through (13) mentioned below.

(9) Dsconnect the gas hose from charging gau ge.

(10) Install chargng gauge on charging valve of back head completely .
(11) When tum the handle of charging gauge clockwise , gas pressure in back head is indicated
on pressure gauge.
(12) 1I gas pressure is low, again perform operations (1) through (8) . Repeat untl gas
pressure rises 10 specified pressure.
(13) 1I gas pressure is excessive, slowly turn the adjuster 01 charging gauge counterclockwise,
then gas pressure leaks Irom back head. When correct amount 01 gas pressure is shown, close
the adjuster clockwise .
When gas pressure is excessively high, breaker will not operate.
Ensure that gas pressure is at specfied pressure and o-ring in charging gauge is installed.

 20 Model Charging Pressure(bar)

1
~~ JSB 10 16""17

~ ~~
18 JSB20 16""17
JSB30 16""17

16
V
~~ \fI'I' JSB35 16"""'17
V JSB40 16""17

----~
JSB43 16"'17
14
JSB45 16""'17
JSB 50 16""'17
JSB 60 16""17
JSB70 16""17
JSB 81 16""17

~
JSB 100 16""'17

\~ro~~ JSB 121 16""'17

8
v--:: \~~---- JSB 130 16""'17

L-;;~~ JSB 151 16""'17

6
v P
~~\J~~ JSB18G 6""'7
~ .
JSB 20G 6"'7
4 k----- JSB 30G 6""7
JSB 40G 9""'10
JSB 50G 9"'10
20 o 20 40 60
Surrounding temperature ("Cl
(Fig. 5-7-2)

.JISUNG
HEAVY INDLJST'FUES CO. , LTC .
5-7-2. Accumulator

Must be tightened Ihe accumulator body and accumulator cover before charging
the nitrogen gas in accumulator assembly.

Use nitrogen gas only.

The temperature of the hydraulic breaker main body must normal when inspection or
charglng of nitrogen gas in accumulator.

Be sure lo use a charging gauge for charging the nitrogen gas.

(If the nltrogen gas 15 charged from gas cylinder without charging gauge,
the diaphragm may be damaged)

Handle

Plug Charging valve N2 cylinder

()"i"' ~

(Flg.5-7-3)

.....SUNG
HEAvV INOUSTRIES CC., l.TD.
 A) Inspection 01 charging pressure
(1) Turn the handle of charging gauge counterclockwise.
(2) Remove the plug on the accumulator and tighten cha rging gauge completely.
(3) Remove the cap of adjuster from accumulator.
(4) Turn the adjuster counterclockwise slowly to indicate accumulator charging pressure.
(5) Remove charging gauge and tighten plu g and cap.

(En::,ure O-rings must be installed in plu g and cap.)

B) Charging accumulator with nitrogen gas

(1) After perlorming steps same inspection of charg in g press ure .
(2) Connect gas hose to charging gauge and N2 gas cylinder.
(3) Turn the adjuster counterclockwise after remove the cap from adjuster.
(4) Slowly turn handle of N2 gas cylinder counterclockwise to charge accumulator with

N2 gas. For gas charging pressure, reter in Fig. 5-7-4

(5) When accumulator is charged with N2 gas completely. close the adjuster fully.
(6) Turn the handle of N2 gas cylinder clockwise to close.
(7) Loosen adjuster of charging gauge to discharge N2 gas remaining in gas hose.
(8) Remove the gas hose from charging gauge to N2 gas cylinder.
(9) After removing gas hose, adjust the pressure referring A) Inspection of charglng pressure
(10) After charged accumulator with N2 gas, check gas leakage from adj uster, plug

hole of accumulator.

~
~ AOG 50G , ~5~~~
G ' ~
_L---- L-----~SG ZOG, 30 .__
I

60 ~30 ___

L---- ~OO . I2~ .'
JSaS~ . ___ ~

~
==-

20

o
-20 o 20 40 60 80
Surrounding temperature ("e)

(Fig. 5-7-4)

@
.JISUNG
HEAVV INDUSTRIES CC., LTO.
5-8. Pressure setting
The pressure setting lor hydraulic breaker must be lower than the base machine pressure setling

in order lo prolect Ihe main pump of base machine.

Normally, set Ihe pressure lor hydraulic breaker aboul 5-10kg!cm 2 lower than base machine

pressure setting , when the main pressure 01 base machine is lower Ihan below table.

i1 hydraulic breaker setting pressure higher than below table :

will be shorten durable of main pump and shorten service life 01 seals & tool in hydrau lic breaker.

i1 hydraulic breaker setting pressure lower than below table :

hydraulic breaker performance will be downed.

Recommended Setting pressure 10r hydraulic breaker(bar)

JSB 10, 20, 30, 35, 40, 43 160"'180

JSB45,50 180"'200
JSB 60 200"'220
JSB70 200"'220
JSB 81, 18G 200"'220
JSB 100, 121, 130 220"'250
JSB 20G, 30G 220"'250
JSB 40G, 50G, 151 220"'250

.JISUNG
HEAV'Y fNOUST'RIES ca., LTO .
 5-9. Seal inspection

Replace seals every 2000 hours of actual operation.

1) If any hydraulic oilleakage from hydraulic breaker is discovered, faulty seals shoul d be replaced.
To figure where seals are bad, rete r to following drawings:

o X o X o X X
O-O ~- (fj ~-~-rrl

Back up ri ng - O-ring & dust seal U-packing & Buffer ri ng

worn,distorted worn, deteriorated deformed, wom,distorted, perished

2) When bad seal is found , the cause ot the damage must be determined and rectified .
When seal is changed , apply grease to seal and seal seat, and hold sea! firmly with
thumb , index and middle fingers , as per marking.
Be careful not to break seal through excessive deformation .

...ISUNa
HeAVY INDUSTRIES CC. , LTD_
5-10. Wear inspection

5-10-1. Front cover

If the clearance between tool and front cover is too big, this could cause of damage,

or breakage 01 tool through pistan irregular contact.

The following table is shown the wear limit 01 hydraulic breaker tool and front cover tor

reference purposes.

Front cover

Tool

I Model Wear Limit (mm)

I

JSB10, 20, 30, 35,40, 43, 45, 50,60 4

JSB 70, 81, 100. 18G 6

JSB 121, 130, 20G, 30G, 40G, 50G, 151 8

~ISUNG
HEAVV INDUSTRies CO., LTD.
5-10-2. Tool pin

Change the 1ace 01 tool pins every 100 to 150 hours 01 actual operation.
Replace tool pins every 500 hours of actual operation.

A) When each tool pin is excessively deformed , it is difficult to replace the tool , therefore, after operate
the hydraulic breaker every 100 to 150 hours, change the face 01 each pin which comes in contact
with the tool(the faces of each pin can be used) .

B) When replacing each tool pin , check each parts for wear, breakage, scores, etc. , especially,
and remove burrs and swelling on tool pins.

e ) Replace tool after grinding the worn parts of front cover and tool pins.

W hen changing tool pins direction, place tool pins

by opposite side.

Remove burrs and swelling

with grinder or the like
5-11, Inspection and replacement 01 through bolt

Discharge completely N2 gas in back head prior to loosen through bolts.

1) Discharge nitrogen(N2) gas in back head completely prior to loosen through bolts.

2) Remove all through bolts, and inspect for presence of any cracks and damages on through bolts.

3) When through bolts are assembled, tighten bolts one turn al a time in diagonal sequence ; nol

each nut completely al! at once turn of times, not completely al once.

4) Use torque wrench of specified ran ge.

(Refer to torque table)

.JISUNG
HEAVY INDUSTRIeS ce., L.T D .
5-12 Torque table

(1) Before startng the hydraulic breaker operation, check all kind of bolts and nuts for tightness
ncluding the through bolts, socket bolts for accumulator, valve housng socket bolts, valve cover
socket bolts an d bracket bolts.
Also be sure tghten agan any loose bolts and nuts according to the specified torq ue.
Using the hydraulc breaker wth loose bolts and nuts wll cause not only oil leakages but also
damages to the screw threads and breakage to the bolts. These can lead also defective operaton .
(2) After first 10 hours of operating , retighten the bolts and nuts of all components and sections.
(3) At first, lightly tighten the bolts and nuts by referring to the followin g torque force .
The bolts and nuts should be screwed down alternately and diagonal/y until the bolts and nuts
are tightened to the unform torque .

Through bolt
Model Torque (Kg-m)
JSB 10 ,20,30,35,40,43 150
JSB 45,50 150
JSB 60 150
JSB 70 250
JSB 81, 100 250
JSB 121,130 250
JSB 18G, 20G 250
JSB 30G, 40G 250
JSB 50G, 151 360

Braket bolt
Model Torque (Kg-m)
JSB 10,20,30.35,40,43 80
JSB 45.50 100
JSB60 250
JSB 70 250
JSB 81,100 250
JSB 121. 130 300
JSB 18G, 20G 300
JSB30G.40G 300
JSB 50G, 151 350

Socket bolt - valve cover

Model Torque (Kg-m)
JSB 18G / JSB 20G 50
JSB 30G / JSB 40G 50
JSB 50G 50
 Socket bolt - valve housing
Model Torque (Kg-m)
JSB 18G / JSB 20G 50
JSB 30G / JSB 40G 50
JSB 50G 50

Socket bolt - accumulator cover

Model Torque (Kg-m)
JSB 81, 100 50
JSB 121,130 50
JSB 18G, 20G 50
JSB 30G , 40G 50
JSB 50G, 151 50

Accumulator body
Model Torque (Kg-m)
JSB 81, 100 60
JSB 121, 130 60
JSB18G,20G 60
JSB 30G, 40G 60
JSB 50G, 151 60

Flange adaptor
Model Torque (Kg-m)
JSB 18G / JSB 20G 20
JSB 30G / JSB 40G 20
JSB50G 20

Bolt-mount cap
Model Torque (Kg-m)
JSB 70 150
JSB 81 , 100, 121 150
JSB 130 150
JSB18G,20G 150
JSB 30G, 40G 200
JSB 50G, 151 200
5-13. Storage

When operation is interrupted or finished

When operation is interrupted or after finish ed move the base mac hine on
level ground . Remove mud fro m the hydrau lic breaker and set the hydrau lic b reaker on
wood blocks .

Do not touch the tool when hydraulic breaker just stop to work, because very hot.

- Check whether oil leaks from hydraulic system and whether the tool is damaged .
- II the hydraulic breaker is operated in river, dry the hydraulic breaker body and apply the grease
to the tront head .

When hydraulic breaker is not used for a long time-3 weeks more

If the following procedures are neglected, the rust is generated in the main body
to cause serous troubles.

- Discharge the nitrogen gas with the back head and accumulator, and then push the piston
to avoid rust into the cylinder.
- Assemble the tool and store the hydraulic breaker indoors after applying the grease to
every part, especially internal parts 01 tront head.

6. Operation
Before starting the base machine which the hydraulc breaker is mounted , check to use the machine
safely and to prevenl any trouble .

6-1. Tool installation

Installation

Personal injury can result from dropping

the tool during replacement.
Be sure to use a crane when handing the
tool and such heavy parts.

Wear the safety shoes to protect feet.

1) Set the hydraulic breaker horizontally on wood blocks so Ihat the acc umulator may be upper side .
2) Remove the rubber plug or spring pin (j) and the stop pin into front head from opposite side by
using a hammer and a press pin o(Press pin is stored in tool box)

Before tapping the stop pin, make sure that there Is no person where they come out.
After the rubber plug 00 removed and installed 2 or 3 times, the rubber plug (J) by new
ones.

3) Uft up the tool pins @ after insert !he press pin

into the hale of 1001pin from bottom side,
and remove Ihe tool pins from tron! head .
4) Insert the 1001 inlo fronl head.

Apply the grease on the surface 01 shank

area and Impact area of tool.

5) Insert tool pins, and then assemble the slop

pn and rubber plug or sprng pn in fronl head.
6) Using a hammer and a press pn, fasten Ihe rubber
plug or spring pin inl0 tronl head .

Removal

The removal 01 tool in reverse arder of nstallation .

 6-2. Safety operation

1) Precautions for safety operation

Injury or death can result trom improper operation or poor maintenance.

Make sure of the safety trom any trouble or any accident around the base machine
before starting.

Inspection
Check the base machine and the hydraulic breaker to use safely and to preven! any trouble before
operation.
Warming up the machine
Especially in winter or cold area, warm up the base machine at first before the breaker operation .
Safety maintenance
Before starting the work, examine the geological and geographical features of work site and be
careful of the ground crack or Ihe building collapse .

2) Cautions, when driving or stopping base machine

Drivlng
Carry out driving while the hydraulic breaker is kept horizonlally wilh ground and is 40 lo 50cm
above ground.
Cautions on slope driving
When driving down on the slope, decrease the engin e rpm and keep the angles wilh boom and arm
0
90 to 110

Stopping
When Ihe machine is stopped, the hydraulic breaker stand vertically and sel Ihe tool end on the
ground.

@
.JISUNG
HEAVV INDUBTRIEG ec., LTC .
3) Safety operation

Stop working the hydraulic breaker, if hydraulic hoses

vibrate excessively.

Check the N2 gas pressure into accumulator & back

head of hydraulic breaker.

Stop the hydraulic breaker operation as soon as the

object is broken.

If operation continued , id le blows, could result

in excessive wear of major co mponents, or

parts damage such as inner bu sh or piston.

Do not use hydraulic breaker lo move rocks with end of

tool or with hydraulic breaker body.

Do not use tool as a lever.

Hydrau lic breaker eould be damaged at through bo lt,

tool, front head, inner bush and front cover.

Move impaet poinl of objeet, if the object

does not break within 30 seconds.

Do no! use hydraulic breaker in water. Corrosion of

hydraulic breaker, or non-Iubrication, could result in

further damage of the hydraulic componenls .

Under water kit mus! be installed when hydraulic breaker

lar working in water.

Please conlact lO our dealer, il you need.

@
 Do not use hydraulic breaker as hammering.

Because of hydraulic breaker is much heavier than

excavator bucket , such usage could result in damage

of the front head or swing mechanism of the

base machine.

Do not operate hydraulic breaker with boom or arm

cylinders fully extended(bottomed out) .

This may result in hydraulic breaker shock, and

damage to the base machine.

Maintain 100mm cylinder stroke of base

machine at leas\.

Do not curl the tool tip into arm or boom

of base machine when travelling or parking

carrier.

Do not strike in one spot tor more than 30 seconds.

It objecl dose not break, stop breaking after than

change Ihe spot of object.

Working too long in one spot will create

excessive stone dusl under tool. Dust dampens

impact effect, and can be damage pistan sea!.

Never use hydraulic breaker as a transporter.

This could result in tppng carrier, or damaging

on base machine.

Operate the hydraulic breaker only to Ihe tronl and rear

of base machine.

Do nol use hydraulic breaker al eilher side of base

machine.

This may result in tipping excavator, or in

damaging carner swing device .

.JISUNG
HEAVY INDU.&TAlES CO . , LTO.
6-3. Function of adjuster (JSB18G / JSB20G / JSB30G / JSB40G / JSBSOG)

6-3-1. Cyl i nder adj uster

The JSB hydraulic breaker is designed so that the bpm (blows per min ute)

can be adjusted with the operating pressure and oil consumption kept constant

by changing the piston stroke, enabling the hydraulic breaker to be used widely.

However when the bpm is increased, the limpact force will decrease.

Therefore the bpm must be adjusted in accordance with job condition .

1n, Bracket

i,1

The cylinder adjuster is installed lo the right side 01 Ihe cylinder.

The cylinder adJuster is fully tightened when the breaker is delivered.

When the cylinder adjuster is tightened fully, the piston stroke become maximum and the impact

blows(bpm) becomes the minimum.

The other waV, when the adjuster is loosened about two tu rns , the piston stroke becomes the

minimum and the impact blows(bpm) becomes the maximum.

Even the adjuster is loosened over two turns, the impact blows does not increase.

@
.JISUNG
HEAVY INOUBTALES ce., LTD.
 6-3-2. Valve adjuster

The valve adjuster is installed on the valve housing.

The impact blows and the o! consumption increase when the adjuster is opened and when

it is closed, the impact blows and the oil comsumtion decrease .

When the oil flow from base machine is lower or when the hydraulic breaker has been

installed on large base machine, the valve adjuster can control amount of oil flow artificially.

The hydraulic breaker do not operate If the valve adjuster is fully closed.

Nut--e
Nut

Valve adjuster

Valva housng

Adjustment

I AdIPI6.......
Cylinder adjuster
........
Open
-
-dllDw_
Nochange
-
' . -
No change
I
..

Increase
' _,_ o .
,~

__Decrease
....
r~ ,tdllMy l
Fully
CIosed Nochange Nochange Oecrease lncrease closed
Open Increase Decrease Increase Decrease 2 1
"2
Valve adjuster
Glosad Decrease Increase Decrease Increase Tumout
_...... -, .- -, ----_ .. _.- _._... ~ -,,_ ... ... ,- - _....__ .... _
._._ .. ... ...._, ...
~ ~~-. " ~

...- -'. ... ... ... .....- -_.. .. -- ._-.- _._._. .. ..-

Charging pressure Increase

_ _ ' 0- .. "' - ' "
Decrease
.- - I~C~~_ Decrease
, _... Increase
" -'---"- Specified
in back head Decrease Increase Decrease Increase Decrease

@
.JISUNC3
HEAVV INCUSTRIES ce. , LTC .
7. Trouble -Shooting
This trouble-shooting guide has been prepared to aid the operator to locate the probable cause and then
remedy when trouble has occurred. If trouble has been caused , obtain details as fol lowing check points
and contact your local service shop or distributor.

Check below mentloned items and contact service shop to check and repair any
tem which operator cannot remedy.

Check point

Check polnt(Cauae) Remedy

1. Spool stroke is insufficient. After stop engine,
~ Adjust pedal link and control cable joint.
depress the pedal and check it spool moves full
stroke.

~ Recharge with nitrogen gas or check.

2. Hose vibration becornes bigger al hydraulic
breaker operation.
~ High pressure line oil hose vibrate excessively.
~ Recharge with gas.
(Accumulator gas pressure is lowered) II accumulator or back head is recharged but
~ Low pressure line oil hose vibrate excessively.
gas leaks at once, diaphragm or charging valve
(Back head gas pressure is lowered) may be damaged.

~Pull out tool and check.

3. Piston operates but does not strike tool.(Tool
shank is damaged or seizing.)
4. Hydraulic oil is insufficient.
5. Hydraulic oil is deteriorated or contaminated.
~Hydraulic oil color change to white or no viscous.
(White colored oil contain air bubbles or water.)
It the tool is seizing, repair with grinder or
change the tool and/or tool pins.
~ Relill hydraulic oil.
~ Change all hydraulic ol in hydraulic system of
base machine.

6. Une filter element is clogged. ~ Wash or replace the filter element.

7. Impact rate increases excessively.(Breakage or
~ Adjust or replace damaged part and check
misadjustment of valve adjuster or nitrogen
nitragen gas pressure in back head.
gas leakage from back head. )
B. Impact rate decreases extremely.(Back head
~
"-
Adjust nitrogen gas pressu re in back head.
gas pressure is excess.)
9. Base machine meander or weak at traveling.
(Base machine pump is defective or improper ~ Contact base machine service shop.
set 01 main re liet pressure.)

@
..JISUN13
HEAVV INOUBTR1ES ca ., LTD .
 Trouble shooting guide

Symptom Cause ReqUlred actlon

1. Excessive nitrogen gas pressure 01 1.Re-adjust nitrogen gas pressure in

back head back head
2.Stop valve(s) closed 2.0 pen stop valve
3.Lack 01 hydraulic oil 3.Fill hydraulic oil
No blow out
4Wrong pressure adjustment Irom 4.Re-adjust setting pressure
reliel valve 5.Tighten or replace
5.Faulty hydraulic hose connection 6.Replace back head o-ring, or seal
6.Hydraulic oil in back head inlection retaner seals
- - -i -- - - - - - - -..- - - - - - " - '
1.Line leakage or blockage 1.Check lines
2.Clogged tank retum line lilter 2.wash filter, or replace
3.Lack 01 hydraullc oi! 3. AII hydraulic oil
4.Hydraulic oi! contamination, or heat 4.Replace hydraulic ol
deterioration
Low impact power 5.Poor main pump performance 5.Contact authorized serviee shop
6.Nitrogen gas in back head lower 6. Relill nitrogen gas
7.Low I10w rate by mis-adjustment 01 7. Re-adj ust valve adjuster
valve adjuster
8,Tool out 01 range for blowing position 8.Push down tool by excavator operation
- - - - . - - ----11---- ... . ..- .. ~ ....

1.Low nitrogen gas pressure in 1.Refill nitrogen gas and check

accumulator accumulator.Rep!aee diaphragm il need
Irregular impact 2.Bad piston or valve sliding su rface 2.Contact authorized local distributor
3.Piston moves down/up to blank blow 3.Push down tool by exeavator
hammer chamber. operation
- - t - - -..__....... .. _ .. _.-- ................. ............................. - .. ........

~ ~

1.Tool diameter incorrect 1.Replaee tool with genuine parts

2.Tool and tool pins would be jammed 2.Smoothen rough surfaee of tool
Badtool by tool pins wear 3.Smoothen rough surface 01 nner bush.
movement
3.Jammed nner bush and tool Replace nner bush ifjed
4.Deformed tool and pistan impact area 4. Replace tool by new

SUd~en reduction po~er 1,

1.Gas leakage from accum ulator 1.Replaee diaphragm il need
and pressure line
2.Diaphragm damage
vibration I
1.Replace seals by new
Oilleakage rom
1. Cylinder seal worm
frontcover

Gas leakage Irom back head 1.0 -ring and / or gas sea! damage 1.Replace related seals by new
8.Service tOOl5
8-1. Standard service tools
Dimension Application (JSB Series)
Description
(mm) 10 20 30 35 40 43 45 50 60 70 81
rjJ 1 1 1 1 1 1 1 1

~ * 1 1 1
12 1 1 1
14 1
17 1 1 1 1

SPANNER 27 1 1 1
1

~
30 1 1 1 1
32
36 1
41
46
50
55
14 X17 1 1
17X19 1 1

SPANNER 19 x 22 1 1
-
OPEN END 22X24
24x27 1 1 1 1 1 1 1 1
27x30
,
30X32
32X36 1 1 1
36X41 1
41 1 1 1
46 1 1
50 1

;r
SPANNER
55 1
60
65 1
70
75 1 1
85
5 1 1 1 1 1 1 1
-1
8 1 1 1 1
10 1 1 1 1 1 1
L-WRENCH
12 1 1 1 1 1

~ 14
17
19
1
1
1
1

21
T-WRENCH 14 1 1 1 1 1 1 1 1 1 1 1
PIN BAR 12>10X130 1 1
~~ 12>15X230 1 1
GREASE GUN 300ee 1 1 1 1 1 1 1 1 1 1 1

.JISUNG
HeAVV INOusmlES ca LTC
Standard service tools
Dimension Application
Description
(mm) JSB 100 JSB 121 JSB 130 JSB 151 JSB18G JSB20G JSB30G JSB40G
Ef

~ *
12
14
17
1
1
1
1
1
1
1 1 1 1 1

SPANNER 27 1 1

~
30
32 1
36 1 1 1
41 1 1
46 1 1
50 1 1 1 1
55 1 1 1 1
14X 17 1 1 1 1 1 1 1
17X19 1 1 1 1 1
SPANNER 19 x22 1
OPEN END 22X24 1
24x27 1 1 1 1 1
27X30 1 1 1
30X32 1 1 1 1 1
32X36 1
36X41
41
46
50
SPANNER
55 1

:i? 60
65
70
75
1
1

1
1
1 1
85 1 1 1 1 1
5 1 1 1 1 1 1 1 1
-
8 1
10 1
L-WRENCH
12 1 1 1 1 1 1 1 1

~ 14
17
19
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
21 1 1 1 1
T-WRENCH 14 1 1 1 1 1 1 1 1
PlNBAR <P10x130
~ ) <P15X230 1 1 1 1 1 1 1 1
GREASE GUN 300cc 1 1 1 1 1 1 1 1

 8-2. Nitrogen gas charging kit (PINo. FB00310K)

O'"
5

Charging kit detail

I No. Part Name Part No.

1
Q ty I
1 Pressure gauge JSB203200 1
2 Charging gauge JSB10320A 1
3 Cap JSB103202 1
4 Gas hose JSB403200 1
5 JSB303200 (10.2Q)
N2gas cylinder 1
6 JSB303100 (3.4Q)
O- ring JSB513212 1
 9. Tool selection
9-1. Guide to tool choice

The correct choice of the most suitable tool tor a certain job is crucial not
only in increasing hydraulic breaker productivity, but also tor the lite of the
tool itself.

o
A B e

A : Wedge Chisel
- Suitable tor all kinds ot digging or narrow trenching on softJmedium stratilied rocks.

B: Moil Polnt Tool

- Suitable tor line/medium concrete demolition or tor soft, non stratilied rocks.
- Second mlning 01 softJmedium hard blocks.

C: Blunt Tool
- Suitable tor breaking blocks 01 up lo medium hardness or to reduce the size 01 small blocks.

@
.JISUNG
HEAVV INOUS1'1=lII!!B ce., Ll'C
9-2. Tool claim judgment

Hence, to help users use our products eo rreetly , and ensure long operating life, these claim
judgement eriteria present defect examples that ean oceur during use, and the disposition standards
applieable in eaeh case .

Breakage of pistan impact area or tool pins contact corners

(Fig.1 and 2)
Breakage of piston impaetin g point or of tool pins contaet corners is extre mel y rare o This
phenomenon oceurs or when strikin g force is being eoneentrated on the too l eorners due to
unsatisfactory flatness of pistan and tool impacting point. If such defeet oecurs, affected tools may
not be accepted under warranty.

~ a :-= ---- .....------.....------...............

(Fig.1)
--0

o: C7 =---_0 (Fig.2)

.JISUNG
HEAVV INDUST1:Hes CC . , L.TD
 Plastic deformation 01 piston impact area(Fig.3)

The possibility of tool tip plastic deformation occurring due to piston is extremely slim.

Such defects may occur due to material stren gth deficiency, or brittleness , re sulti ng from

unsatisfactory heat-treatment. If such defecl occu rs, affecled producls may be accepted under

warranly.

o: =-- - Q
(Fig.3)

Breakage inside basic line(Fig.4 and 5)

Should producl breakage occur in any direclion al a point inside the tront cover, as shown in<Fig.5>,
from the basic Une shown in<Fig.4>, this may be due lo defective material, defective heal-Ireatment;
tool deformalion, or unsalisfaclory shaping of 1001 neck. Should such defect ouucr, affecled products
may be accepled under warranly.

In addition lo Ihe causes described above, producl breakage nside the basic line may also occur if
Ihe interval belween the fronl cover and 1001 widens due lo excessive wear of tront cover, coupled
with excessive bending load being applied lo hydraulic breaker. If any trace of seizure, caused by
friclion between Ihe fron! cover and 1001, is observed on the surface of the 1001 body, and if it is clear
that producl breakage is centered around the area of such seizure, affected products may be rejected
under warranty .

.JISUNG
HeA.VY INDUSTRIES ca" LTD
 Basic Line
Inside - I--- -- Outside

..."",.............""""'t\ '1--- - fron! cover

Inner bush
(Fig.4)

[[] [ ="'-'---~ (Fig.5)

Breakage outside basic line(Fig. 6,7 and 8)

Should product breakage accur al a paint outside Ihe lront cover, as shown in <Fig.6>, from the
basic line shown in <Fig.4>, Ihis may be due lo excessive bending load being applied lo Ihe 1001.
Such bending load occurs when, after 1001 has been inserted into material , the tool is pulled or
pushed, or when Ihe tool is struck and pushed when it is not perfectly perpendicular to the surface
01 the material being worked on. Fractures, in general , are of the lorm shown in <Fig .7>. Fatigue
breakage, 01 clamshell form, develops in Ihe areas near breakage start poinls , caused by stress
concentration resulting lrom bending loads , and Ihen qu ickly radiates outward. Such type 01
breakage may also occur due lo scarring 01 the 1001 body during use . As breakage occurring outside
the basic line are caused by improper working habits, as explained aboye, products incurring such
delects shall not be accepted under warranly. However, il a fatigue fracture start poinl occurs within
the tool body , instead 01 on the surface of 1001 as shown in <Fig.8> , affected products will be
accepted under warranty , as such breakage indicales material defect.
ce = jJ ~

o: = 11 ~

O: : ~ ~

(Fig.6)

, y'---)

ce :------l ll'---_~
(Fig.7)

(1
O: : III ~

(Fig.8)
 Crushing of tool tip (Fig.9)
Breaker tools are heat-treated t o exhibit high breakage-and wear-resistance; and defects such as
crushing of the tool tip<Fig .9> are not to be expected under normal operating conditions. However, if a
tool is hammering continuously for a long period of ti me without crushing or puncturi ng the material
bein g worked on, the temperature of th e ti p rises extremely high, inducing annealin g of the heat
treated material, and bringing on plastic deformation(crushing), rather than wear. As explained above,
crushing of the tool tip is caused by improper working methods, and, therefore, affected producls will
be rejected under warranty.

0): =_ _ __ 0

(Fig. 9)

Tool tip wear (Fig.10)

The rates and types of tool tip wear vary with work material and work method . If the diameter of the
worn tip of a chisel point tool is less than 2/3 of Ihe tool body diameter, as shown in <Fig.1 O>; and if
the lip of a new pointed tool is worn down in excess of 50mm lengthwise from the tip, this is
considered normal tool wear. Hence, tools exhibiting such normal wear, as shown in <Fig.1 O>, will be
rejected warranty claim .

50fTm

D .so
3

----------~
Chisel po int tool Pointed tool
(Fig.10)