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November 1999 Copyright 1999 Komatsu

DataKom Publishing Corporation

CEAM005500

Operation & MaintenanceManual

JPB3600VHYDRAULIC BREAKER

This material is proprietary to Komatsu America International Company and is not to be reproduced, used, or disclosed exceptin accordance with written authorization from Komatsu America International Company.

It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes oradd improvements at any time without incurring any obligation to install such changes on products sold previously.

Due to this continuous program of research and development, periodic revisions may be made to this publication. It is recom-mended that customers contact their distributor for information on the latest revision.

SERIAL NUMBERS JPB3600V All

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Model JPB3600V Quick Reference

Page 2

Part Number DESCRIPTION

Assembly Side RodsWG86382942 Side rod bolt Pull the nuts to 290 ft-lbs and release.WG86383841 Nut Pull the nuts to 150 ft-lbs in a crisscross

pattern. Align the notches. Next, pull fivemore flats: Two flats, two flats and one flatin a crisscross pattern. Go 1/4 past notchand release to remove pretwist in rod.

Bracket Cap BoltsFixing cap bolts 480 ft-lbs.

Wear plate BoltsWear plate bolts 550 ft-lbs.

Accumulator

UP TO SERIAL # 120278:

WG86392487 H.P. accumulator 580 psi charge pressureWG86381340 Accumulator bolts 370 ft-lbs.WG86265048 Inflation screw 16 ft-lbs.WG86413457 Accumulator fixing bolts 720 ft-lbs.

SERIAL # 120279 & UP:WG86494978 H.P. accumulator 725 psi charge pressureWG86381340 Accumulator bolts 370 ft-lbs.WG86265048 Inflation screw 16 ft-lbs.WG86413457 Accumulator fixing bolts 720 ft-lbs.

Quick Reference Torques

Specifications

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Model JPB3600V Table of Contents

Page 3

Forward Avant Propos 5

Safety Securite S1

Ten Commandments Dix Commandements O1

Overall Dimensions Encombrement O2

Technical Specifications Caracteristiques Techniques O3

Mounting Montage O6

Tool Mounting Montage de Outil O8

Operation & Adjustment Utilisation & Reglage O10

Maintenance Entretien O13

Underwater Operations Sous - Marine les Fonctionnements O15

Tool Guide Guide Outil O16

Trouble Shooting Incidents Techniques M1

Grease Station Centrale de Graissage G1

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Model JPB3600V Forward

Page 4

FOREWORD

The contents of this manual are considered to be

proprietary and confidential to KOMATSU andshould not be reproduced without prior written per-mission from KOMATSU.

Nothing contained in this document is intended toextend any promise, warranty or representation,expressed or implied regarding the KOMATSUproducts described herein. Any such warranties orother terms and conditions of sale of productsshall be in accordance with the standard termsand conditions of sale of such products, which areavailable upon request.

This manual contains instructions and technicaldata to cover all routine operations and scheduledmaintenance tasks by operation and maintenancestaff. Major overhauls are outside the scope ofthis manual and should be referred to an autho-rized KOMATSU service department.

The design specification of this machine has beencertified as complying with E.C. directives. Anymodification to any part is absolutely prohibitedand will result in the CE certification and markingbeing rendered invalid.

KOMATSU reserves the right to make changesand improvements to products without notice andwithout incurring any obligation to make suchchanges or add such improvements to productssold pre-viously.

AVANT PROPOS

Le contents de ce manuel est considr comme

appartenant KOMATSU et comme confidentiel, ilne doit pas tre reproduit sans I'autorisation critepralable de la socit KOMATSU

Aucun lment du contenu de ce document nestentendu comme reprsentant aucune promesse,garantie, ni reprsentation, ni explicates, niimplicites, eut gard aux produits KOMATSU qui ysont dcrits. Toute garanties de cette nature outout autres termes et conditions de vente des pro-duits, doivent tre conformes aux termes et condi-tions standard de vente de la socit KOMATSU,termes et conditions que l'on pourra obtenir surdemande.

Ce manuel contient des instructions et des don-nes qui couvrent toutes les oprations et lestdches de maintenance rgulire effectuer par lepersonnel d'exploitation et de maintenance. Lesrvisions gnrales sortent du cadre de ce manuelet doivent tre renvoyes un service d'entretienagr KOMATSU.

Les spcifications de cet appareil ont t homo-logues comme tant conformes aux directives dela CEE. Toute modification dune pice quelconqueest absolument interdite et auralt pour con-squence l'invalidation de I'homologation CE.

La socit KOMATSU se rserve le droit d'ap-porter des modifications ou d'ajouter des perfec-tionnements aux produits sans pravis et sansencourir en quoi que ce soit l'obligation d'apporterde telles modifications ni d'ajouter de tels perfec-tionnements aux produits vendus antrieurement.

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Model JPB3600V Safety

0 C

WARNING!

ATTENTION!

WARNING!- Pressurized com-ponent or system.

ATTENTION!- Composant ousystme sous pression

WARNING!- Consult the oper-ation andmaintenance manual beforebeginning any maintenance.

ATTENTION!- Consulter lemanuel d'utilisation et d'entre-tien avant d'entreprendre touteinterventions.

WARNING!- Pressurized vessel(accumulator).

ATTENTION!- Rcipient souspression (accumulateur)

WARNING!- For operating temperature below0 C, consult the operation and maintenance

manual.

ATTENTION!- Pour l'utilisation en dessous de0 C, consulter le manuel d'utilisation etd'entretien.

WARNING!- Risk of flying chips of rock- Keep clear, wear a helmet and

safety glasses.

ATTENTION!- Risques de projections- Rester distance, porter uncasque et des lunettes de scurit.

Lifting point.

Point de levage.

Page S1

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Page S2

SAFETY

WARNINGS

"Warnings" call attention to instructions which mustbe followed precisely to avoid injury or death.

CAUTION

"Caution" calls attention to instructions which mustbe followed precisely to avoid damaging the prod-uct, process or its surroundings.

NOTES

Notes are used for supplementary information.

SAFETY PRECAUTIONS

All mechanical equipment can be dangerous whenused without care or if it is in bad condition.

Ensure that the operator reads and understandsthe decals and consults the manuals before main-tenance or operation.

Ensure that the operation and maintenance manu-als remain at operator's disposal.

Ensure that maintenance personnel are adequate-ly competent and have read the maintenancemanuals.

Safety is not only a matter of warnings. Every timethe operator is working with the breaker, theoperator must be able to foresee any risks andknow how to avoid them.

Never undertake a new job or maintenanceoperation without being sure you and other peoplein the environment will be safe.

SECURITE

ATTENTION

L'indication "ATTENTION" prcise que les instruc-tions doivent tre suivies absolument pour vitertout accident grave.

PRECAUTIONS

L'indication "PRECAUTION" prcise que lesinstructions doivent tre suivies absolument pourviter d'endommager le produit, la procdure ouson environnement.

NOTES

L'indication "NOTE" donne des complmentsd'information.

PRECAUTION POUR LA SECURITE

Tous les appareils mcaniques peuvent tre dan-gereux s'ils sont utiliss sans prcautions ou silssont en mauvais tat d'entretien.

Vrifier que l'oprateur lise et comprenne les ti-quettes, consulte les manuels avant toute opra-tion et maintenance.

Assurer vous que le manuel d'exploitation et demaintenance reste la disposition de l'utilisateur.

Assurer vous que les personnels sont forms dunemanire adquate, qu'ils sont comptents et qu'ilsont lu les manuels de maintenance.

La scurit n'tant pas uniquement une affaired'instructions, chaque fois que l'oprateur travailleavec un brise roche, il doit penser aux risques quipeuvent survenir en cours de travail et prvoir lesmoyens de les viter.

Ne jamals commencer un travail ou une oprationde maintenance sans tre certain que vous et lespersonnes alentours resteront en scurit.

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Page S3

GENERAL INFORMATION

A rock breaker is an accessory for mini-excavators,

backhoes or other excavators according to themodel.

The operator must have the necessary knowledgeand must be allowed to operate such carriers.

The operator must know the safety instructions con-cerning the carrier and comply with them.

In addition to the usual safety equipment, such ashelmet and safety shoes, the operator will, if needbe, have available:- Safety glasses, industrial gloves, dust mask andear protector.

Ample, loose clothing, watches or bracelets can insome circumstances be dangerous.

The operator will not absorb any alcoholic drinks ormedicines liable to generate sleepiness.

It is imperative to be informed and comply with alllocal laws and regulations concerning the breakersand their use.

MOUNTING ON CARRIER

Each model of breaker is suited to a specific carrier.

The operator must be informed of the technicalinstructions given by the manufacturer, such asCarrier minimum weight, working pressure, flowrate, hoses, dimensions and connection to carrier'shydraulic circuit.

Failure to follow these instructions could result inpermanent damage to the hydraulic hammer!

INFORMATIONS GENERALES

Un brise roche est un accessoire adaptable aux

mini-pelles, tracto-pelles ou pelles hydrauliquesselon le modle.

L'oprateur doit avoir acquis les connaissancesncessaires et doit tre autoris conduire de telsengins porteurs,

Il doit s'informer des consignes de scuritpropres lengin porteur et les respecter.

En plus de l'quipement de scurit habituel(casque, chaussures de scurit), l'oprateurdevra, si la nature des travaux l'impose, se munird'quipements tels que:- Lunettes et gants de protection, masque anti -poussires, casque anti - bruit, etc.

Les vtements amples, flottants, les braceletsmontre et autres sont proscrire car dangereuxen certaines circonstances.

L'oprateur ne doit pas absorber de boissonalcoolise ni de mdicament provoquant la som-

nolence pendant le travail.

Il est par allieurs impratif de prendre connais-sance et de respecter les rglements locaux con-cernant les brise roches et leur utilisation surchantier.

MONTAGE SUR PORTEUR

Chaque modle de brise roche est adapt untype d'engin porteur.

L'oprateur dolt prendre connaissance des pre-scriptions d'utilisation fournies par le constructeurdu porteur, telles que:- Poids minimum du porteur, pression d'utilisation,dbit, dimensionnement des flexibles et raccorde-ment au circuit hydraulique du porteur.

Le non respect de cos prescriptions peut endom-mager gravement le brise roche!

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Page S4

When someone helps to install the breaker, makesure any hand signals will be well understood.

Unexpected boom movements, when installing thebreaker, could result in hand injury:- Be sure the carrier is immobile and stable.- Keep your hands clear when moving the boomend between fixing plates.- Do not use your fingers to "feel" pin alignment.

When connecting the breaker hoses to the carriercircuit, be sure the circuit is not under pressure(check that the hydraulic tank is not pressurized)or at high temperature.

The carrier engine must be stopped.

Check that HP and LP return hoses are wellconnected.

Take all necessary steps to prevent oil leakageswhen connecting the breaker.

HYDRAULIC FLUIDS

Hydraulic fluids and lubricants can be dangerousto health if not used properly.

Avoid ingestion, skin contact and inhalation.

Safety data sheets for oil and lubricants should beobtained from the lubricant supplier.

Should hydraulic oil come into contact with eyes,rinse them abundantly and consult a doctor.

Lorsque un aide participe au montage du briseroche, s'assurer que les instructions donnes pargestes soient blen comprises.

Un mouvement inattendu du bras de pelle lors dumontage du marteau, peut tre la cause d'accidentaux mains:- S'assurer que le porteur est immobile et stable.- Ne pas laisser les mains proximit lors de ladescente de l'extrmit du bras entre les plaquesde fixation.- Ne pas vritier I'alignement des passages d'axesavec les doigts.

Lors du raccordement du brise roche au circuithydraulique du porteur, s'assurer que le circuitnest pas sous pression (penser au rservoir pres-suris) ou temprature leve.

Le moteur de l'engin porteur dolt tre arrt.

Veillez ce que les flexibles d'alimentation et deretour soient correctement branchs.

Prendre toutes les mesures ncessaires pourviter au maximum les pertes d'huiles lors du

branchement du brise roche.

FLUIDE HYDRAULIQUE

Les huiles hydrauliques et lubrifiants peuvent tredangereux pour la sant sils sont utiliss incor-rectement.

Ne pas avaler, mettre en contact avec la peau,ni Inhaler les manations.

Les fiches de paramtres de scurit pour leshuiles et lubriflants doivent tre obtenues auprsdu fournisseur.

Si de I'huile hydraulique entre en contact avec lesyeux, rincer les abondamment et consulter unmdecin.

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Page S5

Should hydraulic oil come into contact with skin,wash it off immediately.

Fine jets of hydraulic fluids at high pressure canpenetrate the skin causing serious injury.- Be sure the circuit is not under pressure prior toany intervention.- Do not use your hand to check for hydraulic fluidleakages.- If hydraulic fluid penetrates the skin, get medicalhelp immediately.

HYDRAULIC ACCUMULATOR

Rock breakers incorporate one or two hydraulicaccumulators containing nitrogen under pressure.

Never attempt to open the accumulator covers.

If an accumulator needs to be repaired, contactyour KOMATSU distributor.

OPERATION

If the carrier is in a work area where there arerisks of falling objects or rocks, the cabin must beequipped with an approved FOPS protection.

Prior to starting work, the operator will make surethere are no buried electricity, gas or water pipesor lines.

The operator must take every step to illuminate orlight up his working area and permanently takecare of ground stability.

The rock breaker will be used on a clear workingarea oriented in such a way, that inevitable rockchips produced by the contact of the tool with theground are not dangerous for the operator or anybystanders.

Nettoyer immdiatement la peau si de I'huile entreen contact avec celle-ci.

Les jets d'huile hydraulique sous pression peuventpntrer la peau et provoquer de gravesblessures.- Ne jamais intervener sur un circuit hydrauliquesous pression.- Ne jamais utiliser la main pour chercher unefuite.- Si de I'hulle hydraulique pntre sous la peau,consulter immdiatement un mdecin.

ACCUMULATEUR HYDRAULIQUE

Les brises roches comprennent 1 ou 2 accumula-teurs qui contiennent de I'azote sous pression.

Ne jamais dmonter les couvercies d'accumula-teurs.

Si une intervention est ncessaire sur un accumu-lateur, consulter votre distributeur KOMATSU leplus proche.

UTILISATION

S'il y a un risque de chutes d'objets ou de blocsdans la zone de travail, la cabine de l'engin por-teur doit tre quipe d'un systme de protectionhomologu "FOPS'.

Avant le dmarrage de travaux l'oprateur doirs'informer, de tous passages de conduitesd'1ectricit, gaz, eau ou autres prsentant undanger, dans sa zone d'intervention.

L'oprateur doit prendre si ncessaire toutes pr-cautions, pour signaler ou clairer sa zone de tra-vail et s'assurer en permanence de la stabilit duterrain sur lequel l'engin porteur doit voluer.

Le brise roche doit tre utilis sur une aire de tra-vail dgage avec une orientation telle que lesinvitables clats de roche, produits par le contactde l'outil avec le terrain, soient sans danger pourle voisinage et l'oprateur.

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Page S6

Stand clear from a breaker in operation.

It is highly recommended to have a protection gridin front of the excavator and in all places wherespecial care and safety are necessary.

Depending on the job done with the breaker, alargequantity of dust could be produced.- Avoid inhalation.Use water spraying to drop dust.

Do not use the breaker for any other applicationthan what it is intended for: Splitting blocks,digging trenches, demolition and excavations.

Never use the breaker as a lever.

Never use the breaker to lift loads.

Using a rock breaker without tool retaining pins isforbidden. Do not use any other tools than those

recommended by the manufacturer.

After a certain working time the rock breakertemperature could be high. Therefore avoid allcontact with any parts until it has completelycooled down and the pressure relieved in thehydraulic circuit.

Should the tool be changed, wait for cooling anduse proper gloves to protect your hands.

CAUTION: The vibrations of the breaker exceed8.2 ft/sec.

Do not touch the rock breaker while it is in opera-tion. Do not leave any object on the breaker.

Ne pas rester proximit du brise roche enfonctionnoment.

Il est vivement recommand de prvoir une grillede protection devant le poste de conduite de l'en-gin porteur et tous les endrolts indispensables lascurit de l'environnement immdiat du chantier.

Pendant l'utilisation du brise roche, principalementen dmolition, une quantit importante depoussibres peut tre produite.- Ne pas inhaler.Utillser de l'eau pour abattre les poussires.

Ne pas se servir du brise roche hydrauliqueautrement que pour les applications prvuescasse de blocs, travaux de tranches, fouilles,dmolitions.

Ne pas utiliser le marteau comme levier.

Ne pas utiliser le marteau pour soulever descharges.

L'emploi d'un brise roche hydraulique sansclaveftes de retenue d'outil est interdit. Ne pas

utiliser d'autres outils que ceux prvus par leconstructeur.

La temprature du brise roche aprs le travail peuttre leve: Eviter tout contact avec les pices dubrise roche, attendre le refroidissement complet deces dernires et la dcompression totale descircuits hydrauliques.

En cas de changement d' outil, attendre que labroche soit refroidie et se protger les mains avanttoute intervention.

ATTENTION: Les vibrations sur I'apparelldpassent 2,5 m/s.

Ne pas toucher le brise roche en fonctionnement,ni laisser aucun objet sur le brise roche.

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Page S7

MAINTENANCE AND REPAIRING

All components, accessories, pipes and connec-

tors added to the rock breaker should be:

- Of good quality, procured from a reputablemanufacturer and, wherever possible, be of a typeapproved by KOMATSU.

- Compatible with the breaker maximal workingpressure.

- Accompanied by instructions for safe installation,operation and maintenance.

When replacing HP and return hoses, use onlyhoses compatible with the maximum working pres-sure equipped with crimped end fittings.

The use of spare parts other than those includedin the KOMATSU approved parts list may createhazardous conditions over which KOMATSU hasno control. Therefore, KOMATSU cannot be heldresponsible for equipment on which non-approved

spare parts are installed.

MAINTENANCE ET REPARATION

Tous les composants, accessoires, tuyauteries et

connecteurs ajouts au brise roche doivent tre:

- De bonne qualit, produits par un fabricant debonne rputation et d'un type agr par KOMAT-SU toutes les fois que cela s'avre possible.

- Compatible avec la pression de travailmaximale autorise du brise roche.

- Accompagns d'instructions pour pouvoireffectuer l'installation, l'exploitation et la mainte-nance sans danger.

En cas de remplacement des flexibles d'alimentation et retour n'utiliser que des flexiblescompatibles avec la pression d'utilisation maxi-mum, quips d'embouts sertis.

L'utilisation de pices de rparation autres quecelles qui sont incluses dans la liste des pices quisont approuves par KOMATSU, peut engendrerdes conditions dangereuses sur lesquelles lasocit KOMATSU n'a aucun contrle, par con-

squent, la socit KOMATSU ne peut tre tenuecomme responsable des quipements sur lesquelsil est mont des pices de rparation non homo-logues.

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Model JPB3600V Ten Commandments

1

2

3

4

5

6

7

8

9

10

Dont ever modify the hydraulicinstallation set by the dealer.

Ne jamais pousser I'acclrateur jusqu' dpasser la limite indiqueau moment des essais de mise enroute.

Avoid any violent movement whenthe breaker is operating.

Eviter toute manoeuvre brutale dubras, alors que le brise roche esten phase de frappe.

Applied pressure is perpendicularto the material to be broken andalways follows the tool.

Imprimer au brise roche la bonnepousse, toulours perpendicu-

lairement la face du matriau dmolir.

Do not leave the breaker in thesame spot for long periods oftime (Short bursts = Production= Long tool life).

Ne pas insister plus de 15 sec-ondes sur le mme point,lorsque le matriau est partic-ulirement dur et tenace.

Never use the tool as a lever orto lift heavy loads.

Ne jamais se servir de l'outil dubrise roche comme s'il s'agissaitd'un levier ou d'un crochet delevage.

Avoid blank firing at all times.

Ne pas faire frapper le briseroche vide, c'est dire sansappul suffisant sur le matriau dmolir.

Lubricate the tool every twohours, using only a molybdenumbisulphide grease. If a lubricatingstation is available, make sure itis full and check the proper oper-ation of the pump before eachshift.

Lubrifier l'outil toutes les deuxheures de travail environ, en util-isant une graisse au bisulfure de

molybdne. S'il y a une centralede graissage, veiller son rem-plissage en dbut de poste detravail et vrifier son bon fonc-tionnement.

Replace the tool bushing whenthe wear limits are reached.

Remplacer la douille d'usurelorsque celle-ci atteint la limited'usure.

Continuously check for loosenuts, bolts and fittings and imme-diately replace loose or brokenitems.

Arrter immdiatement le briseroche lorsqu'un tirantd'assemblage est desserr oucass.

Stop the breaker immediatelywhen the blows per minutedecrease below normal operatingparameters or the hoses vibrateexcessively.

Arrter immdiatement le briseroche lorsque les flexibles vibrentde facon excessive.

Page O1

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Page O2

Model JPB3600V Dimensions

Operating Weight 5767 LbsPoids Total 2616 kg

Dimensions in MillimetersLes Cotes Sont Donnes en Millimtres

15 0

18 0

15 0

2011 0

38 0

11 0

20

14 X 27

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Model JPB3600V Technica

Page O3

TECHNICAL SPECIFICATIONS

Carrier recommended weight

Recommended oil flow

Minimum pressure at excavatorpressure relief valve

Admissible counter pressure

of the HP hose (inside)

of the LP hose (inside)

Weight (without adaptation kit, or tool)

Approximate weight in working order

Height with standard moil point

Overall width

Striking rate

Adjusted pressure on breaker

Protection against idle running

Tool diameter

IMPORTANT:The maximum authorized oiltemperature is 176 F at breaker and158 F in the excavator tank.

Rock breakers are designed tofunction with mineral oil with aviscosity of 32 cst at 104 F.

For use with other fluids such asengine oil or synthetic fluids, consultyour KOMATSU distributor.

CARACTERISTIQUESTECHNIQUES

Adaptation sur pelles de poids con-seiII:

Dbit d'huile recommand

Pression minimale de dclenchementdu clapet de scurit de la pelle

Contre pression admissible

de la tuyauterie haute pression(intrieur)

de la tuyauterie basse pression(intrieur)

Poids (sans kit mcanique. ni outil)

Poids moyen en ordre de marche

Hauteur avec outil pic standard

Largeur hors tout

Cadence de frappe

Pression rgle sur le marteau

Protection contre marche vide

corps d'outil

IMPORTANT:La temprature d'huile maximaleautorise esi 80 C au marteau et 70C au rservoir de la pelle.

Les brises- roches sont tudis pourtonctionner avec de I'huile minraledune viscosit de 32 cst 40 C.

Pour utilisation avec d'autres fluides,huiles moteur ou synthtiques,consulter votre distributeurKOMATSU.

KOMATSU

27.5 to 41 Tons

48/70gpm 180/265 lpm

3045 psi 210 bar

85 psi 6 bar

1.25 in 30 mm

1.25 in. 30 mm

5125 lbs 2325 kg

5490 lbs 2490 kg

101 in. 2565 mm

25.2 in. 640 mm

510 to 1160 bpm

2400 psi 165 bar

Yes Oui

5.91 in. 150 mm

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Page O4

IMPORTANT

Prior to any mounting, the operator must check

that the carrier characteristics correspond to therequired specifications, mainly:- Weight, flow and setting of relief valve(s) mount-ed on breaker line. (Refer to technical specifica-tions sheet).

Prior to any mounting, a flow and pressure test ofthe breaker circuit is imperative.

The operator will make sure that the hydraulicinstallation is acceptable as given and it cannotallow the inverse feeding of the breaker by the"return line".

Note: The breaker pressure line (HP line) is locat-ed on the right side of the breaker.Some carriers might have inverted piping (pres-sure line on the left side of the carrier boom).

Clearly identify HP pressure and return lines oncarrier boom.

If necessary, cross over the breaker hoses to allow

proper connection.

IMPORTANT

Avant tout montage, l'oprateur dolt s'assurer que

le porteur devant tre quip, correspond aux sp-cifications donnes principalement:- Poids, dbit et pression de tarage du(des)clapet(s) de dcharge situ(s) sur la ligne briseroche (Voir feuille spcifications techniques).

Un contrle du dbit et de la pression du circuitbrise roche est Indispensable.

Il doit vrifier que l'installation hydraulique est con-forme au schma de principe fourni et qu'elle nepermet pas I'alimentation inverse du marteau parle circuit "retour".

Note: La ligne d'alimentation (HP) est situe cotdroit du brise roche.Certains porteurs peuvent avoir des circuits inver-ss ( HP gauche du bras).

Identifier clairement les circuits HP et BP du bras.

Si ncessaire, croiser les flexibles de raccorde-

ment du brise roche pour permettre un branche-mentcorrect.

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Page O5

Precautions to be taken when connecting thebreaker

Feeding the rock breaker by the "breaker" LP line,(which is theoretically possible when the carrier isfitted with an extra spool with 3 positions) is forbid-den; otherwise the rock breaker may bedamaged.

It is therefore essential to

Take necessary steps to avoid activating the spoolin the wrong position: From P to return circuit ofrock breaker.- For instance, adaptation of a stop under the con-trol pedal (fig. 1) or mounting of a non-return valveon rock breaker LP line between the breaker andthe spool (fig. 2).

Prcautions prendre lors du raccordement

L'alimentation du brise roche par le circuit retour"marteau" thoriquement possible lorsque le por-teur est quip d'un distributeur supplmentaire 3positions, doit absolument tre vit6 sous peined'endommager le brise roche.

Pour cola, il faut

Prendre les mesures ncessaires pour empcherde commander le distributeur dans la mauvaiseposition: Passage de P vers circuit retour du briseroche.- Montage dune bute sous la pdale decommande (fig. 1), par example, ou bien montaged'un clapet anti-retour sur la ligne retour du briseroche, entre marteau et distributeur (fig. 2).

Fig. 1

Fig. 2

Normal workingMarche normale

Normal workingMarche normale

Mechanically impossible (stop)Rendu mcanicanique impossible (bute)

PossiblePossible

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Model JPB3600V Mounting

Page O6

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Model JPB3600V Mountin

Page O7

MONTAGE SUR PELLE PREEOUIPEE

Revoir les Instructions g6n6rales de socurit6, entre

autres, chapitre: Montage sur porteur.

- Descendre le balancier entre les flancs.

- Engager l'axe (rep. 1) et l'immobiliser.

- Descendre la biellette entre les flancs correspon-dants.

- Engager I'axe (rep. 2) et l'immobiliser.

- Vrifier le dbaftement du marteau et l'absenced'intertrences en positions extrmes.

- Brancher les flexibles de raccordement (rep. 3)du marteau (Veillez au raccordement).

- Vrifier le dbaftement du marteau:Les flexibles ne doivent pas tre tendus, pines oufrofter contre le bras dans n'importe quelle posi-tion.

Ne pas vrifier I'alignement despassages d'axes avec les doigts!

MOUNTING ON EXCAVATOR

Review the general safety instructions.

- Move the dipper stick end between thecorresponding sides of the fixing cap.

- Insert the pin (mark. 1) and secure it.

- Move the linkage between the correspondingsides of the fixing cap.

- Insert the pin (mark. 2) and secure it.

- Swing the breaker to each end position andmake sure that there is no interference with anyparts of the boom end.

- Connect the breaker hoses (mark. 3) onto pipeline at the boom (mind the proper connection).

- Swing the breaker to each end position.Hoses must not be caught, tight or rub against thecarrier boom in any position.

Do not use fingers to "feel" pin alignment!

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Model JPB3600V Tool Mountin

Fig. A Fig. B

Fig. CFig. D

Page O8

Fig. EFig. F

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Model JPB3600V Tool Mountin

TOOL MOUNTING

On a brand new breaker, remove the plasticprotection cover at the bottom of the front guide.

Lift the breaker and position it horizontally.

Use a screwdriver to push in the lock and keep itpushed in.Using a different screwdriver, tear off the plasticplug and push the retainer and the second plasticplug out.

Remove the plastic plug and the retainer.Remove the second retainer.Hand grease the tool shank, the bushings and theretainers.

Using a lifting device sized according to the weightof the tool, lift the tool keeping it horizontal.

Insert the tool into the front guide. Make sure thatthe flat edges are well positioned in order to insertthe tool retainers.

Do not use fingers to feel the alignment!

Use a screwdriver to push in the lock and keep itpushed in.

Insert the retainer by hand. Push it to the end witha screwdriver and the lock will release itself.

Do not use fingers to push the retainer tothe end!

Insert the second retainers.Mount the plastic plugs.

TOOL REMOVING

Remove the tool retainers.Remove the tool.

Mind the tool temperature!

Should the breaker be stored without the toolmounted, remount the tool retainers and the plas-tic plugs.

MONTAGE DE L'OUTIL

Dans le cas d'un brise roche neuf, enlever le bou-chon de protection.

Lever le brise roche et I'amener l'horizontal.

A I'aide d'un tournevis repousser le verrou, le tenirrepousser. A I'aide d'un second tournevis, percerle bouchon de protection, repousser la clavette etle bouchon de protection suprieur.

Enlever le bouchon et la clavette.Dmonter la deuxime clavetteGraisser l'emmanchement de l'outil, les douilles etles clavettes.

En utilisant un moyen de levage appropri aupoids des outils, lever l'outil en le maintenant hori-zontal.

Engager l'outil dans le guide avant. Veillez l'ori-entation des plats de l'outil par rapport au trou desclavettes.

Ne pas vrifier I'alignement avec le doigt!

A I'aide d'un tournevis repousser le verrou, et lemaintenir repouss

Engager la clavette la main, la repousser fond I'aide d'un tournevis: Le verrou ressort automatiquement.

Ne pas repousser la clavette avec le doigt!

Monter la deuxime clavette.Monter les bouchons de protection.

DEMONTAGE DE L'OUTIL

Dmonter les clavettes.Extraire l'outil.

Attention la temprature!

Si le marteau doit tre stock sans outil,remonter les clavettes et les bouchons.

Page O9

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Model JPB3600V Operation

Revolr les Instructions gnrales de scurit prin-cipalement chapitre "utilisation".

Avant d'utiliser le brise roche pour la premire fois,habituez vous contrler

- La positionLe brise roche doit toujours tre perpendiculaire la surface du matriau casser.

- La poussePour que lnergie du marteau soit transmise aumatriau et provoque sa rupture, il faut que l'outilsoit maintenu fermement en appui contre lematriau pendant toute la dure de frappe. Lapousse se rgle en abaissant le bras du porteur,et, au besoin pour corriger la position du briseroche et le maintenir perpendiculaire la surface dmolir en manoeuvrant les commandes de godetou de balancier.

- Il faut que la pousso soit correcteSi la pousse est insuffisante, lnergie du briseroche au lieu d'tre transmise au matriau sedissipera en partie dans l'outil, dans le brise rocheet dans le bras du porteur, crant des vibrations

anormales et provoquant des frappes vides.

Si par contre la pousse est trop forte, au point desoulever le porteur, lors de la rupture du matriau,l'excavateur retombera brusquement en avant.Cela provoquera des chocs dangereux etdestructeurs pour l'outil, les claveftes, les butesdu brise roche, le bras et autres parties du porteur.

Les vrins de bras du porieur ne doiventpas tre en bute avant ou arrire, lis n'yrsisteraient pas.

- Ne pas faire frapper le marteau videAvant de faire frapper le marteau, l'outil doit treen appui contre la surface casser.Les frappes vide (outil insuffisamment appuy)provoquent la destruction rapide des clavettes deretenues et sont la cause de casses d'outils.Lorsque le brise roche frappe vide, les coups ontun son aigu, mtallique.

Review the general safety instructions.

Before operating the breaker, train yourself tocheck:

- The positionThe rock breaker must be perpendicular to thematerial face at all times.

- Down pressureTo allow the breaker energy to be transmitted tothe material and break it, the tool must be firmlypressed against the material while hammering.Down pressure is adjusted by pulling down thecarrier boom and, if required, correcting the break-er position. Keep the breaker perpendicular to thematerial face by operating dipper stick or bucketcontrols.

- Down pressure must be correctIf the down pressure is insufficient, the breakerenergy will be partly dissipated into the tool, thebreaker itself and into the carrier boom, instead ofbeing transmitted to the material. This generates

abnormal vibrations and induces blank strikes.

If, on the other hand, the down pressure is so highas to lift the carrier at the moment of the breakageof the material, the carrier will drop suddenly.This will create dangerous and destructive shocksfor the tool, tool retainers, breaker thrusts, carrierbooms and other parts.

The carrier boom cylinders can bedamaged if they reach the end of theirstroke.

- Avoid blank strikesPrior to hammering, the tool must be pressedagainst the material face.Blank strikes (tool not properly in contact with thematerial) lead to fast wear of the tool retainer andare the origin of tool breakages.When blank striking, the breaker sounds highpitched and metallic.

Page O10

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Page O11

Pendant le travail maintenir le brise rocheperpendiculaire

Si le brise roche nest pas perpendiculaire, l'outilglisse sous l'effet de la pousse et coince entre lesdouilles de guidage.Les frottements importants crs entre outil etdouilles provoquent des grippages conduisant lacasse de l'outil, la destruction des douilles, voirl'extraction de la douille infrieure.L'nergie dissipe dans les plaques latrales ou lecaisson du marleau, provoque la rupture dessoudures.

Ne pas faire frapper le brise roche au mmeendrolt plus de 15 secondes.

Si la roche n'a pas casse pendant cette priode,repositionner le marteau un autre emplacement.Faire fonctionner le marteau trop longtemps lamme place peut provoquer un chauffementimportant de l'outil:- L'extrmit peut tre refoule (champignonnage),l'emmanchement peut gripper.Lors de la casse de blocs, il est prfrable de nepas les aftaquer au centre. Le rendement est bien

meilleur en procdant par degr et en attaquantd'abord les faces les plus favorables.

Ne pas utillsor l'outil comme levier- Pour finir de casser le matriau.- Pour dplacer les blocs.Les forces importantes appliques au marteausont l'origine:- De fissuration des soudures du berceau ou desplaques latrales.- De la destruction de la douille infrieure parcrasement.- De la rupture de l'outil.

When In use, keep the breaker perpendicular

If the breaker is not perpendicular, the tool mayslip off and get stuck between guiding bushings.Severe friction created between tool and bushingsleads to seizing which will result in tool breakages,bushing breakages or the lower bushing sliding off.Energy dissipated into the side plates or into thecradle of the breaker leads to welding breakage.

Never operate the breaker at the same place formore than 15 seconds.

If the material has not been broken at this time,reposition the breaker in another spot.Operating the breaker too long at the same placemay heat up the tool. This may cause the pointmay dull (mushrooming) and the shank may seize.When breaking boulders, do not start from thecenter. Production is higher when breaking slices,beginning at the most favorable faces.

Do not use the tool as a lever- To finish splitting the rock.- To move boulders.High forces applied onto the breaker may be theorigin of:- Cracks in the cradle or side plate welds.- Destruction of lower bushing by crushing it.- Tool breakage.

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Page O12

Ne pas utiliser le marteau sous l'eau

Dans le cas d'un travail sous l'eau (mme pour

une courte dure), il est ncessaire de pressuriserla partie avant du marteau, pour viter que l'eaune pntre l'intrieur.

Consulter page O13.

Le marteau doit tre pressuris avant d'treimmerg et jusqu' ce qu'ii soit retir de l'eau.

Note : La pressurisation est aussi indispensablechaque fois que des dbris peuvent pntrer dansle marteau (purgeage, par example).

Par temps froid, ne pas commencer le travailsans avoir prchauff le marteau

Dmarrer le porteur et faire prchauffer I'huile.

Lever le brise roche pour que l'outil ne soit pas enappui sur le sol, alimenter le marteau avec undbit rduit (moteur du porteur au ralenti) pendant

cinq minutes.Commencer le travail en augmentantprogressivement le dbit.

Graisser l'emmanchement de l'outil

Si le marteau nest pas quip dune central degraissage automatique, graisser l'outil toute 2heures de travail environ (5 ou 10 coups depompe graisse).

Utillser de la graisse au bisulfure de molyb-dne

Do not use the breaker under water

For underwater operation (even for a short time), it

is essential to pressurize the breaker front part toprevent water from entering inside the breaker.

See page O13.

The breaker must be pressurized prior to beingplunged into water and remain so while it is underwater.

Note: Pressurization is also essential every timethere is a possibility for debris to enter the frontpart (scaling, for example).

If the weather is cold, do not start workingwithout preheating the breaker

Start up the carrier and preheat oil.

Raise the breaker from the ground so that the toolis hung up. Feed the breaker with reduced flow(idle the carrier engine) for 5 minutes.

Start work, increasing the flow gradually.

Grease the tool shank

If the breaker is not equipped with an automaticlubricating station, grease the tool shank every 2hours (5 to 10 shots with a hand grease pump).

Use molybdenum bisulphide grease

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Model JPB3600V MaintenanceDailyToutes les jours

WeeklyToutes les semaines

Page O13

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Model JPB3600V Maintenance

Page O14

EVERY 2 HOURS

Grease the tool shank.

DAILY

Check the breaker attachment at the boom end.

Make sure that a side rod is not broken.

WEEKLY

Check tightening of side fixing cap bolts.

Check tightenning of wear plate screws.

Remove the tool.

Check the tool shank and striking face condition.

Replace the tool if deeply scratched.

Check the tool retainer condition.

Replace if it shows important marks.

Check the lower bushing wear.

Call your KOMATSU distributor if wear limit isreached.

Check the grease level of the automatic greaser ifinstalled.

TOUTES LES 2 HEURES D'UTILISATION

Graisser l'emmanchement de l'outil.

TOUSLES JOURS

Vrifier la fixation du marteau en bout de bras.

Vrifier qu'un tirant d'assemblage ne soit pascass.

CHAQUE SEMAINE

Contrler le serrage des boulons de fixation desplaques latrales.

Contrler le serrage des palques de guidage dansberceau.

Dmonter l'outil.

Vrifier ltat de l'emmanchement et de la face defrappe.

Remplacer loutil s'il prsente des grippagesimportants.

Vrifier ltat de la clavette de retenue.

La remplacer si elle prsente des traces de chocimportants.

Contrler l'usure de la douille infrieure.

Demander lintervention d'un technicianKOMATSU pour la remplacer quand la limits del'usure est atteinte.

Vrifier le niveau de graise dans la centraleautomatique si monte.

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The KOMATSU Model JPB3600V in the stan-dard version must not be used for underwaterwork, even for very short periods of time. If thechamber between the piston and the tool fillswith water when the piston strikes, the waterwill not be evacuated fast enough and a consid-erablepressure rise will then occur and destroy thepiston seal (with a risk of piston seizure).

Compressor Pressure: Pressure from the compressor must be at least 22 psi above the water pressureat the working depth. Water pressure equals 14.5 psi for every 30 feet of depth. Through the first 30 feet,36.5 psi of air pressure is required.

Tool Life: KOMATSU working tools are made from a special steel far superior to any tool steel commer-cially available. Unlike other tools on the market, our steel is hardened all the way through - no thin shell ofhard steel which wears quickly. When the tools lose their edge, either at the tip or on the sides, it is possibleto sharpen them without repeating heat treatment, using one of the following methods:

A) With a milling or planning machine for chisels and spades, or with a lathe for the moils and blunt tools.These operations must be completed using an adequate type of hard metal tool.

B) By sharpening: This operation must be performed using a coolant to prevent the tool from overheating.

As a general rule, never let the tool cool quickly or suddenly, even when it is used with the breaker.

Dipping the tool into water when it has been heated in the course of work or leaving it in the snow in thewinter, will result in a drenching effect on the tip or cutting bit and increase the risk of breakage.

Tools are covered by KOMATSU against metal defects (very uncommon). It is not unusual that someoperations (working at angles or blank firing) lead to tool breakage, including inside the chuck housing.

The use of after market tools will void your warranty for any claim related to parts in contact with the tool(including the main piston).

Caution

Page O15

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Model JPB3600V Tool Guid

Page O16

How a demolition tool cracks rock and concrete

When the hammer piston strikes the top of a demolition tool, it sends a compressive stress wavedown to the working end of the tool. Provided that the demolition tool is in contact with the rock orconcrete which requires breaking, it is this compressive stress wave which fractures the rock.Then, immediately following the compressive wave, a tensile stress wave is formed due to thehammer piston lifting from the top of the demolition tool.

The cycle of compressive and tensile stresses flowing down the tool is repeated for each hammerblow. Obviously, anything that interferes with the strength of the compressive stress wave duringservice, for example "blank firing" or bending of the demolition tool due to leverage, will result inloss of breaker efficiency of up to 80% and possible failure of the tool itself.

Correct operating conditionsThe continuous cycle of compressive and tensile stresses in the demolition tool, even under cor-rect operating conditions, creates fatigue stress in the tool which can lead to the fatigue failure ofthe tool before it is worn out. Anything that interferes with the cycle of compressive and tensilestresses will also increase the level of fatigue stress being applied to the demolition tool and, thus,increase the risk of early fatigue failure of the tool.

The main cause of increased fatigue stress in a demolition tool is any form of side pressure duringservice which creates bending. Thus, utilizing the tool as a lever, using an incorrect driving angleor attempting to break ground using the pull of the excavator, are all detrimental to the life of ademolition tool and should be avoided.

The hydraulic power available in the machine far exceeds the strength of a demolition toolif it is used incorrectly and can "snap the tool like a pencil".

Demolition tool fatigue failure

Demolition tool fatigue failure will occur in approximately 4 inches from either side of the chuckfront face or through the retainer pin flat. Another slightly less common failure area can fall approx-imately 8 inches from the working end, subject to the nature of use. The fracture face itself will nor-mally exhibit semi-circular polished area with the remainder being of rougher appearance. The pol-ished semi-circular area is the fatigue area and generally starts from a damage mark or otherstress initiated on the outside of the demolition tool and spreads inward.

The fatigue area slowly widens until the stresses being applied to the demolition tool cause sud-den failure of the remaining section. Generally, the size of the fatigue area indicates the level ofstress applied to the tool, i.e., the smaller the fatigue area, the higher the stress level. However, itmust be borne in mind that once initiation of a fatigue crack has taken place, it requires a lowerstress level to cause it to grow.

Caution

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Page O17

Causes of increased fatigue stress in a demolition tool

A. Free running (or blank firing)Free running occurs when the hammer piston strikes the top of the demolition tool when the work-ing end is not in proper contact with the rock or concrete to be broken. This includes jobs wherethe tool slides off the working area and also when breakthrough of thin concrete slabs or bouldersoccurs.

B. Cold:Low temperatures cause a demolition tool to be more susceptible to fatigue failure. Tools shouldbe warmed before use.

C. Mechanical and thermal damage:

Any form of damage to the surface of a demolition tool renders it more liable to suffer fatigue fail-ure. Thus, all care must be exercised to prevent scratches, gouges or weld marks occurring due toaccidental damage and galling caused by contact between the tool and the chuck bushing throughthe lack of lubrication or excessive bending.

D. Lubrication:Care must be taken to avoid metal-to-metal contact that, as a result of galling, could cause deepdamage marks which, in turn, may lead to the formation of fatigue cracks and eventually failure ofthe demolition tool. Make sure that the shank of the demolition tool is well lubricated before insert-ing it into the hammer.

E. Corrosion:A rusty demolition tool is more likely to suffer fatigue failure. Keep tools well greased and shelteredfrom the weather when not in use.

Typical failures

KOMATSU demolition tools are manufactured from first class materials and then heat treated toproduce a fatigue and wear resistant tool. Thus, when the tool has apparently failed to give a satis-factory service life, a brief visual inspection can often give a quick indication of the failure cause.

Wear is dictated by the conditions of the material being broken. In general, however, the followingguidelines apply:

Blank tools worn more than 1/3 of their diameter, or moils and chisels worn back more than2 inches from the working end, are classed as reasonable life.

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Page O18

KOMATSU demolition tool guide

A B C D E F

Ref Tool type Application

A Moil point Low abrasive, homogenous materialB Chisel Plastic or heterogeneous materialC In-line chisel Plastic or heterogeneous materialD Blunt Crumbly rockE In-line asphalt cutter Asphalt cutter and trenchingF SpadeFrost Asphalt and trenching

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Fatigue breakage with typicalfatigue wrinkles due to steeldefect.100 % WARRANTY

Failure due to blank firing orexcessive wear of bushingsand/or chuck housing.

NO WARRANTY

Failure due to- operation with worn out retaining pins- blank firing- twisting tool

NO WARRANTY

Breakage due to impropercontact between the tool'stip and rock or concrete.

NO WARRANTY

Mushrooming or fast wearingcaused by operating too longon the same spot.

NO WARRANTY

Typical failure caused bymisalignment betweendown pressure, hammer, and

tool (prying, levering, etc).

NO WARRANTY

Page O19

BREAKAGE CHART

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Model JPB3600V Trouble Shooting

Page M1

PANNES POSSIBLES REMDES

A - Fulte d'hulle au niveau du marteau.

Joints d'tanchit endommags ou uss. Con-sultez votre distributeur KOMATSU le plus proche.

B - Le marteau manque de puissance, les flexiblesde raccordement battent.

L'accumulateur est dgonfl, la membrane de I'ac-cumulateur est perce. Vrifier la temprature deI'huile. En cas d'chauffement important, faire vri-fier par un technicien, le rglage des clapets dedcharge du circuit de pelle. Consultez votredistributeur KOMATSU le plus proche.

C - Le marteau fonctionne normalement puis lacadence ralentit et le marteau s'arrite. Quelquetemps aprs le marteau redmarre puis s'arrte.

L'huile hydraulique est trop chaude.Le porteur doit tre vrifi pour trouver l'origine del'chauffement. Si ncessaire rduire la pressionde frappe du marteau.

D - Un tirant d'assemblage est cass.

Arrdter le travail immdiatement.Consultez votre distributeur KOMATSU le plusproche.

E - Aprs adaptation au porteur, le marteau tapequelques coups puis s'arrte.

Le flexible retour est bouch, vrifier le coupleur(si monte).

Recommandation: Le brise roche ayant une puis-sance globale leve, veiller au bon refroidisse-ment de I'huile. Un mauvals rglage du clapet desurpression du porteur peut tre la cause d'unchauffement important de I'huile entrainant unmauvais fonctionnement du brise roche.

TROUBLE SHOOTING REMEDIES

A - Oil leakage on hammer.

Damaged or worn seals.Call your KOMATSU distributor.

B - The breaker loses power; high vibrations inbreaker hoses.

The accumulator is deflated or diaphragmpunctured. Check the oil temperature.If oil is too hot, ask a technician to check thebreaker circuit relief valve setting.Call your KOMATSU distributor.

C - The hammer operates normally, then slowsdown and stops. A few minutes later the hammerwill start again then stop again.

Hydraulic oil is too hot.Excavator circuit must be checked for heat source.If necessary, reduce the breaker operating pres-sure.

D - One side rod bolt has broken.

Stop working immediately and call your KOMATSUdistributor.

E - After connection to carrier, the breaker oper-ates for few blows then stops.

The return hose is plugged. Check the quickcoupling seat (if installed).

Recommendation: Check oil temperature andsettings of carrier relief valves. If relief valve is notadjusted properly, oil may heat up quicker due tothe high total power of rock breaker. This willcause the rock breaker to perform poorly.

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TECHNICAL PROBLEMS

Before looking for a hammer problem, look for a problem in the installation like bad quick couplers or aplugged filter [see page M3 for how to check the installation].

Make sure that the hammer has not been hooked up backwards.

Make sure that the hammer has the proper tool.

Make sure that the down pressure has been applied.

Make sure that no valve(s) are closed.

For any other problem refer to the Trouble Shooting page M1. If you cannot identify the problem, BEFOREcalling your KOMATSU dealer, collect the following information. A complete diagnosis cannot be done with-out it.

Low Pressure Gauge 0-160 Psi

Return and Supply Lines (Same Size as Breaker)

Flow Meter

Flow Scale

Oil Temperature Gauge

Pressure Gauge

Needle Valve

Page M2

A. Flow rate in high pressure line running to the hammer at operating temperature and operating pressure.B. Value of high pressure at hammer inlet when hammer is operating (use a 0-3000 psi gauge).C. Value of back pressure in return line (use a 0-300 psi gauge).D. Setting of relief valve in the system. For more details, please refer to page M3.

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Page M3

How to check hydraulic circuit and installation

Mount a flow meter in place of the hammer. Also, mount a low pressure (0-300 psi) gauge on the outlet of

the flow meter in order to test the back pressure in the return circuit.With the flow meter in place, activate the circuit and bring the machine up to operating temperature. Do nottest the machine cold.

If the control valve is equipped with solenoid, switch on the solenoid before starting the engine to avoiddamage to the flow meter. Do not switch on or off the solenoid when the engine is running. Adjust the flowoutput to match the requirements of the breaker (48 to 70 gpm).

After the flow has been adjusted, load the flow meter to the hammer operating pressure 2400 psi value plus600 psi. If necessary, readjust the flow to keep the hammer flow value constant for pressure varyingbetween 1000 psi and hammer operating pressure value (2400 psi) plus 600 psi.

Relief valve problems

If you cannot reach the proper oil flow at the hammer operating pressure value plus 600 psi, you may havea bad system relief setting or a bad hammer control valve.

To check system relief valve, see excavator manual for proper relief setting. Build pressure with the flowmeter to determine relief cracking pressure (usually 50 to 200 psi below relief setting). Reset relief if need-ed.

There should be 400 to 500 psi between hammer regulated pressure value and system cracking pressureor heat may develop.

Pump problems

If you cannot produce proper oil flow against pressure varying from 1000 psi to hammer operating pressureplus 600 psi, the pump could be bad or there is excessive leakage in the circuit.

Hammer control valve problems

If relief valve and pump are good, open and close valve three or four times. The valve spool may be stick-ing or back pressure is developing on return line.

With the flow adjusted and the flow meter loaded to hammer operating pressure value plus 600 psi, takenote of the low pressure gauge reading.

The return pressure should be less than 85 psi. If the back pressure is more than 85 psi, the restrictioncausing this higher pressure must be found and eliminated.

After the flow meter test is completed, disconnect the flow meter and connect the hoses to the hammer.Mount a high pressure gauge (0-3000 psi) on the hammer HP line and take the machine outside. Run thehammer on a heavy 3 inch by 40 inch by 40 inch steel plate on hard ground and take note of the pressurereading. Call your KOMATSU dealer if pressure adjustments are needed.

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Model JPB3600V

Page M4

This Page Left Blank Intentionally

Cette Page est Laisse Blanche Intentionnellement

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Model JPB3600V Grease Station

November 1999

GREASE STATION

MANUALForm No. CEAP000100

Revision 0

Greaser

Page G1

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Page G2


This Page Left Blank Intentionally

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Page G3


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Page G4

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Page G5

Grease Station Parts List

Item Part Number DESCRIPTION

WG82720L 1 Lubricating Station

1 WGLCN247674 1 Reservoir2 WGLCN247676 1 Hose3 WGLCN247675 1 Stirring paddle4 WGLCN247679 1 Washer5 2 Bearing ring, part of kit WGLCN2464346 1 Bearing, part of kit WGLCN2464347 WGLCN246424 1 O-ring8 WGLCN246425 1 Intermediate plate9 1 Shim, part of kit WGLCN24643410 2 Snap ring, part of kit WGLCN24643411 1 Inner ring, part of kit WGLCN24643412 WGLCN246427 1 Eccentric cam13 3 Screw, part of kits WGLCN246435 & WGLCN246436

14 3 Washer, part of kits WGLCN246435 & WGLCN24643615 1 O-ring, part of kits WGLCN246435 & WGLCN246436 & WGLCN24643716 WGLCN246426 1 Pump housing17 WGLCN246422 2 Closure plug18 1 Socket with cord, part of kit WGLCN24642919 1 Flat packing part of kits WGLCN246429, WGLCN246440, WGLCN246441,

WGLCN24643120 4 Screw, part of kits WGLCN246440 & WGLCN24644121 1 Plug, part of kit WGLCN24644022 WGLCN246423 1 Sealing plug25 WGLCN5050 1 Grease fitting27 1 Woodruff key, part of kits WGLCN246435 & WGLCN24643628 1 Radial seal, part of kits WGLCN246435 & WGLCN24643629 1 12V DC motor, part of kit WGLCN24643529 1 24V DC motor, part of kit WGLCN24643630 WGLCN246421 1 Housing cover31 1 Hose not sold32 1 Plug, part of kit WGLCN24644133 1 Socke, part of kit WGLCN24643134 1 Check valve, part of kit WGLCN60026876235 1 Pump element, part of kit WGLCN60026876236 1 Gasket, part of kit WGLCN60026876237 WGLCN249567 1 Pressure relief assembly38 1 Plug for motor, part of kits WGLCN246435 & WGLCN24643639 WGLCN242125 1 Grease cap40 WGLCN5045 1 Grease fitting41 WGLCN246428 1 Adapter for relief assembly42 WGLCN247671 1 Lid43 WGLCN247664 1 Fixed paddle44 WGLCN247677 1 O-ring45 WGLCN247678 1 Adapter46 WGLCN219141382 1 Gasket, part of kit WGLCN600268762

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Grease Station Service Parts/KitsItemPart Number DESCRIPTION

WG5045 1 Grease fitting 40WG5050 1 Grease fitting 25WG242125 1 Grease cap 39WG246321 1 Pressure relief assembly 37WG246420 1 Printed circuit bord 26WG246421 1 Housing cover 30WG246422 1 Closure plug 17WG246423 1 Sealing plug 22WG246424 2 O-ring 7WG246425 1 Intermediate plate 8WG246426 1 Pump housing 6WG246427 1 Eccentric cam 12WG246428 1 Adapter for relief assembly 41WG246429 Power kord kit contains:

1 Socket with cord 181 Flat packing 19

WG246431 Optional manual lube cord set contanins:1 Flat packing 191 Socket with cord 33

WG246434 Bearing and seal kit contains:1 Washer 42 Bearing ring 51 Bearing 61 Shim 92 Snap ring 101 Inner ring 11

WG246435 12V DC Motor kit contains:3 Screw 133 Washer 143 O-ring 151 Woodruff key 271 Radial seal 281 12V DC motor 291 Plug for motor 38

WG246436 24V DC motor kit conatains:3 Screw 133 Washer 143 O-ring 151 Woodruff key 271 Radial seal 281 24V DC motor 291 Plug for motor 38

WG246437 Housing seal kit contains:3 O-ring 151 Radial seal 28

WG246440 Power plug kit contains:1 Flat packing 194 Screws 201 Plug 21

WG246441 Optional manual lube plug set contains:1 Flat packing 194 Screws 201 Plug 32

WG247664 1 Fixed paddle 43WG247671 1 Lid 42WG247673 1 Reservoir 1WG247675 1 Stirring paddle 3WG247676 1 Hose 2WG247677 1 O-ring 44WG247678 1 Adapter 45WG247679 1 Washer 4WG219141382 1 O-ring 46WG600268762 Pump element assembly contains:

1 Check valve 341 Pump element 351 Gasket 36

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JPB3600V - om.PDF