Serial No.

: SMT-12F-007

OPERATING MANUAL

SMTechnology Co.,Ltd.

DATE : NOV. 2011 1/38

[ Part Ⅰ] Operating Manual

1. Safety Precautions

1.1 Safety Precautions

1) This manual contains safety, operation, and routine maintenance instructions. It

does not contain service disassembly instructions. If needed, complete service
disassembly and assembly instructions are contained in the manual, which can
be ordered from your SMT Hydraulic Breaker authorized and certified dealer.

2) Breaker Operator and maintenance personnel must always comply with the
safety precautions given in this manual and on the decal and tags attached
to the breaker and the hose.

3) These safety precautions are given for your safety. Review them carefully before
operating the breaker and performing general maintenance or repairs.

4) Supervising personnel or the owner operator should develop additional

precautions relating to the specific work area and local safety regulations.
Place the added precautions in the space provided under local safety
regulations.

5) Please read the following warning.

! DANGER
SERIOUS INJURY OR DEATH COULD RESULT FROM THE IMPROPER REPAIR OR SERVICE OF THIS
BREAKER.
REPAIRS AND/OR SERVICE TO THIS BREAKER MUST ONLY BE DONE BY AN AUTHORIZED AND
CERTIFIED DEALER.

1.2 General Safety Precautions

1) The SMT Hydraulic Breaker Series will provide safe and dependable performance
of operation in accordance with the instructions given in this manual. Read and
understand this manual and any decals and tags attached to the breaker before
operation. Failure to do so could result in personal injury or equipment damage.
a) Operate the breaker in accordance with all laws and regulations which affect

DATE : NOV. 2011 2/38

 you, your equipment and the work site.
b) Do not operate the breaker unless you have read the carrier equipment manual
and throughly understand all safety, operation and maintenance instructions.
c) Ensure that all maintenance procedures recommended in this manual are
completed before using the equipment.
d) The operator must not operate the breaker or the carrier if any people are
within the area where they may be injured by flying debris or movement of
the equipment.
e) Know the limits of your equipment.
f) Establish a training program for all operators to ensure safe operation.
g) Do not operate the breaker unless throughly trained or under the supervision
of an instructor.
h) Become familiar with the carrier controls before operating the carrier and
the breaker.
i) While learning to operator the breaker and carrier, do so at a slow pace. If
necessary, set the carrier mode selector to the slow position.
j) Make sure all controls(levers and pedals) are in the neutral position before
starting the carrier.
k) Before leaving the carrier, always lower the boom and ensure the carrier is
stable. Never be the machine with the engine running. Always engage the
parking brake.
l) Stop the engine before attempting to make any repairs, adjustments or
servicing to either the carrier or the breaker.
m) Do not operate the breaker at oil temperatures above 175˚F/80˚C. Operation
at higher temperatures can damage to the internal components of the breaker
and back-hoe/excavator and will result in reduced breaker performance.
n) Do not operate a damaged, leaking, improperly adjusted, or incompletely
assembled breaker.
o) Do not modify this breaker in any manner.
p) Use only the breaker Tools manufactured by JAB. Application of the breaker
Tools produced by other manufacturers may damage the equipment and will
void the warranty.
q) To avoid personal injury or equipment damage, all breaker repair, maintenance
and service must only be performed by authorized and properly trained
personnel.
r) If you do not understanded how to safely operate your breaker, contact an
authorized JAB Dealer for assistance.
s) Keep this manual with the breaker.
t) Do not operate this equipment if you are taking medication which may affect
your mental judgement or physical performance.
u) Do not operate the equipment if you are under the influence of drugs or alcohol.
v) Remove the breaker from the carrier during transport.

DATE : NOV. 2011 3/38

2) Warning Sticker
- Show smaller than actual size
(a) Used Earing Protection
(b) Used Head Protection
(c) Used Breathing Protection
(d) Used Foot Protection
(e) Read The Manual Before Use

(a) (b) (c) (d) (e)

3) Safety Symbols

! DANGER ! WARNING IMPORTANT

This safety symbol may This safety symbol
This safety symbol
appear on the appears in these
appears in these
breaker. It is used to instructions to identify
instructions to identify
alert the operator of an action or condition
an action that could
an action that could that could result in
cause bodily injury to
place him, her or damage to the
the operator or other
others in a life breaker or other
personnel.
threatening situation. equipment.

(a) The safety symbols are to emphasize all operation, maintenance and
repair action which, if not strictly followed, could result in a life-threatening
situation, bodily injury or damage to equipment.
(b) Always observe the safety symbols. They are included for your safety
and for the protection of the breaker.

4) Greasing Sticker

1. With the breaker mounted on carrier, apply pressure to

the Tool.
2. Fill the cavity with the recommended grease.
3. Grease whenever the Tool looks dry.
4. When installing a new Tool, liberally coat the upper 1/3 of
the Tool with grease before inserting.
5. Failure to comply with these instructions can result in
damage to the breaker and will void the warranty.

DATE : NOV. 2011 4/38

1.2 Stickers and Decals placed on the Hydraulic Breaker

1) Stickers placed on the Breakers - SMT20, SMT30, SMT40, SMT50, SMT70, SMT100

2) Stickers placed on the Breakers - SMT150, SMT160, SMT200, SMT250, SMT350, SMT400

DATE : NOV. 2011 5/38

 ITEM CONTENT STICKER PICTURE

① NAME PLATE

② EAR PROTECTION

③ DANGER

④ GREASING

DATE : NOV. 2011 6/38

 ITEM CONTENT STICKER PICTURE

Back-Head Not
⑤ Charged with
N2 Gas

⑥ VALVE ADJUSTER

⑦ CYLINDER ADJUSTER

PRESSURIZED
⑧ ACCUMULATOR SET

⑨ TRACTION

DATE : NOV. 2011 7/38

2. Technical Data

2.1 Standard Specifications (Silenced & Top Bracket)

Model
UNIT SMT20 SMT30 SMT40 SMT50 SMT70 SMT100 SMT150 SMT160
Description

Kg 126 152 295 375 571 861 1,300 1,300

Operating Weight
lbs 278 335 650 827 1,259 1,898 2,865 2,865

bar 140 150 160 180 180 190 210 210

Setting Pressure
psi 2,030 2,175 2,320 2,611 2,611 2,756 3,046 3,046

bar 90 ~ 120 90 ~ 120 110 ~ 140 120 ~ 150 130 ~ 160 150 ~ 170 150 ~ 180 150 ~ 170
Operating
Pressure
psi 1,280 ~ 1,707 1,280 ~ 1,707 1,565 ~1,991 1,707 ~ 2,134 1,849 ~ 2,276 2,134 ~ 2,418 2,176 ~ 2,611 2,176 ~ 2,466

l/min 20 ~ 40 25 ~ 50 40 ~ 70 50 ~ 90 60 ~ 100 80 ~ 110 90 ~ 120 90 ~ 120

Oil Flow Range
gal/min 5 ~ 10.5 6.5 ~ 13 10.5 ~ 18.5 13 ~ 24 16 ~ 26.5 21 ~ 29 24 ~ 32 24 ~ 32

Impact Rate bpm 700 ~ 1,200 600 ~ 1,100 500 ~ 900 400 ~ 800 400 ~ 800 450 ~ 630 450 ~ 700 450 ~ 700

Hose Diameter inch 1/2 1/2 1/2 1/2 3/4 3/4 1 1

Tool Shank
Diameter mm/inch 45 / 1.8 53 / 2.1 68 / 2.7 75 / 2.9 85 / 3.3 100 / 3.9 120 / 4.7 125 / 4.9
(Moil Point Type)

ton 1.2 ~ 3.0 2.5 ~ 4.5 4~7 6~9 7 ~ 14 11~16 13 ~ 20 16 ~ 22

Selection of
Machine
lbs 2,645 ~ 6,613 5,511 ~ 9,920 8,818 ~ 15,432 13,227~19,841 15,432~30,864 24,250~35,274 28,660~ 44,100 35,270~48,500

* The above specifications are subject to change without prior notice for the quality
enhancement.
* In case of Top Bracket type, overall weight is the weight including only frame
assembly without the top bracket.

DATE : NOV. 2011 8/38

 2.2 Standard Specifications (Silenced & Top Bracket)

Model
UNIT SMT200 SMT220 SMT250 SMT350 SMT400 SMT450 SMT500 SMT550
Description

Kg 1,500 1,660 1,766 2,071 2,632 3,180 3,450 3,991

Operating Weight
lbs 3,307 3,658 3,893 4,566 5,803 7,011 7,606 8,799

bar 210 210 210 230 230 230 250 250

Setting Pressure
psi 3,046 3,046 3,046 3,336 3,336 3,336 3,626 3,626

bar 160 ~ 180 160 ~ 180 160 ~ 180 160 ~ 180 160 ~ 180 160 ~ 180 160 ~ 180 160 ~ 180
Operating Pressure
psi 2,276 ~ 2,560 2,276 ~ 2,560 2,276 ~ 2,560 2,276 ~ 2,560 2,276 ~ 2,560 2,276 ~ 2,560 2,276 ~ 2,560 2,276 ~ 2,560

l/min 100 ~ 150 100 ~ 150 120 ~ 180 150 ~ 210 180 ~ 240 190 ~ 250 200 ~ 260 210 ~ 290
Oil Flow Range
gal/min 27 ~ 40 27 ~ 40 32 ~ 48 40 ~ 56 48 ~ 63 50 ~ 66 51 ~ 69 55 ~ 77

Impact Rate bpm 350 ~ 600 400 ~ 600 350 ~ 500 300 ~ 450 300 ~ 450 300 ~ 600 250 ~ 400 200 ~ 350

Hose Diameter inch 1 1 1 1 1 -1/4 1 -1/4 1 -1/4 1 -1/4

Tool Shank
Diameter mm/inch 135 / 5.3 135 / 5.3 140 / 5.5 150 / 5.9 155 / 6.1 160 / 6.3 165 / 6.5 175 / 6.9
(Moil Point Type)

ton 18 ~ 21 18 ~ 21 18 ~ 26 25 ~ 30 28 ~ 35 35 ~ 48 30 ~ 45 40 ~ 55
Applicable Carrier
Weight
lbs 39,683~46,297 39,683~46,297 39,683~57,320 55,115~66,138 61,729~77,161 77,161~105,821 66,138~99,208 88,185~121,254

* The above specifications are subject to change without prior notice for the quality
enhancement.
* In case of Top Bracket type, overall weight is the weight including only frame
assembly without the top bracket.

DATE : NOV. 2011 9/38

3. Construction and Main Parts

Through Bolt
The Front head, the cylinder and the
Back-Head of the main body are tightly
fixed with four through bolts.

Back-Head
The Gas charging valve is built in and the
inside is charged with N2-gas.

Valve Ass'y
The Cylindrical control valve is built in the
cylinder and controls piston reciprocation.

Piston
Kinetic energy of the piston is converted
into hammering energy after hitting the
Tool. The hammering energy transmitted to
the Tool breaks rocks.

Front Head
The front head supports the whole breaker.
The Thrust ring and the thrust bushing
prevents shock from the Tool.

Tool
The specially heat-treated Tool is directly
applied to break rocks. It is used as moil
point, wedge point and flat Tool according
to the application(optional).

Accumulator Ass'y
The accumulator compensates for pressure
in the hydraulic circuit and prevents
pulsation. It is not usually necessary to refill.
Use N2-gas only.

DATE : NOV. 2011 10/38

 3.1 Checking - before installation instructions

! WARNING

▶ CHECK THE "SPECIFICATIONS" SECTION OF THIS MANUAL TO DETERMINE CORRECT BACKHOE

AND EXCAVATOR SIZES AND HYDRAULIC PRESSURE, AND HYDRAULIC FLOW REQUIREMENTS.
▶ IF HYDRAULIC PRESSURE, HYDRAULIC FLOW ARE EXCEEDED, THE BREAKER WARRANTY IS VOID.
▶ CHECK THE NITROGEN GAS! - THE BACK HEAD AND THE ACCUMULATOR.

WARNING
!
▶ BE SURE THE FLUID IN THE HYDRAULIC SYSTEM IS CLEAN.
▶ CHECK THE HYDRAULIC FILTER. REPLACE THE FILTER IF DIRTY OR DETERIORATE.
▶ HOSE AND PIPING MUST BE FLUSHING.

! WARNING

▶ THE CONTAMINATED PART MUST BE CLEANED WITH NO DELAY.

▶ HYDRAULIC OIL OR LIGHT OIL IS HIGHLY RECOMMENDABLE.

! WARNING

▶ THE CIRCUIT RELIEF SETTING PRESSURE IS NOT FIXED, BUT IT WILL BE ADJUSTED BY PUMP
CAPACITY.

■ Recommended circuit relief setting pressure and back pressure

Model
SMT20 SMT30 SMT40 SMT50 SMT70 SMT100 SMT150 SMT160 SMT200 SMT220 SMT250 SMT350 SMT400 SMT450
Unit
Relief Setting
Pressure (bar) 140 150 170 170 195 190 210 210 210 210 210 230 230 230

Back Pressure
4 4 4 4 4 4 5 5 5 5 5 5 5 5
(bar)

■ Since SMT's hydraulic breaker operates with various kinds of hydraulic construction
machines, it should be installed after serviceman's check of the base machine to
display its full performance. Necessary preparations prior to installation and operation
of the hydraulic breaker are as follows.

DATE : NOV. 2011 11/38

3.2 Installation Top Bracket

■ Top Bracket Type

DATE : NOV. 2011 12/38

4. Principle of Operation

The relation between the pressure affected area A1 of the

piston rear chamber and the pressure affected are A2 of
the piston front chamber is A1>A2. High-pressure oil is always
applied to A2 and, when oil pressure applied to A1 is changed
from high to low pressure and vice versa, piston C2
reciprocates. Similarly the relation between the pressure
affected area A3 of the valve high-pressure chamber and
the pressure affected are A4>A3. High-pressure oil is always
applied to A3, A4 and A3<A4. Therefore, the Valve is move
the A4 side and vice versa, valve C4 changes to alter the
port to the piston rear chamber B1 from the high-pressure side
to the low-pressure side and vice versa and, in accordance
with the reciprocation of valve C4, piston C2 reciprocates.
Further the Back-Head is charged with N2-gas. When the
piston moves backward, the N2-gas is compressed to store
the gas energy and, when the piston hammers, the gas energy
is converted into piston hammering energy.

< Piston start up >

When high-pressure oil is applied to the IN port of the hydraulic

breaker, the high-pressure oil acts upon the piston front
chamber A2 and valve high-pressure chamber V1 to hold
down the valve. As the piston rear chamber B1 is connected
to the OUT port through the valve and changed to the
low-pressure side, piston C2 start moving backward under the
high-pressure oil applied to the pressure affected area A2 of
the piston front chamber. At this time, N2-gas in the Back-Head
is compressed.

DATE : NOV. 2011 13/38

< Valve charging >

When the piston moves backward and the piston rear

chamber B1 is connected to the valve change port B3,
the high-pressure oil acts upon the valve change
chamber V4 and the valve changes.
At this time, the piston rear chamber B1 is disconnected
from the valve low-pressure chamber V3 and connected
to the valve high-pressure chamber V1 and pressure in
the piston rear chamber B1 increase.

< Piston hammering stroke >

When piston C2 reaches top dead center, high-pressure oil

from the valve high-pressure chamber V1 acts upon the
piston rear chamber B1 and the hammering stroke.
Converted into the compressed gas energy in the Back-Head.
The valve is held open because high-pressure chamber V1
and valve change chamber V4.

DATE : NOV. 2011 14/38

5. Preparation for Installation and Operation

5.1 Hydraulic pipe lines for exclusive use.

Operation of the hydraulic breaker requires installation of hydraulic pipe lines for
exclusive use of the hydraulic breaker. As hydraulic pipe lines vary depending
on base machines, the service engineer must first check hydraulic pressure, oil
capacity, pressure loss and other conditions of the base machine before installing
hydraulic pipe lines. Use only genuine parts In case of replacement

WARNING
!
▶ THE HYDRAULIC SYSTEM TO THE BASE MACHINE MUST BE CHECKED BY AN AUTHORIZED
SERVICE ENGINEER BEFORE FIRST USE AND AFTER ANY MODIFICATIONS.

! WARNING

▶ MAKE SURE THAT THE BREAKER VALVE OF THE HYDRAULIC SYSTEM IS PROPERLY.

DATE : NOV. 2011 15/38

6. Operation (Breaking)

6.1 Proper position of the Tool

Proper position must be applied for an effective use of hammering force. When
position is incorrect, hammering energy of the piston is too weak to break rocks.
Instead, hammering force applies shocks to the breaker itself and the arm and
boom of the base machine, thereby resulting in damage to those parts.

On the contrary, when position is excessive enough to break rocks with the front
of the base machine raised, the machine may suddenly tilt forward the moment
rocks are broken. Then, the breaker body or the end of bracket may violently hit
against rocks and result in damage.

DATE : NOV. 2011 16/38

 It is undesirable to carry out hammering under the below condition, because
vibrations during hammering may be transmitted to the tracks of the base
machine. During hammering, however, proper position must be always applied
to the breaker. Special care must be taken not to hammer under abnormal
condition.

6.2 Alignment of the Tool

Apply same direction of boom force in line with the Tool and place the Tool in the
rock with hammering surface as vertical as possible. If hammering surface is
oblique, the Tool may slip during hammering. This causes the Tool to seize and to be
broken and the piston to be damaged. When breaking, fully stabilize the Tool first
and then select the point of a rock on which hammering can be performed in a
stable condition.

DATE : NOV. 2011 17/38

 6.3 Operation Precautions

IMPORTANT
▶ APPLY DOWNWARD FORCE TO THE BOOM UNTIL THE REAR OF THE CARRIER IS RAISED OFF THE
GROUND.
- THE BREAKER IS MORE EFFICIENT WHEN ADEQUATE DOWNWARD FORCE IS APPLIED.

IMPORTANT
▶ RELOCATE THE BREAKER OFTEN
- THE BREAKER TOOL SHOULD BE MOVED TO A NEW LOCATION OF THE WORK EACH TIME THE
TOOL PENETRATES BUT DOES NOT CRACK THE MATERIAL.

IMPORTANT
▶ DO NOT BREAK CONTINUOUSLY IN ONE PLACE - CONTINUOUS PENETRATION IN THE SAME
AREA FOR LENGTHILY PERIODS WILL CREATE EXCESSIVE TEMPERATURES AT THE END OF THE
TOOL RESULTING IN LOSS OF TEMPER(HARDNESS) OF THE TOOL AND CAUSING MUSHROOMING
OF THE TIP OF THE TOOL, AND MAY LEAD TO FAILURE OF THE BIT.

IMPORTANT
▶ DO NOT USE THE TOOL AS A LEVER.

IMPORTANT
▶ EXTERNAL ILLUMINATION ENVIRONMENT
▶ THE HYDRAULIC BREAKER MUST WORK FROM EXTERNAL ILLUMINATION OF ABOVE
MINIMUM 300LUX, ON THE JOBSITE.

IMPORTANT
▶ DO NOT USE UNDERWATER WITHOUT AIR APPLICATION KIT
- NO PART OF THE JAB HYDRAULIC BRAKER SERIES MAY BE SUBMERGED IN WATER WITH IT
FIRST ADAPTING THE BREAKER FOR UNDERWATER USE.
- USE OF THE BREAKER UNDERWATER REQUIRES AN UNDERWATER APPLICATION KIT AND AN AIR
COMPRESSOR CAPABLE OF PRODUCING 6000LPM / 150PSI.
▶ UNDERWATER USAGE OF THE BREAKER WITHOUT THE UNDERWATER KIT AND AIR COMPRESSOR
WILL CAUSE INTERNAL DAMAGE TO THE BREAKER.
- SEE THE "UNDERWATER OPERATION OF THE BREAKER"

DATE : NOV. 2011 18/38

 IMPORTANT
▶ BEFORE LEAVING THE CARRIER, ALWAYS LOWER THE BOOM AND INSURE THE CARRIER IS
STABLE. NEVER LEAVE THE MACHINE WITH THE ENGINE RUNNING.
▶ ALWAYS ENGAGE THE PARKING BRAKE.

1) Stop operation as soon as hoses vibrate excessively.

Excessive vibration of high and low pressure hoses of the breaker calls for an
instant disassembly and repair. Contact the nearest service station appointed
by JAB. For caution's sake, check oil leakage at the Back-Head.
. The operator is required to pay attention to following points during operation.

Visually inspect whether there is a surplus of the Tool

when the breaker is lifted.

2) Avoid all blank hammering

As soon as rocks are broken, stop hammering. Continuous blank hammering will
not only damage front head and loosen and break bolts, but also adversely
affect base machine. Blank hammering occurs when proper position of the Tool
is not applied to the breaker or the Tool is used as a lever.(Hammering sound
changes during blank hammering.)

3) Stop operation as soon as hoses vibrate excessively.

Avoid moving rocks with the side of the bracket, because it is the major factor
to breaking bolts installed on the bracket and to damage of the Tool, the boom
and arm.

DATE : NOV. 2011 19/38

4) Do not use the Tool as a lever.

If breaking rocks by using the Tool as a lever, the bolts and the Tool may break.

5) Do not continue to hammer for more than one minute.

When rocks are not broken after more than one minute of hammering at the
same point, change the place to be hammered. Extended hammering at the
same place causes the Tool to wear out excessively.

DATE : NOV. 2011 20/38

6) On a hard and large rock, start breaking at an edge.

Even a hard and big rock can be relatively easily broken when hammering
begins at a crack or an edge.

7) Operate the breaker at proper engine speed.

Break rocks at the specified engine speed. Raising engine speed more than
necessary does not strengthen the hammering force but increase oil temperature
to the detriment of the pistons and the valves.

8) Do not operate the breaker in water and mud.

Do not operate the breaker when components(except Tool) are immersed in

water and mud. The piston and similar components may gather rust and become
damaged at an early stage.

DATE : NOV. 2011 21/38

9) Do not allow the breaker to fall to break a rock.

Dropping the breaker onto a rock will apply excessive force to the breaker or
the base machine, causing damage to many parts of the breaker and the base
machine.

10) Do not hammer with the base machine cylinders moved to stroke end.

Hammering with each base machine cylinder moved to it's end stroke (fully
extended or retracted) will do considerable damage to the cylinder and each
part of the base machine.

DATE : NOV. 2011 22/38

11) Do not lift things with the breaker.

Lifting materials by hanging wire in the bracket or the Tool not only causes
damage to the breaker but also is very dangerous when operating.

12) Warm up base machine engine prior to operation.

Especially in winter, the base machine engine should be warmed up for five to
ten minutes (about oil temperature 30℃~40℃ / 80℉~105℉) before breaker
operation. Follow the Instruction Book for the Base Machine for warming-up
of the engine.

13) Do not touch the Tool during hydraulic breaker operation. During breaker
operation, the breaker parts can reach high temperatures.

14) When operating the breaker you must use the ear, eye and breathing protection.

15) Accumulator type danger

Attention! Pressurized container! Do not open without reading the manual

or consulting the authorized service personnel!

16) Greasing danger

With the breaker mounted on the carrier, apply down pressure on the Tool.
and fill cavity with the recommended grease through the marked grease nipple.

17) Always wear the eye protection when removing the stop pin.

Remove the stop pin by doing it in and out with a punch and hammer.

DATE : NOV. 2011 23/38

7. Installation and Removal of the Hydraulic Breaker

When the bucket and the breaker operation are performed alternately, the bucket
and the breaker can be easily exchanged by the hydraulic hoses and the two pins.
There is however, a risk of the hydraulic circuit contamination Accordingly, install
and remove as follows.

1) Move the base machine to stable ground free from mud, dust and dirt. Stop
the engine. Turn off the main switch and deflate air from the oil tank if it is
pressurized.

2) Turn the shut off valve (installed to the end of the boom arm) 90 degrees to the
off position to prevent the hydraulic oil from flowing out.

DATE : NOV. 2011 24/38

3) Loosen the hose plug on the breaker arm. Collect small amount of oil flowing
out at this time and put into a container.

4) Be careful to prevent mud or dust from entering the oil hoses and the pipe lines.
Plug the oil hoses with the hose plug and the pipe lines with the union caps.
Bind the high-and low pressure hoses with a wire to prevent them from getting
muddy.

. Oil hose plug

The Oil hose plug is a stopper aimed at preventing
mud or dust from entering the oil hose attached
to the hydraulic breaker during the bucket operation

. Union cap

The Union cap prevents mud or dust

from entering the pipe lines attached to
the machine body.

5) To remove the breaker, pull out the pins in the bucket link and the arm.

When leaving the breaker outdoors, set the breaker on wood blocks and cover
with sheets.

6) When leaving the breaker removed for a long period

. Clean the exterior of the breaker.

. Remove the Tool from the front head and spray with the rust preventive oil.
. Bleed N2-gas from the Back-Head before pushing the piston into the cylinder.
. Apply the grease to each part of the breaker and then install the Tool again.

7) To install the hydraulic breaker, reverse the aforementioned removal procedures.

The bucket operation easily contaminates the end part of the hoses and the pipe
lines. The contaminated part must be cleaned with no delay. Hydraulic oil or light
oil is highly recommendable.

DATE : NOV. 2011 25/38

■ Hydraulic breaker maintenance list and point

Inspection Item Inspection Point

. Looseness, missing and damage to the . Through bolts

bolts and the nuts . Bracket mounting bolts

. Accumulator bolts

. Looseness of the hose fittings, . Hydraulic pipes for the breaker

visible damage to the hoses and oil . Oil hoses

leakage

. Abnormal oil leakage . connections of the Back-Head and the

cylinder

. Clearance between the front head &

the Tool

. Abnormal wear and cracks on the Tool . Tool

. Greasing . Grease at start and every 2 or 3 hours

using the head grease pump

. Pumping : 5~10 times

. Hydraulic oil level and contamination . Conditions of the hydraulic oil

. Missing the rubber plugs and the snap . Rubber plugs

rings . Snap rings

. Auto-Greasing kit, looseness, missing . G-adapter

and damage

. Air supply Kit, looseness, missing and . W-adapter

damage

. The Back-Head gas and the accumulator . Filling the Back-Head gas and the

gas accumulator

DATE : NOV. 2011 26/38

8. Repair and Inspection

8.1 Inspection Points

THROUGH BOLT

FLANGE BOLT

VALVE COVER BOLT

VALVE BOX BOLT

ACCUMULATOR BODY BOLT

ACCUMULATOR COVER BOLT

Model
Unit SMT20 SMT30 SMT40 SMT50 SMT70 SMT100 SMT150 SMT160 SMT200 SMT220 SMT250 SMT350N SMT400 SMT450
Divide
Through Bolt Kg.m 30 40 40 40 100 150 175 200 225 225 240 300 370 450
Charging Valve Kg.m 20 20 20 20 20 20 20 20 20 20 20 20 20 20
Flange Adapter Bolt Kg.m - - - - - - 20 - - 20 - - - 20
Valve Cover Bolt Kg.m - - - - - - 35 - - 40 - - - 40
Valve Body Bolt Kg.m - - - - - - 35 - - 40 - - - 40
Acc' Body Bolt Kg.m - - - - - - 60 60 - 60 60 60 60 60
Acc' Cover Bolt Kg.m - - - - - - 30 30 - 35 35 40 40 40

DATE : NOV. 2011 27/38

 8.2 Daily Breaker Inspection

Before starting operation, be sure to inspect the breaker referring to the

following table.

Inspection Item Inspection Point Remedy

Looseness, missing . Through Bolts . Check looseness
and damage to the . Bracket mounting bolts . Re-tightened securely
bolts and the nuts
Looseness of the hose . Hydraulic pipes for the . Re-tighten securely
fittings, visible damage breaker . Replace seriously damaged
to the hoses and oil . Oil hoses parts.
leakage
Abnormal oil leakage . Connections of the
Back-Head and the cylinder
. Clearance between the front
head & the Tool
Abnormal wear and cracks . Tool . Deformed, burred and worn
on the Tool Tool should be repaired.
. Excessively a worn Tool needs
to be replaced.
Greasing . Grease at start and every . Grease the front head
2 or 3 hours using the
head grease pump
. Pumping : 5~10 times
(Greasing position and
method shown at left)
Level and contamination . Conditions of the . Contamination of hydraulic
of the hydraulic oil hydraulic oil oil varies with operating
conditions, but oil color
tells the level of
contamination
. Criteria for judging
contamination is specifically
set by SMT.
Missing th rubber plugs . Rubber plugs . A seriously damaged one must
and the snap rings . Snap rings be replaced
DATE : NOV. 2011 28/38
 . Criteria for judging
contamination is specifically
set by SMT.
Missing th rubber plugs . Rubber plugs . A seriously damaged one must
and the snap rings . Snap rings be replaced

8.3 Regular Breaker Inspection and Maintenance

Regular inspection is essential for keeping the hydraulic breaker operating in

the best condition. Consult with the JAB service station for regular inspection
and maintenance. Customers are recommended to contact the local dealer
for inspection within six months after delivery.

8.4 Replacement of the Tool

The Tool is deformed by burrs occurring after long-term use. When a Tool tip
is worn out, The Tool is liable to slip. Then, sharpen the Tool tip. Grinding the Tool
tip many times to sharpen the edge, but it will make the heat-treated hardened
with a new Tool. If the gap between the Tool and the Tool bush becomes large,

* Change timing of the Tool Bush (mm)

Divide Dimension
Width of Wear
Model Tool Bush Tool Dia
SMT20 Ø 45 Ø 45 3
SMT30 Ø 53 Ø 53 4
SMT40 Ø 68 Ø 68 4
SMT50 Ø 75 Ø 75 4
SMT70 Ø 85 Ø 85 5
SMT100 Ø 100 Ø 100 6
SMT150 Ø 120 Ø 120 7
SMT160 Ø 125 Ø 125 7
SMT200 Ø 135 Ø 135 8
SMT220 Ø 135 Ø 135 8
SMT250 Ø 140 Ø 140 8
SMT350 Ø 150 Ø 150 9
SMT400 Ø 155 Ø 155 11
SMT450 Ø 160 Ø 160
SMT500 Ø 165 Ø 165

DATE : NOV. 2011 29/38

 SMT550 Ø 170 Ø 170

■ Tool replacement

1) Remove the stop pin and the Tool pin

with a 330mm-long steel bar.
When reassembling, align the groove in the
Tool and the Tool pin hole and insert
the Tool pins.

2) Reverse disassembly procedures to install a

replacement Tool.
Before installing a new Tool, check each part
for wear, breakage, scores, etc.
Remove burrs and swellings on each Tool pin,
apply a coat of grease to the movable areas of
the Tool pin and the Tool and finally install
the Tool.
Excessively deformed the Tool pins will make
replacement of the Tool difficult. The Tool pins
must be checked every 100 to 150 hours of
operation.

* If the replacement Tool is not a genuine part, we do not guarantee the

performance of other parts of the breaker.

8.5 Disassembly and Reassembly of the Breaker

Since the breaker body is manufactured by state-of the art processing techniques
and consists of the high-quality hydraulic parts, it is dangerous to disassemble the
breaker at a workshop. Contact your local dealer when disassembly is called for,
otherwise quality and performance of the breaker cannot be guaranteed.

DATE : NOV. 2011 30/38

9. Inspection and Charging N2-Gas at the Back-Head

! WARNING

▶ CHARGING GAS PRESSURE CHANGES ACCORDING TO THE TOOL CONDITION. LAY DOWN
AND LET THE TOOL EXTEND FULLY.
▶ STAY CLEAR OF THE TOOL WHILE CHARGING THE BREAKER WITH GAS. THE TOOL MAY BE
IMPACTED THE BREAKER BY THE PISTON AND FORCED OUT ABRUPTLY.
▶ WHEN THE THROUGH BOLTS ARE CHANGED THE N2 GAS MUST BE DISCHARGED WITH THE
BACK HEAD, AS IT IS HIGHLY PRESSURIZED.
▶ USE NITROGEN GAS ONLY.
▶ SEE "CONVERSION TABLE FOR CHARGING N2 GAS PRESSURE TO THE BACK HEAD"

9.1 Inspection of N2-Gas in the Back-Head

1) Make sure that the cap and the valve of the gas charging kit(⑤) are fully
tightened. Screw the gas charging kit(⑤) into the charging valve of the
Back-Head after removing the plug.
2) At this time the handle must be short to prevent the gas from coming out.
3) Push the handle into the charging valve fully, so the gas pressure inside the
Back-Head is indicated on the pressure gauge.
4) If the gas pressure is normal, unscrew the gas charging kit after discharging
gas inside the gas charging kit. Reinsert the plug to the breaker.
5) If the gas pressure is higher or lower, charge it as described below.

* Charging of N2 -Gas into the Back-Head

1) Connect the charging hose(④) to N2-gas cylinder(①) after screwing the bomb
adapter(④) onto adapter nut(②) and installing than to the N2-gas cylinder.
2) Connect the gas charging kit(⑤) to the charging hose(④) after unscrewing
the cap on the gas charging kit.
3) Install the gas charging kit(⑤) to the charging valve of the Back-Head. At this
time the handle of the gas charging kit must be up position to prevent the gas
from coming out.
4) Push the handle of the gas charging kit fully and turn the handle of the N2-gas
cylinder counter clockwise gradually to charge the Back-Head.
5) When the gas pressure exceeds 10% higher then the specified pressure, close
the N2-gas cylinder by turning the handle clockwise.
6) Leave the handle of gas charging kit up. generated pressure makes, it return

DATE : NOV. 2011 31/38

 back to original position naturally.

7) Remove the charging hose(④) from the N2-gas cylinder(①) and the gas charging
kit(⑤), and the screw the cap onto the gas charging kit.
8) Push the handle of the gas charging kit fully, and the gas pressure inside the
Back-Head is indicated on the pressure gauge. When the pressure is higher,
discharge a small amount of gas from the Back-Head repeatedly opening and
closing the valve and then gas pressure falls to the specified pressure.
9) When the gas pressure reaches to the specified pressure, close the valve and
release the handle.
10) Open the valve completely and discharge gas inside the gas charging kit.
Remove the gas charging kit from the charging valve of the Back-Head and
install the plug to the charging valve.

9.2 N2-Gas Charging tools to the Back-Head

3 2

BACK HEAD CHARGING PRESSURE

MODEL SMT20 SMT30 SMT40 SMT50 SMT70 SMT100 SMT150 SMT160

UNIT (bar) 12 16 16 16 16 16 6 16

MODEL SMT200 SMT220 SMT250 SMT350 SMT400 SMT450 SMT500 SMT550

UNIT (bar) 16 6 13 15 13 6 13 13

① N2-Gas cylinder
② Bombe adaptor nut
③ Bombe adaptor
④ hose

DATE : NOV. 2011 32/38

 ⑤ Gas charging kit

10. Inspection and Charging N2-Gas at the Accumulator

! WARNING

▶ USE SPECIAL CARE TO HANDLE AND STORE THE N2-GAS CYLINDER AS IT IS A HIGHLY
PRESSURIZED CONTAINER.
▶ USE NITROGEN GAS ONLY.
▶ STANDARD ACCUMULATOR GAS PRESSURE 55kg/cm2/780PSI AT 20℃/68℉ AMBIENT
TEMPERATURE. DO NOT OVER PRESSURIZE THE ACCUMULATOR.
▶ SEE "CONVERSION TABLE FOR CHARGING N2-GAS PRESSURE TO THE ACCUMULATOR".

* Cautions for charging N2-gas to the Accumulator

▶ Be sure to use the gas charging kit for charging the N2-gas. If charging gas leaks
directly from the cylinder, the diaphragm may be broken off.
▶ If charging for handling N2-gas to only the accumulator, make sure that the
accumulator body and the cover are tightened fully.

1) Make sure the cap and the valve of the gas charging kit(⑤) are fully tightened.
2) Remove the cap(⑪) from the accumulator and tighten the charging valve(⑫)
fully.
3) Check if the O-rings(⑥)(⑧) are installed to the bushing(⑦). Remove the plug(⑨)
and the screw in the bushing.
4) Install the bushing(⑦) to the gas charging kit(⑤).
5) Loosen the charging valve(⑫) gradually. The charging pressure is indicated on
the pressure gauge.
6) Close the valve clockwise when the gas pressure is normal. When the gas
pressure is higher, repeat loosening and tightening the valve of gas charging kit.
The pressure is lowered gradually.
7) Loosen the valve of the gas charging kit to discharge the N2-gas in the gas
charging kit(⑤)
8) Remove the gas charging kit(⑤) and tighten the plug(⑨) and the cap(⑪).

DATE : NOV. 2011 33/38

 10.1 Charging on N2-Gas into the Accumulator

1) Connect the charging hose(④) to the N2-Gas cylinder(①) after screwing the
bomb adapter(③) on to the adapter, the nut(②) and installing to the N2-Gas
cylinder.
2) Connect the gas charging kit(⑤) to the charging hose(④) after unscrewing
the cap on the gas charging kit.
3) Remove the cap(⑪) from the accumulator and tighten the charging valve(⑫)
fully.
4) Check if the o-rings (⑥)(⑧) are installed to the bushing(⑦). Remove the plug(⑨)
and screw the bushing.
5) Loosen the accumulator charging valve(⑫) after checking if the bushing(⑦)
is installed to the gas charging kit.
6) Turn the handle of the N2-Gas cylinder counter clockwise slowly to charge gas.
7) Charge gas in accordance with the conversion table for charging N 2-Gas
pressure to the accumulator.
8) Turn the handle of the N2-Gas cylinder clockwise to close the cock.
9) Close the accumulator charging valve.
10) Loosen the valve of the gas charging kit to discharge the N2-Gas remaining
in the charging hose.
11) Remove the charging hose, the gas charging kit and the bushing and tighten
the plug(⑨) and cap(⑪).

10.2 The N2-Gas charging tools to the Accumulator

① N2-Gas cylinder
② Bombe adaptor nut
③ Bombe adaptor
④ Hose
⑤ Gas charging kit
⑥ O-ring
⑦ O-ring-hex bushing
⑧ O-ring
⑨ O-ring plug MODEL SMT150 SMT220 SMT250 SMT350
⑩ O-ring UNIT(bar) 60 60 60 60
⑪ O-ring cap
⑫ Accumulator charging valve MODEL SMT400 SMT450 SMT500 SMT550

DATE : NOV. 2011 34/38

⑬ O-ring UNIT(bar) 60 60 60 60
11. Trouble-Shooting Guide

The trouble-shooting chart is prepared to help operators locate causes and

remedies instantly when troubles occur. When any trouble is found, have a good
grip of the problem and contact your local dealer.

TROUBLE CAUSE REMEDY

1. Breaker fails to hammer (a) Defective hose or pipes (a) Check, clean and repair piping
(1) Sufficient high pressure . Clogged or damaged piping or replace with new ones.
oil does not flow to (b) Defective control valve and (b) Check and repair Valve and its
breaker inlet. related parts related parts or replace with
(2) Sufficient high pressure . Missing or damaged tie Tool or new ones.
oil flows to breaker control cable
inlet. (c) Insufficient hydraulic oil (c) Refill the oil tank.
(d) Internal breaker defects (d) Consult with our service
station.
2. Breaker hammers with (a) Defective hose or pipes (a) Check, clean and repair piping
hammering force reduced. . Clogged or damaged piping or replace with new ones.
(1) Sufficient high pressure (b) Defective control valve and (b) Check control Valve and
oil does not flow to related parts related parts or replace with
breaker inlet. . Deformed pedal new ones.
(2) Sufficient high pressure . Deformed control valve
oil flows to breaker . Stuck control valve
inlet. . Insufficient control valve
stroke due to loose screws
(c) Clogged filter in return line of (c) Clean or replace.
base machine tank
(d) Insufficient hydraulic oil (d) refill.
(e) Contaminated or deteriorated (e) After flushing tank, change
hydraulic oil oil entirely
(f) Defective pump (f) Ask service station for base
machine service.
(g) Internal breaker defects (g) Consult with our service
. Entry of contaminated articles station.
(h) Decrease in N2-gas sealing (h) Adjust the gas pressure
pressure of Back-Head referring to Chpt. 9,10
3. Hammering force plummets (a) Defective Back-Head (a) Ask our service station for
suddenly and high pressure . Gas leakage repairs
hose vibrates excessively
during operation.
4. Excessive oil leakage from (a) Worn cylinder seals (a) Ask our service station for
front head or Tool. repairs
5. Piston works but does not (a) Stuck Tool (a) Remove front parts and pull
hammering. out Tool and check it.

DATE : NOV. 2011 35/38

 hose vibrates excessively
during operation.
4. Excessive oil leakage from (a) Worn cylinder seals (a) Ask our service station for
front head or Tool. repairs
5. Piston works but does not (a) Stuck Tool (a) Remove front parts and pull
hammering. out Tool and check it.

12. Hydraulic Oil

12.1 Selection of Oil

The Selection of the hydraulic oil determines the efficiency of the hydraulic
breaker performance. Please consult with our service station under following
conditions.

(a) When used in special regions where the climate is extremely cold or hot
and, viscosity may be changed at different constant ambient air temperatures.
(b) When recommended brands of hydraulic oil are not available.
(c) When hydraulic oils supplied for the base machine differ from the
recommended one.

Hydraulic Oil
Grease
Maker Viscosity Grade
Summer SAE68 Winter SAE46 NLGI NO.2
Shell Shell Tellus T68 Shell Tellus T46 Alvania Grease2
Esso Nuto H68 Nuto H46 Beacon Q2
Mobil Mobil DTE16 Mobil DTE15 Mobil Grease Special
Gulf Harmony 68 Harmony 46 Gulf Crown EP2
Caltex Lando CZ68 Lando CZ46

! WARNING

▶ If uses animal vegetable hydraulic oil in the base machine, there is a possibility
the damage easily in the seal parts etc.

12.2 Oil Contamination

Contaminated oil results in malfunctions of the breaker as well as the base

machine and causes damage to the parts. Pay special attention to oil
contamination. Contaminated oil should be changed without delay. When
changing oil, thoroughly wash the oil tank, the cylinder and the pipes. Cleaning
or replacing the oil filter also requires check for oil contamination.

■ Replacement of the filter : after first 50 hours and every 100 hours
■ Replacement of the hydraulic oil : every 500 hours

DATE : NOV. 2011 36/38

 ! WARNING

▶ Hydraulic Oil Temperature and viscosity

Do not operate the hydraulic breaker at oil temperatures from 20℃/68℉ to
80℃/176℉. Operation at higher temperatures can damage the internal components
of the breaker and the excavator, there will result in reduced breaker performance.

12.3 Criteria of Oil contamination and Malfunction (General Analysis)

Analysis Item Criteria Causes and Effects when exceeds the criteria
Adhesiveness Within ± 10% Adhesiveness rarely decreases soiled because of
(40℃ cst) hydraulic oil. Entry of different kind of oil may reduce
the adhesiveness which contributes to rising oil
temperature, wear and stretch of bearings and
gears and malfunction of hydraulic oil.
Oxidizing Level Less than 0.3 Use of a lubricating oil during long period of time
(mg KOH/g) under high of a lubricating (higher than 60℃) will
oxidize it.
Oxidizing level rises as oxidization proceeds. Sludge
will be produced during the process, leading to
unsatisfactory operation of the breaker, erosion of
metals or obsolescence of seal materials.
Moisture Less than 0.1(%) Moisture causes rust, wear and stretch. Moisture of
0.3% gathers a considerable amount of rust and
considerable amount or rust moisture of 0.5% more
will cause damage to the machine.

12.4 Criteria of Malfunction by the Hydraulic Oil Color

(Simple discrimination by ASTM color)

Hydraulic oil turns black as the breaker fails to display best performance. The old
oil is assumed to be contaminated when there is a visual difference between
the oil and new oil color, and functions begin to deteriorate when hydraulic oil
turns darker than the new oil color (ASTM number) by more than two.

DATE : NOV. 2011 37/38

DATE : NOV. 2011 38/38