OPERATION MANUAL

JISAN
Hydraulic Breaker
Operation Manual
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Preface

We totally appreciate your purchasing a JISAN hydraulic breaker.

The hydraulic breaker, developed by JISAN’s plentiful experiences and know‐how for
many years, will satisfy customers under any working conditions with its highest
power and long‐time durability. However, without proper handling, regular
inspection, the advanced demolition tool fails to display its excellent quality, resulting
in various problems.
This operation manual shall be thoroughly read by customers before the first
installation and operation in order to prevent any mishandling of hydraulic breakers.
We guarantee that a faithful understanding of the operation manual shall contribute
to the best capacity.
If you have any further questions about operation of hydraulic breakers, please do
not hesitate to contact us or visit our website www.jisanbr.net.
We wish you a great success with us.

JISAN All MEMBERS

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Contents
1. Safety Precautions ......................................................................................................................... 5

2. Technical Specification .................................................................................................................. 8

3. External Dimension ..................................................................................................................... 10

4. Preparation for Installation & Operation .................................................................................... 15

1) General View of breaker installed ....................................................................................... 15

2) Hydraulic pipe lines for exclusive use.................................................................................. 15

5. Checking instruction before installation ..................................................................................... 16

6. Recommend circuit relief setting pressure and back pressure. .................................................. 17

7. Hydraulic Oil ................................................................................................................................ 22

8. OPERATION.................................................................................................................................. 24

1) Proper position of the tool .................................................................................................. 24

2) Alignment of the tool .......................................................................................................... 25

3) Operation precautions ........................................................................................................ 26

9. Installation & Removal of the Breaker ........................................................................................ 32

10. Maintenance ............................................................................................................................. 33

1) Inspection points‐ Inward valve type .................................................................................. 33

2) Daily inspection ................................................................................................................... 34

3)Regular breaker inspection and maintenance ..................................................................... 36

4) Replacement of tool ............................................................................................................ 36

5) Breakage of tool .................................................................................................................. 38

11. Trouble Shooting Guide ............................................................................................................. 39

1) Problems in operation......................................................................................................... 39

2)Gas leakage .......................................................................................................................... 40

3) Oil leakage ........................................................................................................................... 41

12. Warranty Policy ......................................................................................................................... 42

1) Warranty ............................................................................................................................. 42

2) Delivery report .................................................................................................................... 45

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DO NOT OPERATE THE BREAKER UNLESS THE FOLLOWING SAFETY INSTRUCTIONS

HAVE BEEN THOROUGHLY READ AND UNDERSTOOD! READ THIS MANUAL BEFORE
INSTALLING, OPERATING OR MAINTAINNING THIS EQUIPMENT!

■ Flying debris from the breaker, breaker tool, tock or other material may cause serious or fatal

injury to the operator. Personal protection equipment must be used. Never operate the

breaker when bystanders are in the work area.

■ On some machines/carries, the breaker can enter the operator’s compartment. Make sure

that suitable impact shields are used when operating the breaker with this type of

equipment.

■ Do not operate the breaker unless all safety decals described in this manual are in place. The

decals must be inspected periodically to ensure that all wording is legible. The decals must be

replaced if illegible.

■ When operating the breaker, ear, eye, and breathing protection must be used at all times.

■ The breaker will become very hot during the operation. Allow some times for the breaker to

cool down before touching breaker parts.

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1. Safety Precautions
This manual contains safety, operation, and routine maintenance instructions. It does not contain

assembly and disassembly service procedure instructions.

1) Please read the following warning.

Serious injury or death could result from the improper repair or service of hydraulic breakers.

Repairs and/or services must only be done under the guide of JISAN company engineer.

2) General safety precautions

■ The JISAN hydraulic breakers will provide safe and dependable service if operated in

accordance with the instructions given in this manual. Read and understand the manual any

decals and tags attached to the breaker before operation. Failure to do so could result in

personal injury or equipment damage.

■ Operate the breaker in accordance with all laws and regulations which affect you, your

equipment, and the work site.

■ Do not operate the breaker until you have read the carrier equipment manual and

thoroughly understood all safety requirements, operations and maintenance instructions.

■ Ensure that all maintenance procedures recommended in this manual are completed before

using the equipment.

■ The operator must not operate the breaker or carrier if any people are found within the

danger zone where they may be injured by flying debris or movement of the equipment.

■ Know the limitation of your equipment.

■ Establish a training program for all operators to ensure safety operation.

■ Do not operate the breaker unless thoroughly trained or under the supervision of an

instructor.

■ Get used to the carrier controls before operating the carrier and the breaker.
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■ While learning about the breaker and the carrier, please do so at a slow pace. If necessary,

set the carrier mode selector to the slow working position.

■ Make sure all control (levers and pedals) are in the neutral position before starting the

carrier.

■ Before leaving the carrier, always lower the boom and insure the carrier is stable. Never leave

the machine when the engine is running. Always engage the parking breaker locked.

■ Stop the engine before attempting to make any repairs, adjustments, or servicing to either

the carrier or the breaker.

■ Do not operate the breaker at oil temperature above 175℉/80℃.Operation at higher

temperatures can damage the internal components of the breaker and as well as backhoe /

excavator, and will result in low breaker performance.

■ Do not operate the breaker in the severe conditions such as, a damage, leaking, improperly

adjusted, or incompletely assembled breaker.

■ Do not modify breaker tool in any manner.

■ Use the breaker tools manufactured by JISAN only. Using the breaker tool produced by

another manufacture may damage the equipment and will void the warranty.

■ To avoid personal injury or equipment damage, all breaker repair, maintenance and service

must only be performed by authorized and properly trained personnel.

■ If you do not understand how to operate your breaker, contact JISAN company for assistance.

■ Do not operate this equipment if you are taking medication which may affect you mental

judgment or physical performance.

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Warning sticker

Hearing Protection Eye Protection Breathing Read the manual

Protection before use

3) Safety symbols

This safety symbol may appear This safety symbol appears in This safety symbol appears in

on the breaker. If is used to alert these instructions to identify an these instructions to identify

the operator of an action that action that could cause bodily an action or condition that

could place him / her or other in injury to the operator or other could result in damage to the

a life threatening situation. personnel. breaker or other equipment.

Safety symbols are to emphasize all operators, maintenance, and repair action, which, if not

strictly followed, could result in a life‐threatening situation, bodily injury or damage to equipment.

Always observe safety symbols. They are symbols for your safety and for the protection of the

tool.

4) Greasing sticker
GREASING
1. With breaker mounted on carrier, apply down pressure on tool.

2. Fill cavity with recommended grease.

3. Grease whenever tool looks dry.

4. When installing a new tool, liberally coat the upper 1/3 of the

tool with grease before inserting.

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2. Technical Specification
MODEL INWARD VALVE TYPE

SMALL MEDIUM

DESCRIPTION JSB200 JSB300 JSB400 JSB600 JSB800

Tool Diameter mm 45 53 68 75 85

inch 1.77 2.12 2.68 2.95 3.35

Weight of Main Body kg 71 86 164 203 282

lb 157 189 362 448 622

Operating Top Type kg 131 159 308 392 597

Weight lb 289 350 678 863 1317

(with Tool) Box Type kg 125 151 293 373 569

lb 276 333 646 822 1254

Side Type kg 129 156 302 384 586

lb 284 343 665 847 1292

Impact Rate bpm 700‐1200 600‐1100 500‐950 450‐800 400‐800

Operating Pressure psi 1280‐1700 1420‐1846 1704‐2130 1710‐2030 1850‐2140

bar 90‐120 100‐130 120‐150 120‐140 130‐150

Required Oil Flow l/min 20‐40 30‐55 45‐75 55‐95 70‐105

gal/min 5‐10 8‐15 12‐20 15‐25 18‐28

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

Noise Level dB 106.8 108.5 116.9 108.7 114.5

ton 1.2‐3.0 2.0‐4.0 4.0‐7.0 5.0‐9.0 6.0‐11.0

Applicable Carrier Mini‐Excavators & Skid‐STEER Loaders

type ‐ Backhoe‐Loaders

Excavators

z The above specifications are subject to change without prior notice for the quality enhancement.

z Operating weight include Cap, Rod weight by AEM regulation.( Except for pin, hose and fitting)

z The above Noise level is Box type.

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INWARD VALVE TYPE INWARD VALVE TYPE OUTWARD VALVE TYPE

MEDIUM LARGE LARGE

JSB900 JSB1600 JSB1900 JSB3500 JSB4000 JSB5500 JSB6500

100 135 140 155 175 185 210

3.94 5.31 5.51 6.10 6.52 7.09 7.31

472 694 837 1157 1256 1685 1795

1041 1530 1845 2551 2758 3715 3825

902 1573 1851 2760 2985 3910 3926

1988 3468 4081 6086 6559 8620 8628

859 1498 1763 2629 2837 3724 3738

1894 3302 3887 5796 6246 8210 8219

885 1543 1816 2708 2916 3836 3842

1951 3402 4003 5970 6429 8456 8459

350‐700 350‐650 350‐500 300‐450 260‐420 250‐350 260‐360

2130‐2420 2420‐2610 2420‐2610 2562‐2847 2568‐2992 2847‐3131 2849‐3139

150‐170 170‐190 170‐190 180‐200 190‐220 200‐220 210‐230

85‐115 110‐160 130‐190 170‐220 180‐240 210‐280 220‐290

22‐30 29‐42 34‐50 50‐66 53‐74 56‐74 57‐75

3/4 1 1 1.25 1.25 1.25 1.25

112 113.5 118 120 124 120 120

10.0‐15.0 16.0‐22.0 16.0‐25.0 25.0‐35.0 40.0‐55.0 45.0‐55.0 55.0‐120.0

Backhoe‐Loaders ‐

Excavators

z The above specifications are subject to change without prior notice for the quality enhancement.

z Operating weight include Cap, Rod weight by AEM regulation.( Except for pin, hose and fitting)

z The above Noise level is Box type.

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3. External Dimension
1) Box type
JSB200/JSB300

JSB200 JSB300

A 292 292

B 182 212

C 332 332

D 206 212

E 816 890

JSB400/JSB600/JSB800/JSB900/JSB1600

JSB400 JSB600

JSB400 JSB600 JSB800 JSB900

JSB800
JSB900
A 360 360 396 440

B 237 246 292 346

C 433 449 490 535

D 239 334 374 438

E 1019 1211 1324 1468

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JSB1600/JSB1900/JSB3500/JSB5000

JSB1600 JSB1900 JSB3500 JSB5000

A 495 515 530 600

B 387 407 420 462

C 715 743 754 810

D 520 551 561 595

E 1708 1769 1876 1971

JSB5500/JSB6500

JSB5500 JSB6500

A 480 529

B 390 420

C 648 698

D 470 500

E 1460 1640
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2) Top type
JSB200/JSB300

JSB200 JSB300

A 196 210

B 194 200

C 296 302

D 185 191

E 867 937

JSB400/JSB600

JSB400

JSB400 JSB600
JSB600
A 362 392

B 228 232

C 410 410

D 308 288

E 967 1160

F 234 234

G 1201 1394
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JSB800/JSB900

JSB800 JSB900

A 410 500

B 284 328

C 470 540

D 355 405

E 1299 1428

F 290 300

G 1589 1728

JSB1600

JSB1600

A 560

B 428

C 654

D 595

E 1673

F 415

G 2088
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JSB1900/JSB3500/JSB5000

JSB1900 JSB3500 JSB5000

A 560 660 720

B 431 470 520

C 654 760 830

D 608 722 780

E 1752 1955 2343

F 415 462 500

G 2167 2417 2843

JSB5500/JSB6500

JSB5500 JSB6500

A 560 560

B 384 419

C 654 654

D 545 583

E 1412 1615

F 415 415

G 1827 2030
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4. Preparation for Installation & Operation

1) General View of breaker installed

2) Hydraulic pipe lines for exclusive use

Operation of the hydraulic breaker requires installation of hydraulic pipe lines for exclusive use of

the hydraulic breaker. Use only genuine parts in case of replacement because hydraulic pipe lines

(hoses, pipes, and fittings) are made of materials carefully selected in consideration of durability.
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5. Checking instruction before installation

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Hose & Tube pipe size

JSB200 JSB300 JSB400 JSB600 JSB800 JSB900

Diameter Mm 9.4/12.7 12.7 12.7 19.1 19.1 19.1

Inch 3/8,1/2 1/2 1/2 3/4 3/4 3/4

JSB1600 JSB1900 JSB3500 JSB4500 JSB5000 JSB5500

Diameter Mm 25.4 25.4 31.8 31.8 31.8 31.8

Inch 1 1 1 1 1 1

6. Recommend circuit relief setting pressure

and back pressure.

Unit JSB200 JSB300 JSB400 JSB600 JSB800 JSB900

Relief Setting Pressure Kg/cm2 150 160 170 180 190 200

Back Pressure 10 10 10 10 10 10

Unit JSB1600 JSB1900 JSB3500 JSB4500 JSB5000 JSB5500

Relief Setting Pressure Kg/cm2 210 210 220 220 220 220

Back Pressure 10 10 10 10 10 10

Since JSB hydraulic breaker operates with various kinds of hydraulic construction machines, it

should be installed after our serviceman has carried out the necessary check on the base

machine to utilize its full performance

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1) Inspection and charging N2 gas in back head

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Back head sticker symbol

- Appears on the back head charging valve

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2) Inspection and charging N2 gas in accumulator

■Cautions for charging N2 gas to the accumulator

‐Be sure to use the 3‐way valve assembly for charging the N₂gas. If charging gas

leaks directly from the cylinder, the diaphragm may be broken off.

‐ If charging N₂gas to only the accumulator, make sure that the accumulator body

and cover are fully tightened.

‐Make sure that the cap and valve of the 3‐way valve assembly are fully tightened.

‐ Remove the cap from the accumulator and tighten the charging valve fully.

‐ Check if O‐rings are installed to the bushing. Remove the plug and screw in the bushing.

‐ Install the bushing to the 3‐way valve assembly.

‐ Loosen the charging valve gradually. The charging pressure is indicated on the pressure gauge.

‐ Close the valve clockwise when the gas pressure is normal. When the gas pressure is higher,

repeat loosening and tightening the valve assembly. The pressure is lowered gradually.

‐ Loosen the valve of the 3‐way valve assembly to discharge the N2 gas in the 3‐way valve

assembly.

‐ Remove the 3‐way valve assembly and tighten the plug the cap.

‐ Charging N2 gas into the accumulator

‐ Connect the charging hose to N2 gas cylinder after screwing the bomb adapter on to adapter,

nut and installing to the N2 gas cylinder.

‐ Connect the 3‐way valve assembly to the charging hose after unscrewing the cap on the 3‐way

valve assembly.

‐ Remove the cap from the accumulator and tighten the charging valve fully.
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‐ Check if O‐rings are installed to the bushing. Remove the plug and screw the bushing.

‐ Loosen the accumulator charging valve after checking if bushing is installed to the 3‐way valve

assembly.

‐ Turn the handle of the N2 gas cylinder counterclockwise slowly to charge the gas.

‐ Charge the gas in accordance with the conversion table for charging N2 gas pressure to

accumulator.

‐ Turn the handle of N2 gas cylinder clockwise to close the cock.

‐ Close the accumulator charging valve.

‐ Loosen the valve of the 3‐way valve assembly to discharge the N2 gas remaining in the charging

hose.

‐ Remove the charging hose, 3‐way valve assembly and bushing and tighten the plug and cap.

■Conversion table for charging N2 gas pressure to accumulator

‐ Inward valve type (JSB1600, JSB1900, JSB2800, JSB3500, JSB4500) & Outward valve JSB5500

Accumulator Ambient Temperature(°C/°F)

Gas pressure
0/32 10/50 20/68 30/86 40/104

Kg/cm2 50 52 55 58 61

psi 711 739 780 824 867

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7. Hydraulic Oil
■ Selection of oil

Selection of oil determines the efficiency of hydraulic breaker performance. Please consult

with our service station under following conditions.

A. When Used in special regions where climate is severe(extremely cold or hot weather), the

viscosity of the hydraulic oil changes with the change of ambient temperature.

B. When recommended oil are not available.

C. When hydraulic oil supplied differently from the recommended type.

■Hydraulic oils and Greases recommended for Hydraulic breaker by JISAN:

■ Oil Contamination

Contaminated oil results in malfunctions of the breaker as well as the base machine and cause

damage to parts. Pay special attention to oil contamination. Contaminated oil should be changed

without any delay. When changing oil, thoroughly wash oil tank, cylinder and pipes. Cleaning or

replacing oil filter also requires check for oil contamination.

■Replacement of filter: after first 50 hours and every 100 hours thereafter.

■Replacement of hydraulic oil: every 500 hours

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8. Operation
1) Proper position of the tool
Proper position must be applied for an effective use of breaking force. When position is incorrect,

blowing energy of the piston is too weak to break rocks. Instead, blowing force applies shocks to

the breaker body, tool and boom of the base machine, thereby resulting in damage to those

parts.

On the contrary, when position is excessive enough to breaker rocks 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.
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It is undesirable to carry out hammering under the below condition, because vibrations during

hammering may be transmitted to 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.

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 piston to be damaged.

When breaking, fully stabilize the tool first and t then select the point of a rock on which

hammering can be performed in a stable condition.

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3) Operation precautions

Apply down force to the boom dipper until the front of the backhoe and carrier is arised off the

ground. The breaker is more efficient when adequate down force is applied.

Relocate the breaker often. The breaker tool should be moved to a new location of the work time

the tool penetrates but dose no crack the material.

Do not break continuously in one place. Continuous penetration in the same area for lengthily

periods will create excessive temperatures at the end of tool resulting in loss of temper(hardness)

of the bit and causing mushrooming of the tip of the bit, and may lead to failure of the bit.

Do not pry with the bit and breaker.

The contaminated part must be cleaned with no delay. Hydraulic oil or light oil is highly

recommended.
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■Stop operation as soon as hose vibrate excessively.

Excessive vibration of high and low‐pressure hoses of breaker calls for an instant disassembly and

repair. For caution’s sake, check oil leakage at back head. The operator is required to pay

attention to follow points during operation.

■ Avoid 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 breaker or the tool is used as a lever (hammering sound

changes during blank hammering).

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■ Do not move rocks.

Avoid moving rocks with side of the bracket, because it is the major factor to brewak bolts

installed on the bracket, tool and damage boom and arm.

■ Do not use tool as a lever

When breaking rocks by using tool as a lever, bolts and tool may be broken too.

■ Do not continue to hammer for more than one minute

When rocks are not broken after more than one minute’s hammering at the same point, change

the place to be hammed. Extended hammering at the same place causes the tool to wear out

excessively.
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■ On a hard and large rock, start breaking from the edge

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

■ Operate breaker at proper engine speed

Break rocks at the specified engine speed. Raising engine speed more than necessary does not

strengthen hammering force but increase oil temperature to the detriment of pistons and valves.

■ Do not operate the breaker in water and mud

Do not operate breaker when all components except tool are immersed in water and mud. Piston

and similar components may gather rust and become a damaged breaker at an early stage.
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■ Do not allow the breaker to fall to break a rock

Falling down the breaker will apply excessively force to the breaker or the base machine, causing

damage to many parts of breaker and the base machine.

■ Warm up base machine engine prior to operation

Especially in winter, the base machine engine should be warmed up for five to ten minutes

30℃‐40℃(86℉‐105℉)before breaker operation. Follow the instruction book for base machine

to warm up engine.

■ Do not lift things with the breaker.

Lifting materials by hanging wire in the bracket or tool not only causes damage to the breaker but

also is very dangerous when operation.

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■ Do not touch tool for breaker working

During the breaker is working, high temperature of the tool will be generated.

■ When operating the breaker, you must use ear and body protection.

You must use ear and breathing protection when the breaker is operating.

■ Accumulator type‐ Danger

Attention to pressurized container! Do not open without reading the manual or consulting with

the authorized service personal!

■ Greasing

With breaker mounted on carrier, apply down pressure on tool and fill cavity with recommended

grease through the grease nipple.

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9. Installation & Removal of the Breaker

When the bucket and breaker operation are

performed alternately, the bucket and breaker can be

easily exchanged by the hydraulic hoses and two

pins. There is. However, a risk of the hydraulic circuit

contamination. Accordingly, install and remove as

follows. 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 oil tank if it

is pressurized.

■ Turn 90°the stop valve installed to the end of arm to prevent hydraulic from flowing out.

■ Loosen hose plug on the breaker arm

Collect small amount of oil flowing out at this time and put into a container.

■ Be careful to prevent mud or dust from entering oil hoses and pipe lines.

Plug oil hoses with hose plug and pipe lines with union caps. Bind high and low‐pressure hoses

with a wire to prevent them from getting mud.

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

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

■ When leaving the breaker removed for a long period of time.

Clean exterior of the breaker. Remove tool from the front head and spray with rust preventive oil.

Bleed N2 gas from the back head before pushing piston into cylinder. Apply grease to each part of

the breaker and then install tool again.

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10. Maintenance
1) Inspection points‐ Inward valve type

Part Unit JSB200 JSB300 JSB400 JSB600 JSB800 JSB900 JSB1600 JSB1900 JSB3500 JSB4500

Tie rod fixing torque A kg*m 35 40 40 100 100 150 250 250 270‐330 350‐400

ACC fixing torque B kg*m ‐ ‐ ‐ ‐ ‐ ‐ ‐ 60‐65 60‐65 350‐400

ACC plug fixing torque C kg*m ‐ ‐ ‐ ‐ ‐ ‐ 8‐12 8‐12 60‐65

Side bolt fixing torque D kg*m 60 80 100 145 145 145 200 250 30‐40 8‐12

Socket bolt N2 gas H kg*m ‐ ‐ ‐ ‐ ‐ ‐ ‐ 30‐40 250‐270 40‐50

pressure

2
Back head N2 gas ‐ kg/cm 15 16.5 16.5 16.5 16.5 16.5 16.5 16.5 6‐7 320‐400

pressure ‐ psi 213 235 235 235 235 235 235 235 85‐99 16‐18

2
ACC N2 gas pressure ‐ kg/cm ‐ ‐ ‐ ‐ ‐ ‐ ‐ 54‐55 54‐55 227‐256

‐ psi ‐ ‐ ‐ ‐ ‐ ‐ ‐ 767‐782 767‐782 58‐63

Valve adjuster terning K ‐ ‐ ‐ ‐ ‐ ‐ 2.5‐3.0 2.5‐3.0 2.5‐3.5 824‐296

position
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2) Daily inspection
Before starting operation, be sure to inspect the breaker referring to the following table.

Inspection Item Inspection Point Remedy

Looseness, missing and damage to ◆Through bolts ◆Check looseness

bolts and nuts ◆Bracket mounting bolts ◆Retighten securely

Looseness, of hose fittings, visible ◆Hydraulic pipes for breaker oil ◆ Retighten securely

damage to hoses and oil leakage hoses ◆ Replace seriously damaged parts

Abnormal oil leakage ◆Connections of back head and ◆Consult with Jisan company for

cylinder further inspection

◆Clearance between front head

& tool(But small leakage is normal

from front head)

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Inspection Item Inspection Point Remedy

Abnormal wear and crack on tool ◆Tool ◆Deformed, burred and worn out tool

should be repaired

◆Excessively worn tool needs to be

replaced.

Greasing ◆Grease at start every 2‐3 hours ◆Grease front head

using grease pump.

◆Pumping 5‐10 times(Greasing

position and method shown at

left.)

◆ When greasing, press the tool

against on the ground.

Level and contamination of hydraulic ◆ Conditions of hydraulic oil ◆Contamination of hydraulic oil carries with

oil operating conditions.

The oil color tells the level of contamination.

◆Criteria for judging contamination is

specifically set by Jisan company.

◆When contamination is excessive, drain and

flush the hydraulic oil tank and fill it with new

oil.

Missing rubber plugs and snap rings ◆Rubber plugs ◆A seriously damaged part must be

◆Snap rings replaced.

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3) Regular breaker inspection and maintenance

Regular inspection is essential for keeping hydraulic breaker operating in the best condition.

Consult with JISAN for regular inspection and maintenance within six months after delivery.

4) Replacement of tool
Tool is deformed of burrs produced in a long‐term use. When a tool tip is worn out, tool is liable

to slip. Then, sharpen the tool tip. Grinding the tool tip many times to sharpen the edge, however,

it will make a heat‐treated hardened surface layer disappear and it will wear out the tool rapidly.

In this case, replace with a new tool. If a gap between tool and lower bush becomes large, piston

fails to fit in tool resulting in damage. When the gap is found in over 9mm, replace upper bush

together with the tool.

◆ Replacement of order

‐ Remove snap‐ring and tool pin in order with a 330mm‐long steel bar. When reassembling, align

groove in tool to tool pin hole and insert tool pin.

‐ 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 and frictional areas of the tool pin and tool, and finally install tool.

Excessively, deformed tool pins will make difficult replacement of tool. Therefore, tool pins are

required to be checked every 100 to 150 hours of operation.

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‐If replacement of tool is not a genuine part, we do not warranty the performance of other parts

of the breaker.
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5) Breakage of tool
The service life of various tools depends on the manner handling them.

The tool can sufficiently withstand the vertically acting load, but it is weak to the perpendicularly

acting load. Especially, the tool is affected by the negative conditions, such as, force by craning

operation, tilted blowing, wrenching, idle strokes, etc.

Its service life becomes shorter.

There are several ways of breakage of tool.

Each cause of breakage can be inferred by observing breakage sections.

Further the breakage case which is not caused by low‐quality materials or insufficient

heat‐treatment but by wrong way of handling, which the manufacture is not responsible for the

breakage.

(See below figure) the breakage section has the origin on the outer surface, a narrow area of

fatigue breakage and a wide area of rough grey area and final breakage part has the share‐lip

form. Such an undulation on the breakage section and its inclination to the right and left witness

that the breakage is caused by excessive force which exceeds the toughness of the tool.

Such a breakage is supposed to occur careless handling of the tool. To avoid such a breakage,

more carefulness and attention are required in handling the breaker.

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11. Trouble Shooting Guide

1) Problems in operation
If the breaker do not work or below frequency and blow power get worse, check the arranging

method. And then inspect according to the following order.

Symptom Cause Required action

No blow out ◆Excessive back head gas pressure ◆Re‐adjust N2‐gas pressure

◆Stop valve closed ◆Open stop valve

◆Lack of hydraulic oil ◆Fill hydraulic oil

◆Wrong adjustment of pressure ◆Tighten or replace

reducing valve

◆Faulty hydraulic hose connection ◆Replace back head o‐ring, or

◆Oil back head infection step seal of seal retainer

Low impact power ◆Line leakage or blockage ◆Check lines

◆Clogged tank return line filter ◆Wash filter, or replace

◆Lack of hydraulic oil ◆Fill hydraulic oil

◆Hydraulic oil contamination, or heat ◆Replace hydraulic oil, rinse tank

deterioration and replace hydraulic oil inside

◆Back head N2‐gas low lines

◆Low flow rate by mis‐adjustment off ◆Refill nitrogen gas

low control pressure reduction valve ◆Re‐adjust reduction valve

◆ Tool out of range for blowing ◆Rush down tool by excavator

position operation

Irregular impact ◆Low accumulator gas pressure, of ◆Refill N2‐gas

bad accumulator ◆Rush down tool by excavator

◆Piston moves down/up to blank operation

blow hammer chamber

Gas leakage ◆O‐ring damage in related parts ◆Replace relevant O‐ring

Oil leakage ◆Cylinder seal kit worn ◆Replace seal kit

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Pressure Line ◆Accumulator gas leakage ◆Replace o‐ring, or refill N2 ‐gas

vibration ◆Accumulator diaphragm damage ◆Replace diaphragm

Bad tool movement ◆Tool diameter incorrect ◆Replace tool with genuine

◆Tool and pin jammed from tool replacement parts

retainer pin wear ◆Smoothen rough surface of tool

◆Jammed lower bush and tool ◆Smoothen rough surface of

◆Deformed tool and piston contact lower bush interior

area ◆Replace tool

2) Gas leakage
Trouble Cause Remedy

Gas leakage from the top of ◆Defective or damaged in ◆Repair or replace charging

charging valve charging valve valve

Gas leakage between charging ◆Defective o‐ring in charging

valve and back head valve ◆Replace

◆Charging valve loose in back ◆Re‐tighten

head

Gas leakage between cylinder ◆Defective o‐ring in back ◆Replace

and back head head

Gas leakage from drain plug ◆Defective gas seal in seal

hole retainer

◆Defective step seal in seal ◆Repair or replace seal

retainer retainer and piston

◆Seizing of piston and seal

retainer
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3) Oil leakage
Even if oil is leaking, it is necessary to replace parts at all times. Check the following points listed

in the chart below. The user can check the marked points before calling the dealer.

Area of oil leakage Condition Causes & Remedies

A Between the tool and ◆A large amount of oil is leaking ◆Seals damaged

lower bush ◆Check if it is coming from oil or ◆Replace

grease

B Surface of breaker ◆Oil leaking from the hose and ◆Loose breaker hoses and bolts

flange adapter portion ◆Retighten

C Valve housing bolts ◆Oil leakage from reassembly of ◆During assembly from lubrication

and cap bolts valve after overhaul oil & anti‐rust oil applied

D Between main valve ◆Oil leakage from reassembly of ◆Clean oil

and surface of breaker after overhaul ◆Check that seal is damaged

cylinder ◆Loosen bolts

◆Replace with new seal

E Between cylinder and ◆Oil leakage ◆Loose tie rod nuts

back head ◆Oil leaks again ◆Damaged O‐ring

◆Retighten

◆Replace

F Between cylinder and ◆Oil is leaking ◆Loose plugs assembled on the

front head surface of cylinder

◆Retighten

◆Replace damaged seals

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12. Warranty Policy

This warranty policy is made by JISAN HEAVY INDUSTRY Ltd., for proper quality guarantee to

end‐customers.

1) Warranty
The company provides Distributor who purchases hydraulic breaker or parts “PRODUCTUS” from

the company with the following warranty.

‹ The Terms of Warranty

The warranty provided by the company hereunder shall extend either for a period of a 14 months

from the date of shipment to Distributors, as determined by the date of Bill of Lading or for a

period of 12 months from the date of sale by Distributor to Buyer, as determined by the date of

Distributor’s invoice for the products to the buyer, whichever comes first.

Distributor shall advise the company of the date of sale of the products to the Buyer either by

facsimile or mail not later than 15 days after the date of sale. Warranty will be applied to the

Original purchaser only.

‹ The Contents of Warranty

All delivered products will be checked for defects, damages or missing parts to assure

performance upon arrival. The distributor has to inform The Company with a written claim on any

missing or damaged part within two weeks, 14 days, after receipt of products.

Damage occurred by transportation shall be claimed by the receiver directly to the transportation

company.

The damages shall be recorded on the shipping documents and the claim has to be made

immediately.

The Company will not warrant any damage that is occurred by incorrect of careless handling,

excessive stress, normal wear and tear or similar cases not due to faults of The Company.
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The distributor or Buyer must submit Delivery Report presented separately or attached in manual

to The Company within 15 days when any failure shall occur. If not, The Company will not take

the responsibility on claim. Any defects found in workmanship and faulty material will be

repaired by Distributor and The Company will reimburse to Distributor as follows:

‐‐Spares on The Company account

‐‐Airfreight up to 20kgs on The Company

‐‐Customs clearance fee, labor charge, trucking charge to end‐user and other all changes on

Distributor account.

The distributor will keep the damaged products for inspection and analysis by a The Company

engineer Reimbursement will be carried out within 30 days after The Company’s decision if any

written claim report with photos is applied to warranty or not. The Company will make its best

efforts to settle any claim made by Distributor in a shortest time.

‹ The exception of warranty

This warranty shall not apply in the following circumstances, even if within the above warranty

period.

1. If a report detailing the specific alleged defect and/or damage, as well as the actual

conditions under which the products were used and satisfactory proof thereof, including

photographs, were not sent to The Company within 2 months from the date of such alleged

or damage is discovered.

2. If the distributor does not, promptly after The Company so requests, furnish to any

reasonable information available to the distributor and necessary for The Company to

analysis the warranty claim.

3. If the allegedly damaged and/or defective product is lost or not provided to The Company at
 OPERATION MANUAL
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distributor’s site for inspection within one year of reported damage.

4. If the product involved was used in conjunction with other parts than genuine parts.

5. If the subject product was altered or modified by the distributor, the buyer or any user of

the products without the express written consent of installation.

6. If the defect complained of in such products is caused solely or partly by improper use,

repair, Improvement, maintenance, storage or installation.

7. If the defect is caused by act of god, or in full/part by the negligence or intentional act of the

distributor, the buyer or any user of the products or any other person.

8. This warranty does not apply to any tools served with the product, reserve parts and

following wearing parts: Tool, tool pin set, seal kit, accumulator bladder, front head, bushing,

etc. and normal wear recognized generally.

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2) Delivery report
This report is for checking that beaker is correctly delivered and equipped on machine.

Distributor should correctly draw up this because this will be a major data when warranty claim

arise in the future. This report must be drawn up in typewritten and informed within 7 days after

the date when delivered breaker to customer, and also The Company by registered air mail within

30 days after the date, otherwise warranty claims shall not be carried out accordingly.

Machine

1. Maker/Model: Manufacturer and model name of the carrier

2. Operating Weight

3. Operating Hours: Actual operating hours at time or Date delivered out breaker

4. Oil filter: If there is it mark “Y”, if not mark “N”

If there is not it or condition is bad, breaker should be troubled easily.

Therefore lease recommend customer to install it in or change new one.

5. Others: Performance or condition of engine and hydraulic pump

Breaker

1. Model& Serial No.: Model name and Serial No. of the breaker

2. Operating Pressure: Actual operating pressure

3. Relief set pressure: Actual relief valve setting pressure for breaker

4. Operating Oil Flow: Actual required operating flow

5. Gas Pressure: Actual pressure in accumulator or gas chamber

Warranty Period

1. Warranty Start: Date delivered the breaker

2. Expired date: Date to be 6 months from the date delivered to customer

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Delivery Report
Reference No.:______
Distributor Name:

Nation: City:

Customer Name:
Nation: City:

Machine Maker/Model: Operating

Weight: kg
Breaker: Model: S/No:
Oil Pressure: Oil Flow:

Warranty Start: Expiry Date:

I hereby acknowledge that the subject was delivered in satisfactory condition and
operates properly, and that I receive operation manual and instruction as to it is
proper operation, preventive maintenance, and that all aspect of the standard
warranty have been fully explained to me.

Signature of Customer: Title:

Distributor: Date:
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JISAN
Hydraulic Breaker
Parts List

Model Name

Serial Number

Date of Installation

Jisan Heavy Industry Ltd.

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Foreword
The parts list is composed of all parts of Jisan hydraulic breaker.

If you intend to order parts, please write down the followings and

contact Jisan or an approved distributor in local sites.

1.Model Name:

2.Model Serial No.:

3.Parts No. And Parts Name:

4.Quantity

5.Customer's contact information:

Please use genuine parts of Jisan in order to maintain the breaker

performance.

Have in mind that Jisan will not guarantee the defects which might be

caused by using non‐genuine parts of Jisan.

Jisan Heavy Industry Ltd.

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Foreword
The parts list is composed of all parts of Jisan hydraulic breaker.

If you intend to order parts, please write down the followings and

contact Jisan or an approved distributor in local sites.

6.Model Name:

7.Model Serial No.:

8.Parts No. And Parts Name:

9.Quantity

10.Customer's contact information:

Please use genuine parts of Jisan in order to maintain the breaker

performance.

Have in mind that Jisan will not guarantee the defects which might be

caused by using non‐genuine parts of Jisan.

Jisan Heavy Industry Ltd.

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Foreword
The parts list is composed of all parts of Jisan hydraulic breaker.

If you intend to order parts, please write down the followings and

contact Jisan or an approved distributor in local sites.

11.Model Name:

12.Model Serial No.:

13.Parts No. And Parts Name:

14.Quantity

15.Customer's contact information:

Please use genuine parts of Jisan in order to maintain the breaker

performance.

Have in mind that Jisan will not guarantee the defects which might be

caused by using non‐genuine parts of Jisan.

Jisan Heavy Industry Ltd.

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