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Thank you very much for purchasing a TOP Series Hydraulic Breaker. These hydraulically

operated, gas-assisted breakers have been developed by a highly experienced team of engineers.

Reflecting many strength and durability improvements, these breakers are composed of the

minimum number of parts to ensure powerful, trouble-free operation.

Proper handling, maintenance and inspection are crucial in order to obtain the optimum

performance for the longest possible period of time.

Carefully read this instruction Manual before using the breaker to ensure satisfactory results. If

you have any question, please contact our agents or us.

When replacing parts, be sure to use only OKADA genuine parts. Otherwise, the performance

and durability of the breaker may be seriously impaired.

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Содержание TOP Series

Страница 1: ...O OK KA AD DA A H HY YD DR RA AU UL LI IC C B BR RE EA AK KE ER R OWNERS AND OPERATORS INSTRUCTION MANUAL PARTS LIST S N 2980 and after 091118kk ...

Страница 2: ... of parts to ensure powerful trouble free operation Proper handling maintenance and inspection are crucial in order to obtain the optimum performance for the longest possible period of time Carefully read this instruction Manual before using the breaker to ensure satisfactory results If you have any question please contact our agents or us When replacing parts be sure to use only OKADA genuine par...

Страница 3: ...y 1 Introduction to safety 4 2 Forward 5 3 People make the difference 5 Safety Section Be sure to read 4 Basic precautions 6 5 Precautions on installation and removal 8 6 Precautions on inspection 11 7 Precautions on usage 13 8 Precautions on storage 17 ...

Страница 4: ... is ignored and the machine is operated incorrectly This sign alerts the operator of death or serious injuries that can result if this sign is ignored and the machine is operated incorrectly This sign alerts the operator of injuries or property damage that can result if this sign is ignored and the machine is operated incorrectly This sign alerts the operator that the machine can be damaged or its...

Страница 5: ... make judgments concerning their own physical and mental conditions Trained have read and understood the operator s instructional manual the load rating chart if applicable hand signals chart and warning decals and maintenance aspects of the machine Licensed if required by law Careless operation of this machine can result in death or serious injuries The operators and maintenance personnel are ask...

Страница 6: ...ers and vehicle traffic enclose the work site using protection sheets or the like to prevent debris from flying out When a guide is used in a joint work etc follow the predetermined signs the guide gives Safety label Read the safety label affixed on the machine and gain a good understanding of it Keeps the safety label clean all the time to assure a clear view of it If the safety label should be p...

Страница 7: ...ters may become projectiles possibly causing workers serious injuries When leaving the operator s seat Before leaving the operator s seat firmly lower the hydraulic hammer and shift the hydraulic backhoe safety lock lever to the LOCK position If one happens to touch the travel lever or the swing control lever it may abruptly start moving resulting in serious injuries When leaving the driver seat f...

Страница 8: ...mass serious injuries may occur Using wooden props or the like firmly prop the hydraulic hammer to prevent it from turning sideways causing serious injuries The operation shall be performed by a well trained worker and achieve safeguarding by making the work site inaccessible during work hours When the hydraulic hammer bracket pin or bucket pin have sharp burrs be sure to remove them before starti...

Страница 9: ... the bracket pin always wear a hard hat safety goggles safety shoes dust proof mask ear mufflers and protective leather gloves Make sure there are no bystanders around Metal chips may scatter causing serious injuries to your eyes if the chips come into eyes Precautions on hydraulic hose installation and removal Be sure to tighten the hydraulic hose fittings to the correct torque If the hydraulic h...

Страница 10: ...ct with the ground so that the unit is in a stabilized posture If the chisel set pin upon removal falls and hits a person serious injuries may occur In attaching the chisel do not touch the chisel portion from the chisel set pin retaining site toward the shank This is because the hand or finger may be trapped between the chisel and the front cap resulting in serious injuries Slightly raise the chi...

Страница 11: ... from the operation lever Because if anyone unaware of the inspection underway operates the machine serious injuries may result Action to take when a problem is noted If bolts nuts and pins are loose the hydraulic breaker may fall off and cause severe injury If bolts and nuts are found loose tighten them with the proper torque If pins are fallen off or damaged replace them with new ones When crack...

Страница 12: ...umulator or back cap is filled with any other gas than nitrogen gas an explosion may occur resulting in serious injuries Do not use any gas except nitrogen gas in them There is a danger of explosion Do not attempt to weld either of them and keep any flame away When discarding an accumulator there is a need to remove the gas beforehand So contact our Company or its distributor for gas removal Regar...

Страница 13: ...th a protection cover As for the cab glass use such safety glass as laminated coated sheet glass Broken materials may fly up possibly causing serious injuries Encircle the work site with protection sheets to prevent rocks from flying out Keep the site inaccessible to bystanders and structures Precautions on work site environments Do not operate the machine under the cliff or near the cliff ledge V...

Страница 14: ...accident can occur in which a person might be caught or hit by the machine Precautions on crane work Do not perform crane work with the hydraulic hammer unit attached In this condition the hydraulic backhoe can turn over causing serious injuries Precautions on electric shock Where there are aerial wires near the work site consult the power company concerned and follow its directions The hydraulic ...

Страница 15: ...resulting in gas explosions with serious injuries Precaution on burn Do not touch the chisel just after completion of work The chisel that just finished work is hot and may cause a burn if touched Precaution on dust Dust and dirt scatter about when crushing structures Prevent dust flying by means of water sprinkling Breathing in asbestos fibers could develop lung cancer Try not to inhale scatterin...

Страница 16: ... Pay attention to floor strength When operating the machine in the building make sure the floor is strong enough When the machine weight is compounded by hydraulic hammer impacts the floor might cave in causing serious injuries Beware of falling objects When operating the machine in the building beware of the direction in which a beam etc might fall In dismantling work a beam for instance may fall...

Страница 17: ...remove the hydraulic hammer from the backhoe for storage retain the hydraulic hammer in the manner to prevent rollover In addition make the place inaccessible to anyone If the hydraulic hammer turns over and pins a person serious personal injury accident will happen ...

Страница 18: ... breaker during operation Rocks flying from the breaker can cause serious accidents PRIOR INSPECTION Check that there is sufficient hydraulic oil and that it is not contaminated Check that hoses bolts and nuts are secure Grease the shank part of the chisel THINGS TO AVOID Do not use the breaker in water special specifications are available for underwater work Do not operate the breaker when the cy...

Страница 19: ...isel may jump out Do not stand in front of the chisel to avoid accidents When disassembling or repairing the breaker The back cap may jump out due to gas pressure This is very dangerous Be sure to release gas from the back cap before disassembly Before filling the back cap with gas be sure to completely tighten the side rod When replacing the gas valve The gas valve body may jump out due to gas pr...

Страница 20: ...and Flow 23 Handling 24 Maintenance and Inspection 26 Trouble Shooting 29 Disassembly and Reassembly 31 Instruction for accumulator 42 Assembly Drawing 51 Exploded View 52 Breaker Body Parts List 53 Bracket Parts List 54 Routine and Periodic Inspection 56 Tightening Torque Chart 58 Chisel Warranty Guide 60 ...

Страница 21: ... cushion chamber MPa 0 3 0 4 psi 43 57 Tool diameter mm 155 inch 6 1 Piping diameter mm 25 inch 1 Carrier output flow range L min 240 270 gpm 63 72 Set pressure of secondary relief valve MPa 20 7 psi 3000 The operating weight varies depending on the type of bracket and the base machine The specifications above are subject to change without notice The performance data vary depending on the base mac...

Страница 22: ...m Piping for the hydraulic excavator for use with the hydraulic breaker is to be arranged as illustrated below Hydraulic pipes identified with suffix A for those used at high pressure side and suffix B for those used at low pressure side ...

Страница 23: ...umps straight to the tank on excavator If return dumps straight to tank and back pressure is still too high look for other restriction such as a partially closed ball valve couplers clogged return filter or undersized plumbing 6 To set your Circuit Relief Valve Secondary Relief Valve run the engine back up to full throttle and press down on the breaker pedal Next turn the restriction knob on the f...

Страница 24: ...wards and do break in at half engine speed in order to break in of parts Note Do not tilt the chisel during break in period 3 Precautions during operation Position the chisel on the material to be broken so that the crawler or the front wheels of the tires float slightly then start hammering by applying pressure Once the material shatters stop hammering immediately Avoid using the chisel as a leve...

Страница 25: ...e stop valves to the breaker 3 Be sure to blind the disconnected hoses The entry of sand and mud into the hydraulic hoses and pipes can be a cause for trouble 5 Changing the chisel 1 Remove the plug and shaft retainer and then push out the shaft Note Refer to the tightening torque chart regarding the tightening torque of the plug 2 Push out the chisel set pins from the bottom using a screwdriver 3...

Страница 26: ...addition cavitations may be caused by the entry of air All of these factors may lead to trouble in the breaker 4 Avoid using the breaker at an oil temperature above 80 C 176 F The recommended working temperature ranges from 50 to 80 C Check that the cooler fins are not clogged and keep them clean Soiled fins will impair the operation of the oil cooler 5 Entry of water in the hydraulic oil causes p...

Страница 27: ...ed Retighten valve box set bolts or replace O ring D Between the valve box and the valve cap Valve cap bolt loosened or O ring worn damaged or hardened Retighten valve cap bolts or replace O ring E Between the accumulator and the cylinder Accumulator set bolts loosened or O ring worn damaged or hardened Retighten accumulator set bolts or replace O ring F Between the back cap and the cylinder Loose...

Страница 28: ...ue to the sliding action between the shank bushing causing depletion of oil that results in early wear Make it a practice to grease it up regularly 5 Continued use of chisel with worm tip not only degrades the crushing performance but also leads to breakage of the chisel Make sure that the edge of chisel is kept sharp at all time 6 Quenching the chisel may cause breakage Avoid using it in such a s...

Страница 29: ... damage is mended quickly the parts become irreparable Excavator Use of excavator when oil temperature is above 80 C 176 F Avoid using the excavator above 80 C Do not rev up the engine more than required Clogging by foreign matter in the piping Disassemble and remove the foreign matter 3 Major causes and suggested remedies for irregularity in operation MAJOR CAUSES SUGGESTED REMEDIES Breaker Impro...

Страница 30: ...aulic breaker if the oil temperature is above 80 C 176 F Disorderly operation of the pressure valve in the tank and clogging of cooler fins or filter elements Send these parts to the manufacturer s designated service factory for repair or replacement Improper selection and damage of directional valve Repair or replace EARLY WEAR AND DAMAGE OF PARTS MAJOR CAUSES PLACES Lack deterioration or contami...

Страница 31: ... with the side rods from the cylinder 5 Fit an eyebolt into the head part of the piston and by using a round bar as a lever pull the piston together with the cylinder sleeve If it is difficult to pull the piston insert a round bar from the front cap side and hammer out the piston At this time slowly pull the piston taking care not to gall the piston If you have any hoisting device place the piston...

Страница 32: ...sealing the tape seal or replacing the O ring PROCEDURE FOR REPLACING THE FRONT CAP BUSHING AND THE SHANK BUSHING When replacing the front cap bushing be sure to replace the shank bushing as well 1 Remove the flange plugs and shaft retainers and then push out the shafts Hydraulic press or hammer Steel disc Welding 2 For removal of the front cap bushing and shank bushing weld a steel disk as shown ...

Страница 33: ...e oil stone should be as large as possible Then finish the surface with 800 grinding paper to a surface roughness of 6 3S or less 2 Surface roughness of the cylinder s inner surfaces B and C other than the above mentioned surface 12 5S To repair scratches on the inner diameter surface use a coarse round oilstone while applying cleaning oil To remove burrs inside the seal grooves use a comb shaped ...

Страница 34: ...until the surface roughness of 12 5S or less is obtained To finish the surface use grinding paper When an electric power supply is available use a portable electric drill with grinding paper wrapped around the end of a rod to roughly repair the scratches To finish the surface use a flex hone Quick finishing is possible with this method Repairing the piston end and chisel s impact surface Repair an...

Страница 35: ...ding the upper part of the piston with hand To ensure smooth insertion place a wooden block under the piston To facilitate insertion drive in the piston by hitting portions A and B in the figure alternately with a plastic hammer If a crane is available hoist the piston with the cylinder sleeve using an eyebolt and insert them into the cylinder which has been placed upright 3 Install the valve and ...

Страница 36: ...nitrogen gas in the cushion chamber For charging procedure refer to the section Procedure for Inspecting the Cushion Chamber Gas Pressure 9 Force grease in several times using a grease gun through the grease nipple located on the lower side of the front cap PROCEDURE FOR INSPECTING CUSHION CHAMBER GAS PRESSURE The OKADA breakers have been shipped from the factory with nitrogen gas charged in the b...

Страница 37: ... the cap 5 Turn the handle of the charging device clockwise As you turn the handle you will feel resistance at a certain position Turn the handle farther The pressure gauge will indicate the charging pressure Note The gas pressure changes depending on the length of the chisel s protrusion Check the pressure when the chisel is extended as far as possible If the gas pressure is improper adjust it Th...

Страница 38: ...essure will gradually lower Tighten the cap when the proper pressure is reached 2 Regarding the steps to be taken hereafter follow the procedure used to remove the charging device Replenishing nitrogen gas After checking steps 1 to 3 take the following steps 1 Connect a regulator to the nitrogen gas cylinder 2 Remove the cap of the charging device and connect the regulator to the charging device u...

Страница 39: ...en the proper gas pressure is obtained turn the main valve of the nitrogen gas cylinder clockwise to stop the gas supply Turn the handle of the charging device counterclockwise to prevent the nitrogen gas replenished in the cushion chamber from leaking Then remove the charging device Note Do not use gases other than nitrogen gas When nitrogen gas is charged the chisel may jump out To prevent injur...

Страница 40: ...hamber Press the piston from the front cap side into the cylinder as following procedures Remove the cover and gas cap Screw the gas charging valve into the gas valve body and remove the dust cap to release the N2 gas from the back cap Turn the handle of the gas charging valve clockwise and completely release the N2 gas from the back cap Keep this situation until all works are completed Remove the...

Страница 41: ...surface of the front cap Completely cover it with a plastic sheet or other protective material Do not leave the breaker outdoors in any cases Note Any failure due to lack of above procedures are not covered by warranty and are sure to shorten the life of breaker ...

Страница 42: ...lator bladder to the sun can lead to deterioration 6 Read this manual before attempting to handle the accumulator After a proper understanding of the accumulator is obtained proceed with the required maintenance work Removing the plug on the upper side of the accumulator cover while the gas charging valve loosened could result in N2 gas spurting out Be sure to tighten the gas charging valve before...

Страница 43: ...e accumulator charging kit where plug 8 was screwed in Note If using the X type accumulator charging kit use the adapter 10942211 The handle for the charging kit is not needed ４ Make sure that the cap and the release valve are tightened ５ Gradually turn the gas charging valve counterclockwise until the gauge reacts Record the gas pressure Release valve Cap ...

Страница 44: ... torque Cap 6 with O ring Uniform Torque 80 N m 59 ft lb 100107 ７ Open the release valve of the accumulator gas charging kit to release residual pressure ８ Remove the accumulator gas charging kit and then tighten plug 8 with O ring to the uniform torque Check that there is no gas leakage Plug 8 with O ring Uniform Torque 80 N m 59 ft lb 100107 ...

Страница 45: ... gas charging kit is tightened 2 Install a regulator in the N2 gas cylinder and then connect a hose between the N2 gas cylinder and the accumulator gas charging kit Be sure to use a well charged N2 gas cylinder that is over 6 MPa 870 psi 3 Loosen the regulator handle counterclockwise as far as possible Release valve Important ...

Страница 46: ...der 6 Adjust the gas pressure to the specified pressure by turning the regulator handle Note Gas pressure varies depending on temperature Adjust the N2 gas pressure according to ambient temperature Note Refer to page 90 for the specified pressure 7 Tighten gas charging valve 4 clockwise to 29 N m 21 ft lb ...

Страница 47: ...sure 10 Remove the gas charging hose and gas charging kit from the accumulator 11 Tighten cap 6 with O ring to the uniform torque Cap 6 with O ring Uniform Torque 80 N m 59 ft lb 100107 12 Tighten plug 8 with O ring to the uniform torque and then check that there is no gas leakage Plug 8 with O ring Uniform Torque 80 N m 59 ft lb 100107 ...

Страница 48: ...48 Exploded view 6 4 7 5 8 9 3 2 10 1 12 11 Hex 22 Hex 22 Hex 5 This part can not disassemble A A A A ...

Страница 49: ... 7 O ring E1012014 1 8 Plug 15401448 1 9 O ring E1012014 1 10 Cap screw A0303A4569 12 11 O ring E1162231 1 12 Accumulator back up ring 31380253 1 Specification Gas Nitrogen Gas Gas pressure 20 68 F 6 0 3 MPa 870 44 psi Torque Plug 8 With O ring Accumulator Upper side 80 N m 59 ftlb Cap 6 With O ring Accumulator side face 80 N m 59 ftlb Cap screw 10 Accumulator cover for fixing AC 3Y 440 N m 325 ft...

Страница 50: ...50 Blank page ...

Страница 51: ...51 Assembly drawing TOP300 S N 2980 Acc gas charging valve Gas valve body Flow control shaft Acc gas charging valve Gas valve body Flow control shaft ...

Страница 52: ...151 146B 146A 131 136 138B 138A 141 137 132 133 139B 139A 39C 39D 39D 39C 39F 39E 39A 39B 39C 39D 35A 39B 39A 19D 19C 19E 19F 21 104 101 103 72 77 76 71 79 65A 65B 62B 62A 11A 11B 11A 11B 11A 11B 2 3 61 75 78 74 B A 13 11B 11A 69A 69B 73 ネームプレート R R 82 102 85 86A 86B 92 94B 84B 86B 86A 31C 88 81 91 94A 85 93 84A 88 89C 89A 89B 89B 89A 17A 17B 38 39D 39C 48C 48B 48A 49B 49A Dark green color ...

Страница 53: ...31 Back nut washer 4 7 31A E1022080 O ring G80B 2 2 3 131 156514101 Accumulator body 1 8 31B E2122080 Back up ring G80T2 2 2 3 132 156514212 Accumulator cover 1 8 31C E1022090 O ring G90B 3 2 3 133 156514311 Bladder 1 8 31D E2122090 Back up ring G90T2 4 2 3 136 15401442 Gas charging valve body 1 8 33 E1022105 O ring G105B 1 2 3 137 E1012005 O ring P5B 1 8 35A E1012022A O ring P22AB 5 2 3 138A 1540...

Страница 54: ...cription 1 15657711 Bracket body 1 2 15657131 Front plate 2 6 15657736 Bracket cover 1 11 15657151 Front bolt 7 12 10635W52 Front bolt nut 7 13 C642A0523 Washer 7 M52 14 15657761 Back supporter 1 15 10636W52 Hard lock nut 7 21A 15657762 Cover 1 21B 15657763U Cover base 2 22A A023K4198 Bolt 8 UNC3 4x75mm 22B C612B019 Spring washer 8 3 4 22C C642B0193 Washer 8 3 4 15657151X1 Front bolt ASSY Hard loc...

Страница 55: ...late L 1 3 Top bracket 1 4 15657V61A Guide box A 1 5 15657V61B Guide box B 1 6 15657V61C Guide box C 1 7 BC30072 Damper 2 85 x 118 8 9 BC30071a Damper 4 85 x 140 10 BC40066A Front bolt 6 RD46 X 540 11 BC40067 Front bolt nut 6 36T 12 BC40068 Front bolt lock nut 6 27T 13 BC40006A Washer 6 14 Tie bolt 12 15 16 Nut 12 17 Spring washer 12 ...

Страница 56: ...y 3 months or 300 hours 1 3 Front cap bushing Wear or damage Remove flaws or replace Every 3 months or 300 hours 1 3 All seals Replace Every 12 months or 1000 hours 1 Accumulator bladder Replace Every 12 months or 1000 hours 1 Valve Flaws on the sliding surface Repair flaws Every 12 months or 1000 hours 1 Cylinder Flaws on the inner surface loosen plug Repair flaws retighten Every 12 months or 100...

Страница 57: ...57 Blank page ...

Страница 58: ...er case bolt N A N A 6 Acc set bolt 880 649 7 Cap screw 440 325 8 Clamp bolt 250 184 9 Plug 540 400 10 Front bolt nut Convex 3330 2460 Concave 730 540 11 Cover bolt 480 354 12 Gas charging valve 29 21 13 Cap 80 59 14 Plug 80 59 Note Refer to the Reassembly procedure for tightening method 021313 2 3 1 5 6 4 8 7 9 10 11 7 14 13 12 Breaker body Accumulator VCB bracket V8Z bracket ...

Страница 59: ...3 2 Apply grease anti seize on the thread of front bolts and both nuts 3 3 Screw the convex nuts in the bolts and tighten at the specified torque referring the table below Repeat tightening each nut a couple of times to average each torque 3 4 Apply grease on the taper portion of convex nuts and then tighten them at the specified torque Convex nut Concave nut TOP300 2460 245lbs 540 75lbs 3330 330N...

Страница 60: ...e fatigue failure of the tool itself Cause and Effect of Fatigue The continuous cycle of compressive and tensile stresses in the working tool even under correct operating conditions create fatigue stress in the tool which can lead to the fatigue failure of a working tool before it is worn out Again anything which interferes with the cycle of compressive and tensile stresses will also increase the ...

Страница 61: ...ubricated before locating in the machine e Corrosion A rusty working tool is more likely to suffer fatigue failure thus keep tools well greased and sheltered from the weather when not in use Demolition Tool Fatigue Failure A working tool fatigue failure will generally occur approximately 100 mm 4 either side of the chuck front face see Figure 3 or through the retainer pin flat Another slightly les...

Страница 62: ...tly failed to give a satisfactory service life a brief visual inspection can often give a quick indication of the cause Fig 5 Typical fractures caused by excessive bending of the working tool Warranty claims rejected Fig 5 Fig 6 Typical of high stress fracture usually caused by using the machine to pull Warranty claims rejected Fig 6 Fig 7 Typical fracture caused by levering tool while buried in t...

Страница 63: ...nty claim rejected Wear Fig 10 Fig 11 Mushrooming this is caused by driving the point into hard dense material for too long a period of time without penetration This generates intense heat softening the point thus causing it to mushroom This is not a manufacturing fault Warranty claims rejected Fig 11 Fig 12 Note fatigue lines originate from internal point not outer diameter Very rare failure type...

Страница 64: ...64 ...

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