OKADA TOP Series Owners And Operators Instruction Manual & Parts List
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OKADA TOP Series Owners And Operators Instruction Manual & Parts List

Hydraulic breaker
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OWNERS AND OPERATORS
INSTRUCTION MANUAL
&
PARTS LIST
(S/N 2980 and after)
091118kk

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Summary of Contents for OKADA TOP Series

  • Page 1 OWNERS AND OPERATORS INSTRUCTION MANUAL & PARTS LIST (S/N 2980 and after) 091118kk...
  • Page 2 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.

  • Page 3: Table Of Contents

    1. Introduction to safety…………………………. 2. Forward………………………………………... 3. People make the difference…………………. Safety Section (Be sure to read) 4. Basic precautions…………………………….. 5. Precautions on installation and removal…… 6. Precautions on inspection…………………… 7. Precautions on usage………………………... 8. Precautions on storage……………………….

  • Page 4: Introduction To Safety

    Safety 1. Introduction to safety Virtually all accidents occur as result of handling or operating a machine without observing fundamental safety rules. Before starting the handling, operation, servicing, and storing of the machine, carefully read this Manual and the Operation Manual for the hydraulic backhoe until you are convinced of all descriptions given in them. The hazard indications shown in this Manual and those affixed to the machine are used as in the following.

  • Page 5: Forward

    Safety 2. Foreword This Manual gives the precautions to be taken in using this product so it can be operated safety and efficiently. Before starting to use this machine, carefully read this manual and master how to operate it. This machine is the attachment used as mounted on the hydraulic backhoe. Therefore, it is necessary for its user to read and understand the Operation Manual for the hydraulic backhoe also.

  • Page 6: Basic Precautions

    Safety 4. Basic precautions Strictly follow the Safety Rules ● This machine shall be operated by only those who have received enough training in advance. ● Maintenance shall be performed by only those maintenance personnel who have received enough training in advance.
  • Page 7 Safety Wearing work clothes and safety aids ● Do not wear baggy clothes, ornaments, etc. that may be caught by levers and other machine parts, or oil-stained clothes that are easy to catch fire. ● Wear a hard hat, safety shoes, dust-proof mask, ear mufflers, and work gloves. Broken rocks, concrete pieces, and metal splinters may become projectiles, possibly causing workers serious injuries.

  • Page 8: Precautions On Installation And Removal

    Safety 5. Precaution on installation and removal Preparation prior to operation ● Make sure that hydraulic hammer installation to the hydraulic backhoe and removal from it is made in a leveled, spacious lot of hard ground. In the event a person should be held between the machine and a solid mass, serious injuries may occur.
  • Page 9 Safety Bracket pin area ● During operation, do not insert your hand or fingers in the hydraulic hammer's bracket pin hole. The hand or fingers can be trapped resulting in serious injuries. ● During operation, do not touch the hydraulic hammer bracket or the hydraulic backhoe arm. ●...
  • Page 10 Safety Precaution on chisel replacing ● Before attaching a chisel, slightly raise the hydraulic hammer 'front cap side from the level ground, and place a wooden block under the front. Put the rear end in contact with the ground so that the unit is in a stabilized posture.

  • Page 11: Precautions On Inspection

    Safety 6. Precaution on inspection How to inspect ● Before performing inspection, lower the hydraulic hammer on a spacious hand-ground area, and see that the hydraulic backhoe's safety lock lever is changed over the LOCK position. If the hydraulic backhoe starts moving during inspection, serious injuries can result. ●...
  • Page 12 Safety DANGER ● The accumulator is packed with high-pressure nitrogen gas. If handled incorrectly, therefore, it may cause serious personal injuries. ● Use special care in handling the accumulator, and never attempt to disassemble it under any circumstances. If the accumulator or back cap is filled with any other gas than nitrogen gas, an explosion may occur, resulting in serious injuries.

  • Page 13: Precautions On Usage

    Safety 7. Precautions on usage Precautions on safety aids ● When operating the machine, always wear work clothes suitable for the job. Avoid wearing baggy clothes or ornaments, which can be caught by control levers or other machine parts, resulting in serious injuries.
  • Page 14 Safety Precautions on backhoe turning ● Do not turn the backhoe with the boom or arm extended. This can cause the backhoe to turn over, resulting in serious injuries. ● Before swinging the arm or traveling, check for any obstacles around the work site; and give a signal using the horn, etc.
  • Page 15 Safety Precaution on gas pipes ● Before operation, check the site to see that no gas pipes or water pipes are buried underground. Occasionally, incidents occur where the machine strike or deflects gas pipes, resulting in gas explosions with serious injuries. Precaution on burn ●...
  • Page 16 Safety Avoid backhoe work crosswise against the crawler track ● Perform backhoe work in the fore-aft direction of the backhoe. When performed at a position perpendicular to the crawler track, the work becomes unstable, possibly causing serious injuries. Pay attention to floor strength ●...

  • Page 17: Precautions On Storage

    Safety 8. Precaution on storage Precaution on storage ● When you 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.
  • Page 18 Safety PRECAUTIONS WHEN USING HYDRAULIC BREAKERS SAFETY FIRST ● When leaving the hydraulic excavator, lower the breaker to the ground and turn the engine off. ● Never attach a cable or sling to the breaker to hoist a load. Doing so is extremely dangerous. ●...
  • Page 19 WARNING ● Keep all people and equipment away from the breaker during operation. Rocks flying from the breaker can cause serious accidents. ● Use care because the chisel may come out suddenly, when replacing the chisel. ● When filling the back cap or accumulator with nitrogen gas: ●...
  • Page 20 - Contents of Instruction Manual - Specifications…………………………………….. 21 Piping Installation ………………………….….… 22 Procedure for Setting pressure and Flow…….. Handling ………………………………………..24 Maintenance and Inspection ………………..…. 26 Trouble Shooting …………………………...…… 29 Disassembly and Reassembly ……………...…. 31 Instruction for accumulator …………………….. 42 Assembly Drawing …………………………..…..

  • Page 21: Specifications

    SPECIFICATIONS Model TOP300 2925 Operation weight (w/o bracket) 6448 2727 Overall length (w/o bracket) inch 14 - 18 Working pressure 2030 - 2620 Frequency 280 - 420 0.3 - 0.4 gas pressure (Gas cushion chamber) 43 - 57 Tool diameter inch Piping diameter inch...

  • Page 22: Piping Installation

    Piping installation ● Piping Diagram 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).

  • Page 23: Procedure For Setting Pressure And Flow

    1500 psi and record flow. Do the same at 2000, 2300, 2500 and 2800 psi. Record flow results on the Product Registration Form that came in the manual and mail it in to Okada. (8) For final confirmation, it is recommended to check the Working Pressure to verify it is within range. For this final step, disconnect the flow meter and connect the hoses to the breaker but Tee in a 5000 psi Pressure Gauge into the pressure line at the inlet of the breaker.

  • Page 24: Handling

    (3) Check that the screwed connections of the hoses, bolts and nuts are tight. Retighten these if loose. (4) Grease the shank part of the chisel. (With down pressure applied to chisel, apply Okada Chisel Paste to Shank Bushing until it squeezes out from the working tool or chisel set pin area.) (5) Run the excavator for about 10 minutes to warm up the machine.
  • Page 25 4. Installing and removing the breaker (1) Remove the two pins of the bucket and replace the bucket. (2) To operate the bucket without using the hydraulic breaker, close the stop valve on the excavator’s arm (turn the valves off) and disconnect the hoses connecting the stop valves to the breaker.

  • Page 26: Maintenance And Inspection

    Maintenance and inspection 1. Inspection of hydraulic oil and filter element (1) The hydraulic excavator installed with the hydraulic breaker uses the engine and hydraulic oil more severely than does an excavator alone. Therefore, the hydraulic oil deteriorates more quickly, causing trouble in the breaker.
  • Page 27 3. Grease-up ● Grease every 2 hours through the grease nipple on front cap using high quality Chisel Paste. ● While greasing; the breaker must be stood up-right then with the weight of the carrier; press the working tool all the way until it stops. ●...
  • Page 28 5. Wear limit dimension of parts inch ● Piston and chisel must be replaced when the striking surface of the piston and chisel has been sunk or damaged. 6. Precaution for handling chisel (1) Chisel can sufficiently withstand shocks exerted in the vertical direction, but they are likely to break if subjected to impacts applied in a lateral direction or prying.

  • Page 29: Troubleshooting

    Troubleshooting 1. Major causes and suggested remedies for poor starting MAJOR CAUSES SUGGESTED REMEDIES Increase in sliding resistance of piston owing to Replace the U-packings. U-packing damage. Increase in sliding resistance of piston owing to natural hardening of U-packings occurring in low Winter Push the chisel and stroke the piston.
  • Page 30 4. MAIN CAUSES AND SUGGESTED REMEDIES FOR A DECREASE IN NUMBER BLOWS AND IMPACT FORCE MAJOR CAUSES SUGGESTED REMEDIES Improper pressure of the sealed gas. Regulate the sealed gas to the correct pressure. Wear of shank bushing beyond limit. Replace the shank bushing. Wear beyond limit, damage or deformation of the striking surface of the piston, and the shank section, impact receiving Replace the piston or chisel (use only genuine parts).

  • Page 31: Disassembly And Reassembly

    Disassembly and reassembly 1. PRECAUTION BEFORE DISASSEMBLY (1) Be sure to carry out the disassembly and reassembly of the hydraulic breaker in a clean environment. Dust is harmful to the hydraulic breaker. If possible, do the job in your factory. (2) Always use genuine parts for replacement.
  • Page 32 3. INSPECTION AND REPAIR AFTER DISASSEMBLY (1) Inspecting the seals Replace any worn, deformed or deteriorated seals with new ones as shown below. ● Worn or deteriorated U-packings ● Deformed, worn, flawed, twisted or deteriorated O-rings (2) Inspection of the piston and valve sliding surfaces ●...
  • Page 33 ● REPAIRING SCRATCHES The entry of foreign matter into the hydraulic breaker or the use of degraded or contaminated hydraulic oil can result in scratches on the inner wall of the cylinder, the external surface of the piston, the external surface of the valve, or on the inner wall of the cylinder sleeve.
  • Page 34 Surface roughness of the cylinder sleeve: 6.3S Scratched surfaces with a surface roughness of 25S or greater cannot be repaired. Surfaces with smaller scratches can be repaired using #800 grinding paper. Do not use an oilstone. Surface roughness of the valve (H): 3.2S Scratched surfaces with a surface roughness of 25S or greater cannot be repaired.
  • Page 35 (1) Install the U-packings in the cylinder sleeve and cylinder. ● Before installing the seals, immerse them in hydraulic oil. ● Fit the U-packings in the grooves completely after making sure that its direction of installation is correct. ● Be careful so as not to damage the U-packing lip. A damaged lip can cause oil and gas leakage. Notice of installation <Green Seal>...
  • Page 36 PROCEDURE FOR INSPECTING CUSHION CHAMBER GAS PRESSURE The OKADA breakers have been shipped from the factory with nitrogen gas charged in the back cap at the predetermined pressure. The nitrogen gas pressure, however, will decrease over time and use, resulting in reduced blowing force.
  • Page 37 (1) Remove the cover and gas caps. (2) Turn the handle of the charging device counterclockwise as far as possible (until it can no longer turned). (3) Screw the charging device into the gas valve body. (4) Turn the cap of the charging device clockwise to lock the cap. (5) Turn the handle of the charging device clockwise.
  • Page 38 Removing the charging device (1) Turn the handle of the charging device counterclockwise as far as possible. (2) Loosen the cap with an adjustable wrench to discharge the nitrogen gas that remains in the charging device. (3) Remove the charging device from the gas valve body and tighten the gas and cover caps to lock them. Proper tightening torque Torque Part...
  • Page 39 (4) Turn the handle of the charging device clockwise. When the pointer of the charging device begins to move, stop turning the handle. (5) Gently turn the main valve of the nitrogen gas cylinder counterclockwise again. While monitoring the meter, replenish nitrogen gas until the proper gas pressure is obtained.
  • Page 40 Storage precautions (1) After the hydraulic breaker is removed from the excavator: ● Firmly close and cap the stop valves of the excavator and plug the hydraulic hoses. ● Grease and store the breaker indoors or completely cover it with a plastic sheet or other protective material. Do not leave the breaker outdoors in the rain.
  • Page 41 ● Spray anti-rust on the lower part of the piston and inner 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.

  • Page 42: Instruction For Accumulator

    Instruction for OKADA accumulator 1) Be sure to use nitrogen gas only for the accumulator. 2) Keep the working pressure below the predetermined maximum working pressure for the accumulator of 18 MPa (2620 psi). 3) Always release all the charged N gas in the accumulator before disassembling it.
  • Page 43 ２. Remove plug 8 (with O-ring) on the upper side of the accumulator cover. Avoid facing plug 8. It could fly out and cause serious personal injury. ３. Install the accumulator charging kit where plug 8 was screwed in. Note: If using the X type accumulator charging kit, use the adapter (10942211).
  • Page 44 ６. If the gauge pressure is within the range limit, tighten gas charging valve 4 to 29 Nm (21 ft lb). Then screw cap 6 (with O-ring) to the uniform torque. Cap 6 (with O-ring) Uniform Torque 80 Nm (59 ftlb) [100107] ７.
  • Page 45 How to charge N Be sure to use nitrogen gas only for the accumulator. Make sure that the release valve of accumulator gas charging kit is tightened. Release valve Install a regulator in the N gas cylinder, and then connect a hose between the N gas cylinder and the accumulator gas charging kit.
  • Page 46 Loosen gas charging valve 4 to counterclockwise about 1 turn. Open the main valve for the gas cylinder. Adjust the gas pressure to the specified pressure by turning the regulator handle. Note: pressure varies depending temperature. Adjust the N gas pressure according to ambient temperature.
  • Page 47 Close the main valve for the gas cylinder. Open the release valve for the accumulator gas charging kit to release the residual pressure. 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]...
  • Page 48 Exploded view Hex.22 Hex.22 Hex.5 A - A This part can not disassemble.
  • Page 49 Parts List AC-3Y Part Name Part Number Q’ty Accumulator body 15651410 Accumulator cover 15651421 Bladder 156514311 Gas charging valve 15401442 O-ring E1012005 15401446 O-ring E1012014 Plug 15401448 O-ring E1012014 Cap screw A0303A4569 O-ring E1162231 Accumulator back up ring 31380253 Specification Nitrogen Gas Gas pressure (20℃) [68°F] 6±0.3 [MPa]...
  • Page 50 Blank page...

  • Page 51: Assembly Drawing

    Assembly drawing TOP300 S/N 2980- valve body Acc gas charging valve Acc gas charging valve Gas valve body Flow control shaft...

  • Page 52: Exploded View

    Exploded view drawing TOP300 S/N 2980- 146B 146A 139B 139A 138B 138A ネームプレート Dark green color...

  • Page 53: Breaker Body Parts List

    Breaker body parts list Part No. Part Name Assy Part No. Part Name Assy Q’ty Q’ty 156510101 Cylinder 21320353 Gas cap 15651020 Piston 21320354 Cover cap 15651030 Cylinder sleeve E1012016 O-ring (P16B) #1 #4 E1022190 O-ring (G190B) E1161008 O-ring (A8A) #1 #4 E2122190 Back-up ring (G190T2)

  • Page 54: Bracket Parts List

    K10525 Flange plug (GPF1) E1012029 O-ring (P29B) 21350350 Gas valve body 21350351 Gas valve 21321352 Spring TOP300 S/N 2980 - Bracket Exploded view TOP300 VCB Bracket Erro ○ Part No. Part Name Q’ty Description 15657711 Bracket body 15657131 Front plate 15657736 Bracket cover 15657151...
  • Page 55 Bracket Exploded view TOP300 V8Z Bracket Parts No. Parts Name Q’ty Description 15657V11A-A Side plate R 15657V11A-B Side plate L Top bracket 15657V61A Guide box A 15657V61B Guide box B 15657V61C Guide box C BC30072 Damper 85 x 118 8,9 BC30071a Damper 85 x 140 BC40066A...

  • Page 56: Routine And Periodic Inspection

    Routine and periodic inspection Part Check Item Countermeasure Frequency Grease nipple(s) Grease-up Every 2 hours All bolts and nuts Tightness Retighten Everyday Chisel set pin(s) Wear or damage Replace Everyday Tightness Retighten Everyday Flange plugs for retainers Insufficiency, deterioration or Replenish or replace Everyday contamination...
  • Page 57 Blank page...

  • Page 58: Tightening Torque Chart

    Tightening torque chart Breaker body V8Z bracket VCB bracket Accumulator TOP300 Part name Nm ftlb Side rod back nut 3230 2382 Front bolt nut 2352 1736 Valve box set bolt 1270 Valve cap bolt 1270 Adjuster case bolt Acc. set bolt Cap screw Clamp bolt Plug...
  • Page 59 Hard Lock Nuts Installation Procedure Cap nut installation 1-1. Degrease the thread of front bolt and the nut. 1-2. Apply threadlocker on the thread of front bolt. (High strength threadlocker recommended) 1-3. Tighten the nuts by hand. Front bolt insert Insert the front bolts into the bracket from the retainer side.

  • Page 60: Chisel Warranty Guide

    Chisel Warranty Guide The purpose of this guide is to enable you to advise your customer as the correct application of OKADA Working Tools and assist you to resolve complaints immediately they occur. When a tool has apparently failed to give satisfactory service life, a visual inspection often quickly resolves the cause and saves transport costs and frustration when warranty is rejected.
  • Page 61 b) Cold Low temperature causes a working tool to be more susceptible to fatigue failure. Tools should be warmed before use. c) Mechanical and thermal damage Any form of damage to the surface of a working tool renders it more liable to suffer fatigue failure. Thus all care must be exercised to prevent accidental gouging, or contact welding (‘galling’...
  • Page 62 Typical Failures (guide to warranty claims) OKADA AIYON working tools are manufactured from first class materials and then heat treated to produce a fatigue and wear resistant tool. Thus when a tool has apparently failed to give a satisfactory service life, a brief visual inspection can often give a quick indication of the cause.
  • Page 63 Fig. 9. Typical scratches (seizure, galling) caused by leverage, incorrect hammering angle, or lack of lubricants. Warranty claims rejected. Scratches, seizure, galling Fig. 9 Fig. 10. Typical wear caused by repeated dry firing, and repeated continuous hammering more than 1 minute at one spot.

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