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OKADA TOP Series Shop Manual

Hydraulic breaker
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TOP SERIES SHOP MANUAL
FOR
OKADA DEALERS
R082206KO

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  • Page 1 TOP SERIES SHOP MANUAL OKADA DEALERS R082206KO...

  • Page 2: Safety First

    Carefully read this instruction Manual before using the breaker to ensure satisfactory results. If you have any question, please contact us or our agents. 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

    CONTENTS Piping Installation ……………………………………. Handling …………………………………….…………. Maintenance and inspection ………………………… Trouble shooting ……………….…………………….. Disassembly and re-assembly …….….…………….. Instruction for X Type accumulator ………………… Instruction for Y Type accumulator ………………… Routine and periodic inspection ……………………. Under water application ……………………………... Chisel warranty guide ……………………………….. Hydraulic piping requirements…..…………………..

  • Page 4: Piping Installation

    Piping installation Piping Diagram Piping for the hydraulic excavator for use with the hydraulic breaker is to be arranged as illustrated below. When placing order for pipes and/or hoses, please specify the following: h Manufacturer and model of the hydraulic excavator h Model number of the hydraulic breaker used h Identification numbers of the pipe(s) and/or hose(s) required  ...
  • Page 5 Inspection and adjustment after plumbing The following inspection and adjustments must be performed after the completion of piping work to ensure the maximum performance of OKB breaker and carrier machine to prevent the serious mal-functions. 1) Flushing Before turn on the engine, be sure to recheck the follows, a) To see whether installed hydraulic circuit is wrong.
  • Page 6 Caution : Never adjust the fixed main relief valve on the carrier in order to reduce the hydraulic pressure. Also, even if the existing pressure is lower than the specified pressure for the breaker, do not touch the main relief valve. In case of piping method is “Take out from main pump directly”, firstly adjust the set pressure of relief valve added in between hydraulic pump and control valve at from 1 to 1.5 MPa over than existing pressure value so that added and existing main relief valve never interfere the each...

  • Page 7: Handling

    Handling 1. Preparation Before starting Open/Close position (1) Check the level of hydraulic oil and replenish it if necessary. Be sure to use the same kind of hydraulic oil. (2) Confirm that the stop valves are fully open. (3) Check that the screwed connections of the hoses, bolts and nuts are tight.
  • Page 8 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 9: 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 10 3. Grease-up Grease up several times a day through the grease nipple on the side of the front cap using a grease gun. h If the sliding surface of chisel becomes dry under severe operation condition, refill grease. h For greasing, it is sufficient to press the grease gun several times. Note: While greasing , the breaker must be stood up-right and the chisel must be at the shank bottom to ensure that the grease will be provided between the chisel and the bushes.
  • Page 11 If gas is depleted shorter than expected although the above problems are not found, replace the back cap O-ring, cylinder sleeve O-ring, and sleeve U-packing. Note: h Before installing new U-packings, apply a slight coat of hydraulic oil to their surface. h Pay attention not to damage or cut U-packing or O-ring when installing.
  • Page 12 (2) If the hydraulic breaker is not to be used for a long period of time: ○ Release all gas from the gas cushion chamber. 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 N gas from the back cap.

  • Page 13: 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 Push the chisel and stroke the piston.
  • Page 14 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 Replace the piston or chisel (use only genuine striking surface of the piston, and the shank section,...

  • Page 15: 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 16 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 17 ● 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. These scratches may increase oil leakage, generate excessive heat, and damage the U-packing.
  • Page 18 How to repair the scratches on the piston and cylinder Cylinder Piston Remove the tips of scratches using an oilstone, never try to remove the whole scratches. Round the corners of the repaired scratches using abrasive paper (#800).

  • Page 19: Reassembly Procedure

    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 20 (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.
  • Page 21 (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 22 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.
  • Page 23 (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 24: Instruction For X Type Accumulator

    Instruction for OKADA X Type accumulator Application Model: TOP205, 250 and 300 Warning 1) Be sure to use the only Nitrogen gas for the accumulator. 2) Keep the working pressure under predetermined maximum working pressure of the accumulator that is 17.6 MPa (2560 psi).
  • Page 25 4) Connect a nitrogen gas cylinder to the N gas charging valve with a gas hose. The nitrogen gas in cylinder must be filled over 5.9 MPa (853 psi) for OKB308, 310, 312B and 316 or 4.4 MPa (640 psi) for OKB318, 324 and 330.
  • Page 26 Disassembling Danger Be sure to release any pressure inside the accumulator through the gas charging valve. Also stop the engine of carrier and release the residual pressure from the piping and the breaker. Procedure 1) Clean the accumulator thoroughly. Remove the cover cap (No.14 in Fig.3) using spanner. Slightly loose the gas charging valve.
  • Page 27 Parts list for T180-3X Fig. 3 Part Name Q’ty Accumulator body Bladder Accumulator O-ring Accumulator buck-up ring Accumulator cover Accumulator cover O-ring Gas charging valve body Gas charging valve w/O-ring Accumulator cover cap w/O-ring Accumulator set screw...

  • Page 28: Instruction For Y Type Accumulator

    Instruction for OKADA Y Type accumulator Application Model: TOP205, 250 and 300 Maintenance and inspection 1) Be sure to use the only Nitrogen gas for the accumulator. 2) Keep the working pressure under predetermined maximum working pressure of the accumulator that is 17.6 MPa (2560 psi).
  • Page 29 ３.  Install the accumulator charging kit on the accumulator cover, then tighten it until locking it with spanner. ※ When use the X type accumulator charging kit, please use the adapter. However, do not need a handling of the adjuster. ４. ...
  • Page 30 ６.  If gauge pressures within the limits of range tighten the gas charging valve 4 to clockwise way tightly. Then tighten the cap 6 (With O-ring) to the uniform torque. Cap 6 （With O-ring） Uniform Torque 150[Nm] (111 [ft lb]) ７. ...
  • Page 31 How to charge N2 gas Be sure to use the only Nitrogen gas for the accumulator. １.  After process (1-3) of 2: Inspecting gas pressure (Page 3), make sure to tighten the release valve of Accumulator gas charging valve. Release valve ２. ...
  • Page 32 Loosen the gas charging valve 4 to the ４.  counterclockwise around 1 turn. ５.  Open the main cock of Gas cylinder to the counterclockwise. ６.  Fill the N2 Gas until correct pressure by turning the regulator handle to the clockwise way. N2 gas pressure 20 C [68 F] 6±0.3 MPa (870±44 [psi]) ※Gas pressure are varied by temperature.
  • Page 33 ７.  Tighten the gas charging valve 4 of accumulator side face to the clockwise way strongly. Close the main cock of Gas cylinder. ８.  Open the release valve of Accumulator ９.  gas charging valve. Then emit the gas inside gas charging hose. １０. ...
  • Page 34 Exploded view Hex.22 Hex.22 Hex.5 ‑ This part can not disassemble.
  • Page 35 Parts List AC-2Y AC-3Y Part Name TOP205 TOP300 Part Number Q’ty Part Number Q’ty Accumulator body 15401410 15651410 Accumulator cover 15401421 156514212 Bladder 154014311 156514311 Gas charging valve 15401442 15401442 O-ring E1012005 E1012005 15401446 15401446 O-ring E1012014 E1012014 Plug 15401448 15401448 O-ring E1012014...

  • Page 36: Routine And Periodic Inspection

    Routine and periodic inspection Part Check Item Countermeasure Frequency Back nut Tightness Retighten Everyday Chisel set pin Wear or damage Replace Everyday Front bolt nut Tightness or damage Retighten or replace Everyday Accumulator set bolt Tightness Retighten Everyday Valve box set bolt Tightness Retighten Everyday...

  • Page 37: Under Water Application

    Caution of preparation for the under water application 1. Upon completion of daily usage for underwater work, all parts marked as the diagonal should be thoroughly cleaned and sprayed with an anti-rust preventive solution for protection. 2. The bracket front bolts, the bracket and the link pins should be cleaned and greased.
  • Page 38 TOP series under water application piping Maximum pressure should be adjusted to 5 kgf/cm (71psi). Exchange the existing sunk plug to the hydraulic adapter. Exchange the existing grease nipple to the sunk plug after filling the passage with grease.
  • Page 39 Precautions under water working Take the special cautions to properly maintain whole hydraulic apparatus. 1. Never use the standard type OKB breaker under water. Otherwise, both carrier and the breaker will be damaged severely. 2. OKB305 and larger model can be modified so as to be suited for under water hammering, install the special parts as shown on the under water application sheet.

  • Page 40: 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 41 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 42 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 43 Fig. 9. 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.

  • Page 44: Hydraulic Piping Requirements

    Hydraulic piping requirements for TOP series Back pressure Piping Max. Working Piping Condition Allowable Accum. Oil flow relief set pressure I.D. back Model Piping pressure Oil temp. pressure I.D. flow °C l/min l/min inch inch °F 8-15 18-38 17.5 50-60 1170-2180 4.8-10.1...

  • Page 45: Tightening Torque Chart

    TOP series tightening torque chart Acc. Gas Side rod Model Unit Front bolt Valve Adjuster Acc. set Clamp Valve box charging back nut set bolt cap bolt case bolt bolt bolt valve ft-lb 1180 ft-lb 1180 ft-lb 1180 ft-lb 1180...

  • Page 46: N 2 Gas Pressure By Temperature

    (Nitrogen) gas pressure by temperature gas pressure into the back cap -20°C 0°C 20°C 40°C 60°C 80°C 100°C -4°F 32°F 68°F 104°F 140°F 176°F 212°F 0.26 0.28 0.32 0.34 0.36 0.38 TOP25 0.69 0.75 0.85 0.96 TOP30 0.69 0.75 0.85 0.96 TOP35 0.86...

  • Page 47: Chisel Chart

    TOP series Chisel chart Part Number inch inch inch inch inch 301-500 1.58 1.97 19.69 15.44 30,35 302A-600 1.78 2.41 23.62 3.15 24.26 303-700 1.97 2.68 27.56 4.57 37.49 T45B-700 1.78 2.68 27.56 2.37 74.97 60, 60B 305-900 2.37 3.35 35.44...

  • Page 48: Bolt Chart

    TOP series Bolt chart TOP25 TOP30 TOP35 TOP45 TOP45B Valve cap bolt - - - - - - - - - - - - - - - Valve box set bolt - - - - - - - - -...
  • Page 49 TOP series Bolt chart TOP60 TOP60B TOP90 TOP100 TOP200 A030C4149 A030C4149 A030A4559 A030C4129 A030A5349 Valve cap bolt M18 X 50F M18 X 50F M20 x 45 M18 X 40F M24 x 55 A030C4149 A030C4149 A030A5359 Valve box set bolt - - -...
  • Page 50 TOP series Bolt chart TOP210 TOP300 A030A5359 A030A6079 Valve cap bolt (M24 x 60) (M30 x 70) A030A5359 A030A6079 Valve box set bolt (M24 x 60) (M30 x 70) A030A3699 A030A3699 Clamp bolt (M16 x 35) (M16 x 35) 101120200...

  • Page 51: Seal Chart

    TOP series Seal chart TOP25 TOP30 TOP35 TOP45 TOP45B Valve box O-ring - - - - - - - - - - - - - - - E1022040 E1022045 E1022045 E1022060 E1022060 Valve box cap O-rng G40B P45B P45B G60B...
  • Page 52 TOP series Seal chart TOP60 TOP60B TOP90 TOP100 TOP200 E1012030 E1012030 E1012022A P30B P30B P22AB Valve box O-ring - - - - - - E1012049 E1012049 E1012039 P49B P49B P39B E1022060 E1022060 E1022065 E1022060 E1022070 Valve box cap O-rng G60B...
  • Page 53 TOP series Seal chart TOP210 TOP300 E1012016 E1012022A (P16B) (P22AB) Valve box O-ring E1012035 E112042 (P35B) (P42B) E1022080 E1022105 Valve box cap O-rng (G80B) (G105B) E2122165 E1022190 Back cap O-ring (G165T2) (P190B) 10250160 10250140 (U160B) (U140B) 10230160 U-packing (Lower) 10230140...

  • Page 54: Unit Conversion Table

    Unit conversion table Length 39.37 3.281 1.094 0.01 0.3937 0.03281 0.01094 0.0254 2.540 1/12 1/36 0.3048 30.48 0.9144 91.44 Area 1550 10.76 1.196 0.6452X10 1/144 1/1296 0.09290 0.8361 1296 Cubic volume c.c. (cm L(litter) gal (UK) gal (US) 6.102X10 1.308 1000 220.0 264.2...
  • Page 55 Pressure Pa (N/m kgf/cm Torr (mmHg) 0.1020X10 0.1450X10 0.9869X10 0.7501X10 0.1020X10 0.1450X10 0.9869X10 0.7501X10 1.020 14.50 0.9869 750.1 9.807X10 0.9807 14.22 0.9678 735.6 6.895X10 0.06895 0.07031 0.06805 51.71 101325 1.01325 1.033 14.696 133.3 0.1333X10 0.1360X10 0.01934 1/760 Temperature °C °F t-273.15 (t-273.15) t+273.15...

  • Page 56: Thread Standard

    Thread standard ○  JIS B 8363 Parallel Pipe Threads (PF) OKADA Male thread O.D. Female thread I.D. Inch size Thread size inch inch NPF03 1/8-28 0.38 0.34 NPF06 1/4-19 13.2 0.52 11.4 0.45 NPF09 3/8-19 16.7 0.66 15.0 0.59 NPF13 1/2-14 21.0...
  • Page 57 ○  JIS B 8363 Parallel Pipe Threads (PF) ○  British Standard Pipe - BSPP OKADA Male thread O.D. Female thread I.D. Inch size Thread size inch inch NSF03 1/8-28 0.38 0.34 NSF06 1/4-19 13.2 0.52 11.4 0.45 NSF09 3/8-19 16.7 0.66...
  • Page 58 ○  JIS B 8363 Tapered Pipe Threads (PT) ○  British Standard pipe - BSPT OKADA Male thread O.D. Female thread I.D. Inch size Thread size inch inch PT03 1/8-28 0.38 0.34 PT06 1/4-19 13.2 0.52 11.4 0.45 PT09 3/8-19 16.7 0.66...
  • Page 59 ○  JIS B 2351 Parallel Pipe Threads (G) OKADA Male thread O.D. Female thread I.D. Inch size Thread size inch inch PFO03 1/8-28 0.38 0.34 PFO06 1/4-19 13.2 0.52 11.4 0.45 PFO09 3/8-19 16.7 0.66 15.0 0.59 PFO13 1/2-14 21.0 0.83...

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