OKADA TOP Series User manual

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

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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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-
- C Co on nt te en nt ts s o of f S Sa af fe et ty 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

4
DANGER
IMPORTANT
CAUTION
WARNING
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.
This sign alerts the operator of imminent death or serious injuries that can result if this sign 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 life can markedly decrease if this sign
is ignored and the machine is operated incorrectly.
For each item of operation, description is given the Safety Section. However, it is impossible for our
company to predict all the potential hazards in all conditions and circumstances.
Consequently, the danger Caution, Important, and other indications affixed on the machines do not cover all
hazards that can happen.

5
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.
3. People make the difference
People who use or operate hydraulic hammers must be:
COMPETENT
●Physically-good vision, hearing, coordination, and capable of safety performing all functions required for
the operation of the machine
●Mentally-able to understand and apply established rules, regulations, and safe practices. Be alert, using
good judgment for safety to themselves and others. Desire to do their job correctly and in a responsible
manner.
●Emotionally-be calm and capable of withstanding stress and 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 asked to thoroughly read this Manual
and the Operation Manual for the hydraulic backhoe before starting operation or
maintenance work.
Keep this Manual near the machine as a handbook for ready reference. All
personnel are advised to read it at periodical intervals.
●Always keep this manual handy, and read it repeatedly.
●If this Manual should be lost or damaged, promptly place an Manual together with the
machine.
●When you transfer the machine, be sure to hand over the Manual together with the
machine.
●As a result of continuous improvements, the current machine may differ in detail specification
from machines sold in the past. If you have any questions in this regard, please ask our
Company or its distributor.
WARNING

6
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.
●In operating the machine on the street, etc. Where there are bystanders 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 peeled away or rubbed and blurred, place an order for a replacement with our
Company or its distributor.
Certificate
Protection sheets

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.
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, firmly lower the hydraulic hammer, stop the engine, and lock all the keys.
Always return the key to the supervisor.

8
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.
●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
starting operation. Otherwise burrs, etc. can cause injuries.
When removing burrs,
wear the protector.

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.
●Do not insert a bar or the like in the hydraulic hammer's bracket pin hole in a forcible attempt to align it
with the backhoe arm bucket pin hole. The bar, etc. maybe snapped back and hit a person, causing
serious injuries.
●Wipe the bracket pin well to remove grease or oil before starting operation. The bracket pin may slide
down causing serious injuries.
●When striking 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 hose is improperly
mounted, the hydraulic oil may blow out, causing serious injuries.
●Before disconnecting the hydraulic hose, securely close the stop valve. In disconnecting the hydraulic
hose joint, avoid facing the joint, and loosen it gently and slowly while releasing the internal pressure. If
hot hydraulic oil blows out and enters an eye, loss of sight may occur. Refer to table 1 in the page 20 for
the tightening torque of the hydraulic hoses.

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. 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 chisel side.

11
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.
●Never get on the boom arm of the hydraulic backhoe. If your feet slide, causing you to fall down, serious
injuries may occur.
●During inspection, an "INSPECTION UNDERWAY" label must be suspended 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 cracks are found on the hydraulic hammer bracket or the hydraulic backhoe, promptly repair the
cracks. Never operate the machine with the cracks uncorrected. If the hydraulic hammer or the
hydraulic backhoe arm should fall from the cracked portion, serious injuries may occur.
DO NOT OPERATE
INSPECTION UNDERWAY

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Safety
●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.
●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.
●Regarding any repair, ask our Company or its distributor.
DANGER

13
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.
●When operating the machine, always wear a hard hat, safety goggles, safety shoes, dust-proof musk,
ear mufflers, and protective leather gloves. Flying debris, noise, etc. may cause considerable injuries.
●Wrap the backhoe cab with 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. Vibrations of the hydraulic hammer
may cause landslides or falling rocks, leading to serious injuries.
●Do not operate the machine on soft ground or unstable ground strewn with rocks, concrete blocks, etc.
On such sites, your backhoe may turn over, causing serious injuries.
Protection sheets

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. If no such precaution is taken, an 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 hammer and the hydraulic backhoe are conductive machines. If either touches
electric wires, serious injuries cause result.

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
●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 scattering dust.

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
●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 in an unexpected direction, causing serious injuries,.

17
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.

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.
●Remove the chisel before transporting the breaker.
●
Keep all people and equipment away from the 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 cylinders of your excavator are located at their stroke end.
●Do not charge gases other than nitrogen gas into the gas cushion chamber and accumulator.

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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:
●The chisel 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 pressure. Be sure to completely
release internal gas before replacing the gas valve.

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- Contents of Instruction Manual -
Specifications……………………………………..
21
Piping Installation ………………………….….…
22
Procedure for Setting pressure 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