OKADA HYDRAULIC BREAKER

OWNERS AND OPERATORS

INSTRUCTION MANUAL
&
PARTS LIST
(S/N 2796 and after)

040513TH
_/ _/ _/ _/ _/ _/ _/ _/ _/ _/ _/ _/ _/ _/ _/ _/ _/ _/ _/ _/ _/ _/ _/ _/ _/ _/ _/ _/ _/ _/ _/ _/ _/ _/ _/ _/ _/ _/ _/ _/ _/ _/

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.

_/ _/ _/ _/ _/ _/ _/ _/ _/ _/ _/ _/ _/ _/ _/ _/ _/ _/ _/ _/ _/ _/ _/ _/ _/ _/ _/ _/ _/ _/ _/ _/ _/ _/ _/ _/ _/ _/ _/ _/ _/ _/ _/ _/ _/ _/ _/

2
 - Contents of Safety -

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

3
 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.

DANGER

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.

WARNING

This sign alerts the operator of death or serious injuries that can result if this sign is ignored and the
machine is operated incorrectly.

CAUTION

This sign alerts the operator of injuries or property damage that can result if this sign is ignored and the
machine is operated incorrectly.

IMPORTANT

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.

4
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.

WARNING
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.

5
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.

Protection sheets

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

6
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.

7
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.

8
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.

9
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.

10
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.
●

DO NOT OPERATE
INSPECTION UNDERWAY

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.

11
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.

● 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.

12
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.

Protection sheets

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.

13
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.

14
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.

15
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,.

16
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.

17
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.

18
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.

19
 - 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
Assembly Drawing …………………………..….. 43
Exploded View ………………………………...… 44
Breaker Body Parts List ……………………..…. 45
Bracket Parts List……………………………….. 46
Routine and Periodic Inspection ………………. 48
Tightening Torque Chart………………………… 50
Chisel Warranty Guide………………………….. 52

20
 SPECIFICATIONS
Model TOP200
Operation weight kg 1640
(w/o bracket) lb 3616
mm 2205
Overall length (w/o bracket)
inch 86.8
MPa 14 - 18
Working pressure
psi 2030 - 2620

Frequency bpm 465 - 625

N2 gas pressure MPa 0.5 - 1.0

(Gas cushion chamber) psi 71 - 142
mm 125
Tool diameter
inch 4.9
mm 25
Piping diameter
inch 1”
Set pressure of MPa 18.6
secondary relief valve psi 2700
L/min 150 - 200
Carrier output flow range
gpm 39.5 - 53
• 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 machine.

21
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).

22
Procedure for Setting Pressure and Flow

***Note- Checking and adjusting pressure and flow is mandatory each time a breaker is installed on
a carrier. Improper flow can seriously hinder the performance of the breaker, void the warranty
and or cause severe damage to the breaker.

(1) Flow meter is to be hooked up in place of the attachment. The high pressure line (cab side) at the front
end of the stick will connect to the inlet side of the flow meter. The return line at the opposite front end
of the stick will connect to the outlet of the flow meter.

(2) Open both ball valves.

(3) If your flow meter has a restriction knob, run it out counter clockwise so no restriction is applied.

(4) Set the Carrier to B or Breaker mode, if it has the option, then run carrier until hydraulic oil reaches
operating temperature.

(5) Run carrier up to full throttle, press foot pedal to start breaker circuit. Have a fellow technician observe
max oil flow with no restriction applied, this is you’re Carrier Output Flow. Also, observe the Back
Pressure with no restriction applied, you should always be under 300 PSI of back pressure. Release the
foot pedal and record the max flow and max back pressure on your Warranty Registration form that is
included in the manual.
Note: If Back Pressure is over 300 PSI, make sure your return line dumps 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 flow meter in clock wise to
increase restriction to the point where the relief valve is fully open and zero flow is observed. Set relief
to specification.
Note: Most relief valves will raise pressure approximately 500 psi with a quarter turn in the clockwise
and vise-versa to lower the pressure.

(7) To set and record Internal Oil Flow to PQ characteristic, back off the restriction knob on the flow meter
to 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. Operate the breaker and observe the
Working Pressure. This number should fall within the specifications or adjustments need to be made. If
the working pressure is above specified limits, slightly lower the Oil Flow until Working Pressure comes
into range.

23
Handling

1. Preparation Before starting

(1) Check the level of hydraulic oil and replenish it if necessary. Be sure to Open/Close position
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. Retighten these if loose.
(4) Grease the shank part of the chisel.
(With chisel pushed firmly up inside the breaker or with down pressure
on tool; force grease into this part with 10 strokes from a grease gun.)
(5) Run the excavator for about 10 minutes to warm up the machine. Start
operation only after the oil temperature has risen.

50 to 80 °C
Recommended working oil temp. range
122 to 176 °F

2. Running-in
For the first one hour of the use of your breaker, position the chisel vertically onto the material to be broken,
apply pressure downwards and do running-in at half engine speed in order to run in the sideways of all parts.
Note: Do not tilt the chisel during running-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 lever or ripper
and hitting any object against the chisel.
Apply pressure Stop immediately when
Caution: Force prying the material with
continuously. material shatters.
the chisel may lead to breakage of the
chisel.
● When the chisel no longer goes into the
material, change the hammering position.
Do not hammer the material continuously
for more than one minute at one spot.
Otherwise, not only the chisel burns but
also oil temperature rises abnormally, and
these lead to trouble.
● Do not immerse the front cap of the
breaker in water or sludge in all cases.
Do not pry. Do not immerse in water
or sludge.

24
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.
(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.

Plug Retainer Shaft

(2) Push out the chisel set pins from the bottom using a
screwdriver. Eye bolt

(3) Pull the chisel out.

Chisel set
pin

25
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. The deteriorated or contaminated oil must be replaced with fresh oil as specified. Do not use low-
grade or regenerated oil.
● Here is a simple method for determining the condition of the oil. Lack of viscidity or viscosity and
formation of air bubbles indicate badly deteriorated oil. The appearance of blackish brown color and
the emission of an offensive odor are proof of deterioration. The oil must be changed immediately in
this case.
● When changing the oil, remove all the oil from the inside of the tank and the hydraulic cylinder, then
thoroughly clean the interior of the tank. Do not add new oil to the oil. Be sure to replace all the oil.
(2) Take care not to allow foreign matter to enter the hydraulic oil. Allow no foreign matter to enter the hoses and
nipples during disconnection and connection of the hoses when changing the breaker and bucket. The entry
of sand or other foreign matter in the hydraulic oil will cause a serious damage. The filter must be cleaned or
replaced at the proper time.
(3) Always replenish with the same hydraulic oil in order to maintain the correct volume of oil. Using the breaker
with insufficient oil will cause the oil to be deteriorated. In 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 problems. If you are not going to use the hydraulic breaker, store
the breaker indoors. Also, remove the drains from the tank at periodic intervals.

Change of hydraulic oil Every 600 hours

Change of filter element Every 100 hours
Change of engine oil and engine oil filter To excavator manufacturer’s specification

Note: If deterioration or contamination is serious, replacement must be done as soon as possible even the listed
time has not reached.

2. Tightness of bolts and nuts

(1) Before starting work, check all the bolts and nuts for tightness including the side rod nuts of the breaker,
accumulator set bolts, valve cap bolts and front bolt nuts of the bracket. Also be sure to retighten any loose
bolts and nuts to the specified torque. Using the breaker with loose bolts and nuts will lead not only to oil
leakage but also damage of the screw threads and bolt breakage. These can also cause defective operation.
(2) After the first 10 hours of use, retighten the bolts and nuts of all components and sections.
(3) At first, lightly tighten the bolts and nuts by referring to the following tightening torque. The bolts and nuts
should be screwed down alternately and diagonally until all the bolts and nuts are tightened to the uniform
torque.
Note: Refer to the attached tightening torque chart.

26
3. Grease-up
Grease up every 2 hours through the grease nipple on the side of the front cap using a grease gun.
● If the sliding surface of chisel becomes dry under severe operation condition, refill grease.
● 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. Do not fill up the space between
the piston and chisel with grease, otherwise the dust seal may be damaged or it leads to defective hammering.

D E
4. Inspection for oil leakage
Location Possible Cause Remedy
Between the front Cylinder U-packing
A cap bushing and the damaged, worn or Replace U-packing.
chisel. hardened.
Between the back Clamp bolt loosened, O- Retighten clamp bolt.
B cap and the hose. ring worn or damaged. Replace O-ring.
Valve box set bolts B
Between the cylinder Retighten valve box set bolts
C and the valve box. loosened, or O-ring worn,
or replace O-ring.
damaged or hardened. C
Between the valve Valve cap bolt loosened,
Retighten valve cap bolts or
D box and the valve or O-ring worn, damaged
replace O-ring.
cap. or hardened.
Loosened side rods, or
Between the back Retighten side rods or replace
E cap and the cylinder. back cap O-ring worn or
back cap O-ring.
damaged.

5. Inspection for gas leakage

Location Possible Cause Remedy
O-ring worn or hardened. Replace gas valve O-ring.
Gas valve body inlet.
Weak spring tension. Worn gas valve Replace spring or gas valve.
Loose gas valve body.
Between the gas valve Retighten gas valve body.
Gas valve body O-ring worn or
body and cap mount. Replace gas valve body O-ring.
hardened.
Between the back cap and Side rods loosened, or back cap O-ring Retighten side rods or replace
the cylinder. worn or hardened. back cap O-ring.
● Leaking point can be easily identified by applying soapy water.

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: ● Before installing new U-packings, apply a slight coat of hydraulic oil to their surface.
● Pay attention not to damage or cut U-packing or O-ring when installing.

27
6. Wear limit dimension of parts

A B C
mm 108 133 10
inch 4.3 5.2 0.4

● Piston and chisel must be replaced when the striking surface of the piston and chisel has been sunk or damaged.

7. 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. To avoid breakage of chisel, adjust the excavator
arm so that the chisel can move straight down.
(2) Chisels are prone to become brittle if subjected to low temperature. Avoid operating at the full capacity from
the very beginning when used in cold area. Also, avoid leaving the chisel outdoors at night, and protect it with
vinyl sheet.
(3) Deep indentations caused by hitting or deep rusting on chisels may result in breakage.
(4) The shank part of the chisel may develop heat due 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 situation that it may plunge into nearby
pool of water after crushing a rock, etc.

8. 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.
(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.
● Apply hydraulic oil to the lower part of the piston and grease the chisel shank.

28
Troubleshooting
1. Major causes and suggested remedies for poor starting

MAJOR CAUSES SUGGESTED REMEDIES

Increase in sliding resistance of piston owing to U-
Replace the U-packings.
packing damage.
Increase in sliding resistance of piston owing to natural
Breaker

hardening of U-packings occurring in low Winter Push the chisel and stroke the piston.
temperature.
Repair the shallow flaws with an oil stone and
Damage of valve, valve box and valve box sleeve.
abrasive paper. Replace it if the flaws are deep.
Damage in the sliding areas between the cylinder and
Repair the flaws with an oil stone and abrasive paper.
piston.
Neglect in opening the stop valve or keeping the stop
Fully open (turn on) stop valve or repair valve.
valve closed.
Excavator

Insufficient hydraulic pressure or discharge owing to

Repair or replace parts.
damage to the secondary relief valve.
Improper selection and damage of the directional valve. Repair or replace.
Clogging by foreign matter in the piping. Disassemble and remove foreign matter.
● Remove scratches on the surface of valve using sand paper. Do not use an oil stone.

2. Main causes and suggested remedies for occasional stopping during operation

MAJOR CAUSES SUGGESTED REMEDIES

Repair flaws with an oil stone and abrasive paper.
Breaker

Damage of cylinder, piston, cylinder sleeve, valve, valve

(Unless damage is mended quickly, the parts become
box and valve box sleeve.
irreparable.)
Use of excavator when oil temperature is above 80°C Avoid using the excavator above 80°C. Do not rev up
Excavator

(176°F). 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

Improper pressure of the gas sealed in the gas cushion Regulate the nitrogen gas pressure to proper
chamber. pressure.
Wear of shank bushing beyond limit. Replace shank bushing.
Breaker

Damage of cylinder, piston, cylinder sleeve, valve, valve

Remove flaws with an oil stone and abrasive paper.
box and valve box sleeve.
Insufficient gas pressure of accumulator or damaged
Recharge nitrogen gas or replace the bladder.
bladder.
Lack of hydraulic oil. Replenish with the same oil.
Deterioration or contamination of the hydraulic oil. Replace all oil with fresh oil.
Send the main relief valve to the manufacturer’s designated
service factory for adjustment.
Excavator

Defective operation or improper set pressure of the Regulate the secondary relief valve to correct the set
main relief valve and secondary relief valve. pressure.
Or repair or replace the damaged spring, seat, valve or
piston.
Insufficient discharge and pressure owing to a hydraulic Send the excavator pump to the manufacturer’s
pump malfunctioning. designated service factory for repair.
Use of the excavator while oil temperature has risen
Avoid using the excavator above 80°C (176°F).
abnormally above 80°C (176°F).

29
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
Breaker

surface of the piston, and the shank section, impact receiving Replace the piston or chisel (use only genuine parts).
surface and tip of chisel.
Damage or wear of cylinder, piston, cylinder sleeve, Repair flaws with an oil stone or polishing paper or
valve, valve box and valve box sleeve. replace.
Insufficient gas pressure of accumulator or damaged
Recharge nitrogen gas or replace the bladder.
bladder.
Half opening of stop valve. Fully open the valve.
Clogging by foreign matter in the piping. Disassemble and remove foreign matter.
Lack of hydraulic oil. Replenish with the same hydraulic oil.
Deterioration or contamination of hydraulic oil. Replace all oil with fresh oil.
Send the main relief valve to the manufacturer’s designated
service factory for adjustment.
Defective operation or improper set pressure of the Regulate the secondary relief valve to correct the set
Excavator

main relief valve and secondary relief valve. pressure.

Or repair or replace the damaged spring, seat, valve or
piston.
Insufficient discharge and pressure owing to a hydraulic Send the excavator pump to the manufacturer’s
pump malfunctioning. designated service factory for repair.
Use of the excavator when oil temperature is above Avoid using the hydraulic breaker if the oil temperature
80°C (176°F). is above 80°C (176°F).
Disorderly operation of the pressure valve in the tank, Send these parts to the manufacturer’s designated
and clogging of cooler fins or filter elements. 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

Damage or formation rust on the cylinder, piston, valve,
Lack, deterioration or contamination of hydraulic oil or use valve box and cylinder sleeve.
of regenerated oil. Damage or wear of relief valves, pump or operating
valve.
Damage to the sliding parts between the cylinder and
Entry of foreign matter during mounting or dismounting of
piston, and the sliding parts of the valve.
the breaker, insufficient oil flushing after installation of
Damage to the U-packings, clogging of the filter
piping, or entry of drains in the hydraulic oil tank.
elements or damage to the relief valves
Deformation or hardening of the U-packings and O-
Abnormal rise of oil temperature.
rings.
Damage and wear of shank bushing, the shank section
Insufficient greasing.
of the chisel, and front cap bushing.
Loosening of screwed parts owing to insufficient or
Wear and breakage of bolts, or gas leakage.
uneven tightening.
Damage to the cylinder and piston, wear of the shank
Excessive prying of chisel during operation. bushing, and front cap bushing, or failure of chisel or
side rod.
Breakage of bolts, wear of chisel or damage of relief
Continuous blowing for more than 1 minute.
valves and pump, and striking surface of piston.
Embrittlement of U-packings, damage to the cylinder
Underwater use of a breaker with standard specification and piston (contamination of hydraulic oil or damage to
the hydraulic apparatus of the excavator).

30
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. The use of parts other than the genuine parts will adversely
affect the product’s performance and durability.
(3) Release all gas from the back cap.

2. DISASSEMBLY PROCEDURE
(1) Remove the chisel.
(2) Loosen the nipple, valve cap bolt, and valve box set bolt, and remove the valve cap. Draw out the valve
with the valve box sleeve. Then remove the valve box.
(3) Remove the back nut and draw out the back cap.

Belt Support

(4) Draw out the front cap together 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 upright,Pistonfit Cylinder
an eyebolt into the head part of the piston and hoist the sleeve
piston together with the cylinder sleeve to easily remove it
(6) Remove the cylinder sleeve from the piston.
(7) Remove the U-packings and O-rings from the cylinder
sleeve.
● It is recommended to use a 2 to 3 mm diameter rod Levethat is
tapered and pointed at the end when removing O-rings. r
(8) Remove the U-packings from the cylinder.
(9) Disassemble the cover cap, and gas valve body from the
back cap in this order.

31
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

● Check the sliding surfaces of the piston for flaws and blow surface for deformation. Remove the flaws
and repair or replace the deformed parts.
● Check the valve sliding surfaces for flaws and remove or replace the flawed parts.
(3) Inspection of the front cap
● Replace the worn or deformed front cap bushing.
● Check the shank bushing for wear and flaws and replace the worn shank bushing.
● Replace the worn or deformed chisel set pin.
(4) Inspection of the cylinder plug
● The cylinder has been set with a plug. In a very rare case, this plug may loosen and case a small oil leak.
The loosened plug must be tightened after resealing 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 above and drive out
them by hammering or using a hydraulic press.
(3) Remove burrs and flaws on the inner surface of the front cap using a bar grinder after removing the front
cap bushing and the shank bushing.
(4) Refrigerate the shank bushing and the front cap bushing with 15 kg (33 lbs) of dry ice in an ice box for 3
hours. Then insert the shank bushing into the front cap from the chisel side. After aligning the shaft
grooves, insert the shafts and shaft retainers, and then install the flange plugs.
● Be sure to wear leather gloves while doing this process. Complete this process swiftly, otherwise the
bushing may stop on the way.
(5) Install the front cap bushing in the same way as the shank bushing.

32
● 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. If these scratches are unattended, parts may seize,
causing the breaker to malfunction. In the worst possible case, the breaker may become inoperative. The
valve, valve box and valve box sleeve can also be scratched in the same way. It is, therefore, necessary to
detect scratches early in their development and repair the scratches in an appropriate manner. Delay in
repairing scratches may make repair impossible.
Note: The criteria for judging scratches and finishes are based on the standard external surface roughness
piece which conforms to JIS B 0659.

G I
H

F E E D
C B A

Cylinder

(1) Surface roughness of the upper large diameter section (A) of the cylinder: 6.3S
Pay special attention to the area from the end surface to the first groove and repair any scratches in the area
to prevent charged gas from leaking. To remove scratches, use a round or half-round oilstone while applying
cleaning oil. The diameter of the 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 diamond file. To finish the surface, use a
coarse square oilstone while applying cleaning oil. Then use #800 grinding paper to finally finish the surface.
● When an electric power supply is available, use a portable electric drill with grinding paper wrapped
around the end of a rod to roughly remove the scratches. Then use flex hone to finish the surface. Quick
finishing is possible with this method.

Piston
(1) Surface roughness of the upper and lower small diameter sections (D and F): 1.6S to 3.2S
To repair scratches, use a coarse square oilstone while applying cleaning oil until the surface roughness is
6.3S or less. Then finish the surface using #800 grinding paper.
(2) Surface roughness of the large diameter labyrinth section (E): 3.2S to 6.3S
To repair scratches on the external diameter section, use a square oilstone while applying cleaning oil until
the surface roughness is 12.5S or less. Then use grinding paper to finish the surface. To repair scratches at
the corners of the labyrinth grooves, use a coarse square oilstone while applying cleaning oil. To finish the
groove surfaces, use #800 grinding paper.

33
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. Surfaces with smaller
scratches can be repaired using #800 grinding paper. Do not use an oilstone. If the end surface of the valve has
been deformed or worn out, replace the valve.

Surface roughness of the valve box sleeve (I) and the valve box (G): 6.3S
Scratched surfaces with a surface roughness of 25S or greater cannot be repaired. To repair surfaces with
smaller scratches, use a fine round oilstone while applying cleaning oil 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 any partial wear as necessary. If partial wear is unattended for a long time, serious problems may develop.
If the end of the piston is worn out up to or beyond the protrusion section, replace the piston.

Front cap bushing and shank bushing

If the bushing is excessively worn, replace it according to the replacement procedure. If an excessively worn
bushing is used, problems may develop.

4. PRECAUTIONS BEFORE REASSEMBLY

(1) Thoroughly clean all parts.
(2) Be careful not to allow dust to enter which might cause scoring. Never use dirty cloth to clean the unit.

5. REASSEMBLY PROCEDURE

U-packing Ring packing & O-ring U-packing

O-ring & buck-up ring

34
(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>

Install this U-packing (dark green) in the center groove.

(2) Before inserting the piston in the cylinder all the way, place the cylinder
sleeve over the piston.
● Apply a thin coat of hydraulic oil to the sliding surface of the piston and push
in the piston by holding 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 the valve box sleeve in the valve box. Install the valve
cap, valve cap bolts and clamps in place. Secure the valve box assembly in
the cylinder with the valve box set bolts.
● Apply a thin coat of hydraulic oil to all the sliding surface.
● Do not fail to install the O-ring.
(4) Install the front cap in the cylinder.

35
 (5) Insert the side rods into the cylinder from above the cylinder, and install them
in place.

(6) Pass the side rods through the back cap and install the back cap in the
cylinder.
● Do not fail to install the back cap O-ring.
● Pour 80 cc (0.02 gal) of hydraulic oil into the back cap before passing the
side rods through it.

(7) Tighten the back nuts to the specified torque. When tightening, strictly follow
the torquing sequence of A → D → B → C (alternate diagonal lines) in several
passes.
(8) Charge 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 back cap at the
predetermined pressure. The nitrogen gas pressure, however, will decrease over time and use, resulting in
reduced blowing force. When the blowing force is reduced, check the pressure of nitrogen gas in the back cap.

Proper N2 gas pressure at 20°C (68°F)- - - - - - - - - - - - 0.5 - 1.0 MPa (71 - 142 psi)

36
(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. 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.
● The gas pressure changes depending on the temperature.

37
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
N‚m ft‚lb
Gas cap 41 ± 2 30.4±1.4
Cover cap 637 ± 29 470.2 ± 21.7

Reducing the gas pressure

(1) After checking steps (1) to (5), gently loosen the cap. The pressure 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 using a hose. Loosen the handle of the regulator by turning
it counterclockwise.

(3) Gently turn the main valve of the nitrogen gas cylinder counterclockwise.
Turn the regulator handle clockwise until the regulator meter indicates stated
pressure, and then turn the main valve clockwise to stop the gas supply.

38
 (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.

(6) When 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 injuries, stay away from the chisel.

Recommended front bolt nut tightening method

Refer to the page 49.

39
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.

(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 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 split flanges and rubber blinds, or the dust caps in case of
smaller than TOP100.

Press the piston from the front cap side into the cylinder by using a wooden
or plastic bar.
Notice) Hydraulic oil may fly out from the port on the valve.

40
 ● 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.

41
Blank Page

42
Assembly drawing
TOP200 S/N 2586 -

43
Exploded view drawing
TOP200 S/N 2586 –
27 A
B
103 28
104
25 19A
19B
33
24
19B
19A 1
23
101
19B
35B 19A
21 35A

35B
19B NAME PLATE
39C
69A 39D 39B 19A
69B 39A 18 19D19C 19D
29B 19F 19C
29A 39D
39F 39C 19E
15A
39E
73 15B
72 39D
77 15A
76 39C 38
61
37 dark green U-pacing
17
94A
71 94B
74
79 B 93
78 62B 92 88 89A 81
75
62A

11A 86A
86B
85
84 89B 102
13 84
85
86B
86A
14A
14B

91
3
82

11B
11A 83

200

44
Breaker body parts list
Q’ty Assy Q’ty Assy
No Part No. Part Name No Part No. Part Name
1 153210101 Cylinder 1 71 21350350 Gas valve body 1 D
2 15321020 Piston 1 72 21350351 Gas valve 1 D
3 15321030 Cylinder sleeve 1 73 21321352 Spring 1 D
11A E1022175 O-ring (G175B) 2 A 74 21320353 Gas cap 1 D
11B E2122175 Back up ring (G175T2) 1 A 75 21320354 Cover cap 1 D
13 10230132 U-packing (U132) 2 A 76 E1012016 O-ring (P16B) 1 A,D
14A 10245132 Ring packing (ST132) 1 A 77 E1161008 O-ring (A8A) 1 A,D
14B E1161357 O-ring (A357) 1 A 78 21320355 Cover cap washer 1 D
15A 10230136 U-packing (U136) 2 A 79 21350356 Gas cap packing 1 D
15B 9E3B2136 U-packing (U136T) 1 A 81 153240101 Front cap 1 E
17 E1022180 O-ring (G180B) 1 A 82 15324110 Shank bushing 1 E
18 E1012020 O-ring (P20B) 1 A 83 15324210 Front cap bushing 1 E
19A K10506 Flange plug (GPF1/4) 6 84 21481195 Shaft (20x158) 4 E
19B E1012011 O-ring (P11B) 6 85 15204122 Shaft retainer (20) 4 E
19C K10509 Flange plug (GPF3/8) 2 86A K10519 Flange plug (GPF3/4) 4 E
19D E1012014 O-ring (P14B) 2 86B E10120224 O-ring (P22.4B) 4 E
19E K10525 Flange plug (GPF1) 2 88 21310450 Grease nipple 2 E
19F E1012029 O-ring (P29B) 2 89A K10103A Plug (GM1/8) 2 E
21 15323010 Valve box 1 B 89B K10109A Plug (GM3/8) 1 E
23 15323030 Valve 1 B 91 15324310 Chisel set pin 2 F
24 15323040 Valve box sleeve 1 B 92 101120190 Shaft (20x190) 1 F
25 15323050 Valve cap 1 B 93 15204122 Shaft retainer (20) 1 F
27 A030A5349 Cap screw (M24x55) 4 B 94A 15204123 Plug 1 F
28 C810A024 Spring washer (M24C) 4 B 94B E10120224 O-ring (P22.4B) 1 F
29A 21401157 Flow control plug 1 B 101 15322510 Side rod 4 G
29B 21350157 Flow control plug 1 B 102 21422031 Side rod front nut 4 G
33 E1022070 O-ring (G70B) 1 B,C 103 15322530 Back nut 4 G
35A E1012022A O-ring (P22AB) 1 B,C 104 15322531 Back nut washer 4 G
35B E1012039 O-ring (P39B) 5 B,C
37 A030A5359 Cap screw (M24x60) 8 200 TP200-1200P Point chisel 1
38 C810A024 Spring washer (M24C) 8 200 TP200-1200E Flat-end chisel 1
39A K10506 Flange plug (GPF1/4) 3 B 200 TP200-1200FX Cross cut chisel 1
39B E1012011 O-ring (P11B) 3 B 200 TP200-1200FY In line chisel 1
39C K10512 Flange plug (GPF1/2) 3 B 200 TP200-1200CP Core point chisel 1
39D E1012018 O-ring (P18B) 3 B
39E K10525 Flange plug (GPF1) 1 B
39F E1012029 O-ring (P29B) 1 B 153210SK2 Seal kit 1 A
15323000 Valve box assy 1 B
61 15322010 Back cap 1 153230SK Valve box O-ring kit 1 C
62A E1022175 O-ring (G175B) 1 A 21350350X Gas valve body assy 1 D
62B E2122175 Back up ring (G175T2) 1 A 153240001 Front cap assy 1 E
69A K10519 Flange plug (GPF3/4) 1 15324300 Chisel set pin assy 1 F
69B E10120224 O-ring (P22.4B) 1 15322500 Side rod assy 4 G

TOP200 S/N 2586 –

45
Bracket exploded view
V8Z bracket

No. Parts No. Parts Name Q’ty Description

1 15327V11A-A Side plate R 1
2 15327V11A-B Side plate L 1
3 Top bracket 1
4 15327V61A Guide box A 1
5 15327V61B Guide box B 1
6 15327V61C Guide box C 1
7,8,9 BC30027a Damper 6 70 x 105
10 BC40063 Front bolt 6 RD36 x 440
11 BC40064 Front bolt nut 6 T-29
12 BC40065 Front bolt lock nut 6 T-21
13 BC40343 Washer 6
14,15 Tie bolt 12
16 Nut 12
17 Spring washer 12

46
Bracket exploded view
VCB bracket

○
15 ○
12

No. Parts No. Parts Name Q‘ty Description

1 15327711 Bracket body 1
2 15327131 Front plate 2
6 15327736 Bracket cover 1
11 21423831 Front bolt 7
12 10635V42 Front bolt nut 7
13 C642A0423 Washer 7 M42
14 15327156 Pipe 1
15 10636V42 Hard lock nut 7
21A 15357762 Cover 1
21B 15407763U Cover base 2
22A A023K3768 Bolt 8 UNC5/8x65mm
22B C612B016 Spring washer 8 5/8
22C C642B0163 Washer 8 5/8
21423831X1 Front bolt ASSY (Hard lock type) 7 #11, 12, 13 , 15
(S/N 2796-)

47
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

Flange plugs for retainers Tightness Retighten Everyday

Insufficiency, deterioration or
Replenish or replace Everyday
contamination
Hydraulic oil
2
Replace Every 600 hours *

Bracket Wear or damage Repair or replace Every 1 month or 100 hours *1

Chisel Wear or damage Repair or replace Every 1 month or 100 hours *1

Hydraulic oil filter Replace Every 100 hours *2

Back cap N2 gas Gas pressure Charge N2 gas Every 3 months or 300 hours *1

Shank bushing Wear or damage Remove flaws or replace Every 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

1
All seals Replace Every 12 months or 1000 hours *

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

Flaws on the inner surface,

Cylinder Repair flaws, retighten Every 12 months or 1000 hours *1
loosen plug

Cylinder sleeve Flaws on the inner surface Repair flaws Every 12 months or 1000 hours *1

Piston Flaws on the inner surface Repair flaws Every 12 months or 1000 hours *1

*1 Take steps, whichever comes first.

2
* As prescribed by the carrier machine manufacturer.
*3 Refer to the “Wear limit dimension of parts” for visual decision.
● Shorten the inspection and replacement frequency if the breaker is repeatedly used continuously for many hours.
● The numbers above are not to assure the lifetime of each part.

48
Blank page

49
Tightening torque chart

1 4 8 7 9

11

3 5 6
10

V8Z bracket VCB bracket

TOP200
No. Part name N‚m ft‚lb
1 Side rod back nut 1764 1301
2 Front bolt nut 1764 1301
3 Valve box set bolt 784 579
4 Valve cap bolt 784 579
5 Adjuster case bolt N/A N/A
6 Acc. set bolt N/A N/A
7 Cap screw N/A N/A
8 Clamp bolt 250 184
9 Plug 410 300
Convex 2450 1810
10 Front bolt nut
Concave 580 430
11 Cover bolt 250 184
[021113]
Note: Refer to the Reassembly procedure for tightening method.

50
Hard Lock Nuts Installation Procedure

1. 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.

2. Front bolt insert

Insert the front bolts into the bracket from the retainer side.

3. Hard lock nut installation

3-1. Install the washers in the front bolts.
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

1810±180lbs 430±75lbs
TOP200
2450±240N-m 580±100N-m
[021113]

Note: There may be gaps between the convex and concave nuts after torqueing, but regardless of these gaps,
the lower nut's intrinsic locking energy is more than sufficient.

51
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.

How a Demolition Tool Breaks Rock and Concrete

When the hammer piston strikes the top of a working tool, it sends a compressive stress wave down to the
working end of the tool. Provided the working tool is in contact with the rock or concrete which requires
breaking, it is this compressive stress wave which fractures the rock. Immediately following the
compressive stress wave, a tensile stress wave is formed due to the hammer piston lifting from the top of
the working tool. This cycle of compressive and tensile stresses flowing down the tool is repeated for each
hammer blow.
Obviously, anything that interferes with the ‘strength’ of the compressive stress wave during service, for
example ‘free running’ or bending of the working tool due to leverage, will result in loss of breaker efficiency
of up to 80% and possible 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
level of fatigue stress being applied to the working tool and thus increase the risk of early fatigue failure of the
tool.
1. The main cause of increased fatigue stress in working tool is any form of side pressure during service
which creates bending the tool as a lever, using the incorrect driving angle or attempting to break ground
using the pull of the machine are all detrimental to the life of a working tool and should be avoided (see
Figure 1).

Fig. 1

Remember, the hydraulic power available in the machine far exceeds the strength of a working tool if it is
being used incorrectly and can “snap the tool like a carrot “
2. Other causes of increased fatigue stress in a working tool include:
a) Free running’
In general this is any situation where the hammer piston strikes the top of the working tool, but the
working end is not in proper contact with the rock or concrete to be broken. This includes jobs where the
tool slides off the work and also when break-through of thin concrete slabs or boulders occurs.

52
 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’ or ‘pick up’) due to
contact between the tool and the bushings through the lack of lubrication or excessive bending (see
Figure 2)

Fig. 2
d) Lubrication
Care must be taken to avoid metal to metal contact that, as a result of galling or pick-up, could cause
deep damage marks which, in turn, lead to the formation of fatigue cracks and eventual failure of the
working tool. Ensure that the shank of the working tool is well lubricated 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 less common failure area can fall approximately 200 mm (8”) from the working end, subject
to nature of use.
The fracture face itself will normally exhibit a semi circular polished area with the remainder being of a
rougher appearance (see Figure 4 ).

Fig. 3 Fig. 4

The polished semi-circular are in Figure 4 is the fatigue area and generally stars from a damage mark or
other stress raiser on the outside of the working tool and spreads inwards. The fatigue area slowly widens
until the stresses being applied to the working tool cause sudden failure of the remaining section.

53
Generally, the size of the fatigue area indicates the level of stress applied to the tool, i.e. the smaller the
fatigue are, the higher the stress level, although it must be borne in mind that once initiation of a fatigue
crack has taken place, it requires a lower stress level to cause it to grow.

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.

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 the burden. Warranty claims rejected.

Fig. 7
Wear
Wear is influenced by ground conditions, but as a general guide the following applies:

Fig. 8. Blunt tools worn more than 1/3 diameter or moil points and chisels worn back more than 51 mm (2”)
of working end classed as reasonable life. Warranty claims rejected.

Fig. 8

54
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. Warranty 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 due to steel
defect. 100% warranty accepted other than the core moil point chisels.

Fig.12

55
56