OKADA Hydraulic Breakers

Technical Manual

141201
 - Contents -
Specifications……………………...……….………………………………………..………………..2
Name of main parts……………...…..…………………………………………………..…………..3
Hydraulic breaker working principle……..……………………………………………………….. 4
Installation…………………………..……………………………………………………………..…..6
Handling……………………..……..………………………………………………………………..10
Maintenance and inspection…...…………………………………………………………………..13
Routine and periodic inspection……….…………………………………………………………..20
Disassembly……………………...………..………………………………………………………..21
Reassembly………………………..………………………………………………………………..30
Repair…………………………...…..………………………………………………………………..40
Table for failures and check points………….……………………………………………………..46
Trouble shooting………………..……………….…………………………………………………..47
Underwater application………...…………………………………………………………………..55
Chisel warranty guide………………..……………………………………………………………..57
Tightening torque chart………...………….………………………………………………………..61
Nitrogen gas pressure by temperature..…………………………………………………………..62
Wear parts limit…………………...………….……………………………………………………..64
Unit conversion table………………..……………………………………………………………..69
Thread standard...………..………………….……………………………………………………..71
Parts list…………………………...………….……………………………………………………..76
Hydraulic breaker start-up procedure form……………………………………………………..126
Warranty registration form……………….…….…………………………………………………132

Visit OKADA AIYON website: http://www.okada-aiyon.com/

1
 Specifications

okada okada okada okada okada okada okada okada okada okada okada okada
Unit
150 200 250 400 650 800 900 1000 1300 1500 2600 3600

Vertical
kg 55 80 125 187 260 360 495 545 800 940 1650 2610
bracket
Operating lb 121 176 276 412 573 794 1091 1202 1764 2072 3638 5512
weight* kg 55 80 105 165 225 260 515 — — 830 1585 2410
Horizonta
l bracket
lb 121 176 231 363 496 573 1135 — — 1830 3494 5313

Vertical
mm 970 1070 1135 1450 1513 1639 1894 2062 2125 2234 2589 3016
bracket
Overall inch 38.2 42.1 44.69 57.09 59.57 64.53 74.57 74.57 83.66 87.95 101.93 118.74
length mm 907 979 978 1252 1315 1342 1671 — — 1969 2293 2564
Horizonta
l bracket
inch 35.7 38.5 38.5 49.29 51.77 52.83 65.78 — — 77.52 90.28 100.94

mm 40 40 45 57 70 75 80 90 95 105 135 150

Tool diameter
inch 1.57 1.57 1.77 2.24 2.76 2.95 3.15 3.54 3.74 4.13 5.31 5.91

MPa 17.2 17.2 17.2 17.2 17.2 17.2 17.2 17.2 19.1 19.1 19.1 19.1
2nd relief setting
bar 172 172 172 172 172 172 172 172 191 191 191 191
pressure
psi 2500 2500 2500 2500 2500 2500 2500 2500 2800 2800 2800 2800

MPa 6-13 9-12 9-12 9-12 11-16 12-17 13-17 13-17 13-19 13-19 13-19 13-19

140-
Working pressure bar 60-130 90-120 90-120 90-120 110-160 120-170 140-170 140-190 140-190 140-190 140-190
170
range
870- 1300- 1300- 1300- 1600- 1740- 2030- 2030- 2030- 2030- 2030- 2030-
psi
1890 1740 1740 1740 2320 2465 2470 2470 2750 2750 2750 2750

lpm 12-25 12-25 15-30 23-70 30-65 35-75 45-100 50-110 75-120 65-100 120-175 180-250
Oil flow
6.1- 7.7-
gpm 3.2- 6.6 3.2- 6.6 3.2- 6.6 9-20 12-26 13-29 20-32 21-37 32-46 48-66
18.5 17.2

lpm 12-30 13-40 15-42 30-70 35-70 40-110 56-120 70-135 70-140 80-140 140-210 208-290
Carrier output flow
range 3.3-
gpm 3.2-8 4-11 8-16 9.2-16 11-29 15-32 18-35 18-37 21-37 37-55 55-77
10.6
800- 800- 550- 600- 600- 380- 400-
Blow rate bpm 250-700 350-900 400-900 350-800 300-650
1200 1400 1000 1500 1100 900 1100

MPa 1-1.2 1-1.2 1-1.2 1-1.2 1-1.2 1-1.2 1-1.2 1-1.2 1-1.2 1.2-1.4 1.2-1.4 1.2-1.4
Back cap gas bar 10-12 10-12 10-12 10-12 10-12 10-12 10-12 10-12 10-12 12-14 12-14 12-14
pressure
psi 145-174 145-174 145-174 145-174 145-174 145-174 145-174 145-174 145-174 174-203 174-203 174-203

MPa — — — — — — — 3.9-4.9 5.4-5.9 5.4-5.9 5.4-5.9 5.4-5.9

Accumulator gas
bar — — — — — — — 39-49 54-59 54-59 54-59 54-59
pressure
psi — — — — — — — 566-711 782-853 782-853 782-853 782-853

ton 0.7-1.5 1.0-2.0 1.1-2.5 1.8-4.0 3.0-6.5 4.5-8.0 4.5-9.0 6.0-10 8.0-13 10-15 18-26 25-36
Carrier machine
weight range 1540- 2200- 1760- 3300- 6600- 9900- 9900- 13200- 17600-2 22000- 39700- 55100-
lb
3300 4400 5500 8800 14300 17600 17600 22100 7500 33000 52900 79400

[141201]
• 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.

2
Names of main parts

Top bracket

Back nut

Gas valve

Valve
Head damper
Accumulator

Bracket

Chisel set pin

Front cap bushing

Back cap

Cylinder

Piston

Shank bushing
Front cap

Chisel

Note: The above model is okada2600. The shape and location vary depending on the model.

3
Hydraulic breaker working principle
Start up
When a breaker cycle begins. The high
pressure from excavator comes into “A”
the pressure flows in bottom of the piston
“C” and Accumulator “J”. The valve “E”
keeps down position. Low pressure oil
“D” the upper shoulder area of the piston
connected to return line.
Raising the piston
The high pressure oil acts on the lower
shoulder area “C”. The piston raise up.
Low pressure oil “D” the upper shoulder
area of the piston returns to the oil tank
back.

High pressure

Low pressure
(Return line to the thank)

4
Piston stroke
Pressure flow moves piston up. When lower
shoulder “G” reaches at “H” channel. The high
pressure makes valve move up. At this moment
accumulator “J” absorbs high pressure of oil
in. When the valve reaches upper limit, the
pressure from carrier’s pump and the pressure
from accumulator “J” flows into upper shoulder
of the piston and push down the piston with
gas pressure in gas chamber “B”.
High pressure
Low pressure
(Return line to the thank)
5
Impact stroke
The piston to be descanted by high oil
pressure with compressed gas pressure
impacts on tool “T”. During descending of
the piston, Pilot channel “L” is connected
to return line and the valve descends.
When valve “E” descend, upper area of
the piston “D” is connected return line and
becomes low pressure and start-up position.
Installation

 Piping Diagram

Piping for the hydraulic excavator used with the hydraulic breaker is arranged as shown below.

6
 Inspection and adjustment of piping

The following inspection and adjustments must be performed before installation of the hydraulic
breaker to ensure maximum performance of the hydraulic breaker and carrier, and to prevent serious
malfunctions.

1) Flushing
Before turning on the engine, be sure to check the following.
a) Check whether the installed hydraulic circuit is correct.
b) Check the hydraulic oil tank. If necessary, refill it to the specified range.
c) If a change over valve was added between the pumps and the existing control valve, loosen
the adjusting screw for the added relief valve to a moderate value.

Connect both piping tips at the edge of the arm as shown in Fig. 1 below, and open the stop valves
for both the pressure and return line as shown in Fig. 2 below.
When the engine for the carrier has sufficiently warmed up, reduce the engine speed to minimum
and operate the foot pedal to let the high-pressure oil flow through the hydraulic breaker circuit. At
this time, check for oil leakage or other problems on the carrier.
After confirming the piping condition, step up the engine speed to piping, then after the hydraulic oil
temperature has warmed up, accelerate the engine speed to maximum.
Perform flushing for at least 30 minutes.

Do not leave the operating pedal on for more than 5 minutes continuously at a time.
Important
During flushing, periodically step off the operating pedal and let the hydraulic
apparatus rest for about 1 minute.

ON OFF

Fig. 1 Connection of hose for flushing. Fig. 2 Stop valve ON/OFF status

2) Procedure for setting pressure and flow

Important 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 not only the breaker but
also the carrier machine.

A: Incase you have a flow meter

(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 stop valves.

7
(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 2.0 MPa (20
bar, 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 2.0 MPa (20 bar, 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.

(7) This is optional to set and record Internal Oil Flow to PQ characteristic, back off the restriction
knob on the flow meter to 10 MPa (100 bar, 1500 psi) and record flow. Do the same at 12 MPa
(120 bar, 1750 psi), 14 MPa (140 bar, 2000 psi), 16 MPa (160 bar, 2320 psi), 18 MPa (180 bar,
2610 psi) and maximum. Record flow results 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 35 MPa (350 bar, 5000 psi)
Pressure Gauge into the pressure line at the inlet of the
breaker as shown in Fig. 3. 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.

Fig. 3
B: In case you do not have a flow meter
(1) Set the Carrier to Breaker mode or suitable flow mode, if it has the option, then run carrier until
hydraulic oil reaches operating temperature. If your carrier does not have suitable mode for the
hydraulic breaker, ask your carrier’s dealer to configure the breaker mode.

(2) Install the pressure gauge at the front end of the high pressure line pipe on the arm as shown in
Fig. 4. Accelerate the engine speed to maximum. Step on the foot pedal, then measure the
hydraulic pressure and set the circuit pressure at the specified value by adjusting the
secondary relief valve added to the hydraulic breaker pressure line.
Check again to see whether the existing pressure is higher than the specified value for the
hydraulic breaker, add the relief valve to the piping and reduce the pressure for the hydraulic
breaker.

Note: Refer to page 26 regarding the relief valve set pressure.

8
 CAUTION

Never adjust the fixed main relief valve on the carrier to reduce the hydraulic
pressure. Do not touch the main relief value even if the existing pressure is
lower than the specified pressure for the hydraulic breaker.

(3) Measure the Back Pressure as shown in Fig. 5, you should always be under 2.0 MPa (20 bar,
300 psi) of back pressure.
Note: If Back Pressure is over 2.0 MPa (20 bar, 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.

Fig. 4 Fig. 5
okada okada okada okada okada okada okada okada okada okada okada okada
Unit
150 200 250 400 650 800 900 1000 1300 1500 2600 3600
Recommended lpm 20 30 30 50 60 80 100 120 120 120 190 260
carrier output
gpm 5.3 8 8 13.2 15.9 21.1 26.4 31.7 31.7 31.7 50.2 68.7
flow set at *1

MPa 17.2 17.2 17.2 17.2 17.2 17.2 17.2 17.2 19.1 19.1 19.1 19.1
Carrier relief
bar 172 172 172 172 172 172 172 172 191 191 191 191
valve set at
psi 2500 2500 2500 2500 2500 2500 2500 2500 2800 2800 2800 2800

MPa 6.0-13.0 9.0-12.0 9.0-12.0 9.0-12.0 11.0-16.0 12.0-16.6 14.0-17.0 14.0-17.0 14.0-19.0 14.0-19.0 14.0-19.0 14.0-19.0
Working bar 60-130 90-120 90-120 90-120 110-160 120-166 140-170 140-170 140-190 140-190 140-190 140-190
pressure range 870- 1300- 1300- 1300- 1600- 1740- 2030- 2030- 2030- 2030- 2030- 2030-
psi
1890 1740 1740 1740 2320 2400 2470 2470 2750 2750 2750 2750

Carrier output lpm 12-30 13-40 15-42 30-60 35-70 40-110 56-120 70-135 70-140 80-140 140-210 240-275
flow range gpm 3.2-8 3.3-10.6 4-11 8-16 9.2-18.5 11-29 15-32 18-35 18-35 21-37 37-55 63-73
Piping inner 1/2 or
inches 1/2 1/2 1/2 1/2 1/2 3/4 3/4 3/4 3/4 1 1
diameter 3/4
[141030]
• The specifications above are subject to change without notice.
• The performance data vary depending on the base machine.
*1 Comply with recommendation of carrier’s manufacturer when the numbers differ.

3) Other checks
Check that all functions (electric devices, hydraulic actuator operations, etc.) are operating
correctly. Also check the hydraulic oil level and for possible deterioration or contamination.
This inspection and adjustment procedure is particularly essential for first-time
Important
installation of the hydraulic breaker on the carrier.

9
Handling
1. Preparation before starting

(1) Check the hydraulic oil level and refill if necessary. Be sure to use Open/Close position
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.
(Use 5 to 6 strokes from a grease gun to force grease into this part.)
(5) Run the carrier 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 hydraulic breaker use, position the chisel perpendicular to the material to
be broken, apply pressure downwards and during the running in period operate the machine at half
engine speed.

Note: Do not tilt the chisel during the running-in period.

3. Precautions during operation

Position the chisel on the targeted

material so that the crawler or the
front wheels of the tires float slightly,
then apply pressure to start
hammering.
When 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: Forcefully prying the continuously. material shatters.
material with the chisel could cause
the chisel to break.
If the chisel is no longer penetrating
the material, change the hammering
position. Do not hammer the
material continuously for more than
15 seconds at one spot. Otherwise,
the chisel will heat up and the oil
temperature will rise abnormally,
which could lead to trouble.
Never immerse the front cap of the Do not pry. Do not immerse in water or
hydraulic breaker in water or sludge. sludge.

10
4. Installing and removing the hydraulic breaker
(1) Remove the two pins on the bucket and
replace the bucket.
(2) To operate the bucket without using the
hydraulic breaker, close the stop valve on
the carrier’s arm (turn the valves off) and
disconnect the hoses connecting the stop
valves to the hydraulic breaker.
(3) Be sure to blind the disconnected hoses.
Intrusion of sand and mud into the hydraulic
hoses and pipes could cause trouble.

5. Changing the chisel

(1) okada150, 200, 250, 400, 650, 900, 1000
Push the pin back into the hole with the pin punch or finger.
okada800, 1300, 1500, 2600, 3600
Knock the shaft retainer & shaft out using a hammer and pin punch.
(2) Take the chisel set pin out by using a pin punch by pushing the chisel set pin out from the back of
breaker.
(3) Replace a new chisel after removed. The chisel is heavy, so careful attention needed.

okada150, 200, 250 400, 650, 900, 1000

▶ ▶

okad800, 1300, 1500

▶ ▶

okad2600, 3600

▶ ▶

11
 ▶

Note: Apply grease on front cap bushing, shank bushing, chisel set pins and upper portion of
chisel, but do not apply grease on the top head (striking face) of chisel.

7. Adjuster control method Model: okada900, 1000, 1300, 1500, 2600 & 3600

1. Loosen the lock nut of adjuster.

2. Low frequency (Ultrahigh power) → High frequency (High power)
Turn the adjuster 720 degree to counter-clockwise from the end of stroke.
Note: the adjuster has been preset at low frequency (Ultrahigh power) mode.

High frequency (High power) → Low frequency (Ultrahigh power)

Tighten the adjuster to the end of stroke.

3. Tighten the lock nut of adjuster after setting.

8. okada800, 1300, 1500, 2600 & 3600 auto stop system

Auto stop system has been designed for these models in order to stop operation only after once or
twice of extra hitting when the piston works beyond its working range and then high pressure
connects directly with the return line through the groove located in the large diameter of the piston.
I.E. It stops operation after once or twice hitting.

For example, when the auto stop system works,

When the rock was shattered. When the hydraulic breaker was held in the air.

12
Maintenance and inspection
1. Inspection of hydraulic oil and filter element

(1) A carrier installed with the hydraulic breaker uses the engine and the hydraulic oil more severely
than does a carrier alone. Therefore, the hydraulic oil deteriorates more quickly, which can cause
trouble for the hydraulic breaker. 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 oil condition. Lack of viscidity or viscosity and
formation of air bubbles indicate badly deteriorated oil. A blackish brown appearance and
emission of offensive odors are also proof of deterioration. In such cases, the oil must be
changed immediately.
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 existing oil. Be sure to
replace all the oil.

(2) Take care to prevent foreign matter from intruding into the hydraulic oil. Allow no foreign matter to
enter the hoses and nipples during disconnection and connection of the hoses when changing
the hydraulic breaker and bucket. Intrusion of sand or other foreign matter in the hydraulic oil can
cause serious damage. Filters must be cleaned or replaced at periodic intervals.

(3) Always replenish with the same hydraulic oil in order to maintain the correct volume of oil. Using
the hydraulic breaker with insufficient oil will cause oil deterioration. In addition, air intrusions can
cause cavitations. All of these factors could lead to trouble in the hydraulic breaker.

(4) Avoid using the hydraulic breaker at an oil temperature above 80C (176F). The recommended
working temperature range is from 50 to 80C (122 to 176 F). Check that the cooler fins are not
clogged and keep them clean. Soiled fins will impair the operation of the oil cooler.

(5) Intrusion of water into the hydraulic oil causes problems. When not using the hydraulic breaker,
be sure to store it 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, perform replacement as soon as possible even if

the specified replacement period has not been 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
hydraulic breaker, the accumulator set bolts, the valve cap bolts, and the front bolt nuts of the
bracket. Also be sure to retighten any loose bolts and nuts to the specified torque. Using the
hydraulic breaker with loose bolts and nuts will lead not only to oil leakage but also to damage of
the screw threads and bolt breakage. These can also cause defective operation.

(2) For the first 2 days of use, use suitable torque wrenches every 4 hours to retighten the bolts and
nuts of all components and sections..

13
(3) At first, refer to the attached tightening torque chart (page 61) to lightly tighten the bolts and nuts.
Screw them alternately and diagonally until all the bolts and nuts are tightened to the uniform
torque.

3. Greasing the unit

Every 2 hours of each day’s operation, use a grease gun to grease up through the grease nipple
on the side of the front cap.
 If the chisel sliding surface becomes dry under severe operation condition, refill grease.
 For greasing, press the grease gun according to the following table.

okada 150, 200, 250, 400, 650, 800 Approx. 5 strokes of grease gun
okada 900, 1000, 1300, 1500, 2600, 3600 Approx. 10 strokes

Note: While greasing, stand the hydraulic breaker up-right and set the chisel at the shank bottom
to ensure that the grease will be supplied between the chisel and the bushes. Do not fill up
the space between the piston and chisel with grease, since it could damage the dust seal or
lead to defective hammering.

Specified grease
Lithium grease
Type
Water resistant
170°C ~ 200°C
Dropping point
338°F ~ 392°F
130°C
Max. working temperature
266°F
Grade (thickness) NLGI 00, 0, 1. 2
[100107]

4. Wear limit dimension of parts

When the clearance between the chisel and Holder bush
becomes large, it is strongly recommended to replace
these parts to prevent from wear. Exceeding the following
value may damage other component parts, such as the
piston and cylinder.

Model okada 150-800 900-1500 2600 3600

Wear mm 3 4 5 6
limit inches 0.12 0.16 0.20 0.24

Measure at 10mm inside of the bottom side of the front cap bushing and it cannot be used (unusable) if
the maximum measurement exceeds the wear limits stipulated in the above table. Measure the gap
using brand new chisel or unworn chisel.

Note
1. If the striking surface of the piston and chisel has been sunk or damaged, the piston and chisel must
be replaced.
2. See page 65-68 for more wear limit information.

14
5. Precautions to observe when handling chisels
(1) While the chisel can sufficiently withstand shocks in the vertical direction, it is likely to break if
subjected to impacts applied in a lateral direction or to prying. To avoid breaking the chisel, adjust
the carrier arm so that the chisel can move straight down.
(2) Chisel are prone to brittleness in extremely low temperatures. In cold areas, avoid operating at full
capacity for the first few minutes of operation. Also, avoid leaving the chisel outdoors at night, and
protect it with vinyl sheet.
(3) The chisel could break from deep indentations caused by hitting, or from deep rusting.
(4) The shank part of the chisel could heat up due to sliding action between the shank bushing,
causing oil depletion that can result in premature wear. Make it a practice to grease it up regularly.
(5) Continued use of a chisel with a worn tip can degrade crushing performance and also lead to
breakage of the chisel. Make sure that the chisel edge is kept sharp at all times.
(6) Quenching the chisel could cause breakage. Avoid using it such situations where it could plunge
into nearby pools of water after crushing rocks, etc.

6. 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.

Note: Any failures due to lack of above procedures are not covered by warranty, and are sure to
shorten the life of breaker.

7. Procedure for inspecting cushion chamber gas pressure of okada series

The nitrogen gas pressure 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.

Note: When filling the gas, the hammer must be lying flat with no contact pressure applied to the
working tools as well in cold condition as at operating temperature.

☞ Must put the cap on gas cylinder to avoid damage to valve of gas cyliner and check the valve of
gas has closed while keeping. Especially, do not expose the gas to the sun for a long time.

 Back cap gas charging pressure

Model okada150-1300 okada1500-3600

MPa 1.0 - 1.2 1.2 - 1.4
Back cap
N2 gas bar 10 - 12 12 - 14
pressure range
psi 145 - 174 174 - 203
(@ 20˚C, 68˚F)

15
How to check Nitrogen gas in the back cap

1. Remove the cover cap. 2. Connect the charging adaptor

into the inlet. If the adaptor
already connected with gas
hose, the adaptor will not fit
on the inlet.

3. Check if the main valve and 4. Connect the hose into the 5. Read gas pressure from the
drain valve are firmly closed. charging adaptor. gauge. If it shows lower
pressure than the specified
pressure, charge Nitrogen
gas according to the
procedure.

6. Disconnect the hose from the 7. Disconnect the adaptor form 8. Tighten the cover cap into the
adapter. the charging valve. charging valve.

16
How to Charge Nitrogen gas into the back cap
3. Check if the main valve and
drain valve are firmly closed,
then connect the hose from
the nitrogen gas cylinder.
6. Close the main valve after
charging.
9. Disconnect the adaptor form
the charging valve.
1. Remove the cover cap.
4. Connect the hose into the
charging adaptor.
7. Control the proper pressure
opening the drain valve as
photo.
* Check appropriate gas
pressure at Page 32.
10. Tighten the cover cap into
the charging valve.
17
2. Connect the charging adaptor
into the inlet.
5. Open the valve of gas cylinder
and adjust the outlet pressure
at 2 MPa, then open the main
valve.
8. Disconnect the hose from the
adapter.
Blank
How to check Nitrogen gas in the accumulator
 Accumulator gas charging pressure
Model
MPa
Built-in accumulator
bar
N2 gas pressure
psi
1. Disconnect the cap.
4. Connect the charging
adaptor into the inlet. If the
adaptor already connected
with gas hose, the adaptor
will not fit on the inlet.
7. Turn the gas charging valve
counter-clockwise.
okada1000 okada1300-3600
3.9-4.9 5.4 - 5.9
39-49 54 - 59
566-711 780 - 850
(@ 20˚C, 68˚F)
2. Make sure if the gas charging 3. Disconnect the cover cap.
valve is tightened.
5. Check if these three valves 6. Connect the hose into the
are fully closed. charging adaptor.
Blank
8. Read gas pressure from the Put back them in a reverse way
gauge. If it shows lower than shown from #11 in next page.
the specified pressure, charge
Nitrogen gas according to the
procedure #8 in next page.
18
How to Charge Nitrogen gas into the Accumulator
Blank
Take the same procedure as
shown in #1 to #7 in former
page.
10. Control the proper pressure
opening the drain valve as
photo.
* Charge the gas considering
the temperature in the area.
* Check appropriate gas
pressure at Page 36.
13. Disconnect the charging
adaptor from the inlet.
8. Open the valve of gas bottle.
11. Close the gas charging
valve, the valve of gas bottle
and the 3-way valve, then
release the gas from the hose
opening the drain valve.
14. Tighten the cover cap.
19
9. Open the 3-way valve slowly
and charge the sufficient quantity
of gas which is 0.2MPa higher
than appropriate value of page
35. After that, close the valves of
gas bottle & 3 way.
12. Disconnect the hose from the
adapter.
* Loosen the hose gradually as
there are residual gas inside the
hose.
15. Tighten the cap.
Routine and periodic inspection
Part Check Item Countermeasure Frequency
okada150-800: 5 strokes
Grease nipple(s) Grease-up okada900-3600: 10 stroke 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
Replenish or replace Everyday
or contamination
Hydraulic oil
Replace Every 600 hours *2

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

Remove flaws or
Shank bushing Wear or damage Every 3 months or 300 hours *1,*3
replace
Remove flaws or
Front cap bushing Wear or damage Every 3 months or 300 hours *1,*3
replace

All seals Replace Every 12 months or 1000 hours *1

Flaws on the sliding

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

Accumulator
Replace Every 12 months or 1200 hours *1
bladder

Bottom damper Replace Every 12 months or 1200 hours *1

Pad Replace Every 18 months or 1800 hours *1

Upper damper Replace Every 18 months or 1800 hours *1

*1 Take steps, whichever comes first. These hours show the operation hours of carrier machine.
*2 As prescribed by the carrier machine manufacturer. These hours show the operation hours of hydraulic breaker.
*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.

20
Disassembly
I. Bracket disassembly

WARNING!
Use correct capacity of sling to lift the hydraulic breaker.

WARNING!
Prepare a holding device not to fall the breaker down during assembling and
disassembling. Assembling and disassembling work is very dangerous without the
holding device.

1. Place the breaker vertically. 2. Disassemble hose cover and gas cover.

3. If auto-lube kit is installed on, detach it first. 4. Loosen mount bracket bolt.

21
5. Take out the top bracket with hoist and put 6. Take out upper damper and power cell
on the ground safely. holder.

7. Pull out the power cell form housing.

WARNING!
Check if the eye bolt is firmly screwed in and
the choice of sling is correct to the weight of
power cell.

8. Disassemble the shell pad and bottom

damper.

22
II. Discharge of nitrogen gas in the back head

DANGER
Be sure to release all nitrogen gas in the back cap before disassembling.

1. Remove the cover cap. 2. Connect the gas charging adapter into the
port.

3. Connect the hose of gas charging kit into 4. Open the drain valve and release
the adapter. the gas out completely.

Drain valve

23
III. Power cell disassembly

Size of eye bolts

Power cell weight

Model Eyebolt
kg lb
okada150 M10 58 128
okada200 M10 58 128
okada250 M10 60 132
okada400 M10 75 165
okada650 M10 130 287
okada800 M12 190 419
okada900 M16 250 551
okada1000 M16 310 683
okada1300 M16 406 895
okada1500 M20 517 1,140
okada2600 M24 800 1,764
okada3600 M30 1,280 2,822

24
1. Place the power cell vertically or 2. Loosen the back nuts.
horizontally in choice.

3. Screw out the side rods 4. Dismount the back cap.

5. Remove o-rings from the back head 6. Take out holding pin on cylinder.
after lay it down on wooden block.

25
 6. Extract the piston from cylinder. 7. Remove the cylinder sleeve from the
piston.

CAUTION :
Use wooden or plastic hammer when
disassembling the cylinder sleeve not
to give any damage on it.

8. Remove the seals from the cylinder 9. Dismount the cylinder.

sleeve.

10. Remove the holding pin and O-ring from 11. Remove the shafts and shaft retainers
front cap. for bottom bush and upper bush.

26
 12. Disassembly of bushings
Method A
12-1 : Place the front cap on wooden block as shown in the figure below.
12-2 : Weld a steel disc and drive it out by hammering or by pressing machine.

Steel disc

Welding

Front cap bushing Shank bushing

Method B
Cut the bushings into three pieces using an electric or a gas gouging machine.
Note: Do not cut the front cap itself.

Gas gouging torch

13. Disassembly of cylinder

13-1. Remove seals 13-1. Remove plugs

27
 13-3. Remove the valve cap using 13-4. Remove the valve
eye bolt

13-5. Remove the valve liner

using valve-puller

14. Disassembly of accumulator 14-1. Open charging valve cap.

WARNING!
Be sure to release nitrogen gas from the
accumulator before disassembling.

28
 14-2. Open needle valve cap 14-3. Loosen (open) needle valve, and
completely release the gas without
fail.

14-4. Loosen accumulator cover bolts and 14-5. Remove the bladder.
dismount the accumulator cover.

14-6. Screw out the cap screws. 14-7. Remove the seal from the bottom
of accumulator.

29
Reassembly

I. Accumulator and cylinder assembly

CAUTION :
Before reassembly of the parts, every part must be cleaned.

15-1. Install the seal on the bottom of 15-2. Place the accumulator body, and
accumulator. tighten the cap screws at specified
torque

15-3. Install the bladder (apply grease 15-4. Put accumulator cover, and tighten
around the lip of bladder) the cap screws at specified torque.

15-5. Charge nitrogen gas (see page 15-6. Assemble valve set after applying
20 for charging procedure) enough oil – Two O-rings must be
in place before installation.

30
 15-5. Screw the plugs with O-ring in the 15-5. Assembly seals – Make it sure
cylinder, then tighten them at apply oil inside of cylinder and
specified torque grooves to be assembled seals and
seals.

II. Front cap assembly

CAUTION :
Check the direction and if the place is correspond with retainer pin hole carefully, if the
direction and place is wrong, the bushed must be disassembled again.

16-1. Installation of bushings

Method A: Heat the front cap around 150℃ using gas torch, then insert the shank bushing and
front cap bushing into the front cap with paying attention to the direction of grooves for
retainer pins.

Method B: 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 with paying attention
to the direction of grooves for retainer pins.

Front cap bushing

Groove for retainer pin

Shank bushing

31
 16-2. Insert the shaft and drive the shaft 16-3. Install the O-ring and pin.
retainer in the front cap.

Note: Be sure to insert them to dead end.

III. Piston and cylinder sleeve assembly

17-1. Put the cylinder on the front cap. 17-2. Apply oil on the piston and inside of
cylinder, then insert the piston in the
cylinder.

32
 17-3. Apply oil inside and outside the cylinder 17-4. Install the O-ring and insert the cylinder
sleeve, then install the seals on cylinder sleeve in the cylinder using a plastic or
sleeve rubber hammer. And then insert the
pin in the cylinder.

IV. Back cap assembly

18-1. Apply oil on the O-ring and install it in 18-2. Put the back cap on the cylinder.
the back cap.

33
18-3. Put the front nuts and screw the side rods in them. Screw the back nuts in the side rods
then tighten them at specified torque. (See the tightening torque chart on page 61)

CAUTION :
Set initial torque at 147 N-m (15 kg-m) for model okada150 and 250
at 196 N-m (20 kg-m) for model okada400 – 800
at 490 N-m (50 kg-m) for model okada900 and over
The top units should be tightened, when increasing the torque step by step,
in each direction as the arrow mark on the figure.
A → B → C → D.

34
TURN-OF-NUT Method
(Maximum 490 N-m torque wrench is required)

1st step 2nd step 3rd step 4th step

Model Unit
Torque Turn Torque Turn Torque Turn Torque Turn
N-m 147 – – – – – 294 –
okada150 kg-m 15 – – – – – 30 –
ft-lb 108 – – – – – 217 –
N-m 147 – – – – – 294 –
okada200 kg-m 15 – – – – – 30 –
ft-lb 108 – – – – – 217 –
N-m 147 – – – – – 294 –
okada250 kg-m 15 – – – – – 30 –
ft-lb 108 – – – – – 217 –
N-m 196 – – – – – 441 –
okada400 kg-m 20 – – – – – 45 –
ft-lb 145 – – – – – 326 –
N-m 196 – – – – – 490 –
okada650 kg-m 20 – – – – – 50 –
ft-lb 145 – – – – – 362 –
N-m 196 – – – – – 490 –
okada800 kg-m 20 – – – – – 50 –
ft-lb 145 – – – – – 362 –
N-m 490 – – – – – 931
okada900 kg-m 50 – – – – – 95 2.5/6
ft-lb 362 – – – – – 687
N-m 490 – – – – – 931
okada1000 kg-m 50 – – – – – 95 2.5/6
ft-lb 362 – – – – – 687
N-m 490 – 882 – – 1274
okada1300 kg-m 50 – 90 1/6 – – 130 3/6
ft-lb 362 – 651 – – 940
N-m 490 – 882 – – 1568
okada1500 kg-m 50 – 90 1/6 – – 160 2.2/6
ft-lb 362 – 651 – – 1258
2646
N-m 490 – 882 1470 (3038)
270 1/6
okada2600 kg-m 50 – 90 0.5/6 150 1.5/6 (310) (1.7/6)
1953
ft-lb 362 – 651 1085 (2242)
3724
N-m 490 – 1470 2450 (4312)
380 1.3/6
okada3600 kg-m 50 – 150 1/6 250 1/6 (440) (1.9/6)
2749
ft-lb 362 – 1085 1808
(3183)
※ Values in ( ) is applicable to Middle East, India and Mexico.
Turning flat (nut degree) on 3rd step and 4th step should be turned from previous step

35
Procedure of tightening

1st step
Tighten the back nuts up to 490 N-m with a torque wrench.

2st step
Turn up to Turning Number specified on the chart in former page for each model with ring spanner
and hammer.

* Before turn it at 2nd step, make mark on an apex of top nut and back-head for ensure to tighten up
to the specified turning number.

* Turn it with hammer every 1/6 number → turn top nut “A” 1/6 after then turn “B” and turn “C” and “D”
in cross direction.

* Do not turn one unit full number at one time.

Please turn each nut every 1/6 turning number.

Recommendation of hammer size

– okada150-800 : 10 lb
– okada900, 1000, 1300, 1500 : 12 lb
– okada2600 : 16 lb
– okada3600 : 20 lb

Marking point

Back cap

C A

B D
Back nut

Side rod

36
 18-4. Lay down the assembled power cell and fill hydraulic oil into the back cap.

Model Quantity of hydraulic oil

okada150,200, 250 40 ml 0.01 gal

okada400 50 ml 0.013 gal

okada650 60 ml 0.016 gal

okada800, 80 ml 0.02 gal

okada900 150 ml 0.04 gal

okada1000 180 ml 0.05 gal

okada1300 200 ml 0.05 gal

okada1500 220 ml 0.06 gal

okada2600 340 ml 0.09 gal

okada3600 500 ml 0.13 gal

18-5. Assemble gas charge valve and charge N2 gas and assemble gas valve cap.
(see page 18 for N2 gas charging method)

37
V. Bracket assembly

19. Assemble bottom damper and, o-rings 20. Place the housing on the assembly
and shell pad inside of the housing. hole.

21. Assemble power cell in the housing 22. Assemble power cell holder and upper
with hoist or crane. damper.

38
23. Place the top bracket on the housing. 24. Tighten the bolts of top bracket at
specified torque.
(see torque chart on page 97)

23. Assemble the hose cover and the gas 23. Assemble the hose cover and the
cover. auto-lube kit (optional)

39
Repair
Inspection areas after disassembly
Inspect and repair each specified areas according to the following pages.

H I

C B A

F E E D

Inspection of the seals

Replace the seals with new ones if they are deteriorated,
worn out, or hardened.

If you find the following symptoms in a short period use, find the cause and take steps according to the
situations.

Condition Possible cause Countermeasure

The lip portion is Cosmetic problem on Repair or replace the

abnormally worn out. the piston, or piston.
abnormal wear of the
piston

The sliding face has Cosmetic problem on Repair or replace the

scratches. the piston piston.

The sliding face is glossy Using with Replace the hydraulic

and cracked. deteriorated oil oil.

It is hardened and fragile. Overheating, or using Stop continuous

with deteriorated oil hammering, inspect the
piping, or replace the
hydraulic oil.

40
Condition
The lip portion is
abnormally worn out.
The sliding face has
scratches.
The sliding face is glossy
and cracked.
It is hardened and fragile.
41
Possible cause Countermeasure
Cosmetic problem on Repair or replace the
the piston, abnormal piston, or inspect the
wear of the piston, or piping.
working pressure is
too high
Cosmetic problem on Repair or replace the
the piston, abnormal piston, or inspect the
wear of the piston, or piping.
working pressure is
too high
Overheating, or using Stop continuous
with deteriorated oil hammering, inspect the
piping, or replace the
hydraulic oil.
Cosmetic problem on Repair or replace the
the piston, abnormal piston, or inspect the
wear of the piston, or piping.
working pressure is
too high
Inspection and repair of the cylinder
If scratches are detected, repair them according to the following procedures.

1. Cylinder sleeve insert (Area A)

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 repair scratches, use a round or
half-round oilstone while applying cleaning oil until the surface roughness is 6.3S or less. The
diameter of the oil stone should be as large as possible. Then finish the surface with #800
grinding paper.

2. Cylinder inner surfaces (Areas B and C) other than the above mentioned surface.
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 finish the surface.
Note: Remove the tips of scratches. Never try to remove the whole scratches.

For reference
If an electric power supply is available, use a portable electric drill with Flex Hone to finish the
surface while applying cleaning oil. Quick finishing is possible with this method.
Note: Use the flex hone at 300 to 1250 rpm for 60 seconds or less, according to conditions.

 Cylinder repair using Flex Hone (#240)

 Cylinder sleeve repair using oil stone

42
Inspection and repair of the piston

If scratches are detected, repair them according to the following procedures.

1. Upper and lower small diameter sections (Areas D and

F):
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. Large diameter labyrinth section (Area E)

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
#800 grinding paper to finish the surface.

Note: Remove the tips of scratches. Never try to

remove the whole scratches.

3. 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.

4. 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 could develop.

43
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 #800
grinding paper.

44
Inspection and repair of the cylinder sleeve

To finish the surface, use a coarse oilstone while applying cleaning oil until the surface roughness is
12.5S or less. Then use #800 grinding paper to finish the surface.

Inspection and repair of the valve

1. Valve (Area H)
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.

2. Valve box sleeve (Area I)

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.

3. Valve box (Area G)

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.

For reference
If an electric power supply is available, use a portable electric drill with Flex Hone to finish the
surface while applying cleaning oil. Quick finishing is possible with this method.
Note: Use the flex hone at 300 to 1250 rpm for 60 seconds or less, according to conditions.

45
Table for failures and check points

Decrease or increase in number

Irregularity in operation

Decrease in impact force

Failure

Breaker does not start

Occasional stopping
Check points

blows
Hydraulic pump ○ ○
Oil filter ○
Main relief val ve ○ ○ ○ ○
Carrier

Secondary relief val ve ○ ○ ○ ○

Stop val ve ○ ○ ○
Piping ○ ○ ○
Hydraulic oil ○ ○ ○ ○ ○
Hydraulic oil tempera ture ○ ○ ○ ○
Chisel ○ ○
Chisel set pin ○
Front cap bushing ○ ○
Shank bushing ○ ○
Hydraulic Breaker

Cylinder ○ ○ ○ ○ ○
Piston ○ ○ ○ ○ ○
U-pack ing ○ ○ ○
Valve ○ ○ ○ ○
Valve liner ○ ○ ○
N 2 gas pressu re ○ ○ ○
Accumulator gas p res sure ○ ○
(TOP205/210/300/400,OKB 316/318/ 330)

Code T1 T2 T3 T4 T5

46
Trouble shooting
Do not start or stop soon（Code：T1）

【Check point】 【Cause】 【Remedy】

Stop valve is opened? No Human error Fully open the stop

valve.
Yes
Sufficient pressure and
flow from pump?

Yes No
Deteriorated oil? No Pump failure Contact to carriers’ dealer.

Yes
Change whole oil with new
oil.

Sufficient pressure of No Main relief valve failure Contact to carriers’ dealer.

main relief valve?
Yes

Sufficient pressure of No Incorrect adjustment Adjust at correct pressure

secondary relief valve?

Yes
Secondary relief valve Repair or change
failure secondary relief valve

Clogged oil filter? Yes Change the filter.

No
Clogged piping? Yes Remove foreign body.

No
Correct chisel position No Deformation of chisel or Change chisel or chisel set
when forced into? chisel set pin. pin with new one.

Yes
Proper N2 gas pressure in
No Charge N2 gas.
gas cushion chamber?
Yes
Disassembling breaker Repair or change defective
Internal failure in valve box
part

U-packing failure Change U-packing

Cylinder or piston failure Repair cylinder or piston

Inflow of grease into Remove grease

percussion chamber

47
Irregularity in operation（Code：T2）

【Check point】 【Cause】 【Remedy】

Sufficient pressure and

flow from pump?

Yes No
Sufficient pressure of No Incorrect adjustment Adjust at correct pressure
main relief valve?

Yes
Main relief valve failure Repair or change main relief
valve

Deteriorated oil? No Pump failure Contact to carriers’ dealer

Yes
Change whole oil with new
oil

Sufficient pressure of No Improper pressure Adjust at proper pressure

secondary relief valve? adjustment
Yes
Secondary relief valve Replace secondary relief
failure valve

Proper N2 gas pressure in No Charge N2 gas

gas cushion chamber?
Yes
Disassembling breaker Repair cylinder or piston
Cylinder or piston failure

U-packing failure Change U-packing

Internal failure in valve box Repair or change defective

part

48
Occasional stopping in operation（Code：T3）

【Check point】 【Cause】 【Remedy】

Proper hydraulic oil No Replenish hydraulic oil

quantity?
Yes
Sufficient hydraulic oil
temperature?

Yes No
Oil cooler clogging? Yes Reduced cooling efficiency Clean up or replace oil
cooler

No
Do not use over 80ºC
Enhance oil cooler

Deteriorated hydraulic oil? Yes Change whole hydraulic oil

with new one
No
Foreign body clogging in Yes Remove foreign body
piping?
No
Disassembling breaker Repair cylinder or piston
Cylinder or piston failure

U-packing failure Change U-packing

Internal failure in valve box Repair or change defective

part

49
Decrease or increase in number of blow（Code：T4）

【Check point】 【Cause】 【Remedy】

Stop valve is opened? No Open stop valve

Yes
Foreign body clogging in Yes Remove foreign body
piping?
No
Proper hydraulic oil
temperature?
Yes No
Oil cooler clogging? Yes Reduced cooling efficiency Clean up or replace oil
cooler
No
Avoid using above 80ºC
Enhance oil cooler

Sufficient pressure of main No Improper relief valve Adjust at proper pressure

relief valve? adjustment
Yes
Main relief valve failure Replace main relief valve

Sufficient pressure of No Improper relief valve Adjust at proper pressure

secondary relief valve？ adjustment
Yes
Decrease in number of Secondary relief valve Replace main relief valve
blow? failure
Yes No
Low N2 gas pressure in Improper N2 gas pressure Charge N2 gas pressure
gas cushion chamber

High N2 gas pressure in Yes Improper N2 gas pressure Adjust N2 gas pressure
gas cushion chamber?

No No(Accumulator models)
Low N2 gas pressure in Yes Improper N2 gas pressure Charge N2 gas pressure
accumulator?

No
Bladder failure Replace bladder

Contact OKADA

50
Decrease in impact force（Code：T5）

【Check point】 【Cause】 【Remedy】

Ｙes hydraulicNooil
Proper
temperature?

Yes No
Oil cooler clogging? Yes Reduced cooling efficiency Clean up or replace oil
cooler
No
Avoid using above 80ºC
Enhance oil cooler

Sufficient pressure of main No Improper relief valve Adjust at proper pressure

relief valve? adjustment
Yes
Main relief valve failure Replace main relief valve

Sufficient pressure of No Improper relief valve Adjust at proper pressure

secondary relief valve? adjustment
Yes
Secondary relief valve Replace secondary relief
failure valve

Sufficient N2 gas pressure in No Low N2 gas pressure in Charge N2 gas pressure

gas cushion chamber? gas cushion chamber
Yes Yes(Accumulator models)
Low N2 gas pressure in Yes Improper N2 gas pressure Charge N2 gas pressure
accumulator?
No
Bladder failure Replace bladder

Wear of chisel shank No

portion beyond limit? Replace chisel

Yes

Wear of front cap bushing No Replace front cap bushing

beyond limit?

Yes
Disassembling breaker Wear of shank bushing Replace shank bushing
beyond limit

Wear of piston beyond Replace piston

limit

Wear of valve beyond limit Replace valve

51
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.
Hydraulic breaker

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.
winter temperature.
Damage to valve, valve box, or valve box Repair the shallow flaws with an oil stone and
sleeve. abrasive paper. Replace it if the flaws are deep.
Damage in the sliding areas between the
Repair the flaws with an oil stone and abrasive paper.
cylinder and piston.
Neglect in opening the stop valve or keeping the
Fully open (turn on) stop valve or repair valve.
stop valve closed.
Insufficient hydraulic pressure or discharge
Carrier

Repair or replace parts.

owing to damage to the secondary relief valve.
Improper selection and damage of the
Repair or replace.
directional valve.
Clogging by foreign matter in the piping. Disassemble and remove foreign matter.
Note: Remove scratches on the surface of valve using grinding 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 to cylinder, piston, cylinder sleeve,

Hyd.

(Unless damage is mended quickly, the parts become

valve, valve box, or valve box sleeve.
irreparable.)
Use of carrier when oil temperature is above Avoid using the carrier above 80C(176F). Do not rev
Carrier

80C (176F). up the engine more than required.

Clogging by foreign matter in the piping Disassemble and remove the foreign matter.

3. Major causes and suggested remedies for irregularity in operation

MAJOR CAUSES SUGGESTED REMEDIES
Improper pressure of gas sealed in the gas Regulate the nitrogen gas pressure to proper
cushion chamber. pressure.
Hyd. breaker

Shank bushing worn beyond limit. Replace shank bushing.

Damage to cylinder, piston, cylinder sleeve,
Remove flaws with an oil stone and abrasive paper.
valve, valve box, or valve box sleeve.
Insufficient gas pressure of accumulator, or
damaged bladder. Replace the bladder if big Recharge nitrogen gas or replace the bladder.
tremor can be seen of high-pressure line hose.
Lack of hydraulic oil. Replenish with the same 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 for Regulate the secondary relief valve to correct the set
Carrier

the main relief valve and secondary relief valve. pressure.

Insufficient discharge and pressure owing to a
hydraulic pump malfunction.
Use of carrier while oil temperature has risen
abnormally above 80C (176F).
Or repair or replace the damaged spring, seat, valve or
piston.
Send the carrier pump to the manufacturer’s
designated service factory for repair.
Avoid using the carrier above 80C (176F).

52
4. MAIN CAUSES AND SUGGESTED REMEDIES FOR A DECREASE IN NUMBER
BLOWS AND IMPACT FORCE
MAJOR CAUSES
Improper pressure of the sealed gas.
Hydraulic breaker
Shank bushing worn beyond limit.
Wear beyond limit, damage or deformation of the
striking surface of the piston, and the shank section,
impact receiving surface and tip of chisel.
Damage or wear to cylinder, piston, cylinder
sleeve, valve, valve box, or valve box sleeve.
Insufficient gas pressure of accumulator or
damaged bladder. Replace the bladder if big
tremor can be seen of high-pressure line hose.
Half opening of stop valve.
Clogging by foreign matter in the piping.
Lack of hydraulic oil.
Deterioration or contamination of hydraulic oil.
Defective operation or improper set pressure for
the main relief valve and secondary relief valve.
Carrier
Insufficient discharge and pressure owing to a
hydraulic pump malfunctioning.
Use of carrier when oil temperature is above
80C (176F).
Disorderly operation of pressure valve in the
tank, and clogging of cooler fins or filter
elements.
Improper selection and damage of directional
valve.
EARLY WEAR AND DAMAGE OF PARTS
MAJOR CAUSES
Lack, deterioration, or contamination of
hydraulic oil, or use of regenerated oil.
Intrusion of foreign matter during mounting or
dismounting of the hyd. breaker, insufficient oil
flushing after installation of piping, or intrusion
of drain muck in the hydraulic oil tank.
Abnormal rise of oil temperature.
Insufficient greasing.
Loosening of screwed parts owing to
insufficient or uneven tightening.
Excessive prying of chisel during operation.
Continuous blowing for more than 30 seconds
Underwater use of a hyd. breaker with
standard specification
SUGGESTED REMEDIES
Regulate the sealed gas to the correct pressure.
Replace the shank bushing.
Replace the piston or chisel (use only genuine parts).
Repair flaws with an oil stone or polishing paper or
replace.
Recharge nitrogen gas or replace the bladder.
Fully open the valve.
Disassemble and remove foreign matter.
Replenish with the same hydraulic oil.
Replace all oil with fresh oil.
Send the main relief valve to the manufacturer’s designated
service factory for adjustment.
Regulate the secondary relief valve to correct the set
pressure.
Or repair or replace the damaged spring, seat, valve or
piston.
Send the carrier pump to the manufacturer’s
designated service factory for repair.
Avoid using the hydraulic breaker if the oil
temperature is above 80C (176F).
Send these parts to the manufacturer’s designated
service factory for repair or replacement.
Repair or replace.
PLACES
Damage or formation rust on the cylinder, piston, valve,
valve box, and cylinder sleeve.
Damage or wear of relief valves, pump, or operating valve.
Damage to the sliding parts between the cylinder and
piston, and the sliding parts of the valve.
Damage to the U-packings, clogging of the filter elements,
or damage to the relief valves
Deformation or hardening of the U-packings and O-rings.
Damage and wear of shank bushing, the shank section of
the chisel, and front cap bushing.
Wear and breakage of bolts, or gas leakage.
Damage to the cylinder and piston, wear of the shank
bushing, and front cap bushing, or failure of chisel or side
rod.
Breakage of bolts, wear of chisel or damage of relief valves
and pump, and striking surface of piston.
Embrittlement of U-packings, damage to the cylinder and
piston (contamination of hydraulic oil or damage to the
hydraulic apparatus of the carrier).
53
Diagnosis of oil leakage

1. The grease is melt

down.

2. Small quantity of oil is

dropping during break
time. It is acceptable
range of leakage.

3. Small quantity of oil is

leaking. It is
acceptable range of
leakage.

4. Small quantity of oil is

leaking. It is
acceptable range of
leakage, but it is time
to schedule resealing.

5. Too much oil is leaking.

It is time to replace the
seal kit.

54
Underwater application
1. Preparation before installation
● Never use the standard type hydraulic breaker under water. Otherwise, both the carrier and the
hydraulic breaker will be damaged severely.
● Modify the hydraulic breaker according to the Fig. 1 and install underwater piping kit in the carrier.
Note: Ask your dealer for the underwater piping kit.

Note : Port size of A

okada800 - 1500 = PFO09 (BSPP3/8”)
okada2600 = PFO13 (BSPP1/2”)
okada3600 = PFO19 (BSPP3/4”) Circuit diagram

● Use a suitable air compressor according to the following table.

okada800-1500 okada 2600, 3600

Compressor output 18.4 kW (25HP) or larger 25.8 kW (35HP) or larger
0.5 - 0.6 MPa 0.5 - 0.6 MPa
Air pressure
(5 - 6 bar, 73 - 87 psi) (5 - 6 bar, 73 - 87 psi)
[140618]
● Install the air piping and then measure the air pressure at the hydraulic breaker port to determine that
it is 0.3 - 0.4 MPa (3 - 4 bar, 44 - 58 psi). Adjust the pressure at the air compressor if necessary.

2. Notice before operation

● Adjust the N2 gas pressure in the back cap of the hydraulic breaker according to the following
table.

TOP okada800-1300 okada1500-3600

MPa 1.3 - 1.5 1.5 - 1.7
Under Water
bar 13 - 15 15 - 17
application
psi 185 - 213 218 - 247
MPa 1.0 - 1.2 1.2 - 1.4
Standard bar 10 - 12 12 - 14
psi 142 - 174 174 - 203
[141030]
● For underwater work, after completion of each day’s operations, all parts marked below should
be thoroughly cleaned, caulked, greased, and sprayed with an anti-rust preventive solution for
protection, as shown in the figure below.

Caulking

Greasing

Spraying
Fig. 1

55
 ● Recommendations for anti-rust
Caulking Silicon caulking
Greasing Sumico Moly HD Grease No. 2 or equivalent
Spraying Sumico TFP Spray or equivalent

● Apply grease to the bucket pins.

● Prepare an oil fence in case of oil leakage.

3. Notice during operation

● Supply air before immersing the hydraulic breaker in the water.

● If oil leaks from the hydraulic breaker during operation, stop the operation immediately and check
all seals and hoses for damage or loose fittings. After inspection or repair of parts, perform the
above anti-rust procedure.

● If water is intruding into the cylinder, stop the operation immediately, dismantle the hydraulic
breaker, and perform integral repair. Moreover, when the underwater work is no longer required,
perform a complete overhaul.

● For general operating procedure, refer to the Precautions during operation on page 24.

4. Notice after operation

● Do not stop supplying air after an operation.

● After underwater working, perform hammering on the ground for at least 10 minutes at vertical
position.

● Remove the chisel and chisel set pin(s). Wipe moisture from them and from the inner face of the
front cap, and then spray and grease as specified.

● If water is intruding into the cylinder, stop the operation immediately, dismantle the hydraulic
breaker, and perform integral repair. Moreover, when the underwater work is no longer required,
perform a complete overhaul.

5. Notice during storage

● Spray anti-rust on the lower part of the piston and inner surface of the front cap.

● For long term storage, release all gas from the gas cushion chamber. Press the piston from the
front cap side into the cylinder according the procedure shown on page 32.

● Completely cover the unit with a plastic sheet or other protective material.

● Never leave the hydraulic breaker outdoors.

6. Other
● When unscrew any thread, apply the anti-rust preventive solution as described above.

● Periodically inspect both the hydraulic breaker and the carrier. Use those inspections to check
for intrusion of water into the hydraulic oil.

● Be sure to release moisture from the air compressor through the air tank drain port. Moisture in
the air could cause serious problem to the hydraulic breaker.

56
Chisel Warranty Guide
The purpose of this guide is to enable you to advise your customers regarding the correct application
of OKADA Chisels and to assist you in resolving complaints immediately as they occur.
When a chisel has apparently failed to provide satisfactory service life, a visual inspection often
quickly resolves the cause, saving transport costs and frustration if a warranty is rejected.

How a Chisel Breaks Rock and Concrete

When the piston strikes the top of a chisel, it sends a compressive stress wave down to the working
end of the chisel. Provided the chisel is in contact with the rock or concrete targeted for breaking, it is
this compressive stress wave that fractures the rock. Immediately following the compressive stress
wave, a tensile stress wave is formed due to the piston lifting from the top of the chisel. This cycle of
compressive and tensile stresses flowing down the chisel 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 chisel due to leverage, will result in loss of hydraulic
breaker efficiency of up to 80% and possible fatigue failure of the chisel itself.

Cause and Effect of Fatigue

The continuous cycle of compressive and tensile stresses in the chisel, even under correct operating
conditions, creates fatigue stress in the chisel that can lead to fatigue failure of the chisel before it is
worn out. Again, anything that interferes with the cycle of compressive and tensile stresses will also
increase the level of fatigue stress being applied to the chisel and thus increase the risk of early
fatigue failure of the chisel.

1. The main cause of increased fatigue stress in the chisel is any form of side pressure during
service that causes the chisel to bend like a lever, using the incorrect driving angle, or attempting
to break ground by pulling the machine, all of that are detrimental to the life of a chisel and should
be avoided (see Figure 1).

Fig. 1

Remember, the hydraulic power available in the machine far exceeds the strength of a chisel if it is
being used incorrectly and can “snap the chisel like a carrot “

2. Other causes of increased fatigue stress in a chisel include:

a) ‘Free running’
In general this is any situation where the piston strikes the top of the chisel, but the chisel tip is not
in proper contact with the rock or concrete to be broken. This includes jobs where the chisel slides
off the work or when break-through of thin concrete slabs or boulders occurs.

57
b) Cold
Low temperature can cause a chisel to be more susceptible to fatigue failure. Chisels 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 fatigue failure. Thus all
care must be exercised to prevent accidental gouging, or galling due to contact between the chisel
and the bushings through 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 gouging or galling, cause
deep damage marks that, in turn, lead to the formation of fatigue cracks and eventual failure of the
chisel. Ensure that the shank of the chisel is well lubricated before positioning it in the hydraulic
breaker. The specified grease shown in this manual is recommended.

e) Corrosion
Since a rusty chisel is more likely to suffer fatigue failure, keep chisels well greased and sheltered
from the weather when not in use.

Chisel Fatigue Failure

Chisel fatigue failure will generally occur approximately 100 mm (4”) either side of the chuck front
face ( see Figure 3 ) or through the chisel set pin flat.
Another slightly less common failure area is approximately 200 mm (8”) from the chisel tip,
depending on the nature of use.
The fracture face itself will normally exhibit a semi circular polished area with the remainder being a
rougher appearance ( see Figure 4 ).

Fig. 3 Fig. 4

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

58
Generally, the size of the fatigue area indicates the level of stress applied to the chisel, i.e. the
smaller the fatigue area, 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 chisels are manufactured from first class materials and then heat treated to produce
a wear-resistant chisel. Thus when a chisel 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 chisel. 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 chisel 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

59
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

60
 1
Tightening torque chart
4
& Wrench sizes
7
6

2
HS: Hexagon socket
1 2 3 4 5 6 7
Top
Model Unit Side rod Acc. set Cap Cover Lock Clamp
Cap mount
back nut bolt screw cap nut bolt
bolt
Nm 294 N/A N/A 69 N/A N/A N/A 440
okada150 ftlb 217 N/A N/A 51 N/A N/A N/A 324
Wrench 27 N/A N/A 17 N/A N/A N/A 27
Nm 294 N/A N/A 69 N/A N/A N/A 440
okada200 ftlb 217 N/A N/A 51 N/A N/A N/A 324
Wrench 27 N/A N/A 17 N/A N/A N/A 27
Nm 294 N/A N/A 69 N/A N/A N/A 440
okada250 ftlb 217 N/A N/A 51 N/A N/A N/A 324
Wrench 27 N/A N/A 17 N/A N/A N/A 27
Nm 440 N/A N/A 69 N/A N/A N/A 440
okada400 ftlb 324 N/A N/A 51 N/A N/A N/A 324
Wrench 30 N/A N/A 17 N/A N/A N/A 27
Nm 490 N/A N/A 69 N/A N/A N/A 440
okada650 ftlb 361 N/A N/A 51 N/A N/A N/A 324
Wrench 36 N/A N/A 17 N/A N/A N/A 27
Nm 490 N/A N/A 69 N/A N/A N/A 440
okada800 ftlb 361 N/A N/A 51 N/A N/A N/A 324
Wrench 36 N/A N/A 17 N/A N/A N/A 27
Nm 931 N/A N/A 69 N/A 137 N/A 440
okada900 ftlb 687 N/A N/A 51 N/A 101 N/A 324
Wrench 46 N/A N/A 17 N/A 17 N/A 27
Nm 931 440 245 69 49 137 N/A 440
okada1000 ftlb 687 324 181 51 36 101 N/A 324
Wrench 46 14 12 17 22 17 N/A 27
Nm 1274 588 343 69 49 137 N/A 980
okada1300 ftlb 940 433 251 51 36 101 N/A 723
Wrench 55 17 HS 14 HS 17 22 17 N/A 36
Nm 1568 588 343 69 49 137 N/A 980
okada1500 ftlb 1156 433 251 51 36 101 N/A 723
Wrench 60 17 HS 14 HS 17 22 17 N/A 36
Nm 2646 1080 490 69 49 137 N/A 980
okada2600 ftlb 1951 796 361 51 36 101 N/A 723
Wrench 70 19 HS 14 HS 17 22 17 N/A 36
Nm 3724 1764 637 69 49 137 196 2450
okada3600 ftlb 2746 1300 469 51 36 101 145 1807
Wrench 75 22 HS 17 HS 17 22 17 14 HS 55
[140723]

61
N2 (Nitrogen) gas pressure by temperature
N2 gas pressure into the back cap

Model Unit -20℃(-4°F) 0℃(32°F) 20℃(68°F) 40℃(104°F)

MPa 0.86 - 1.0 0.9 - 1.1 1.0 - 1.2 1.1 - 1.3
okada150 bar 8.6 - 10 9.3 - 11 10.0 - 12.0 10.7 - 13
psi 125 - 150 135 - 162 145 - 175 155 - 186
MPa 0.86 - 1.0 0.9 - 1.1 1.0 - 1.2 1.1 - 1.3
okada200 bar 8.6 - 10 9.3 - 11 10.0 - 12.0 10.7 - 13
psi 125 - 150 135 - 162 145 - 175 155 - 186
MPa 0.86 - 1.0 0.9 - 1.1 1.0 - 1.2 1.1 - 1.3
okada250 bar 8.6 - 10 9.3 - 11 10.0 - 12.0 10.7 - 13
psi 125 - 150 135 - 162 145 - 175 155 - 186
MPa 0.86 - 1.0 0.9 - 1.1 1.0 - 1.2 1.1 - 1.3
okada400 bar 8.6 - 10 9.3 - 11 10.0 - 12.0 10.7 - 13
psi 125 - 150 135 - 162 145 - 175 155 - 186
MPa 0.86 - 1.0 0.9 - 1.1 1.0 - 1.2 1.1 - 1.3
okada650 bar 8.6 - 10 9.3 - 11 10.0 - 12.0 10.7 - 13
psi 125 - 150 135 - 162 145 - 175 155 - 186
MPa 0.86 - 1.0 0.9 - 1.1 1.0 - 1.2 1.1 - 1.3
okada800 bar 8.6 - 10 9.3 - 11 10.0 - 12.0 10.7 - 13
psi 125 - 150 135 - 162 145 - 175 155 - 186
MPa 0.86 - 1.0 0.9 - 1.1 1.0 - 1.2 1.1 - 1.3
okada900 bar 8.6 - 10 9.3 - 11 10.0 - 12.0 10.7 - 13
psi 125 - 150 135 - 162 145 - 175 155 - 186
MPa 0.86 - 1.0 0.9 - 1.1 1.0 - 1.2 1.1 - 1.3
okada1000 bar 8.6 - 10 9.3 - 11 10.0 - 12.0 10.7 - 13
psi 125 - 150 135 - 162 145 - 175 155 - 186
MPa 0.86 - 1.0 0.9 - 1.1 1.0 - 1.2 1.1 - 1.3
okada1300 bar 8.6 - 10 9.3 - 11 10.0 - 12.0 10.7 - 13
psi 125 - 150 135 - 162 145 - 175 155 - 186
MPa 1.0 - 1.2 1.1 - 1.3 1.2 - 1.4 1.3 - 1.5
okada1500 bar 10 - 12 11 - 13 12 - 14 13.0 - 15.0
psi 150 - 175 163 - 188 175 - 203 189 - 218
MPa 1.0 - 1.2 1.1 - 1.3 1.2 - 1.4 1.3 - 1.5
okada2600 bar 10 - 12 11 - 13 12 - 14 13.0 - 15.0
psi 150 - 175 163 - 188 175 - 203 189 - 218
MPa 1.0 - 1.2 1.1 - 1.3 1.2 - 1.4 1.3 - 1.5
okada3600 bar 10 - 12 11 - 13 12 - 14 13.0 - 15.0
psi 150 - 175 163 - 188 175 - 203 189 - 218
[141030]

62
N2 gas pressure into accumulator
-20℃ 0℃ 20℃ 40℃
Model Unit -4°F 32°F 68°F 104°F
MPa 3.3 - 4.3 3.6 - 4.6 3.9 - 4.9 4.1 - 5.3
okada1000 bar 33 - 43 36 - 46 39 - 49 41 - 53
psi 479 - 624 522 - 667 566 - 711 595 - 769
MPa 4.7 - 5.1 5.0 - 5.5 5.4 - 5.9 5.8 - 6.3
okada1300 bar 47 - 51 50 - 55 54 - 59 58 - 63
psi 676 - 739 730 - 797 783 - 856 836 - 914
MPa 4.7 - 5.1 5.0 - 5.5 5.4 - 5.9 5.8 - 6.3
okada1500 bar 47 - 51 50 - 55 54 - 59 58 - 63
psi 676 - 739 730 - 797 783 - 856 836 - 914
MPa 4.7 - 5.1 5.0 - 5.5 5.4 - 5.9 5.8 - 6.3
okada2600 bar 47 - 51 50 - 55 54 - 59 58 - 63
psi 676 - 739 730 - 797 783 - 856 836 - 914
MPa 4.7 - 5.1 5.0 - 5.5 5.4 - 5.9 5.8 - 6.3
okada3600 bar 47 - 51 50 - 55 54 - 59 58 - 63
psi 676 - 739 730 - 797 783 - 856 836 - 914
[140618]

63
Wear parts
The following items are considered as wear parts needing periodic replacement.
It is recommended for our dealers to stock these parts for complete after-sales service.

1. Working tools
2. Shank bushings and front cap bushings
3. Chisel set pins
4. Seal kits
5. Dumpers
6. Side rod assemblies
7. Hydraulic hoses

Seal kit
It is recommended to replace the seal kit every 500-1000 hours of actual operation as well as a case
when it was stored over 6 months in a storage.

– okada150, 250, 400, 650, 800, 900, 1000, 1300 and 1500 : every 600-1000 hours or 6-12 months
– okada2600 and 3600 : every 500-1000 hours or 6-12 months

Chisel set pin

If the chisel set pin is excessively deformed, it is difficult to extract from the front cap. Therefore,
every 100 to 150 hours of operation, flip the face of each pin (Two faces of each pin can be used).

Remove burrs and swelling using grinder

64
Chisel set pin wear limits

okada150, 250, 400, 650, 900 okada800, 1300, 1500, 2600, 3600

Standard value (A) Wear limits (B)

Model
mm inch mm inch
okada150 22 0.87 20 0.79
okada200 22 0.87 20 0.79
okada250 25 0.98 23 0.91
okada400 30 1.18 28 1.10
okada650 36 1.42 34 1.34
okada800 42 1.65 40 1.57
okada900 37.5 1.48 35.5 1.4
okada1000 37.5 1.48 35.5 1.4
okada1300 36 1.42 34 1.34
okada1500 50 1.97 47 1.85
okada2600 70 2.76 67 2.64
okada3600 95 3.74 92 3.62

Working tool wear limits

Standard value Wear limits (X) Wear limits (Y)

Model
mm inch mm inch mm inch
okada150 40 1.57 38 1.50 36 1.42
okada200 40 1.57 38 1.50 36 1.42
okada250 45 1.77 43 1.69 41 1.61
okada400 57 2.24 55 2.17 53 2.09
okada650 70 2.76 68 2.68 66 2.60
okada800 75 2.95 73 2.87 71 2.80
okada900 80 3.15 78 3.07 76 2.99
okada1000 90 3.46 88 3.46 86 3.39
okada1300 95 3.74 93 3.66 91 3.58
okada1500 105 4.13 103 4.06 101 3.98
okada2600 135 5.31 133 5.24 131 5.16
okada3600 150 5.91 148 5.83 146 5.75

65
Upper damper wear limits

Standard value Wear limits (B)

Model
mm inch mm inch
okada150 — — — —
okada200 — — — —
okada250 54 2.13 52 2.05
okada400 54 2.13 52 2.05
okada650 78 3.07 75 2.95
okada800 78 3.07 75 2.95
okada900 78 3.07 75 2.95
okada1000 78 3.07 75 2.95
okada1300 100 3.94 96 3.78
okada1500 100 3.94 96 3.78
okada2600 110 4.33 106 4.17
okada3600 125 4.92 121 4.76

Bottom damper wear limits

Standard value Wear limits (C)

Model
mm inch mm inch
okada150 — — — —
okada200 — — — —
okada250 20 0.79 18 0.71
okada400 20 0.79 18 0.71
okada650 20 0.79 18 0.71
okada800 20 0.79 18 0.71
okada900 20 0.79 18 0.71
okada1000 20 0.79 18 0.71
okada1300 20 0.79 18 0.71
okada1500 20 0.79 18 0.71
okada2600 20 0.79 18 0.71
okada3600 25 0.98 22 0.87

66
Shank bushing wear limits

Wear limits (D) Wear limits (E)

Model
mm inch mm inch
okada150 5 0.20 — —
okada200 5 0.20 — —
okada250 5 0.20 — —
okada400 5 0.20 — —
okada650 5 0.20 — —
okada800 5 0.20 13 0.51
okada900 6 0.24 13 0.51
okada1000 6 0.24 15 0.59
okada1300 6 0.24 9 0.35
okada1500 6 0.24 14 0.55
okada2600 7 0.28 15 0.59
okada3600 8 0.31 16 0.63

Front cap bushing wear limits

Wear limits (F)

Model
mm inch
okada150 3 0.12
okada200 3 0.12
okada250 3 0.12
okada400 3 0.12
okada650 3 0.12
okada800 3 0.12
okada900 4 0.16
okada1000 4 0.16
okada1300 4 0.16
okada1500 4 0.16
okada2600 5 0.20
okada3600 6 0.24
Note: Refer to page 14 for detail.

67
Stopper pin wear limits

Standard diaphragm (G) Wear limits (H)

Model
mm inch mm inch
okada150 10 0.39 8 0.31
Okada200 10 03.9 8 0.31
okada250 10 0.39 8 0.31
okada400 10 0.39 8 0.31
okada650 10 0.39 8 0.31
okada800 15 0.59 13 0.51
okada900 10 0.39 8 0.31
okada1000 10 0.39 8 0.31
okada1300 17.5 0.69 15.5 0.61
okada1500 17.5 0.69 15.5 0.61
okada2600 17.5 0.69 15.5 0.61
okada3600 21.5 0.85 19.5 0.77

Shell pad wear limits

Standard Wear limits Standard Wear limits

Model value (J) value (K)
mm inch mm inch mm inch mm inch
okada150 — — — — — — — —
Okada200 — — — — — — — —
okada250 106 4.17 109 4.29 106 4.17 109 4.29
okada400 114 4.49 117 4.61 135 5.31 138 5.43
okada650 132 5.20 135 5.31 142 5.59 145 5.71
okada800 152 5.98 155 6.10 162 6.38 165 6.50
okada900 167 6.57 170 6.69 172 6.77 175 6.89
okada1000 177 6.97 180 7.09 177 6.97 180 7.09
okada1300 202 7.95 205 8.07 202 7.95 205 8.07
okada1500 222 8.74 225 8.86 222 8.74 225 8.86
okada2600 252 9.92 255 10.04 252 9.92 255 10.04
okada3600 302 11.89 305 12.01 302 11.89 305 12.01
68
Unit conversion table
Length
m cm in ft yd
1 100 39.37 3.281 1.094
0.01 1 0.3937 0.03281 0.01094
0.0254 2.540 1 1/12 1/36
0.3048 30.48 12 1 1/3
0.9144 91.44 36 3 1

Area
m2 in2 ft2 yd2
1 1550 10.76 1.196
-3
0.6452X10 1 1/144 1/1296
0.09290 144 1 1/9
0.8361 1296 9 1

Cubic volume
m3 c.c. (cm3) in3 yd3 L(litter) gal (UK) gal (US)
1 106 6.102X104 1.308 1000 220.0 264.2
-6 -2 -5 -3
10 1 6.102X10 0.1308X10 0.001 0.220X10 0.2642X10-3
0.1639X10-4 16.39 1 1/46656 0.01639 0.3605X10-2 1/231
0.7646 7.646X105 46656 1 764.5 168.2 201.99
-3
0.001 1000 61.02 1.308X10 1 0.2200 0.2642
0.4546X10-2 4546 277.4 5.945X10-3 4.546 1 1.201
-2 -3
0.3785X10 3785 231 4.951X10 3.785 0.8327 1

Weight
kg oz lb ton (metric) ton (UK) ton (US)
1 35.27 2.205 0.001 0.9842X10-3 0.1102X10-2
0.6480X10-4 0.2286X10-2 1/7000 0.6480X10-7 0.6378X10-7 0.7143X10-7
0.02835 1 1/16 0.2835X10-4 0.2790X10-4 1/32000
0.4536 16 1 0.4536X10-3 1/2240 1/2000
1000 35274 2205 1 0.9842 1.102
1016 35840 2240 1.016 1 1.12
907.2 32000 2000 0.9072 0.8929 1

69
Pressure
Pa (N/m2) bar kgf/cm2 psi atm Torr (mmHg)
-5 -4 -3 -5
1 10 0.1020X10 0.1450X10 0.9869X10 0.7501X10-2
10-3 10-8 0.1020X10-7 0.1450X10-6 0.9869X10-8 0.7501X10-5
105 1 1.020 14.50 0.9869 750.1
9.807X104 0.9807 1 14.22 0.9678 735.6
3
6.895X10 0.06895 0.07031 1 0.06805 51.71
101325 1.01325 1.033 14.696 1 760
-2 -2
133.3 0.1333X10 0.1360X10 0.01934 1/760 1

Temperature
K °C °F
t t-273.15 (t-273.15) 9/5+32
t+273.15 t t 9/5+32
(t-32) 5/9+273.15 (t-32) 5/9 t
t 5/9 t 5/9-273.15 t-459.67

Power
PS HP KW kgfm/sec Kcal/h
1 0.986 0.736 75.0 633
1.01 1 0.746 76.1 642
1.36 1.34 1 102 860

Torque
J (Nm) kgfm ftlb
1 1.0197X10-1 7.3746X10-1
9.80665 1 7.2346
1.35552 1.3822X10-1 1

70
Thread standard

○ JIS B 8363 Parallel Pipe Threads (PF)

OKADA Male thread O.D. Female thread I.D.

Inch size Thread
size mm inch mm inch
NPF03 1/8 1/8-28 9.7 0.38 8.6 0.34
NPF06 1/4 1/4-19 13.2 0.52 11.4 0.45
NPF09 3/8 3/8-19 16.7 0.66 15.0 0.59
NPF13 1/2 1/2-14 21.0 0.83 18.6 0.73
NPF19 3/4 3/4-14 26.4 1.04 24.1 0.95
NPF25 1 1-11 33.2 1.31 30.3 1.19
NPF32 11/4 11/4-11 41.9 1.65 39.0 1.54
NPF38 11/2 11/2-11 47.8 1.88 44.8 1.76
NPF50 2 2 59.6 2.35 56.7 2.23

○ SAE J514, 37° Flare

OKADA JIC Inch Male thread O.D. Female thread I.D.

Thread
size size size mm inch mm inch
UNF03 JIC2 1/8 5/16-2 7.9 0.31 6.9 0.27
UNF06 JIC4 1/4 4
7/16-2 11.2 0.44 9.9 0.39
UNF09 JIC6 3/8 0
9/16-1 14.2 0.56 12.9 0.51
UNF13 JIC8 1/2 8
3/4-16 19.0 0.75 17.0 0.67
UNF15 JIC10 5/8 7/8-14 22.3 0.88 20.3 0.80
UNF19 JIC12 3/4 11/16-1 26.9 1.06 24.9 0.98
UNF25 JIC16 1 15/216-1 33.3 1.31 31.0 1.22
UNF32 JIC20 11/4 15/82-12 41.4 1.63 39.1 1.54
UNF38 JIC24 11/2 17/8-12 47.7 1.88 45.5 1.79
UNF50 JIC32 2 21/2-12 63.5 2.50 61.2 2.41

71
○ JIS B 8363 Parallel Pipe Threads (PF)
○ British Standard Pipe - BSPP

OKADA Male thread O.D. Female thread I.D.

Inch size Thread
size mm inch mm inch
NSF03 1/8 1/8-28 9.7 0.38 8.6 0.34
NSF06 1/4 1/4-19 13.2 0.52 11.4 0.45
NSF09 3/8 3/8-19 16.7 0.66 15.0 0.59
NSF13 1/2 1/2-14 21.0 0.83 18.6 0.73
NSF19 3/4 3/4-14 26.4 1.04 24.1 0.95
NSF25 1 1-11 33.2 1.31 30.3 1.19
NSF32 11/4 11/4-11 41.9 1.65 39.0 1.54
NSF38 11/2 11/2-11 47.8 1.88 44.8 1.76
NSF50 2 2 59.6 2.35 56.7 2.23

○ SAE J1453 O-Ring Face Seal

OKADA Male thread O.D. Female thread I.D.

Inch size Thread
size mm inch mm inch
ORS06 1/4 9/16-18 14.2 0.56 12.9 0.51
ORS09 3/8 11/16-16 17.3 0.68 16.0 0.63
ORS13 1/2 13/16-16 20.6 0.81 19.0 0.75
ORS15 5/8 1-14 25.4 1.00 23.6 0.93
ORS19 3/4 13/16-12 30.0 1.18 27.8 1.10
ORS25 1 17/16-12 36.6 1.44 34.5 1.36
ORS32 11/4 111/16-12 42.7 1.68 40.6 1.60
ORS38 11/2 2-12 50.8 2.00 48.8 1.92

72
○ JIS B 8363 Tapered Pipe Threads (PT)
○ British Standard pipe - BSPT

OKADA Male thread O.D. Female thread I.D.

Inch size Thread
size mm inch mm inch
PT03 1/8 1/8-28 9.7 0.38 8.6 0.34
PT06 1/4 1/4-19 13.2 0.52 11.4 0.45
PT09 3/8 3/8-19 16.7 0.66 15.0 0.59
PT13 1/2 1/2-14 21.0 0.83 18.6 0.73
PT19 3/4 3/4-14 26.4 1.04 24.1 0.95
PT25 1 1-11 33.2 1.31 30.3 1.19
PT32 11/4 11/4-11 41.9 1.65 39.0 1.54
PT38 11/2 11/2-11 47.8 1.88 44.8 1.76
PT50 2 2 59.6 2.35 56.7 2.23

○ American Dryseal Pipe Threads (NPT)

OKADA Male thread O.D. Female thread I.D.

Inch size Thread
size mm inch mm inch
NPT03 1/8 1/8-27 10.3 0.41 9.4 0.37
NPT06 1/4 1/4-18 13.7 0.54 12.4 0.49
NPT09 3/8 3/8-18 17.3 0.68 15.7 0.62
NPT13 1/2 1/2-14 21.3 0.84 19.3 0.76
NPT19 3/4 3/4-14 26.9 1.06 24.9 0.98
NPT25 1 1-111/2 33.3 1.31 31.5 1.24
NPT32 11/4 11/4-111/2 42.2 1.66 40.1 1.58
NPT38 11/2 11/2-111/2 48.3 1.90 46.2 1.82
NPT50 2 2-111/2 60.4 2.38 57.9 2.28

73
○ JIS B 2351 Parallel Pipe Threads (G)

OKADA Male thread O.D. Female thread I.D.

Inch size Thread
size mm inch mm inch
PFO03 1/8 1/8-28 9.7 0.38 8.6 0.34
PFO06 1/4 1/4-19 13.2 0.52 11.4 0.45
PFO09 3/8 3/8-19 16.7 0.66 15.0 0.59
PFO13 1/2 1/2-14 21.0 0.83 18.6 0.73
PFO19 3/4 3/4-14 26.4 1.04 24.1 0.95
PFO25 1 1-11 33.2 1.31 30.3 1.19
PFO32 11/4 11/4-11 41.9 1.65 39.0 1.54
PFO38 11/2 11/2-11 47.8 1.88 44.8 1.76
PFO50 2 2 59.6 2.35 56.7 2.23

○ SAE J514, Straight Thread O-Ring Boss

OKADA Inch Male thread O.D. Female thread I.D.

JIC size Thread
size size mm inch mm inch
UNFO03 2 1/8 5/16-24 7.9 0.31 6.9 0.27
UNFO06 4 1/4 7/16-20 11.2 0.44 9.9 0.39
UNFO09 6 3/8 9/16-18 14.2 0.56 12.9 0.51
UNFO13 8 1/2 3/4-16 19.0 0.75 17.0 0.67
UNFO15 10 5/8 7/8-14 22.3 0.88 20.3 0.80
UNFO19 12 3/4 11/16-12 26.9 1.06 24.9 0.98
UNFO25 16 1 15/16-12 33.3 1.31 31.0 1.22
UNFO32 20 11/4 15/8-12 41.4 1.63 39.1 1.54
UNFO38 24 11/2 17/8-12 47.7 1.88 45.5 1.79
UNFO50 32 2 21/2-12 63.5 2.50 61.2 2.41

74
Blank page

75
OKADA HYDRAULIC BREAKERS

PARTS LIST

140618

76
Exploded View
okada150

77
Breaker Body Parts List
okada150
No. Parts No. Part Name Q’ty Remarks No. Parts No. Part Name Q’ty Remarks
1 HB015A0010 Cylinder 1 33 HB015AP330 Point chisel 1
2 HB015A0020 Dust seal 1 33 HB015AX330 Cross cut chisel 1
3 HB015A0030 U-packing 1 33 HB015AE330 Flat end chisel 1
4 HB015A0040 Buffer-ring 1
5 HB015H0060 Adapter 2 HB025A1010 Valve assy 1 15,16,17,18,19
6 HB015H0070 Dust cap 2 HB015A1020 Side rod assy 4 27,28,29
7 HB260A0100 O-ring 2 HB260A1040 Gas valve body assy 1 32,33,34
2,3,4,7,9,10,13,14,15,19,2
8 HB015A0080 Plug 2 HB015A10C0 Seal kit 1 0,37,38
9 HB260A0120 O-ring 5
10 HB015A0100 Back up ring 2
11 HB015A0110 Piston 1
12 HB015A0120 Cylinder sleeve 1
13 HB015A0130 X-ring 1
14 HB015A0140 Step seal 2
15 HB150A0230 O-ring 3
16 HB025A0150 Valve 1
17 HB025A0160 Valve liner 1
18 HB025A0170 Valve plug 1
19 HB025A0180 O-ring 1
20 HB025A0190 O-ring 1
21 HB015A0210 Front cap 1
22 HB015A0220 Front cap bushing 1
23 HB015A0230 Spring pin 1
24 HB025A0260 Grease nipple 1
25 HB015A0250 Chisel set pin 1
26 HB015A0260 Shaft 1
27 HB025A0290 Spring 1
28 HB025A0300 Pin 1
29 HB260A0370 Plug 1
30 HB015A0300 Side rod 4
31 HB015A0310 Back nut washer 4
32 HB015A0320 Back nut 4
34 HB015A0340 Back cap 1
35 HB260A0450 Gas valve 1
36 HB260A0470 Cover cap 1
37 HB260A0480 O-ring 1
38 HB260A0460 O-ring 1
39 HB260A0110 Plug 3

130225

78
Bracket Exploded View
okada150 Vertical bracket

79
Parts List
okada150 Vertical bracket

No. Parts No. Part Name Q’ty Remarks

1 HB015B0010 Bracket 1
2 HB015H0020 Bottom holder 2
3 HB020H0030 Upper holder 2
4 HB015B0040 Top bracket 1
5 HB015B0050 Bolt 6
6 HB015B0060 Spring washer 6
7 HB015H0061 Adapter, NSF09 2
8 HB015H0071 Dust cap, NSF09 2
9 HB015B0090 Bolt 8
10 HB015B0100 Spring washer 8
11 HB015B0110 Nut 8
12 HB015H0081 Hydraulic hose, NSF09 2
13 Pin 2
14 Bushing 4
15 Collar 2
16 HB015H0120 Bolt 2
17 HB015H0130 Nut 4

130809

80
Exploded View
okada200

81
Breaker Body Parts List
okada200
No. Parts No. Part Name Q’ty Remarks No. Parts No. Part Name Q’ty Remarks
1 HB020A0010 Cylinder 1 HB025A1010 Valve assy 1 15, 16, 17, 18, 19
2 HB015A0020 Dust seal 1 HB020A1020 Side rod assy 4 32, 33, 34
3 HB015A0030 U-packing 1 HB260A1040 Gas valve body assy 1 6, 37, 38, 39
2, 3, 4, 7, 9, 10, 13, 14,
4 HB015A0040 Buffer-ring 1 HB020A10C0 Seal kit 1 15, 19, 20, 39
5 HB020H0080 Nipple 2
6 HB020H0090 Dust cap 2
7 HB260A0460 O-ring 3
8 HB015A0080 Plug 3
9 HB260A0120 O-ring 3
10 HB015A0100 Back up ring 3
11 HB020A0110 Piston 1
12 HB020A0120 Cylinder sleeve 1
13 HB020A0130 X-ring 1
14 HB015A0140 Step seal 2
15 HB020A0150 O-ring 3
16 HB025A0150 Valve 1
17 HB025A0160 Valve liner 1
18 HB025A0170 Valve plug 1
19 HB025A0180 O-ring 1
20 HB025A0190 O-ring 1
23 HB020A0230 Front cap 1
24 HB015A0220 Front cap bushing 1
25 HB025A0250 Shaft 1
26 HB025A0260 Grease nipple 1
27 HB015A0250 Chisel set pin 1
28 HB025A0280 Shaft 1
29 HB025A0290 Spring 1
30 HB025A0300 Pin 1
31 HB260A0370 Plug 1
32 HB020A0320 Side rod 4
33 HB025A0330 Back nut washer 4
34 HB025A0340 Back nut 4
36 HB020A0360 Back cap 1
37 HB260A0450 Gas valve 1
38 HB260A0470 Cover cap 1
39 HB260A0480 O-ring 1

35 HB015AP330 Point chisel 1

35 HB015AX330 Cross cut chisel 1
35 HB015AE330 Flat end chisel 1 140408

82
Bracket Exploded View
okada200

83
Parts List
okada200

No. Parts No. Part Name Q’ty Note

1 HB020B0010 Bracket 1
2 HB020H0020 Bottom holder 2
3 HB020H0030 Upper holder 2
4 HB020B0040 Top bracket 1
5 HB020H0040 Bolt 4
6 HB020H0050 Spring washer 4
7 HB015H0050 Bolt 2
8 HB015H0050 Spring washer 2
9 HB025A0040 Nipple 2
10 HB025A0050 Dust cap 2
11 HB015B0090 Bolt 8
12 HB015B0100 Spring washer 8
13 HB035B0060 Nut 8
14 HB020H0101 Hydraulic hose 2
15 Bracket pin 2
16 Bush 4
17 Stop ring 2
18 HB015H0120 Bolt 2
19 HB015H0130 Nut 4

84
Exploded View
okada250

85
Breaker Body Parts List
okada250
No. Parts No. Part Name Q’ty Remarks No. Parts No. Part Name Q’ty Remarks
1 HB025A0010 Cylinder 1 35 HB025AP350 Point chisel 1
2 HB025A0020 Dust seal 1 35 HB025AX350 Cross cut chisel 1
3 HB025A0030 U-packing 1 35 HB025AE350 Flat end chisel 1
4 HB020H0080 Nipple 2
5 HB020H0090 Dust cap 2 HB025A1010 Valve assy 1 15,16,17,18,19
6 HB260A0460 O-ring 3 HB025A1020 Side rod assy 4 32,33,34
7 HB260A0110 Plug 6 HB260A1040 Gas valve body assy 1 6,37,38,39
2,3,6,8,12,13,14,18,19
8 HB260A0120 O-ring 6 HB025A10C0 Seal kit 1 ,39
10 HB025A0100 Piston 1
11 HB025A0110 Cylinder sleeve 1
12 HB025A0120 X-ring 1
13 HB025A0130 Step seal 2
14 HB025A0140 O-ring 3
15 HB025A0150 Valve 1
16 HB025A0160 Valve liner 1
17 HB025A0170 Valve plug 1
18 HB025A0180 O-ring 1
19 HB025A0190 O-ring 1
23 HB025A0230 Front cap 1
24 HB025A0240 Front cap bushing 1
25 HB025A0250 Shaft 1
26 HB025A0260 Grease nipple 1
27 HB025A0270 Chisel set pin 1
28 HB025A0280 Shaft 1
29 HB025A0290 Spring 1
30 HB025A0300 Pin 1
31 HB260A0370 Plug 1
32 HB025A0320 Side rod 4
33 HB025A0330 Back nut washer 4
34 HB025A0340 Back nut 4
36 HB025A0360 Back cap 1
37 HB260A0450 Gas valve 1
38 HB260A0470 Cover cap 1
39 HB260A0480 O-ring 1

130201

86
Bracket Exploded View
okada250

87
Parts List
okada250

No. Parts No. Part Name Q’ty Note

1 HB025B0010 Bracket 1
2 HB025B0020 Bottom damper 1
3 HB025B0030 Head damper 1
4 HB025B0040 Plate 1
5 HB025B0050 Bolt 2
6 HB025B0060 Nut 4
7 HB025B0070 Pad 4
8 HB025B0080 Pad 3
9 HB260B0100 O-ring 11
10 HB025B0100 Pad 1
11 HB025B0110 Pad 1
12 HB025B0120 Cover 1
13 HB025B0130 Cover 1
14 HB025B0140 Cover 1
15 HB025B0150 Hose boots 1
16 HB025B0160 Bolt 4
17 HB025B0170 Spring washer 4
18 Hydraulic hose 2

130201

88
Exploded View
okada400

89
Breaker Body Parts List
okada400
No. Parts No. Part Name Q’ty Remarks No. Parts No. Part Name Q’ty Remarks

1 HB035A0010 Cylinder 1 31 HB040AP370 Point chisel

2 HB035A0020 Dust seal 1 31 HB040AX370 Cross cut chisel
3 HB035A0030 U-packing 1 31 HB040AY370 In line chisel
4 HB020H0080 Nipple 2 31 HB040AE370 Flat end chisel
5 HB020H0090 Dust cap 2
6 HB260A0460 O-ring 3 HB035A1010 Valve assy 1 14,15,16,17,18
7 HB260A0110 Plug 5 HB035A1020 Side rod assy 4 28,29,30
8 HB260A0120 O-ring 5 HB260A1040 Gas valve body assy 1 6,33,34,35
2,3,6,8,11,12,13,17,18
9 HB035A0090 Piston 1 HB035A10C0 Seal kit 1 ,35
10 HB035A0100 Cylinder sleeve 1
11 HB035A0110 X-ring 1
12 HB035A0120 U-packing 2
13 HB035A0130 O-ring 3
14 HB035A0140 Valve 1
15 HB035A0150 Valve 1
16 HB035A0160 Valve plug 1
17 HB035A0170 O-ring 1
18 HB065A0220 O-ring 1
19 HB035A0190 Front cap 1
20 HB040A0260 Front cap bushing 1
21 HB025A0250 Shaft 1
22 HB025A0260 Grease nipple 1
23 HB040A0290 Chisel set pin 1
24 HB025A0280 Shaft 1
25 HB025A0290 Spring 1
26 HB025A0300 Pin 1
27 HB260A0370 Plug 1
28 HB035A0280 Side rod 4
29 HB035A0290 Back nut washer 4
30 HB035A0300 Back nut 4
32 HB035A0310 Back cap 1
33 HB260A0450 Gas valve 1
34 HB260A0470 Cover cap 1
35 HB260A0480 O-ring 1

130201

90
Bracket Exploded View
okada400 Vertical bracket

91
Parts List
okada400 Vertical bracket

No. Parts No. Part Name Q’ty Remarks

1 HB035B0011 Bracket 1
2 HB035B0020 Bottom damper 1
3 HB025B0030 Head damper 1
4 HB035B0040 Top bracket 1
5 HB035B0050 Bolt 12
6 HB035B0060 Nut 12
7 HB025B0070 Pad 4
8 HB035B0110 Pad 1
9 HB035B0100 Pad 1
10 HB260B0100 O-ring 11
11 HB025B0130 Cover 1
12 HB025B0140 Cover 1
13 HB025B0150 Hose boots 1
14 HB025B0080 Pad 3
15 HB020H0101 Hydraulic hose, NSF13 2
16 HB025B0160 Bolt 4
17 HB025B0171 Spring washer 4
18 Pin 2
19 Bushing 4
20 Collar 2
21 HB025H0130 Bolt 2
22 HB015H0130 Nut 4
23 HB015B0100 Spring washer 12
24 HB040B0110 Cover 1
25 HB025B0190 Adapter 2
26 HB020H0091 Dust cap, NSF13 2

130813

92
Exploded View
okada650

93
Breaker Body Parts List
okada650
No. Parts No. Part Name Q’ty Remarks No. Parts No. Part Name Q’ty Remarks
1 HB055A0010 Cylinder 1 37 HB065A0370 Back nut washer 4
2 HB065A0020 Dust seal 1 38 HB065A0380 Back nut 4
3 HB065A0030 U-packing 1 40 HB065A0400 Back cap 1
4 HB025A0040 Nipple 2 41 HB260A0450 Gas valve 2
5 HB025A0050 Dust cap 2 42 HB260A0470 Cover cap 2
6 HB260A0460 O-ring 5 43 HB260A0480 O-ring 2
7 HB065A0070 Plug 1
9 HB260A0100 O-ring 1 39 HB065AP390 Point chisel
10 HB260A0110 Plug 5 39 HB065AX390 Cross cut chisel
11 HB260A0120 O-ring 5 39 HB065AY390 In line chisel
13 HB065A0130 Piston 1 39 HB065AE390 Flat end chisel
14 HB065A0140 Cylinder sleeve 1
15 HB065A0150 X-ring 1 HB055A1010 Valve assy 1 18,19,20,21,22
16 HB065A0160 U-packing 1 HB065A1020 Side rod assy 4 36,37,38
16-1 HB065A2160 Slide seal 1 HB260A1040 Gas valve body assy 2 6,41,42,43
2,3,6,9,11,15,16,16-1,
17 HB040A0160 O-ring 3 HB055A10C0 Seal kit 1 17,21,22,43
18 HB055A0180 Valve 1 HB260A2040 Gas charging kit 2
19 HB055A0190 Valve liner 1
20 HB055A0200 Valve plug 1
21 HB065A0210 O-ring 1
22 HB065A0220 O-ring 1
26 HB065A0260 Front cap 1
27 HB065A0270 Front cap bushing 1
28 HB065A0280 Shaft 1
29 HB260A0340 Shaft retainer 2
30 HB260B0220 Grease nipple 1
31 HB065A0310 Chisel set pin 1
32 HB065A0320 Shaft 1
33 HB025A0290 Spring 1
34 HB065A0340 Pin 1
35 HB065A0350 Plug 1
36 HB065A0360 Side rod 4

130201

94
Bracket Exploded View
okada650

95
Parts List
okada650

No. Parts No. Part Name Q’ty Remarks

1 HB055B0010 Bracket 1
2 HB055B0020 Bottom damper 2
3 HB055B0030 Head damper 3
4 HB055B0040 Plate 4
5 HB055B0050 Bolt 5
6 HB055B0060 Nut 6
7 HB055B0070 Pad 7
8 HB055B0080 Pad 8
9 HB055B0090 O-ring 9
10 HB055B0100 Pad 10
11 HB055B0110 Head plate 11
12 HB055B0120 Damper 12
13 HB055B0130 Cover 13
14 HB055B0140 Cover 14
15 HB055B0150 Cover 15
16 HB055B0160 Cover 16
17 HB055B0170 Bolt 17
18 HB055B0180 Bolt 18
19 HB055B0190 Spring washer 19
20 HB055B0200 Hose boots 20
21 HB055B0210 Hydraulic hose 21

130201

96
Exploded View
okada800

97
Breaker Body Parts List
okada800
No. Parts No. Part Name Q’ty Remarks No. Parts No. Part Name Q’ty Remarks
1 HB082A0010 Cylinder 1 42 HB260A0450 Gas valve 2
2 HB080A0020 Dust seal 1 43 HB260A0470 Cover cap 2
3 HB080A0030 U-packing 1 44 HB260A0480 O-ring 1
4 HB080A0040 Nipple 2
5 HB080A0050 Dust cap 2 40 HB080AP400 Point chisel 1
6 HB260A0460 O-ring 5 40 HB080AX400 Cross cut chisel 1
7 HB065A0070 Plug 2 40 HB080AE400 Flat end chisel 1
9 HB260A0100 O-ring 1
10 HB260A0110 Plug 6 HB080A1010 Valve assy 1 17,18,19,20,21
11 HB260A0120 O-ring 6 HB080A1020 Side rod assy 4 37,38,39
12 HB082A0120 Piston 1 HB260A1040 Gas valve body assy 1 6,42,43,44
2,3,6,9,11,14,15,16,20
13 HB080A0130 Cylinder sleeve 1 HB080A10C0 Seal kit 1 ,21,44
14 HB080A0140 X-ring 1
15 HB080A0150 Step seal 2
16 HB080A0160 O-ring 3
17 HB080A0170 Valve 1
18 HB080A0180 Valve liner 1
19 HB080A0190 Valve plug 1
20 HB080A0200 O-ring 1
21 HB065A0220 O-ring 1
26 HB080A0260 Front cap 1
27 HB080A0270 Shank bushing 1
28 HB080A0280 Front cap bushing 1
29 HB065A0280 Shaft 2
30 HB260A0340 Shaft retainer 3
31 HB260B0220 Grease nipple 1
32 HB080A0320 Chisel set pin 2
33 HB080A0330 Shaft 1
36 HB065A0350 Plug 1
37 HB080A0370 Side rod 4
38 HB065A0370 Back nut washer 4
39 HB065A0380 Back nut 4
41 HB080A0410 Back cap 1

130201

98
Bracket Exploded View
okada800

99
Parts List
okada800

No. Parts No. Part Name Q’ty Remarks

1 HB080B0011 Bracket 1
2 HB080B0020 Bottom damper 1
3 HB080B0030 Head damper 1
4 HB080B0041 Top bracket 1
5 HB080B0051 Bolt 12
6 HB080B0060 Nut 12
7 HB080B0070 Pad 6
8 HB080B0081 Pad 2
9 HB260A0460 O-ring 15
10 HB080B0101 Head plate 1
11 HB080B0110 Damper 1
12 HB080B0120 Cover 4
13 HB080B0130 Cover 3
14 HB025B0140 Cover 1
15 HB080B0151 Cover 1
16 HB080B0160 Hose boots 2
17 HB080B0170 Bolt 4
18 HB025B0160 Bolt 4
19 HB025B0170 Spring washer 4
20 HB080B0201 Pad 2
21 HB080B0211 Hydraulic hose 2
22 HB080B0220 Washer 24
23 HB025B0070 Pad 1
24 Bush 4
25 Pin 2
26 Collar 2
27 HB080B0270 Bolt 2
28 HB080B0280 Nut 4
29 HB080B0290 Adapter 2
30 HB080B0300 Dust cap 2

130812

100
Exploded View
okada900

101
Breaker Body Parts List
okada900
No. Parts No. Part Name Q’ty Remarks No. Parts No. Part Name Q’ty Remarks
1 HB090A0010 Cylinder 1 40 HB090AP400 Point chisel 1
2 HB090A0020 Dust seal 1 40 HB090AX400 Cross cut chisel 1
3 HB090A0030 U-packing 1 40 HB090AE400 Flat end chisel 1
4 HB090A0040 Buffer-ring 1
5 HB150B0320 Adapter 2 - HB090A1010 Valve assy 1 17,18,19,20,46
6 HB080B0300 Dust cap 2 - HB360A1020 Adjuster assy 1 7,21,22,23,24
7 HB260A0140 O-ring 3 - HB090A1030 Side rod assy 4 37,38,39
8 HB065A0070 Plug 2 - HB260A1040 Gas valve body assy 1 9,42,43,44
2,3,4,7,9,11,14,15,
9 HB260A0460 O-ring 3 - HB090A10C0 Seal kit 1 16,20,22,36,44,46
10 HB260A0110 Plug 6
11 HB260A0120 O-ring 6
12 HB090A0120 Piston 1
13 HB090A0130 Cylinder sleeve 1
14 HB090A0140 X-ring 1
15 HB090A0150 Step seal 2
16 HB090A0160 O-ring 3
17 HB100A0170 Valve 1
18 HB100A0180 Valve liner 1
19 HB090A0190 Valve plug 1
20 HB080A0200 O-ring 1
21 HB360A0280 Adjuster 1
22 HB260A0270 O-ring 1
23 HB360A0300 Adjuster case 1
24 HB260A0290 Nut 1
25 HB090A0250 Front cap 1
26 HB090A0260 Shank bushing 1
27 HB090A0270 Front cap bush 1
28 HB090A0280 Shaft 2
29 HB260A0340 Shaft retainer 2
30 HB260B0220 Grease nipple 1
31 HB100A0310 Chisel set pin 1
32 HB065A0320 Shaft 1
33 HB025A0290 Spring 1
34 HB065A0340 Pin 1
35 HB065A0350 Plug 1
36 HB260A0100 O-ring 1
37 HB090A0370 Side rod 4
38 HB100A0380 Buck nut washer 4
39 HB100A0390 Back nut 4
41 HB090A0410 Back cap 1
42 HB260A0450 Gas valve 1
43 HB260A0470 Cover cap 1
44 HB260A0480 O-ring 1
45 HB260A0150 Pin 2
46 HB100A0550 O-ring 1

102
Bracket Exploded View
okada900

103
Parts List
okada900
No. Parts No. Part Name Q’ty Remarks
1 HB090B0010 Bracket 1
2 HB090B0020 Bottom damper 1
3 HB090B0030 Head damper 1
4 HB090B0040 Top bracket 1
5 HB025B0050 Bolt 16
6 HB035B0060 Nut 16
7 HB090B0070 Pad 8
8 HB260B0100 O-ring 18
9 HB090B0090 Pad 2
10 HB090B0100 Head plate 1
11 HB080B0110 Damper 1
12 HB080B0120 Cover 1
13 HB025B0120 Cover 2
14 HB025B0140 Cover 1
15 HB090B0150 Cover 1
16 HB080B0160 Hose boots 2
17 HB090B0170 Bolt 4
18 HB090B0180 Bolt 4
19 HB090B0190 Spring washer 4
20 HB150B0240 Grease hose 2
21 HB090B0210 Washer 16
22 Bushing 4
23 Pin 2
24 Collar 2
25 HB080B0270 Bolt 2
26 HB080T0110 Nut 4
27 HB150B0320 Adapter 2
28 HB080B0300 Dust cap 2

104
Exploded View
okada1000

105
Breaker Body Parts List
okada1000
No. Parts No. Part Name Q’ty Remarks No. Parts No. Part Name Q’ty Remarks
1 HB100A0010 Cylinder 1 47 HB100A0470 Accumulator body 1
2 HB100A0020 Dust seal 1 48 HB100A0480 Bladder 1
3 HB100A0030 U-packing 1 50 HB065A0480 O-ring 1
4 HB100A0040 Buffer-ring 1 51 HB065A0490 Back up ring 1
5 HB100A0050 Nipple 2 52 HB065A0500 Spring washer 4
6 HB080A0050 Dust cap 2 53 HB100A0530 Cap screw 4
7 HB260A0140 O-ring 3 54 HB065A0520 Cap screw 8
8 HB065A0070 Plug 1 55 HB100A0550 O-ring 1
9 HB260A0460 O-ring 3 56 HB065A0540 Valve 1
10 HB260A0110 Plug 9 57 HB065A0550 Nut 1
11 HB260A0120 O-ring 9 58 HB065A0560 Pin 1
12 HB100A0120 Piston 1
13 HB100A0130 Cylinder sleeve 1 40 HB100AP400 Point chisel 1
14 HB100A0140 X-ring 1 40 HB100AX400 Cross cut chisel 1
15 HB100A0150 Step seal 2 40 HB100AE400 Flat end chisel 1
16 HB100A0160 O-ring 3
17 HB100A0170 Valve 1 - HB100A1010 Valve assy 1 17,18,19,20,55
18 HB100A0180 Valve liner 1 - HB260A1020 Adjuster assy 1 7,21,22,23,24
19 HB100A0190 Valve plug 1 - HB100A1030 Side rod assy 4 37,38,39
20 HB080A0200 O-ring 1 - HB260A1040 Gas valve body assy 2 9,42,43,44
9,42,43,44,46,47,48,50,
21 HB260A0260 Adjuster 1 - HB100A1050 Accumulator 1 51,52,53,54,56,57,58
22 HB260A0270 O-ring 1 - HB065A1050 Acc calce assy 1 56,57,58
2,3,4,7,9,11,14,15,16,2
23 HB260A0280 Adjuster case 1 - HB100A10C0 Seal kit 1 0,22,36,44,50,51,55,
24 HB260A0290 Nut 1
25 HB100A0250 Front cap 1
26 HB100A0260 Shank bushing 1
27 HB100A0270 Front cap bushing 1
28 HB100A0280 Shaft 2
29 HB260A0340 Shaft retainer 2
30 HB260B0220 Grease nipple 1
31 HB100A0310 Chisel set pin 1
32 HB065A0320 Shaft 1
33 HB025A0290 Spring 1
34 HB065A0340 Pin 1
35 HB065A0350 Plug 1
36 HB260A0100 O-ring 1
37 HB100A0370 Side rod 4
38 HB100A0380 Back nut washer 4
39 HB100A0390 Back nut 4
41 HB100A0410 Back cap 1
42 HB260A0450 Gas valve 2
43 HB260A0470 Cover cap 2
44 HB260A0480 O-ring 2
45 HB260A0150 Pin 2
46 HB100A0460 Accumulator cover 1

106
Bracket Exploded View
okada1000

107
Parts List
okada1000
No. Parts No. Part Name Q’ty Remarks
1 HB100B0010 Bracket 1
2 HB100B0020 Bottom dumper 1
3 HB100B0030 Upper damper 1
4 HB100B0040 Top bracket 1
5 HB100B0050 Bolt 16
6 HB025B0060 Nut 16
7 HB100B0070 Pad 8
8 HB260B0100 O-ring 18
9 HB100B0090 Pad 1
10 HB100B0100 Head plate 1
11 HB080B0110 Damper 1
12 HB080B0120 Cover 1
13 HB260B0140 Cover 2
14 HB025B0140 Cover 1
15 HB100B0150 Cover 1
16 HB080B0160 Hose boots 2
17 HB100B0170 Bolt 4
18 HB100B0180 Bolt 4
19 HB100B0190 Spring washer 4
20 HB080B0210 Hydraulic hose 2
21 HB100B0210 Washer 16
22 Bush 4
23 Pin 2
24 Collar 2
25 HB080B0270 Bolt 2
26 HB080T0110 Nut 4
27 HB100A0050 Nipple 2
28 HB080A0050 Dust cap 2

108
Exploded View
okada1300

109
Breaker Body Parts List
okada1300
No. Parts No. Part Name Q’ty Remarks No. Parts No. Part Name Q’ty Remarks
1 HB130A0010 Cylinder 1 47 HB150A0480 Accumulator cover 1
2 HB130A0020 Dust seal 1 48 HB150A0470 Accumulator body 1
3 HB130A0030 U-packing 1 49 HB150A0490 Seal 1
4 HB130A0040 Buffer-ring 1 51 HB150A0510 Bladder 1
5 HB150B0320 Adapter 2 52 HB150A0520 Valve 1
6 HB080B0300 Dust cap 2 53 HB260A0550 Nut 1
7 HB260A0140 O-ring 4 54 HB260A0560 Pin 1
8 HB130A0080 Plug 1 55 HB260A0570 Gas charging valve 1
9 HB260A0090 Plug 2 56 HB260A0580 O-ring 1
10 HB260A0100 O-ring 4 57 HB260A0590 Cap 1
11 HB260A0110 Plug 11 58 HB150A0580 Cap screw 6
12 HB260A0120 O-ring 11 59 HB130A0590 Cap screw 6
13 HB260A0150 Pin 2 60 HB150A0600 Heli sert 6
14 HB260A0160 Nipple 1 61 HB150A0610 O-ring 1
15 HB130A0150 Piston 1 62 HB130A0620 Auto stop adjuster 1
16 HB130A0160 Cylinder sleeve 1 63 HB260A0110 Nut 1
17 HB130A0170 X-ring 1 64 HB130A0640 O-ring 1
18 HB130A0180 Step seal 2 65 HB130A0650 Back up ring 1
19 HB130A0190 O-ring 3
20 HB150A0200 Valve 1 41 HB130AP410 Point chisel 1
21 HB150A0210 Valve liner 1 41 HB130AX410 Cross cut chisel 1
22 HB150A0220 Valve plug 1 41 HB130AE410 Flat end chisel 1
23 HB150A0230 O-ring 1
24 HB260A0260 Adjuster 1 - HB150A1010 Valve assy 1 20,21,22,23,61
25 HB260A0270 O-ring 1 - HB260A1020 Adjuster assy 1 7,24,25,26,27
26 HB260A0280 Adjuster case 1 - HB130A1030 Side rod assy 4 37,38,39,40
27 HB260A0290 Nut 1 - HB260A1040 Gas valve body assy 1 43,44,45,46
28 HB130A0280 Front cap 1 - HB150A1050 Accumulator 1 10, 45-60
29 HB130A0290 Shunk bush 1 - HB150A1060 Acc valve assy 1 52,53,54
30 HB130A0300 Front cap bush 1 - HB260A1070 Gas charging va;ve assy 1 10,55,56,57
31 HB130A0310 Shaft 1 - HB130A1080 Auto stop adjuster assy 1 62,63,64,65
2,3,4,7,10,12,17,18,19,23,25
32 HB260A0340 Shaft retainer 4 - HB130A10C0 Seal kit 1 ,36,44,46,49,56,61,64,65

33 HB130A0330 Chisel set pin 2

34 HB260A0370 Plug 1
35 HB065A0350 Plug 1
36 HB130A0360 O-ring 1
37 HB130A0370 Side rod 4
38 HB130A0380 Back nut washer 4
39 HB130A0390 Back nut 4
40 HB130A0400 Side rod front nut 4
42 HB130A0420 Back cap 1
43 HB260A0450 Gas valve 1
44 HB260A0460 O-ring 1
45 HB260A0470 Cover cap 2
46 HB260A0480 O-ring 2

110
Bracket Exploded View
okada1300

111
Parts List
okada1300
No. Parts No. Part Name Q’ty Remarks
1 HB130B0010 Bracket 1
2 HB130B0020 Bottom dumper 1
3 HB130B0030 Head dumper 1
4 HB150B0041 Top bracket 1
5 HB130B0050 Bolt 18
6 HB080B0060 Nut 18
7 HB130B0070 Pad 5
8 HB130B0080 Pad 2
9 HB130B0090 Pad 2
10 HB260B0100 O-ring 18
11 HB130B0110 Head plate 1
12 HB260B0120 Damper 1
13 HB260B0130 Cover 4
14 HB080B0130 Cover 4
15 HB260B0150 Cover 1
16 HB130B0160 Cover 1
17 HB080B0160 Hose boots 2
18 HB260B0180 Bolt 4
19 HB150B0190 Cover 2
20 HB260B0200 Bolt 4
21 HB150B0210 Washer 4
22 HB260B0220 Grease nipple 1
23 HB260A0160 Nipple 1
24 HB150B0241 Grease hose 1
25 HB080B0211 Hydraulic hose 2
26 HB130B0260 Spring washer 18
27 Bush 4
28 Pin 2
29 Collar 2
30 HB130B0300 Bolt 2
31 HB080T0110 Nut 4
32 HB150B0320 Adapter 2
33 HB080B0300 Dust cap 2

112
Exploded View
okada1500

113
Breaker Body Parts List
okada1500
No. Parts No. Part Name
HB150A0010 Cylinder
1
HB150A0011 Cylinder
2 HB150A0020 Dust seal
3 HB150A0030 U-packing
4 HB150A0040 Buffer-ring
5 HB100A0050 Nipple
6 HB080A0050 Dust cap
7 HB260A0140 O-ring
8 HB150A0080 Plug
9 HB260A0090 Plug
10 HB260A0100 O-ring
11 HB260A0110 Plug
12 HB260A0120 O-ring
13 HB260A0150 Pin
14 HB260A0160 Grease nipple
HB150A0150 Piston
15
HB150A0151 Piston
16 HB150A0160 Cylinder sleeve
17 HB150A0170 X-ring
18 HB150A0180 Step seal
19 HB150A0190 O-ring
20 HB150A0200 Valve
21 HB150A0210 Valve liner
22 HB150A0220 Valve plug
23 HB150A0230 O-ring
24 HB260A0260 Adjuster
25 HB260A0270 O-ring
26 HB260A0280 Adjuster case
27 HB260A0290 Nut
28 HB150A0280 Front cap
29 HB150A0290 Shank bushing
Q’ty Remarks No. Parts No. Part Name Q’ty Remarks
1 s/n500 and before 43 HB260A0450 Gas valve 1
1 s/n501 and after 44 HB260A0460 O-ring 1
1 45 HB260A0470 Cover cap 2
1 46 HB260A0480 O-ring 2
1 47 HB150A0470 Accumulator body 1
2 48 HB150A0480 Accumulator cover 1
2 49 HB150A0490 Seal 1
4 51 HB150A0510 Bladder 1
1 52 HB150A0520 Valve 1
1 53 HB260A0550 Nut 1
3 54 HB260A0560 Pin 1
9 55 HB260A0570 Gas charging valve 1
9 56 HB260A0580 O-ring 1
2 57 HB260A0590 Cap 1
1 58 HB150A0580 Cap screw 6
1 s/n500 and before 59 HB150A0590 Cap screw 6
1 s/n501 and after 60 HB150A0600 Heli sert 6
1 61 HB150A0610 O-ring 1
1
2 41 HB150AP610 Point chisel 1
3 41 HB150AX610 Cross cut chisel 1
1 41 HB150AE610 Flat end chisel 1
1
1 HB150A1010 Valve assy 1 20,21,22,23,61
1 HB260A1020 Adjuster assy 1 7,24,25,26,27
1 HB150A1030 Side rod assy 4 37,38,39,40
1 HB260A1040 Gas valve body assy 1 43,44,45,46
1 HB150A1050 Accumulator 1 10, 45-60
1 HB150A1060 Acc valve assy 1 52,53,54
1 HB260A1070 Acc gas charging valve assy 1 10,55,56,57
2,3,4,7,10,12,17,19,23,2
1 HB150A10C0 Seal kit 1 5,36,44,46,49,56,61

30 HB150A0300 Front cap bushing 1

31 HB150A0310 Shaft 4
32 HB260A0340 Shaft retainer 4
33 HB150A0330 Chisel set pin 2
34 HB260A0370 Plug 1
35 HB065A0350 Plug 1
36 HB150A0360 O-ring 1
37 HB150A0370 Side rod 4
38 HB150A0380 Back nut washer 4
39 HB150A0390 Back nut 4
40 HB150A0400 Side rod front nut 4
42 HB150A0420 Back cap 1

130225

114
Bracket Exploded View
okada1500

115
Parts List
kada1500
No. Parts No. Part Name Q’ty Remarks
1 HB150B0010 Bracket 1
2 HB150B0020 Bottom damper 1
3 HB150B0030 Head damper 1
4 HB150B0041 Top bracket 1
5 HB150B0051 Bolt 18
6 HB080B0060 Nut 18
7 HB260B0070 Pad 5
8 HB150B0080 Pad 2
9 HB150B0090 Pad 2
10 HB260B0100 O-ring 18
11 HB150B0110 Head plate 1
12 HB260B0120 Damper 2
13 HB150B0130 Cover 4
14 HB080B0130 Cover 4
15 HB260B0150 Cover 1
16 HB150B0160 Cover 1
17 HB080B0160 Hose boots 2
18 HB260B0180 Bolt 4
19 HB150B0190 Cover 2
20 HB260B0200 Bolt 4
21 HB150B0210 Washer 4
22 HB260B0220 Grease nipple 1
23 HB260A0160 Nipple 1
24 HB150B0241 Grease hose 1
25 HB080B0211 Hydraulic hose 2
26 HB080B0220 Washer 36
27 Bush 4
28 Pin 2
29 Collar 2
30 HB150B0300 Bolt 2
31 HB080B0280 Nut 4
32 HB150B0320 Adapter 2
33 HB080B0300 Dust cap 2

130812

116
Exploded View
okada2600

117
Breaker Body Parts List
okada2600
No. Parts No. Part Name Q’ty Remarks No. Parts No. Part Name Q’ty Remarks
1 HB260A0010 Cylinder 1 47 HB260A0470 Cover cap 2
2 HB260A0020 Dust seal 1 48 HB260A0480 O-ring 2
3 HB260A0030 U-packing 1 49 HB260A0490 Accumulator body 1
4 HB260A0040 Buffer-ring 1 HB260A0500 Accumulator cover 1 s/n 397 & before
50
5 HB260A0050 Nipple 2 HB260A0501 Accumulator cover 1 s/n 398T & after

6 HB260A0060 Dust cap 2 51 HB260A0510 Seal 1

7 HB260A0070 O-ring 3 52 HB260A0520 Washer 4
8 HB260A0080 Plug 1 53 HB260A0530 Bladder 1
9 HB260A0090 Plug 4 54 HB260A0540 Valve 1
10 HB260A0100 O-ring 5 55 HB260A0550 Nut 1
11 HB260A0110 Plug 6 56 HB260A0560 Pin 1
12 HB260A0120 O-ring 6 57 HB260A0570 Gas charging valve 1
14 HB260A0140 O-ring 1 58 HB260A0580 O-ring 1
15 HB260A0150 Pin 2 59 HB260A0590 Cap 1
16 HB260A0160 Grease nipple 1 60 HB260A0600 Cap screw 12
17 HB260A0170 Piston 1 61 HB260A0610 Cap screw 4
18 HB260A0180 Cylinder sleeve 1 62 HB260A0620 Heli sert 4
19 HB260A0190 X-ring 1 63 HB260A0630 O-ring 1
20 HB260A0200 Step seal 2
21 HB260A0210 O-ring 3 43 HB260AP430 Point chisel 1 s/n 397 & before

22 HB260A0220 Valve 1 43 HB260AX430 Cross cut chisel 1 s/n 397 & before

23 HB260A0230 Valve liner 1 43 HB260AE430 Flat end chisel 1 s/n 397 & before

24 HB260A0240 Valve plug 1 43 TP210-1200P Point chisel 1 s/n 398T & after

25 HB260A0250 O-ring 1 43 TP210-1200FX Cross cut chisel 1 s/n 398T & after

26 HB260A0260 Adjuster 1 43 TP210-1200E Flat end chisel 1 s/n 398T & after

27 HB260A0270 O-ring 1
28 HB260A0280 Adjuster case 1
29 HB260A0290 Nut 1 HB260A1010 Valve assy 1 22,23,24,25,63
HB260A0300 Front cap 1 s/n 397 & before HB260A1020 Adjuster assy 1 14,26,27,28,29
30
HB260A0301 Front cap 1 s/n 398T & after HB260A1030 Side rod assy 4 39,40,41,42
HB260A0310 Shank bushing 1 s/n 397 & before HB260A1040 Gas valve body assy 1 45,46,47,48
31
HB260A0311 Shank bushing 1 s/n 398T & after HB260A1050 Accumulator 1 10,47-59
32 HB260A0320 Front cap bushing 1 HB260A1060 Acc valve assy 1 54,55,56
33 HB260A0330 Shaft 4 HB260A1070 Acc gas charging valve assy 1 57,58,59
2,3,4,7,10,12,14,19,20,21,25,
34 HB260A0340 Shaft retainer 4 HB260A10C0 Seal kit 1 27,38,46,48,51,58,63

35 HB260A0350 Chisel set pin 2

36 HB260A0360 Plug 1
37 HB260A0370 Plug 1
38 HB260A0380 O-ring 1
39 HB260A0390 Side rod 4
40 HB260A0400 Back nut washer 4
41 HB260A0410 Back nut 4
42 HB260A0420 Side rod front nut 4
44 HB260A0440 Back cap 1
45 HB260A0450 Gas valve 1
46 HB260A0460 O-ring 2
130423

118
Bracket Exploded View
okada2600

119
Parts List
okada2600
No. Parts No. Part Name Q’ty Remarks
1 HB260B0011 Bracket 1
2 HB260B0020 Bottom damper 1
3 HB260B0030 Head damper 1
4 HB260B0041 Top bracket 1
5 HB150B0051 Bolt 12
6 HB080B0060 Nut 12
7 HB260B0070 Pad 5
HB260B0080 Pad 2 s/n 246 and before, incl 259,258,253,251,249
8
HB260B0081 Pad 2 s/n 272 and after, incl 256,257,260,262,268,

9 HB260B0090 Pad 2
10 HB260B0100 O-ring 18
11 HB260B0110 Head plate 1
12 HB260B0120 Damper 2
13 HB260B0130 Cover 4
HB260B0140 Cover 4 s/n 246 and before, incl 259,258,253,251,249
14
HB080B0130 Cover 4 s/n 272 and after, incl 256,257,260,262,268,

15 HB260B0150 Cover 1
16 HB260B0160 Cover 1
17 HB260B0170 Hose boots 2
18 HB260B0180 Bolt 4
19 HB260B0190 Cover 2
20 HB260B0200 Bolt 4
21 HB260B0210 Spring washer 4
22 HB260B0220 Grease nipple 1
23 HB260A0160 Nipple 1
24 HB150B0241 Grease hose 1
25 HB260B0251 Hydraulic hose 2
26 HB080B0220 Washer 24
27 Bush 4
28 Pin 2
29 Collar 2
30 HB260H0100 Bolt 2
31 HB260B0310 Nut 4
32 HB260B0320 Adapter 2
33 HB260B0330 Dust cap 2

130201

120
Exploded View
okada3600

121
Breaker Body Parts List
okada3600
No. Parts No. Part Name Q’ty Remarks No. Parts No. Part Name Q’ty Remarks
1 HB360A0010 Cylinder 1 42 HB360A0420 Plug 1
2 HB360A0020 Dust seal 1 43 HB025A0180 O-ring 1
3 HB360A0030 U-packing 1 44 HB360A0440 Side rod 4
4 HB360A0040 Buffer-ring 1 45 HB360A0450 Back nut washer 4
5 HB360A0050 Split Flange 2 46 HB360A0460 Back nut 4
6 HB360A0060 Plug 2 47 HB360A0470 Side rod front nut 4
7 HB360A0070 O-ring 4 49 HB360A0490 Back cap 1
8 HB260B0210 Spring washer 8 50 HB260A0450 Gas valve 1
9 HB360A0090 Bolt 8 51 HB260A0460 O-ring 1
10 HB360A0100 Plug 2 52 HB260A0470 Cover cap 2
12 HB260A0090 Plug 4 53 HB260A0480 O-ring 2
13 HB260A0100 O-ring 4 54 HB360A0540 Accumulator body 1
14 HB260A0110 Plug 6 55 HB360A0550 Accumulator cover 1
15 HB260A0120 O-ring 6 56 HB360A0560 O-ring 1
16 HB360A0160 Pin 2 57 HB360A0570 Seal 1
17 HB260A0160 Grease nipple 1 58 HB360A0580 Bladder 1
18 HB360A0180 Piston 1 59 HB260A0540 Valve 1
19 HB360A0190 Cylinder sleeve 1 60 HB260A0550 Nut 1
20 HB360A0200 X-ring 1 61 HB260A0560 Pin 1
21 HB360A0210 Step seal 2 62 HB260A0570 Gas charging valve 1
22 HB360A0220 Slide seal 1 63 HB260A0580 O-ring 1
23 HB360A0230 O-ring 3 64 HB260A0590 Cap 1
24 HB360A0240 Valve 1 65 HB360A0650 Cap screw 16
25 HB360A0250 Valve liner 1 66 HB360A0660 Cap screw 4
26 HB360A0260 Valve plug 1 67 HB360A0670 Heli sert 4
27 HB360A0270 O-ring 1 68 HB360A0680 Heli sert 8
28 HB360A0280 Adjuster 1 69 HB360A0690 O-ring 1
29 HB260A0270 O-ring 1 70 HB360A0700 Washer 4
30 HB360A0300 Adjuster case 1
31 HB260A0140 O-ring 2 48 HB360AP480 Point chisel 1
32 HB260A0290 Nut 1 48 HB360AX480 Cross cut chisel 1
33 HB360A0330 Front cap 1 48 HB360AE480 Flat end chisel 1
34 HB360A0340 Shank bushing 1
35 HB360A0350 Front cap bushing 1 HB360A1010 Valve assy 1 24,25,26,27,69
36 HB360A0360 Shaft 2 HB360A1020 Adjuster assy 1 28,29,30,31,32
37 HB260A0340 Shaft retainer 2 HB360A1030 Side rod assy 4 44,45,46,47
38 HB360A0380 Shaft 2 HB260A1040 Gas valve body assy 1 50,51,52,53
39 HB360A0390 Shaft retainer 2 HB360A1050 Accumulator 1 13,52-67,70
40 HB360A0400 Chisel set pin 2 HB260A1060 Acc valve assy 1 59,60,61
41 HB260A0370 Plug 1 HB260A1070 Acc gas charging valve assy 1 62,63,64
2,3,4,7,13,15,20,21,22,23,27
HB360A10C0 Seal kit 1 ,29,31,43,51,53,56,57,63,69

130201

122
Bracket Exploded View
okada3600

123
Parts List
okada3600
No. Parts No. Part Name Q’ty Remarks
1 HB360B0011 Bracket 1
2 HB360B0020 Bottom damper 1
3 HB360B0030 Head damper 1
4 HB360B0041 Top bracket 1
5 HB360B0051 Bolt 12
6 HB330B0060 Nut 12
7 HB360B0070 Pad 5
8 HB360B0081 Pad 2
9 HB360B0091 Pad 2
10 HB360B0100 O-ring 18
11 HB360B0110 Head plate 1
12 HB260B0120 Damper 2
13 HB360B0130 Cover 4
14 HB080B0120 Cover 4
15 HB260B0150 Cover 1
16 HB360B0160 Cover 1
17 HB360B0170 Hose boots 2
18 HB260B0180 Bolt 4
19 HB260B0200 Bolt 4
20 HB150B0210 Washer 4
21 HB260B0220 Grease nipple 1
22 HB260A0160 Nipple 1
23 HB360B0230 Grease hose 1
HB360B0240 Hydraulic hose NSF32 2 s/n 213 and before
24
HB360B0241 Hydraulic hose NSF25 2 s/n 214 and after
25 HB330B0251 Spring washer 12
26 Bush 4
27 Pin 2
28 Collar 2
29 HB360B0290 Bolt 2
30 HB260B0310 Nut 4

130813

124
Blank page

125
 HYDRAULIC BREAKER
START-UP PROCEDURE FORM

Upon start-up of this hydraulic breaker, each item must be initialed by, the personnel performing the
start-up, and by the customer, as each item is completed. Upon completion of the start-up, the
customer must confirm with his signature that all procedures where reviewed and completed.

Technician Customer
At the time of first use
- Review the operator’s manual to know about safety operation for the
OKADA hydraulic breakers.

- Check the quality and volume of hydraulic oil of the carrier machine. If
hydraulic oil is deteriorated, be sure to replace it with specified hydraulic oil
by manufacturer of the carrier. Also, check the hydraulic oil filter element, if
necessary replace it with new one. Deteriorated, low grade and lack of
hydraulic oil cause serious machine trouble on the breaker and the carrier.

- Check if the piping on the excavator is suitable for Okada hydraulic

breakers. Operating the breaker under condition of high pressure and
excessive oil flow causes severe problems on the breaker. Fill out the
followings,
Set pressure MPa • kgf/cm2 Rated oil flow L/min

- Check if the breaker has nothing wrong visually.

- After mounting the breaker, make sure to run in the breaker. Position the
breaker body at rights to the ground. Lift the breaker from the ground as
shown below. Then operate the breaker by blank hammering (dry firing) for
about 10 seconds 2 or 3 times. In this time, engine speed of the carrier
machine must be minimized.

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- Apply the pressure downward and operate the breaker for about 15 minutes. Technician Customer
Then accelerate the engine speed to half, operate the breaker for about half
an hour. During the running in, check that no-oil leaks from the breaker.

- When injecting the grease, position the breaker upright and apply the
pressure downward so that the chisel pushes in. Then inject the grease at
the grease nipple on front cap every 2 hours a day.

As to the quantity of greasing for one time is as follows,

okada150-800 Approx. 5 strokes of grease gun
okada900-3600 Approx. 10 strokes

Not only lack of lubrication but also entry of dust and the remaining steel
powder could shorten the bushing’s life.

Specified grease
Lithium grease
Type
Water resistant
170°C ~ 200°C
Dropping point
338°F ~ 392°F
130°C
Max. working temperature
266°F
Grade (thickness) NLGI 00, 0, 1. 2

Note : If the space inside of the front cap between chisel shank part and shank
bushing is filled up completely with excessive quantity of grease, there is
a possibility that it leads defective hammering.

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Dairy working
Technician Customer
- Check the hydraulic oil deterioration in the quality. Deteriorated oil could
give out offensive odor and be discolored. If such deteriorated oil is
detected, be sure to change the all-hydraulic oil with the same bland new
one before working. Also clean the inside of the tank, in case that any
impurities such as slugs accumulated in the tank. Deteriorated and
low-grade oil will surely cause serious trouble in the breaker and hydraulic
devices of carrier.

- Check the hydraulic quantity in the tank of carrier to see whether it is within
the specified level instructed by manufacturer of carrier. Lack of hydraulic
oil will cause abnormal oil heating and damage the hydraulic devices of
carrier and the breaker.

- For proper operation, all the hydraulic oil of the carrier and hydraulic oil filter
element must be replaced with new one in periodic interval.

Change of hydraulic oil Every 600 hours

Change of filter element Every 100 hours

- Inject the grease to lubricate the chisel head and bushes in the front cap at
every 2 hours. In addition, before greasing if some compound of grease
with mud stay inside front cap, wipe them out with tatters and so on.
Note : While greasing, breaker must be stood up-right and the chisel must
be at the shank bottom, to ensure that the grease will provide
between the chisel and the bushes. Do not fill up the space between
piston and chisel with grease.

- Confirm the tightness of all bolts. The entire bolts tightened properly are
essential to work the breaker, so hammering with loosened and lost bolts
causes not only bolt breakage and oil leakage but also serious trouble in the
whole breaker.

- When installing new bolt or unscrewed bolt is detected, lose whole bolts.
Then tighten them diagonally and gradually to the specified torque. Refer to
the tightening torque chart on the page of 61.

- Warm up the engine of carrier sufficiently then working the carrier so that
hydraulic oil can be warmed before hammering. After hydraulic oil get warm,
start hammering in condition of lower engine speed for 10 minutes. Then
perform the regular hammering.

Note : During warming up the breaker, keep the posture of the breaker
up-right. In case of warming up a bland new breaker, provide the blank
hammering (dry fire) for 10 seconds with minimum engine speed before
normal warming up.

50C to 80C
Recommended working oil temperature range
122F to 176F

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During hammering
Technician Customer
- Keep the down force applied to the breaker during
hammering so that the breaker body is not vibrated
for the recoil. Listen to the breaker’s sound during
hammering. If the blow number decrease by degrees,
the chisel is not on the orbit of down forcing or
sufficient down force is not applied to the breaker.

- When the material is being broken, stop hammering immediately. The

blank hammering (dry fire) could shorten the life of not only chisel and chisel
set pin but also breaker itself and the carrier.

- At the start of daily work, for around 10 minutes the breaker must be
provided with running-in in condition of half engine speed. 10 times of less
than 1 minutes hammering is enough for running-in.

- Do not continue hammering more than 15 seconds at

one spot. Change the spot if the material is not broken.
Working for long time in one spot could cause seizure
between the bushings and chisel.

- Never use the breaker under water. Entry of water

deteriorates the hydraulic oil and gives serious
damage to the breaker and the carrier. When under
water hammering is necessary, modification for under
water application is required. The detail of under water
application is shown on this manual.

- Do not rock the breaker with carrier while the chisel is

penetrating the material. Other wise, the chisel will
snap off.

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During storage
Technician Customer
- Store the breaker indoor. If the breaker is placed out side, put some
wooden block under the breaker shown below and completely cover it with
some water proof sheet. Exposure to the weather will damage the breaker
by creating some corrosion on the piston and bushes etc. Apply the grease
to the chisel shank portion and bushes inside the front cap.

- Regarding long period storage, release the N2 gas charged in the back cap
and push the piston into the cylinder fully. Then apply hydraulic oil on the
lower part of the piston.

Others
- While the breaker mounted on the carrier in transported, the chisel must be
detached in order to enable the carrier to be compact without damage the
boom.

- Use just OKADA genuine parts for maintenance and repairing. OKADA will
not allow warranty claim, if any imitation parts are used.

- Carefully read the Instruction Manual & Parts List attached in the tool box,
and follow it.

- When failure might be occurred on the breaker, also on the carrier, be sure
to stop working immediately and correct them. Continuing to use the
disordered breaker and carrier will make damage more severely. So when
doing initial instruction about the TOP breaker to an operator and owner, at
least following instruction should be advised to them.

Accumulator
- Applicable model : okada1000, 1300, 1500, 2600, 3600
If the accumulator bladder failure happens, stop the hammering immediately.
When the operator finds whichever phenomena below, it can be inferred that
accumulator bladder breakage occurred.
1) Abnormal vibration of hydraulic hose
2) Blow number decreasing
3) Impact power decreasing

130
 Technician Customer
Besides, using okada series breakers with failed accumulator bladder
continuously will cause below severe damages.
1) Crack of accumulator body or cover.
2) Frequent hydraulic hose damage.
3) Bolts breakage.
4) Damages of carrier’s hydraulic components such as hydraulic pump,
control valve and so on.
5) Other severe damages

Chisel set pins

If chisel set pin breakage occurs, stop the hammering and replace it with
new one. Also as to the okada series models in which 2 pieces of chisel set
pin are fitted, even if only one piece is broken, it would be better to replace
the both chisel set pins with new one.

If the broken chisel set pin is used continuously, the broken chisel set pin will
shattered in small pieces, and entering them between chisel and bushings
cause the chisel seizure. In worst case, chisel cannot be removed. In
addition, if shattered chisel set pin tips are entered in the piston striking area,
the bottom surface of piston will be damaged.

The broken chisel set pin may deform its hole in the front cap. Then service
life of new ones might be shortened.

Side rods
- Looseness and breakage of side rod indicate that the front cap, cylinder and
back cap are not firmly fastened together. This condition causes severe
damage on every portion of breaker body. Therefore be sure to check the
side rods while following the related instructions in our operating manuals.

CUSTOMER: I have reviewed all the above items with the personnel representing OKADA
AIYON and hereby confirm my understanding of the OKADA hydraulic breaker and its
operation. I have been informed of the importance of following proper safety procedures as
outline in the Operator’s manual provided me.

Customer Signature Date Personnel Performing Start-Up Date

READ AND KNOW YOUR OPERATOR’S AND PARTS MANUAL

131
PHONE: +81-6-6576-1268 OKADA AIYON CORPORATION
F A X : +81-6-6576-1280 4-1-18 KAIGAN-DORI MINATO-KU
Email :sales@aiyon.co.jp OSAKA 552-0022 JAPAN

IMPORTANT
OKADA WARRANTY REGISTRATION

DATE / /

ATTACHMENT MODEL : SERIAL NO. :

DATE OF SHIPMENT : / /
DATE OF FIRST PLACED INTO SERVICE : / /

CARRIER MACHINE MODEL : HOUR METER READING : Hr

2nd RELIEF SET PRESSURE : MPa WORKING PRESSURE : MPa

OIL FLOW TO ATTACHMENT: L/min N2 GAS IN BACK CAP : MPa

USER NAME :

ADDRESS :

COUNTRY : E-MAIL :

CATEGORY OF BUSINESS : CONTRACTOR, QUARRY, DEMOLITION, RENTAL

OTHERS ( )

DISTRIBUTOR NAME :

ADDRESS :

PERSON IN CHARGE

This form must be returned to OKADA AIYON within 15 days from date of sale by
facsimile, mail or E-mailing to begin warranty coverage.
OWR103

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4-1-18, Minato-ku, Kaigan-dori, Osaka, 552-0022 Japan
Tel: 81-(0)6-6576-1268
Fax: 81-(0)6-6576-1280
Email: sales@aiyon.co.jp
http://www.okada-aiyon.com 135