Takeuchi TKB102-S Hydraulic Hammer Service Manual

Takeuchi TKB102-S Hydraulic Hammer Service Manual

Out on demolition jobs or breaking rock in a quarry, the TKB102-S hammer lives a hard life—constant impact, dust, and heat. This service manual is what I’d pull out when the hammer starts losing power, running hot, or leaking around the tool bushing. It walks you through how to confirm the fault step by step before you throw expensive parts at it, and it gives you the correct order to strip, inspect, and reassemble the hammer so it hits properly again.

Applications & Use Cases

Trace low impact power by checking oil supply, gas charge, and internal wear in a logical sequence.

Isolate external leaks versus internal seal failures before tearing the hammer apart.

Follow the correct disassembly and reassembly order so you don’t damage sleeves, pins, or sealing surfaces.

Verify tool bushing and retaining system wear and decide if you can adjust or must replace parts.

Align and torque key fasteners correctly after a rebuild, then test the hammer safely on the carrier.

FAQ

Q: Can I keep this manual on a tablet in the field?

A: Yes, it’s practical to use on a tablet or laptop; you can zoom diagrams and keep it clean while working.

Q: Is it worth printing parts of it?

A: Many techs print the procedures or exploded views they use most and keep them in a binder by the service truck.

Safety Note

Always depressurize the hydraulic and gas systems and secure the hammer before loosening any fittings or fasteners.

Takeuchi TKB102-S Hydraulic Hammer Index:

Operation
Foreword
This manual
Important safety information
Warranty
Spare part orders
Product numbers
Model and serial number
Manufacturer
Copyright notice
Modifications and corrections to the product
Product introduction
Overview
Removal from package
Lifting instructions
Main parts
Safety
General safety
Safety instructions
Operation
Operating instructions
Daily operation
Mounting and dismounting the hammer
Movement
Special conditions of use
Storage

Lubrication
Hammer tool greasing
Recommended greases
Manual greasing
Carrier hydraulic oil
Requirements for hydraulic oil
Oil cooler
Oil filter

Maintenance
Routine maintenance
Overview
Inspection and maintenance by the operator
Inspection and maintenance by the dealer
Maintenance intervals
In special applications
Other maintenance procedures
Changing the tool
Wear limits and lubricants for tool removal
Removal of tool on the S-model
Installation of tool on the S-model
Lower tool bushing
Wear limits and lubricants for lower tool bushing
Removal of lower tool bushing

Installation of lower tool bushing
Troubleshooting
The hammer does not start
The hammer operates irregularly
but the blow has full power
The hammer operates irregularly
and blow has no power
Impact rate slows down
The hammer does not stop or has run-on
Oil overheats
Recurrent tool failure
Further assistance

Specifications
Hammer specifications
Technical specifications
Main dimensions
Mounting bracket specifications
Tool specifications

Workshop
Disassembly and assembly
Safety
Main components
Releasing hydraulic pressure from hammer
Releasing pressure from accumulator
Housing plates
Valve body and distributor
Pressure accumulator
Charging accumulators
Body parts
Disassembly and assembly
Tie rods
Testing
Measuring hammer circuit
Measuring hammer operating pressure
Service tools
Special service tools
Standard service tools