Takeuchi TKB302-S Hydraulic Hammer Service Manual

On a TKB302-S hammer that spends its life breaking concrete, rock, and frozen ground, this service manual is what I keep nearby when something doesn’t sound right or hit correctly. It walks you through how to trace leaks, isolate weak impact, and rebuild wear components without just guessing and throwing parts at it. If, for example, the hammer starts short-stroking after a hose change, I’d use this book to verify the hydraulic connections, check for air in the system, then follow the disassembly logic to inspect the internal wear parts in the right order.

Applications & Use Cases

• Confirm a suspected seal or diaphragm failure before pulling the hammer off the carrier.
• Follow the proper sequence to strip, inspect, and reassemble the hammer so it will align and seal correctly.
• Trace low impact power by checking pressures, flows, and internal clearances in a logical order.
• Verify correct tool, bushing, and pin installation after a rebuild to prevent side-loading damage.
• Use the exploded views to identify the exact parts to order and avoid mismatched components.

FAQ

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

A: Yes, it’s practical to keep it on a tablet or laptop so you can zoom in on diagrams and follow steps right next to the machine.

Q: Is it worth printing sections of this manual?

A: Many techs print the key procedures or diagrams they use often, then keep the clean copy in the shop and a marked-up copy in the service truck.

Safety Note

Always depressurize the hydraulic system and secure the hammer before loosening any fittings or starting disassembly.

Takeuchi TKB302-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
– Turning hammer left- or right-handed
– 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
– Installation of tool
– Tool bushing
– Wear limits and lubricants for tool bushing
– Removal of tool bushing (CITY, SCALING)

## Installation of Tool Bushing

– Troubleshooting
– The hammer does not start
– The hammer operates irregularly
– The blow has full power
– The hammer operates irregularly
– 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 high pressure accumulator
– Releasing pressure from low pressure accumulator
– Housing plates
– Pressure adjusting valve
– Charging accumulators
– Body parts
– Swivel couplings
– Disassembly and assembly
– Tie rods
– Testing
– Measuring hammer circuit
– Measuring hammer operating pressure
– Service tools
– Special service tools
– Standard service tools

Takeuchi