Takeuchi TKB402-S Hydraulic Hammer Service Manual

On a breaker like the Takeuchi TKB402-S, you’re pounding through concrete, rock, and frozen ground all day, usually in dust, mud, and vibration. This service manual is what I’d keep handy when the hammer starts losing impact, running hot, or leaking around the tool bushings. It walks you through how to trace a hydraulic or mechanical issue step by step so you confirm the real fault before you pull the hammer off the carrier or start ordering expensive parts.

Applications & Use Cases

• Diagnose weak impact or slow cycling by checking oil supply, gas charge, and internal wear in a logical order.
• Isolate hydraulic leaks and seal failures so you replace the correct O-rings, hoses, or fittings the first time.
• Follow disassembly and reassembly sequences to avoid damaging the piston, bushings, or accumulator during teardown.
• Set and verify basic adjustments after repair so the hammer hits correctly and doesn’t overstress the carrier.
• Identify correct service parts by matching components to the proper diagrams before placing an order.

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 diagrams and follow steps right at the machine.

Q: Is it worth printing sections of this manual?

A: Many techs print the procedures and diagrams they use most, then keep them in a binder that can ride in the service truck.

Safety Note

Always depressurize and support the hammer securely before loosening any hydraulic or gas-charged components.

Takeuchi TKB402-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
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 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