Takeuchi TKB802-S Hydraulic Hammer Service Manual

Out on demolition or concrete-breaking jobs, this TKB802-S hammer lives in dust, vibration, and abuse, so when it starts losing impact or leaking oil, you need a clear plan, not guesswork. This service manual walks you through how to trace faults, confirm the real cause, and then strip and rebuild the hammer in a logical order. For example, if the hammer is striking weakly, this book helps you verify oil supply, isolate whether the problem is in the carrier or the hammer, and then inspect internal parts before you spend money on a full kit.

Applications & Use Cases

• Diagnose weak or intermittent blows by checking pressures, oil flow, and internal wear in a structured sequence.
• Isolate carrier vs. hammer faults so you don’t replace hammer parts when the issue is in the excavator’s hydraulics.
• Disassemble and reassemble the hammer step by step, keeping seals, pins, and sleeves correctly oriented.
• Verify clearances and adjustments after rebuild so the hammer starts, cycles, and stops as it should.
• Plan parts orders by identifying exactly which wear parts are out of spec before you tear the tool down.

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 beside the machine.

Q: Is it worth printing sections of this manual?

A: Many techs print key procedures or exploded views, put them in plastic sleeves, and keep them right on the bench during teardown and assembly.

Safety Note

Always bleed pressure, secure the hammer, and follow the manual’s precautions before loosening any hydraulic or retaining components.

Takeuchi TKB802-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