This is the factory SIS export for the Cat E240B and EL240B track excavators (serial prefixes 5WG and 8SF), covering Systems Operation, Specifications, Testing and Adjusting, Disassembly and Assembly, plus the hydraulic schematic sheets on pages 3016 and 3019, with component locations for the front and rear pump circuits. The hydraulic sections are the heart of it: main and line relief pressures, high pressure cut, negative flow control, swing and travel crossover relief, cylinder cycle times, and the power shift calibration you run through the controller's numbered Test Programs. Disassembly and Assembly walks the undercarriage, final drives, swing frame, and counterweight. The bundle also includes the shared Cat 3116 engine family literature, the 37/41/42-MT starting motor manual, and generic metric/SAE torque charts - plus, honestly, EquipmentManager dealer software guides and Product Link telematics manuals that have nothing to do with fixing the machine, so do not expect every one of these 3123 pages to be excavator repair work.
What's Inside This Caterpillar E240B, EL240B Repair Manual
| System | Pages | Key Topics |
|---|---|---|
| Air Inlet and Exhaust System | 1-65 | Generic 3114/3116/3126 Engine Air Inlet, Turbocharger, Aftercooler, Exhaust Manifold |
| Basic Engine | 66-434 | Generic 3114/3116/3126 Engine Disassembly and Assembly, Cylinder Head, Block, Crankshaft |
| Cooling System | 435-530 | Generic Engine Cooling System, Water Pump, Radiator |
| Electrical and Starting System | 531-1621 | Engine Governors, 37/41/42-Mt Starting Motor, E240B/EL240B Electronic System, EquipmentManager Dealer Software, Product Link Telematics, E240B/EL240B Hydraulic and Electronic Testing and Adjusting - See coverage_composition, This Row Is NOT Uniformly Machine-Specific |
| Engine Arrangement | 1622-1638 | Engine Mounting Arrangement |
| Frame and Body | 1639-1655 | E240B/EL240B Vehicle Systems Disassembly and Assembly (Counterweight Etc.) |
| Fuel System | 1656-2372 | Generic 3114/3116/3126 Fuel System, Governor, Injection |
| Hydraulic System | 2373-2891 | E240B/EL240B Hydraulic System Operation, Specifications and Testing and Adjusting - Main/Line Relief, Cylinder Cycle Times, Swing and Travel Motor Wear Limits |
| Implements | 2892-2908 | Bucket, Linkage |
| Lubrication System | 2909-2970 | Generic Engine Lubrication |
| Operator Station | 2971-2979 | Cab, Controls |
| Power Train | 2980-3014 | Final Drive, Swing Drive Disassembly and Assembly |
| Schematic | 3015-3072 | Hydraulic Component Location Schematics (p3015-3020), Fluid and Electrical Power Graphic Symbols Legend (p3021-3072) |
| Torque Specifications | 3073-3120 | Generic Metric ISO/SAE Fastener Torque by Thread Size, Not Machine-Specific |
| Work Tools | 3121-3123 | Bucket Attachment |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Main relief valve pressure | 27500 ± 490 kPa (4000 ± 72 psi) | p. 1327 |
| Pilot relief pressure (at manifold) | 4400 ± 150 kPa (650 ± 21 psi) | p. 1328 |
| Line relief pressure (boom/stick/bucket, head+rod end) | 31900 ± 980 kPa (4600 ± 140 psi) | p. 1332 |
| High pressure cut start / flow-drop point | ~25500 kPa (3700 psi) start, 15 L/min at ~27000 kPa (3900 psi) | p. 1195 |
| High pressure cut adjustment sensitivity | 1/4 turn of screw changes pressure ~4900 kPa (700 psi) | p. 1195 |
| Maximum pump flow (front/rear pump) | 235 ± 3 L/min (62 ± 1.3 US gpm) | p. 1194 |
| Standard power shift pressure | 2250 ± 98 kPa (330 ± 14 psi) | p. 1325 |
| Swing motor relief pressure (new-overhaul / service limit) | 24500 ± 490 kPa (3550 ± 72 psi) / 24500 +490/-1960 kPa (3550 +72/-285 psi) | p. 1334 |
| Swing motor case drain (new / after overhaul / service limit) | 5 L/min / 10 L/min / 20 L/min | p. 1336 |
| Travel motor crossover relief (new-overhaul / service limit) | 28900 ± 980 kPa (4200 ± 140 psi) / 28900 +980/-2950 kPa (4200 +140/-425 psi) | p. 1337 |
| Travel motor relief pressure (new-overhaul / service limit) | 27500 ± 490 kPa (4000 ± 72 psi) / 27500 +490/-1960 kPa (4000 +72/-285 psi) | p. 1339 |
| Boom cylinder speed (extend / retract) | 4.0 ± 0.8 s / 3.3 ± 0.6 s | p. 1175 |
| Stick cylinder speed (extend / retract) | 4.5 ± 0.9 s / 3.3 ± 0.6 s | p. 1175 |
| Bucket cylinder speed (extend / retract) | 5.0 ± 1.0 s / 3.0 ± 0.6 s | p. 1175 |
| Cylinder rod drift, boom/stick/bucket (all three identical) | 14 ± 6 mm/min (0.6 ± 0.2 in/min) | p. 1173 |
| Swing time, full swing (3 o'clock / 9 o'clock position) | 6.0 ± 0.8 sec | p. 1171 |
| Swing drift on 12 degree slope (brake released / brake locked) | 270 ± 90 mm (10.6 ± 3.5 in) / <=10 mm (0.4 in) | p. 1171 |
| High idle engine speed (hydraulic test setpoint, no load) | 2370 ± 50 rpm | p. 1165 |
Caterpillar E240B, EL240B Common Problems This Manual Covers
Slow hydraulics and weak digging force across all functions
Run the cylinder cycle time checks in Hydraulic System Testing and Adjusting, then verify line relief at 31900 ± 980 kPa and the high pressure cut point (~25500-27000 kPa). Comparing your readings to spec separates a tired main pump from a stuck relief valve or internal cylinder leakage before you spend money.
Manual Section: Hydraulic System - Testing and Adjusting p. 1195Weak or drifting swing, or the house creeps on a slope
Do the swing motor case drain flow test against the published limits of 5 L/min new, 10 after overhaul, 20 service limit, then check swing crossover relief settings. Flow over the limit condemns the motor; flow within it points you at the reliefs and brake instead.
Manual Section: Hydraulic System - Testing and Adjusting (swing motor tests) p. 1336Machine loses power under load or power shift feels wrong after pump or valve work
Recalibrate standard power shift pressure to 2250 ± 98 kPa (330 ± 14 psi) using the controller's numbered Test Program procedures in the Electronic System section, which also covers proportional reducing valve checks and sensor/switch continuity testing.
Manual Section: Electronic System - power shift controller Test Programs p. 1325Cranks slow, starts intermittently, or the starter is dead
Test before you replace: the included 37/41/42-MT starting motor manual covers bench testing, disassembly, and assembly of the starter itself, and the Electronic System troubleshooting section covers wiring and switch continuity checks so you can rule out cables and connections before pulling the motor.
Manual Section: 37/41/42-MT Starting Motor - Testing and Disassembly p. 541Frequently Asked Questions
My E240B digs weak and cycles slow. Does this manual give me actual numbers to test against?
Yes, and that is what makes it worth having. Testing and Adjusting lists cylinder cycle times you can check with a stopwatch: boom extend 4.0 ± 0.8 sec, stick extend 4.5 ± 0.9 sec, bucket extend 5.0 ± 1.0 sec. It also gives line relief at 31900 ± 980 kPa (4600 ± 140 psi) and the high pressure cut behavior, starting around 25500 kPa (3700 psi) with flow dropping to 15 L/min near 27000 kPa (3900 psi). Compare your gauge readings to those and you know whether you are chasing the pump, a relief valve, or internal leakage before you buy parts. p. 1175
Does it have fault codes or a diagnostic code list?
No, because the machine does not have them. This is an early 1990s excavator with a basic electro hydraulic power shift controller, not a modern CID/FMI system. Instead of codes, the controller runs numbered Test Programs for calibration and diagnosis, and the manual walks you through those step by step, including power shift pressure calibration to 2250 ± 98 kPa (330 ± 14 psi), proportional reducing valve checks, and continuity testing on sensors, switches, and the back up switch. Anyone selling you a code list for this machine is making it up. p. 1325
Is the Cat 3116 engine covered, or do I need a separate engine manual?
Engine literature is included: Systems Operation, Specifications, Disassembly and Assembly, and MUI governor coverage for the 3114/3116/3126 family. Fair warning: the engine text is the generic family documentation Cat used across many machines (backhoes, a combine, a tractor, wheel loaders), not written specifically around the E240B installation - it is roughly 45% of the book's page count. For fuel system work, air inlet and exhaust, governor adjustment, and a full teardown it has what you need. Machine-side plumbing and mounting are in the excavator sections. p. 1
I need to do undercarriage and final drive work. Is the teardown actually covered?
Yes. The Vehicle Systems Disassembly and Assembly section covers undercarriage components, final drives, the swing frame, counterweight, and removal and installation of the major structural pieces. Pair it with Testing and Adjusting to confirm the travel motors first: crossover relief spec is 28900 ± 980 kPa (4200 ± 140 psi), service limit down to 28900 +980/-2950 kPa. p. 1337
How does the swing motor case drain test work, and does the manual give wear limits?
It does, and this is the honest way to condemn or clear a swing motor. Testing and Adjusting has you tee a flow meter into the case drain and measure leakage: 5 L/min when new, 10 L/min after overhaul, and 20 L/min as the service limit. Over the limit means the rotating group is worn out and no relief valve adjustment will fix your lazy swing. p. 1336
