Written for one machine only, the Takeuchi TB235 mini excavator, this 326-page Takeuchi TB235 service manual PDF carries factory reference CG7E004. Hydraulic and electric circuit diagrams sit in the Service Data chapter beside the wire harness layout, so the pilot control circuit, main relief valve and solenoid valves can be traced from pump to actuator. Removal and installation work takes in the travel motor, crawler belts, slew bearing, swivel joint, boom, arm and dozer blade, while nearly a fifth of the book is given to troubleshooting sorted by travel, slew, boom, arm and bucket faults. Check carrier roller dimension A against the 76.3 mm standard and replace the roller once it wears to 72.3 mm; a 1/4 taper-thread hose fitting takes 29.4 ± 2.9 N·m. A slow slew rarely tells you which valve is at fault. Searchable text finds the procedure, bookmarks hold your place, and your TB235 is swinging and tracking again by the end of the shift.
What's Inside This Takeuchi TB235 Manual
| System | Pages | Key Topics |
|---|---|---|
| Safety | 3-12 | Safety Alert Symbol, Safety Precautions, Cautions When Working |
| Service Data | 13-72 | Dimensional Drawing, Specifications Tables, Lubricant and Fuel Chart, Performance Criteria, Tightening Torque, Hydraulic Circuit Diagram, Electric Circuit Diagram |
| Function | 73-96 | Piston Pump, Control Valve, Pilot Valve, Travel Motor, Slew Motor |
| Service Standards and Drive System | 97-109 | Service Standards, Engine Removal, Engine Installation, Throttle Lever Adjustment |
| Travel System | 110-114 | Crawler Belt Removal, Crawler Belt Installation, Carrier Roller, Track Roller, Travel Motor |
| Slew System | 115-117 | Slew Motor Removal, Slew Bearing, Swivel Joint |
| Upper Frame | 118-123 | Upper Frame Removal, Cover Removal, Cab Removal |
| Control System | 124-134 | Lever Stand, Control Lever, Pilot Valve, Control Cable Adjustment |
| Attachments | 135-140 | Bucket Removal, Arm Removal, Boom Removal, Swing Bracket, Dozer Blade |
| Hydraulic Components | 141-166 | Hydraulic Tank, Hydraulic Pump, Control Valve, Main Relief Valve, Port Relief Valve |
| Pilot Valves and Air Conditioner | 167-266 | Pilot Valve Construction, Auxiliary Pilot Valve, Travel Pilot Valve, Solenoid Valves, Air Conditioner |
| Troubleshooting | 267-326 | Overall Machine, Traveling, Slewing, Boom, Arm, Bucket |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Check valve torque | 177 N·m | p. 110 |
| Hydraulic hose Union nut (G) 1/8 | 9.8 +4.9 N·m | p. 33 |
| Hydraulic hose Taper thread (R) 1/8 | 11.8 ± 1.2 N·m | p. 33 |
| Carrier roller standard dimension A | 76.3 mm | p. 98 |
| Carrier roller allowable value A | 72.3 mm | p. 98 |
| Hydraulic oil tank capacity | 35 L | p. 142 |
| Engine Oil Capacity (Upper limit) | 4.7 L | p. 21 |
| Hydraulic Tank Capacity | 35 L | p. 21 |
| Fuel Tank Capacity | 53 L | p. 22 |
| Main Relief Valve Pressure (Boom, Arm, Right/Left Travel) | 21.0 +1.4 MPa | p. 23 |
| Main Relief Valve Pressure (Dozer Blade, Slew) | 19.6 +2.0 MPa | p. 23 |
| Pilot Pressure | 3.9 ±0.3 MPa | p. 23 |
Takeuchi TB235 Common Problems This Manual Covers
Takeuchi TB235 mini excavator no operation from boom, arm, bucket or slew with insufficient power
Check pilot pressure first and measure it against 3.9 ±0.3 MPa on page 23. Then test main relief pressure for boom and arm against 21.0 +1.4 MPa. Work through the overall machine troubleshooting procedure before you pull any cylinder or valve.
Manual Section: Overall MachineRight or left travel impossible or machine veers off line during straight travel
Test main relief pressure on the travel circuit against 21.0 +1.4 MPa from page 23, and check the right and left sides separately. If pressure holds on both sides, work through the Traveling troubleshooting charts and inspect the travel motor and travel pilot valve before you tear into the undercarriage.
Manual Section: TravelingUpper structure slewing slow, lacking force, overrunning, or unable to maintain posture
Measure main relief pressure for the slew circuit against 19.6 +2.0 MPa on page 23 before you condemn any parts. If pressure is in range, inspect the slew motor and slew bearing using the Slew System procedures on page 115. Then follow the Slewing troubleshooting charts for overrun and posture holding faults.
Manual Section: SlewingBoom cylinder slow to operate, will not move, or shows spontaneous drop when held raised
Check main relief pressure against 21.0 +1.4 MPa on page 23 first. If pressure is in range and the boom still drops or crawls, inspect the control valve and port relief valve following the Hydraulic Components procedures on page 141. Then work through the Boom troubleshooting chart before you pull the cylinder.
Manual Section: BoomHydraulic piston pump noisy, overheating, or showing insufficient discharge and pressure failure
Check hydraulic oil level and condition first. The tank holds 35 L per page 142. Then measure main relief pressure against 21.0 +1.4 MPa on page 23. If discharge stays short or the noise continues, remove and inspect the hydraulic pump following the Hydraulic Components procedures on page 141.
Manual Section: Piston PumpTrack rollers and carrier rollers worn below allowable dimension on the undercarriage
Measure carrier roller dimension A against the 76.3 mm standard and 72.3 mm allowable values, and track roller dimension A against the 93 mm standard and 87 mm allowable values, per page 98. Replace any roller past the limit using the procedure on page 110. Then torque carrier roller bolts to 66 N·m and track roller bolts to 158 N·m per page 112.
Manual Section: Service Standards and Drive System p. 98Frequently Asked Questions
What are the torque specifications for a Takeuchi TB235 hydraulic hose?
The tightening torque for a 1/8 inch hydraulic hose fitting is 9.8 N·m for the union nut (G) and 11.8 ±1.2 N·m for the taper thread (R). For a 1 inch fitting, the torque is 137.3 N·m for the union nut and 196.1 ±19.6 N·m for the taper thread. p. 33
What are the hydraulic pressure specifications for the TB235?
The main relief valve pressure setting for the hydraulic system is 21.0 MPa for the boom and arm circuits, and 19.6 MPa for the slew and dozer blade circuits. The pilot pressure is 3.9 ±0.3 MPa. p. 23
What are the engine oil and oil filter replacement specs for the Takeuchi TB235?
The engine oil pan requires Diesel engine oil (API: CD class, ACEA-E3, E-4 or E-5). The capacity is 4.7 L (upper limit) and 2.9 L (lower limit), and the oil should be changed every 250 hours after the first 50 hours. p. 21
What is the procedure for bleeding air from the hydraulic cylinder?
After replacing hydraulic oil, run the engine at low-idling speed for 10 minutes. Then, extend and retract each cylinder 4 or 5 times without reaching the stroke end, followed by repeating this at high speed, and finally 4 or 5 times up to the stroke end at low idle. p. 145
What is the tightening torque for the engine foot bolts on the Takeuchi TB235?
The engine foot bolts should be tightened to 102 N·m. This is specified for the engine mounting procedure. p. 103
Is this Takeuchi TB235 Service Manual a digital download?
You download the Service Manual yourself: 326 pages, searchable PDF, available immediately. Keep a copy on every device you use.
Can I print this Takeuchi TB235 manual?
Yes. Many buyers print one chapter at a time for their own shop and keep the rest on a tablet.
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