A TB240 that slews sluggishly or creeps on one track sits idle until someone finds the fault, and this Takeuchi TB240 service manual PDF (OEM ID CG8E001) gives you 505 factory pages on that mini excavator. Hydraulic schematics trace oil from the pump through the control valve and pilot valve to the boom and arm cylinders, travel motors and slew motor, while the wiring diagrams map the electrical circuits you'd chase with a meter. Cylinders and motors take up the biggest section, with crawler removal, slew bearing and swivel joint work covered too, and troubleshooting charts sort faults by travel, slewing and boom. Check main relief with oil at 50°C to 60°C and the engine at maximum RPM, then torque the pump mounting bolts to 102 N·m (75 ft.-lb). Nothing stalls a pump swap like one missing figure. Bookmarked and searchable, it helps you pin the fault before ordering, so the right part arrives the first time.
What's Inside This Takeuchi TB240 Manual
| System | Pages | Key Topics |
|---|---|---|
| Safety | 3-12 | Safety Precautions, Cautions When Working |
| Service Data | 13-85 | Dimensional Drawing, Specification Tables, Performance Criteria, Tightening Torque |
| Function | 86-145 | Control Valve, Pilot Valve |
| Drive and Travel Systems | 146-166 | Drive System, Travel System, Crawler Removal, Crawler Installation |
| Slew and Upper Frame Equipment | 167-184 | Slew Equipment, Upper Frame, Slew Motor, Slew Bearing, Swivel Joint |
| Control and Attachment Systems | 185-202 | Control Device, Attachments, Hoe Attachment, Bucket, Boom, Arm |
| Hydraulic Components | 203-247 | Hydraulic Tank, Hydraulic Pump, Control Valve, Pilot Valve, Solenoid Valve |
| Cylinders and Motors | 248-376 | Pilot Valve, Cylinders, Travel Motor, Slew Motor, Swivel Joint |
| Troubleshooting | 377-429 | Overall Machine, Traveling, Slewing, Boom |
| Other | 430-505 | Maintenance Software Manual, Airconditioner |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Hydraulic pump mounting bolt torque | 102 N·m (75 ft.-lb) | p. 154 |
| Travel motor bolt torque | 97 N·m (71.5 ft.-lb) | p. 166 |
| Tie rod nut torque | 70.6 ± 2.9 N·m (52.1 ± 2.1 ft.-lb.) | p. 227 |
| Cap screw torque (frame and housing) | 32 ± 3 N·m (23.6 ± 2.2 ft.-lb.) | p. 223 |
| Engine Oil Pan Capacity (Upper limit) | 7.4 L | p. 26 |
| Hydraulic Tank Total Oil Capacity | 74 L | p. 26 |
| Travel Reduction Gear Oil Capacity | 0.6 L | p. 26 |
| Main Relief Valve Pressure Setting | 24 MPa | p. 20 |
| Hydraulic Hose Tightening Torque (1/4 size, Union nut) | 24.5 +4.9 0 N·m | p. 40 |
| Bite-type pipe fitting torque (8 mm pipe) | 34.3 ± 4.9 N·m | p. 39 |
Takeuchi TB240 Common Problems This Manual Covers
Takeuchi TB240 boom, arm, and bucket all slow or lacking power under load
Measure main relief pressure with the engine at maximum RPM and hydraulic oil at 50°C to 60°C (122°F to 140°F), gauge on the pressure detection port per page 31. Compare the reading against 24 MPa listed on page 20. If relief pressure checks good, work through the overall machine troubleshooting flow for the slow circuit.
Manual Section: Overall Machine TroubleshootingMachine veers to one side, one track will not travel, or 2nd speed fails
Measure travel motor drain volume on the weak side and compare it against the 1.4 L/min limit on page 387. Drain flow above that limit means the travel motor needs attention. If drain volume is in spec, follow the right, left, and 2nd-speed travel checks in Traveling Troubleshooting starting.
Manual Section: Traveling TroubleshootingUpper structure will not slew, slews slowly, or overruns and fails to hold posture
Measure slewing relief pressure at the pressure detection port with the engine at maximum RPM and hydraulic oil at 50°C to 60°C, following page 32. Secure the upper structure first so it cannot slew in the test direction. Then work the no slew, slow slew, and overrun checks starting.
Manual Section: Slewing TroubleshootingBoom drops spontaneously when held raised, or the boom cylinder moves slowly and lacks force
Check main relief pressure against 24 MPa using the gauge procedure on page 31 before blaming the boom circuit. If relief checks good, run the spontaneous drop and lacks force checks in Boom Troubleshooting, then inspect the boom cylinder following the Cylinders and Motors section beginning on page 248.
Manual Section: Boom TroubleshootingPiston pump noisy, running hot, or leaking oil with insufficient discharge and weak pressure
Check hydraulic pump mounting bolts and torque them to 102 N·m (75 ft.-lb) per page 154. Measure main relief pressure at the detection port following page 31 to separate a pump discharge problem from a relief fault. Then work the noise, heat, and leak checks in Piston Pump Troubleshooting.
Manual Section: Piston Pump TroubleshootingNo pressure reaching the 1st or 2nd auxiliary hydraulic lines at the attachment
Measure pilot pressure at the pressure detection port with the engine at maximum RPM and hydraulic oil at 50°C to 60°C, following page 33. Inspect the solenoid valve and control valve in the Hydraulic Components section starting on page 203, then work the 1st and 2nd auxiliary line checks in Auxiliary Hydraulics Troubleshooting.
Manual Section: Auxiliary Hydraulics TroubleshootingFrequently Asked Questions
How do I reset the service reminder on the Takeuchi TB240?
The maintenance software allows you to adjust the hourmeter. You can use the scrollbar to enter the desired time for the hourmeter and click the update button to synchronize the time to the ECU hourmeter. Note that you cannot revert to a previous hourmeter time once it has been advanced. p. 464
What is the tightening torque for the main relief valve on the Takeuchi TB240 control valve?
The tightening torque for the main relief valve on the control valve is 74 ± 5 N·m (54.6 ± 3.7 ft-lb). p. 243
What is the recommended air conditioner compressor belt tension on the Takeuchi TB240?
The recommended initial belt tension for the air conditioner compressor is 490 ± 98 N (110 ± 22 ft.-lb.), and the recommended value for a used belt is 343 ± 49 N (88 ± 11 lbf). p. 466
What is the procedure for bleeding air from the hydraulic cylinder?
To bleed air from the hydraulic cylinder, start the engine and let it idle for approximately five minutes. With the engine running at slow speed, extend and retract the cylinder four or five times, moving the piston rod to a position 100 mm (3.94 in.) before the end of the stroke. Finally, repeat this at top speed, then run at slow speed and move the piston rod to the stroke end. p. 336
What is the hydraulic tank capacity on the Takeuchi TB240?
The total amount of oil for the hydraulic tank is 74 L (19.5 US gal.), and the tank capacity is 41 L (10.8 US gal.). p. 26
What format is this Takeuchi TB240 manual in?
Instant PDF download. You get the full 505-page searchable Service Manual immediately after payment. Open it on your laptop, tablet, or phone right in the shop.
Is this Takeuchi TB240 Service Manual printable?
Yes. Print the pages or sections you need for your own shop use. Any standard printer works.
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