Takeuchi TB240 Mini Excavator Workshop Manual (CG8E016) (SN 124000003-)
On a TB240 that’s digging footings, trenching services, or working around tight sites, this workshop manual is what I’d keep open any time I’m into the major components. It walks you through how to strip, inspect, and correctly reinstall parts so the machine goes back to work without odd noises, leaks, or fault lamps. For example, if the boom starts drifting down or the swing feels jerky, I’d use this manual to trace the issue, test components in a set order, and then verify everything is aligned and sealed properly during reassembly.
Applications & Use Cases
- Plan a repair sequence before tearing into the upper structure, boom, or undercarriage so nothing gets missed on the way back together.
- Trace hydraulic problems methodically, isolating valves, cylinders, and lines instead of just swapping parts.
- Inspect wear points—pins, bushings, slew area—using the manual’s guidance on what to look and feel for.
- Verify correct reinstallation of hoses, harnesses, and guards after component replacement.
- Support periodic overhauls, helping you route lines cleanly and test functions safely after major work.
FAQ
Q: Can I use this manual on a tablet in the field?
A: Yes, it’s practical on a tablet or laptop so you can zoom diagrams and search text right beside the machine.
Q: Is it worth printing sections?
A: Many techs print the pages they’ll need for a job, mark them up, then update notes in the digital copy later.
Safety Note
Always follow the manual’s isolation, support, and lockout steps before loosening any pressurized or load-bearing component.
Takeuchi TB240 Mini Excavator Index:
- REVISION HISTORY
- FOREWORD
- Directional terms: front, rear, left, right
- Machine serial number
- Symbols used in this manual
- Manual structure
- 1. SAFETY
- SAFETY ALERT SYMBOL
- SAFETY PRECAUTIONS
- Observe all safety rules
- Wear safe clothing and protective gear
- Install an extinguisher and a first aid kit
- Lockout/Tagout (LOTO)
- Use the correct tools
- Regularly replace the safety-critical parts
- Explosionproof lighting
- Prohibit access by unauthorized persons
- Prepare the work area
- When the canopy is tilted up
- Keep the machine clean
- Stop the engine before performing maintenance
- Keep clear of the moving fan and belt
- When working under the machine
- When working on the machine
- Securing the working equipment
- Secure the engine hood and guard when they are open
- Place heavy components in a stable position
- Caution when filling with fuel or oil
- Handling of hoses
- Be careful with hot and pressurized components
- Handling of radiator
- Be careful with oils under pressure
- Release the residual pressure from the hydraulic system before performing maintenance
- Be careful with grease under pressure
- Handling of the accumulator
- Disconnect the battery
- Use caution when handling batteries
- Have a service agent repair welding cracks or other damage
- Checks after maintenance
- Disposing of wastes
- CAUTIONS WHEN WORKING
- Before starting work
- When disassembling or assembling
- When removing/installing the hydraulic unit
- When connecting/disconnecting the hoses or pipes
- Handling of seals
- Pressure adjustment for hydraulic devices
- 2. SERVICE DATA
- DIMENSIONAL DRAWING
- Machine dimensions
- Operating range
- Angle blade
- SPECIFICATION TABLES
- Performance
- Dimensions of complete machine
- Dimensions of base machine
- Engine
- Hydraulic system
- Operating device
- Slew equipment
- Lower machinery
- Working equipment
- Working dimensions (standard arm)
- Main structure
- Digging force
- Dozer blade
- TABLE OF MASSES
- Upper structure
- Lower structure
- Hoe attachments
- LUBRICANT AND FUEL CHART
- PERFORMANCE CRITERIA
- Standard values table
- Hydraulic pump assignment table
- Pump P1
- Pump P2
- Pump P3
- Pump P4
- Methods for inspecting performance
- Hydraulic oil pressure (Main relief valve set pressure)
- Travel speed (5 revolutions)
- Travel speed (10 m)
- Straight-ahead traveling
- Natural travel drop
- Slew time
- Overrun when slewing stops
- Natural slew drop
- Boom cylinder speed
- Arm cylinder speed
- Bucket cylinder speed
- Dozer blade cylinder speed
- Swing cylinder speed
- Natural cylinder drop
- Swing cylinder
- Lever play
- Backlash
- Slew bearing play
- Crawler tension
- TIGHTENING TORQUE
- Hydraulic hose
- Bite-type pipe fitting for steel pipe
- Joint for piping
- Joint for piping (O-ring seal type)
- Bolts and nuts (JIS strength category 10.9)
- HYDRAULIC CIRCUIT DIAGRAM
- 3rd service hard lock specification
- ELECTRICAL CIRCUIT DIAGRAM
- Symbols in electrical circuit diagram
- Wire color symbols
- Wire color table
- Wire types
- Schematic diagram
- Canopy
- Serial No.: 124000003 to 124000790
- Serial No.: 124000791 to 124002938
- Serial No.: 124002939 to 124003902
- Serial No.: 124003903 to 124004196
- Serial No.: 124004197 to 124004336
- Serial No.: 124004337 to 124005104
- Serial No.: 124005105 to 124005868
- Serial No.: 124005869 to 124006058
- Serial No.: 124006059 to 124006358
- Serial No.: 124006359 to 124006434
- Serial No.: 124006435 or later
- Cab
- Serial No.: 124000003 to 124000766
- Serial No.: 124000767 to 124000790
- Serial No.: 124000791 to 124001110
- Serial No.: 124001111 to 124002436
- Serial No.: 124002437 to 124002938
- Serial No.: 124002939 to 124003902
- Serial No.: 124003903 to 124004196
- Serial No.: 124004197 to 124004336
- Serial No.: 124004337 to 124005104
- Serial No.: 124005105 to 124005868
- Serial No.: 124005869 to 124006058
- Serial No.: 124006059 to 124006358
- Serial No.: 124006359 to 124006434
- Serial No.: 124006435 to 124010311
- Serial No.: 124010312 or later
- WIRE HARNESS
- Wiring diagram 03742-00029 (Cab) Serial No.: 124000051 to 124000609
- 03742-00029 (Cab) Serial No.: from 124000610
- 03742-00061 (Cab without travel alarm)
- 03742-00020 (Canopy) Serial No.: 124000003 to 124000609
- 03742-00020 (Canopy) Serial No.: from 124000610
- Body harness: 03742-00038 Serial No.: 124000003 to 124000609
- Body harness: 03742-00038 Serial No.: from 124000610
- Main harness: 03742-00037 (Cab)
- Main harness: 03742-00043 (Canopy)
- Switch harness: 05542-00057 (Cabin)
- Switch harness: 03742-00006 (Canopy)
- Wire harness: 05542-00047 Serial No.: 124000003 to 124000609
- 3. FUNCTION
- PISTON PUMP
- GEAR PUMP
- CONTROL VALVE
- Overview
- Operation
- Bucket
- Boom
- P1 travel
- P1 and P2 inlets
- P2 travel
- Arm
- Swing
- 1st service
- Slew
- Blade
- 2nd service
- Angle blade
- Communication valve
- Main relief valve
- Overload relief valve
- Anti-cavitation valve
- PILOT VALVE (CONTROL LEVER)
- PILOT VALVE (SWING)
- PILOT VALVE (BLADE)
- PILOT VALVE (TRAVEL)
- PROPORTIONAL SOLENOID VALVE (POWER CONTROL)
- EMERGENCY SHUT-OFF VALVE
- Neutral (Positions maintained)
- Boom cylinder raising and arm cylinder dumping operations
- Boom cylinder lowering and arm cylinder excavator operations
- Relief valve operation (When an abnormal high pressure is produced in the cylinder)
- SOLENOID VALVE (LEVER LOCK, SPEED SHIFT TRAVEL)
- Solenoid switching/relief function
- When not energized
- When energized
- Check function
- SELECTOR VALVE
- CYLINDERS
- TRAVEL MOTOR
- Hydraulic motor
- Counter balance valve
- 2-speed mechanism
- 2nd speed control valve
- Swash plate
- Automatic 2-speed switching system
- Parking brake
- Reduction gears
- SLEW MOTOR
- Hydraulic motor
- Relief valve
- The 1st stage
- The 2nd stage
- Make-up valve
- Anti-rebound valve
- When the brake is actuated
- When the Motor Rebounds
- Parking brake
- Timer valve
- Reduction gears
- SWIVEL JOINT
- 4. DISASSEMBLY AND ASSEMBLY
- SERVICE STANDARDS
- Carrier roller
- Track roller
- Sprocket
- Idler
- Clearance for pin and bushing
- Replacing the pin and bushing
- DRIVE SYSTEM
- Engine
- Removing the engine
- Installing the engine
- Hydraulic pump
- Removing the hydraulic pump
- Installing the hydraulic pump
- Fuel tank
- Removing the fuel tank
- Installing the fuel tank
- Fuel filler pump
- Battery
- Removing the battery
- Installing the battery
- TRAVEL SYSTEM
- Removing the crawler
- Installing the crawler
- Removing the steel crawler
- Installing the steel crawler
- Replacing the crawler
- Removing the carrier roller
- Installing the carrier roller
- Removing the track roller
- Installing the track roller
- Removing the idler and track adjuster
- Installing the idler and track adjuster
- Removing the travel motor
- Installing the travel motor
- SLEW EQUIPMENT
- Slew motor
- Removing the slew motor
- Installing the slew motor
- Slew bearing
- Removing the slew bearing
- Installing the slew bearing
- Swivel joint
- Removing the swivel joint
- Installing the swivel joint
- UPPER FRAME
- Upper frame
- Removing the upper frame
- Installing the upper frame
- Covers
- Removing the covers
- Attaching the covers
- Cab
- Removing the cab assembly
- Installing the cab assembly
- Canopy
- Removing the canopy assembly
- Installing the canopy assembly
- Floor frames
- Removing the glass window panes
- Installing glass window panes
- CONTROL DEVICE
- Construction diagram
- Control levers
- Blade lever
- Blade lever (Float)
- Valve bracket (Left)
- Valve bracket (Right)
- Control box L
- Control box R
- Hydraulic pilot unit
- Disassembly and assembly
- Removal and installation of the accumulator
- WORK EQUIPMENT
- Construction diagram
- Arm
- Bucket
- Boom
- Boom bracket
- Blade
- Disassembly and assembly
- Removal and installation of the bucket
- Removal and installation of the link
- Release of residual pressure
- Removal and installation of the arm
- Removal and installation of the boom
- Removal and installation of the boom bracket
- Removal and installation of the blade
- HYDRAULIC TANK
- Removing the hydraulic tank
- Installing the hydraulic tank
- HYDRAULIC PUMP
- Construction
- Special tools
- Inspection and adjustments
- CONTROL VALVE
- Construction
- With second auxiliary line piping included
- With second auxiliary line piping and angle blade included
- Bucket section
- Boom section
- Right travel section
- Left travel section
- Arm section
- Swing section
- 1st auxiliary line piping
- Slew section
- Blade section
- 2nd auxiliary line piping section
- Angle blade section
- Coupling valve section
- Inlet housing
- Main relief valve
- Port relief valve
- Anti-cavitation valve
- Disassembly and Assembly
- Inspection and adjustment
- PILOT VALVE
- Construction
- Special tools
- Installation jig A
- Installation jig B
- Disassembly and Assembly
- Inspection and adjustment
- PILOT VALVE (SWING, BLADE)
- Construction
- Special Jigs
- Disassembly and Assembly
- Inspection and adjustment
- PILOT VALVE (TRAVEL)
- Construction
- Disassembly and Assembly
- Special Jigs
- Disassembly
- Assembly
- Inspection and adjustment
- PROPORTIONAL SOLENOID VALVE (POWER CONTROL)
- Construction
- Disassembly and Assembly
- Inspection and adjustments
- PROPORTIONAL SOLENOID VALVE (1ST/2ND SERVICE)
- Construction
- Disassembly and Assembly
- Inspection and adjustment
- EMERGENCY SHUTOFF VALVE
- SOLENOID VALVE (ANGLE BLADE)
- Construction
- Disassembly and Assembly
- Inspection and adjustment
- SOLENOID VALVE (BLADE FLOAT)
- Construction
- Disassembly and Assembly
- Inspection and adjustment
- SOLENOID VALVE (3RD AUXILIARY LINE PIPING)
- Construction
- Disassembly and Assembly
- Inspection and adjustment
- SOLENOID VALVE (LEVER LOCK)
- Construction
- Disassembly
- Solenoid valve
- Relief valve
- Check valve
- Assembly
- Inspection and adjustment
- SOLENOID VALVE (4TH AUX)
- Construction
- Disassembly and Assembly
- Inspection and adjustment
- SELECTOR VALVE
- Construction
- Disassembly and Assembly
- Inspection and adjustment
- REDUCING VALVE
- Construction
- Disassembly and Assembly
- Inspection and adjustment
- CYLINDERS
- Construction
- Boom cylinder
- Boom cylinder (With emergency shut-off valve attached)
- Arm cylinder
- Arm cylinder (With emergency shut-off valve attached)
- Bucket cylinder
- Dozer blade cylinder
- Swing cylinder
- Angle cylinder
- Disassembly and Assembly
- Special tools
- Disassembly
- Assembly
- Inspection and adjustment
- Inspection after disassembly
- Inspection after assembly
- TRAVEL MOTOR
- Construction
- Hydraulic motor
- Reduction gears
- Counterbalance valve, 2nd-speed control valve, relief block assembly
- Assembly
- Counter balance valve and hydraulic motor
- Reduction gears
- Inspection and adjustment
- SLEW MOTOR
- Construction
- Hydraulic motor
- Reduction gears
- Brake valve
- Special tools
- Disassembly
- Slew motor
- Brake valve and hydraulic motor
- Reduction gears
- Anti-rebound valve
- Assembly
- Anti-rebound valve
- Brake valve and hydraulic motor
- Reduction gears
- Slew motor
- Inspection and adjustment
- SWIVEL JOINT
- Construction
- Disassembly and Assembly
- Inspection and adjustment
- Inspection procedures and remedial actions
- Use limit for parts
- Inspection after assembly
- 5. TROUBLESHOOTING
- ABOUT THE TROUBLESHOOTING SECTION
- Notes on troubleshooting and servicing
- OVERALL MACHINE
- No operation is possible.
- All systems working, but insufficient power.
- Boom, bucket, slew and arm fail to move or are too slow.
- TRAVELING
- No right or left travel.
- Right or left travel speed decelerates and the machine veers to one side.
- 2nd-speed travel is not possible.
- SLEWING
- No slew movement.
- No right or left slew movement.
- Slewing is slow or lacks force.
- Slewing occurs but overrun is large when slewing stops or slewing does not stop.
- When stopped on a slope, the upper-structure cannot maintain its posture.
- BOOM
- Boom cylinder does not move.
- Boom cylinder is slow or lacks force.
- When the control lever is pulled slowly, the boom drops temporarily.
- Spontaneous drop of the boom cylinder is too large.
- ARM
- Arm cylinder does not move.
- Arm cylinder is slow or lacks force.
- Spontaneous drop of the arm is too large.
- BUCKET
- Bucket cylinder does not move or lacks force.
- Spontaneous drop of the bucket is too large.
- BOOM SWING
- Swing cylinder does not move.
- AUXILIARY HYDRAULICS
- Prescribed pressure not supplied to the 1st and 2nd auxiliary lines.
- ANGLE BLADE
- Angle cylinder does not move.
- Angle cylinder lacks force.
- HYDRAULIC PUMP
- GEAR PUMP
- CONTROL VALVE
- PILOT VALVE
- SOLENOID VALVE
- CYLINDERS
- TRAVEL MOTOR
- Hydraulic motor
- 2nd-speed control
- Parking brake
- SLEW MOTOR
- Hydraulic motor, brake valve
- Parking brake
- 6. OTHER
- MAINTENANCE SOFTWARE MANUAL
- CONTENTS
- 1. OUTLINE
- 2. CONNECTION METHODS
- 2-1. Items needed
- 2-2. Installation method
- 2-2-1. Installation of the PLUS+1 Service Tool
- 2-2-2. Installation of the maintenance tool driver
- 2-3. Connection to the machine and startup of the maintenance software
- 3. DESCRIPTION OF FUNCTIONS
- 3-1. Home (Main screen)
- 3-2. Maintenance menu
- 3-2-1. Monitor
- 3-2-2. Inputs
- 3-2-3. Outputs
- 3-2-4. Feedback
- 3-2-5. Error Code
- 3-3. Setting menu
- 3-3-1. Vehicle Status
- 3-3-2. Engine
- 3-3-3. AUX1
- 3-3-4. AUX2/4
- 3-3-5. Misc
- 3-3-6. Liftalarm
- 3-3-7. Immobillzer
- 3-3-8. Pattern change
- 3-3-9. Option
- 3-3-10. Hourmeter
- 3-3-11. Auto engine stop
- AIR CONDITIONER
- [1] Product Overview
- 1. Outline
- 2. Specifications
- [2] Operating and Handling the Air Conditioner
- 1. Outlets and controls
- 2. Controls
- 3. Operation Guidelines
- 4. Air Conditioner Use and Precautions
- 5. Handling the Air Conditioner
- [3] Construction, Operation and Control
- 1. Construction
- 2. Air Conditioner Operation and Control
- [4] Inspection and Maintenance
- 1. Air Conditioner Inspection and Maintenance Table
- 2. Air Conditioner Daily Inspections and Handling Procedures
- 3. Maintenance
- [5] Refrigerant Charging
- 1. Safety Precautions when Charging Refrigerant
- 2. Evacuation
- 3. Refrigerant charging
- [6] Troubleshooting
- 1. Troubleshooting using a Gauge Manifold
- 2. Troubleshooting Table
- HOW TO ENABLE THE AUX4 FUNCTION
- VEHICLE ERROR CODES
Takeuchi
