Kubota Excavator: Workshop Manual

WORKSHOP MANUAL
KUBOTA EXCAVATOR
U30-6S
KiSC issued 06, 2021 A

TO THE READER
This workshop manual provides safety information for service activity, general information such as specifications and
dimensions of the machine, mechanisms and structure descriptions of the machine, and service procedures.
Safety
This section contains safety service descriptions and safety label information.
General
This section contains general instructions, tightening torques, general machine information and special tools.
Maintenance
This section contains information for the recommended oil and general maintenance procedures.
Each section basically consists of mechanism and servicing.
Mechanism
Mechanism part contains information and explanations for the structure, functions, and specifications of the machine
or component parts. This part should be comprehended before proceeding with troubleshooting, disassembling,
assembling, and servicing works.
Servicing
Servicing part contains information and procedures for maintenance, troubleshooting and repair works. The reader
should follow these instructions in order to satisfy any servicing work safely, correctly and quickly.
In this WSM, service specifications and service limits are defined as followings.
Service specifications:
Specification which corresponds to new machine's ex-factory. It is based on quality standard, drawings, or actual
measurements conducted by Kubota. This value is used to determine whether there is a problem with the machine in
the event of a troubleshooting. However, it is necessary to consider degradation due to wear, based on the operating
time of the machine, application or maintenance condition.
Service limits:
Service limit is a value corresponding to the recommended performance limit by taking long term-use wear into
account. When the service limit is reached, the machine is required to have proper repair, overhaul or replacement in
order to keep safe and adequate performance.
All of the illustrations, photographs, specifications, and other information in this manual were created based on the
latest model at the time of publication.
The parts names used in this manual are unified into names representing the functions of the parts. Therefore, it does
not necessarily correspond to the names used in other materials (parts list, operators manual etc.) and the name on
the label / identification plates on the product.
Kubota reserves the right to change all information at any time without notice.
June 2021
© KUBOTA Corporation

SUPPLEMENTARY INFORMATION
For the engine servicing information, refer to the following engine WSM.
NOTE
• The PDF No. may be changed by revision.
Manuals related to the engine (D1803-M-DI-E2-BH-TH1, D1803-M-DI-E2-BH-TH2)

Manual Title PDF No.
WSM 03-M-DI-E2B SERIES 9Y011-0286△ (English)
U30-6S i

ii U30-6S

CONTENTS
1. SAFETY
SAFE OPERATION............................................................................................................................................1-1
1. Before operating the machine .................................................................................................................. 1-1
1.1 General .............................................................................................................................................1-1
1.2 ROPS and OPG ................................................................................................................................1-2
2. Operating the machine .............................................................................................................................1-2
2.1 Starting to operate the machine ........................................................................................................ 1-2
2.2 Working the machine......................................................................................................................... 1-3
2.3 Important information on excavator operation................................................................................... 1-4
2.4 Safety for children .............................................................................................................................1-6
3. After operation ..........................................................................................................................................1-6
4. Safe loading and transport of the machine ............................................................................................... 1-6
5. Maintenance .............................................................................................................................................1-7
6. Safety labels .............................................................................................................................................1-9
6.1 Care of safety labels ....................................................................................................................... 1-17
2. GENERAL
GENERAL WORKING INSTRUCTIONS ........................................................................................................... 2-1
1. General working precautions .................................................................................................................... 2-1
2. Tightening bolts and nuts.......................................................................................................................... 2-1
3. Applying thread-locking fluid..................................................................................................................... 2-1
4. Installing circlips .......................................................................................................................................2-1
5. Installing spring pins .................................................................................................................................2-2
6. Handling split pin ......................................................................................................................................2-2
7. Handling chain joint and split pin .............................................................................................................. 2-2
8. Handling liquid gasket ..............................................................................................................................2-2
9. Replacing O-rings .....................................................................................................................................2-3
10. Replacing oil seals..................................................................................................................................2-3
11. Replacing floating seals .......................................................................................................................... 2-3
12. Connecting hydraulic hoses ................................................................................................................... 2-4
13. Wrapping thread seal tape...................................................................................................................... 2-4
14. Installing elbows with male seat ............................................................................................................. 2-4
15. Connecting and disconnecting quick hose couplings ............................................................................. 2-5
16. Handling the battery ...............................................................................................................................2-5
17. Handling wire harness ............................................................................................................................ 2-5
18. Handling fuses ........................................................................................................................................2-6
19. Handling connectors ...............................................................................................................................2-7
20. Wiring color.............................................................................................................................................2-8
21. Washing the machine with a high pressure washer ............................................................................... 2-8
22. Dispose fluids correctly........................................................................................................................... 2-9
PRELIMINARY WORKING INSTRUCTIONS .................................................................................................. 2-11
1. Vacuuming the hydraulic oil tank ............................................................................................................ 2-11
2. Releasing residual pressure of the hydraulic circuit ............................................................................... 2-11
3. Removing the battery .............................................................................................................................2-12
4. Vacuuming the refrigerant gas................................................................................................................ 2-12
5. Connecting the diagnostic connector ..................................................................................................... 2-13
6. Removing the bonnet, cover, and floor plate .......................................................................................... 2-14
7. Jacking up the machine .......................................................................................................................... 2-16
CONCLUDING WORKING INSTRUCTIONS .................................................................................................. 2-19
1. Charging the refrigerant gas ................................................................................................................... 2-19
2. Bleeding the air from the hydraulic cylinder............................................................................................ 2-20
3. Bleeding the air from the hydraulic pump ............................................................................................... 2-21
TIGHTENING TORQUES ................................................................................................................................2-23
1. Bolts and nuts tightening torque ............................................................................................................. 2-23
U30-6S iii

2. Stud bolts tightening torque .................................................................................................................... 2-23
3. Hydraulic hose fitting tightening torque .................................................................................................. 2-24
4. Hydraulic hoses tightening torque (taper thread) ................................................................................... 2-24
5. Locknuts of adapters with O-ring tightening torque (straight thread)...................................................... 2-24
6. Adapters tightening torque (taper thread)............................................................................................... 2-25
7. Hose clamps tightening torque ............................................................................................................... 2-25
GENERAL MACHINE INFORMATION ............................................................................................................ 2-27
1. Machine model identification .................................................................................................................. 2-27
2. Engine model identification..................................................................................................................... 2-27
3. Specifications .........................................................................................................................................2-29
4. Machine dimensions ...............................................................................................................................2-30
5. Machine mass table................................................................................................................................2-31
GENERAL ELECTRICAL INFORMATION....................................................................................................... 2-33
1. Electrical circuit general description ....................................................................................................... 2-33
1.1 Electrical circuit diagram description ............................................................................................... 2-33
1.2 Electrical circuit diagram unit symbol .............................................................................................. 2-33
1.3 Electrical wiring color coding ........................................................................................................... 2-34
1.4 Electrical wiring clamp..................................................................................................................... 2-34
1.5 Bus description................................................................................................................................2-35
1.6 Composite terminal description ....................................................................................................... 2-35
2. Connector ...............................................................................................................................................2-35
2.1 Connector handling precaution ....................................................................................................... 2-35
2.2 Connector diagram description ....................................................................................................... 2-35
TRANSPORTING THE MACHINE................................................................................................................... 2-37
1. Loading and unloading the machine on a truck ...................................................................................... 2-37
2. Towing the inoperable machine .............................................................................................................. 2-38
SPECIAL JIGS AND TOOLS ........................................................................................................................... 2-41
1. Special tools for the engine section ........................................................................................................ 2-41
1.1 Engine compression pressure measuring kit .................................................................................. 2-41
2. Special tools for the hydraulic section .................................................................................................... 2-41
2.1 Overload relief valve measuring kit ................................................................................................. 2-41
2.2 Travel motor special jigs.................................................................................................................. 2-42
2.3 Universal joint tightening jig ............................................................................................................ 2-45
2.4 Hydraulic cylinder special jigs ......................................................................................................... 2-46
3. Special tools for the air conditioning section .......................................................................................... 2-48
3.1 Manifold gauge................................................................................................................................2-48
3.2 Charging hoses ...............................................................................................................................2-48
3.3 Refrigerant gas vacuum machine ................................................................................................... 2-49
3.4 Refrigerant gas leak tester .............................................................................................................. 2-49
3.5 Refrigerant gas canister .................................................................................................................. 2-49
3. MAINTENANCE
MAINTENANCE INTERVALS TABLE ................................................................................................................ 3-1
LUBRICANT QUANTITY....................................................................................................................................3-7
RECOMMENDED LUBRICANTS ...................................................................................................................... 3-9
DAILY CHECK ................................................................................................................................................. 3-11
1. Checking the coolant level...................................................................................................................... 3-11
2. Checking the fuel level ........................................................................................................................... 3-11
3. Checking the engine oil level .................................................................................................................. 3-12
4. Checking the hydraulic oil level .............................................................................................................. 3-12
5. Checking the fan belt ..............................................................................................................................3-13
6. Checking the radiator, hydraulic oil cooler, and fuel cooler .................................................................... 3-13
7. Checking the engine and electrical wiring .............................................................................................. 3-14
8. Greasing the lubrication points ............................................................................................................... 3-15
EVERY 50 HOURS ..........................................................................................................................................3-17
1. Draining the water from the fuel tank...................................................................................................... 3-17
2. Draining the water separator .................................................................................................................. 3-17
3. Checking the battery...............................................................................................................................3-18
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4. Greasing the swivel gear ........................................................................................................................ 3-19
EVERY 200 HOURS ........................................................................................................................................3-21
1. Checking and adjusting the fan belt ....................................................................................................... 3-21
2. Checking the radiator hoses and clamps ............................................................................................... 3-22
3. Greasing the swivel bearing ................................................................................................................... 3-22
4. Checking and cleaning the engine air cleaner elements ........................................................................ 3-23
5. Checking the fuel line and intake air line ................................................................................................ 3-24
EVERY 250 HOURS ........................................................................................................................................3-25
1. Replacing the engine oil ......................................................................................................................... 3-25
2. Replacing the engine oil filter ................................................................................................................. 3-25
EVERY 500 HOURS ........................................................................................................................................3-27
1. Replacing the travel motor gear oil ......................................................................................................... 3-27
2. Replacing the fuel filter ........................................................................................................................... 3-27
3. Replacing the return filter ....................................................................................................................... 3-28
4. Replacing the fan belt .............................................................................................................................3-29
EVERY 1000 HOURS ......................................................................................................................................3-31
1. Replacing the pilot filter .......................................................................................................................... 3-31
2. Replacing the hydraulic oil and suction filter .......................................................................................... 3-31
3. Replacing the engine air cleaner elements ............................................................................................ 3-33
EVERY 1500 HOURS ......................................................................................................................................3-35
1. Checking the injection nozzles ............................................................................................................... 3-35
EVERY 2000 HOURS ......................................................................................................................................3-37
1. Replacing the engine oil in the front idler and track roller....................................................................... 3-37
2. Checking the alternator .......................................................................................................................... 3-38
3. Checking the starter motor ..................................................................................................................... 3-39
EVERY 3000 HOURS ......................................................................................................................................3-41
1. Checking the fuel injection pump............................................................................................................ 3-41
EVERY 1 YEAR ...............................................................................................................................................3-43
1. Checking the electrical wiring and fuses ................................................................................................ 3-43
EVERY 2 YEARS.............................................................................................................................................3-45
1. Replacing the radiator hoses and clamps .............................................................................................. 3-45
2. Replacing the coolant .............................................................................................................................3-46
3. Replacing the fuel line and intake air line ............................................................................................... 3-47
MAINTENANCE FOR CABIN SPECIFICATION .............................................................................................. 3-49
1. Daily check .............................................................................................................................................3-49
1.1 Checking the washer liquid level ..................................................................................................... 3-49
2. Every 200 hours .....................................................................................................................................3-49
2.1 Checking and adjusting the air conditioning belt ............................................................................. 3-49
2.2 Cleaning the air conditioning filter ................................................................................................... 3-50
2.3 Cleaning the condenser .................................................................................................................. 3-50
3. Every 500 hours .....................................................................................................................................3-51
3.1 Replacing the air conditioning belt .................................................................................................. 3-51
4. Every 1000 hours ...................................................................................................................................3-52
4.1 Replacing the air conditioning filter ................................................................................................. 3-52
5. Every 1 year ...........................................................................................................................................3-52
5.1 Checking the air conditioning and heater hoses ............................................................................. 3-52
6. Every 2 years..........................................................................................................................................3-53
6.1 Replacing the air conditioning and heater hoses ............................................................................ 3-53
7. Service as required.................................................................................................................................3-55
7.1 Checking the refrigerant .................................................................................................................. 3-55
4. MACHINE BODY
MECHANISM .....................................................................................................................................................4-1
1. Machine device layout .............................................................................................................................. 4-1
2. Bucket.......................................................................................................................................................4-3
2.1 Bucket dimensions ............................................................................................................................ 4-3
3. Arm ...........................................................................................................................................................4-4
3.1 Arm dimensions ................................................................................................................................4-4
U30-6S v

4. Boom ........................................................................................................................................................4-6
4.1 Boom dimensions.............................................................................................................................. 4-6
5. Blade ........................................................................................................................................................4-8
5.1 Blade dimensions .............................................................................................................................. 4-8
6. Rubber track .............................................................................................................................................4-8
6.1 Rubber track dimensions .................................................................................................................. 4-8
7. Steel track.................................................................................................................................................4-8
7.1 Steel track dimensions ...................................................................................................................... 4-8
8. Front idler .................................................................................................................................................4-9
8.1 Front idler dimensions ....................................................................................................................... 4-9
9. Sprocket ...................................................................................................................................................4-9
9.1 Sprocket dimensions ......................................................................................................................... 4-9
10. Track roller..............................................................................................................................................4-9
10.1 Track roller dimensions ................................................................................................................... 4-9
11. Carrier roller ............................................................................................................................................4-9
11.1 Carrier roller dimensions ................................................................................................................. 4-9
12. Pins, bushings, and shims .................................................................................................................... 4-10
12.1 Pin, bushing, and shim dimensions............................................................................................... 4-10
SERVICING .....................................................................................................................................................4-13
1. Service specifications .............................................................................................................................4-13
1.1 Service specifications for the machine body ................................................................................... 4-13
2. Testing ....................................................................................................................................................4-15
2.1 Measuring the front attachment horizontal play .............................................................................. 4-15
2.2 Measuring the swivel bearing vertical play...................................................................................... 4-15
2.3 Measuring the swing bracket vertical clearance ............................................................................. 4-16
2.4 Measuring the operating force for levers and pedals ...................................................................... 4-17
3. Repairing ................................................................................................................................................4-17
3.1 Bucket .............................................................................................................................................4-17
3.1.1 Removing the bucket .............................................................................................................. 4-17
3.2 Arm..................................................................................................................................................4-18
3.2.1 Removing the arm .................................................................................................................. 4-18
3.3 Boom ...............................................................................................................................................4-20
3.3.1 Removing the boom................................................................................................................ 4-20
3.4 Blade ...............................................................................................................................................4-22
3.4.1 Removing the blade ................................................................................................................ 4-22
3.5 Swing bracket..................................................................................................................................4-22
3.5.1 Removing the swing bracket................................................................................................... 4-22
3.6 Counterweight .................................................................................................................................4-24
3.6.1 Removing and installing the counterweight ............................................................................ 4-24
3.7 Seat .................................................................................................................................................4-24
3.7.1 Removing the seat .................................................................................................................. 4-24
3.8 Canopy ............................................................................................................................................4-25
3.8.1 Removing and installing the canopy ....................................................................................... 4-25
3.9 Cabin ...............................................................................................................................................4-25
3.9.1 Removing and installing the cabin .......................................................................................... 4-25
3.10 Seat support ..................................................................................................................................4-27
3.10.1 Removing and installing the seat support ............................................................................. 4-27
3.11 Lever lock ......................................................................................................................................4-32
3.11.1 Removing and installing the lever lock.................................................................................. 4-32
3.12 Blade control lever ........................................................................................................................ 4-34
3.12.1 Removing and installing the blade control lever ................................................................... 4-34
3.13 Swing control pedal .......................................................................................................................4-36
3.13.1 Removing and installing the swing control pedal .................................................................. 4-36
3.14 AUX control pedal .........................................................................................................................4-37
3.14.1 Removing and installing the AUX control pedal.................................................................... 4-37
3.15 Hydraulic lock cylinder .................................................................................................................. 4-39
3.15.1 Removing the hydraulic lock cylinder ................................................................................... 4-39
3.16 Swivel bearing ...............................................................................................................................4-40
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3.16.1 Removing and installing the swivel bearing .......................................................................... 4-40
3.17 Rubber track..................................................................................................................................4-42
3.17.1 Removing and installing the rubber track ............................................................................. 4-42
3.18 Steel track .....................................................................................................................................4-44
3.18.1 Removing and installing the steel track ................................................................................ 4-44
3.19 Front idler ......................................................................................................................................4-46
3.19.1 Removing the front idler........................................................................................................ 4-46
3.19.2 Front idler components ......................................................................................................... 4-47
3.19.3 Disassembling the front idler ................................................................................................ 4-47
3.19.4 Assembling the front idler ..................................................................................................... 4-48
3.20 Tension spring ...............................................................................................................................4-50
3.20.1 Removing and installing the tension spring .......................................................................... 4-50
3.21 Grease cylinder .............................................................................................................................4-51
3.21.1 Removing the grease cylinder .............................................................................................. 4-51
3.22 Track roller ....................................................................................................................................4-51
3.22.1 Removing and installing the track roller ................................................................................ 4-51
3.22.2 Track roller components ....................................................................................................... 4-52
3.22.3 Disassembling the track roller............................................................................................... 4-52
3.22.4 Assembling the track roller ................................................................................................... 4-53
3.23 Carrier roller ..................................................................................................................................4-54
3.23.1 Removing and installing the carrier roller ............................................................................. 4-54
5. ENGINE
MECHANISM .....................................................................................................................................................5-1
1. Engine device layout ................................................................................................................................5-1
2. Engine specifications ................................................................................................................................5-4
3. Engine dimensions ...................................................................................................................................5-6
4. Engine performance curves...................................................................................................................... 5-7
SERVICING .......................................................................................................................................................5-9
1. Troubleshooting ........................................................................................................................................5-9
1.1 Engine troubleshooting ..................................................................................................................... 5-9
2. Service specifications ............................................................................................................................. 5-11
2.1 Service specifications for the engine............................................................................................... 5-11
3. Testing .................................................................................................................................................... 5-11
3.1 Measuring engine compression pressure ....................................................................................... 5-11
3.2 Measuring engine oil pressure ........................................................................................................ 5-12
4. Repairing ................................................................................................................................................5-12
4.1 Fuel hose and tank..........................................................................................................................5-12
4.1.1 Removing and installing the fuel tank ..................................................................................... 5-12
4.1.2 Fuel hose routing .................................................................................................................... 5-15
4.2 Engine .............................................................................................................................................5-17
4.2.1 Removing and installing the engine ........................................................................................ 5-17
4.2.2 Removing the alternator ......................................................................................................... 5-22
4.2.3 Removing the starter motor .................................................................................................... 5-24
4.2.4 Removing and installing the injection nozzle .......................................................................... 5-24
4.3 Radiator...........................................................................................................................................5-25
4.3.1 Removing and installing the radiator ...................................................................................... 5-25
4.4 Muffler .............................................................................................................................................5-29
4.4.1 Removing and installing the muffler........................................................................................ 5-29
6. HYDRAULIC SYSTEM
MECHANISM .....................................................................................................................................................6-1
1. Hydraulic device layout.............................................................................................................................6-1
2. Hydraulic system general description ....................................................................................................... 6-3
2.1 Load sensing system general description ......................................................................................... 6-3
2.2 Pilot control system general description............................................................................................ 6-5
3. Hydraulic pump.........................................................................................................................................6-7
3.1 Hydraulic pump specifications........................................................................................................... 6-7
U30-6S vii

3.2 Hydraulic pump hydraulic circuit ....................................................................................................... 6-8
3.3 Piston pump P-Q performance.......................................................................................................... 6-9
3.4 Hydraulic pump function and structure............................................................................................ 6-10
3.4.1 Piston pump working principles .............................................................................................. 6-10
3.4.2 Horsepower control................................................................................................................. 6-11
3.4.3 Flow control (load sensing control) ......................................................................................... 6-12
3.4.4 Standby flow ........................................................................................................................... 6-13
3.4.5 Gain control ............................................................................................................................ 6-14
4. Control valve...........................................................................................................................................6-15
4.1 Control valve specifications............................................................................................................. 6-15
4.2 Control valve hydraulic circuit ......................................................................................................... 6-18
4.3 Control valve spool shift performance ............................................................................................. 6-18
4.4 Control valve function and structure................................................................................................ 6-18
4.4.1 Main relief valve ...................................................................................................................... 6-18
4.4.2 Overload relief valve ............................................................................................................... 6-19
4.4.3 Boom holding valve ................................................................................................................ 6-21
4.4.4 Unload valve ........................................................................................................................... 6-24
4.4.5 High pressure selector function .............................................................................................. 6-26
4.4.6 Pressure compensator valve .................................................................................................. 6-27
4.4.7 Boom and arm regeneration ................................................................................................... 6-28
4.4.8 Straight traveling circuit .......................................................................................................... 6-29
4.4.9 Swivel prior circuit ................................................................................................................... 6-30
4.4.10 Auto-idle signal circuit ........................................................................................................... 6-30
5. Swivel motor ...........................................................................................................................................6-31
5.1 Swivel motor specifications ............................................................................................................. 6-31
5.2 Swivel motor hydraulic circuit .......................................................................................................... 6-32
5.3 Swivel motor function and structure ................................................................................................ 6-32
5.3.1 Swivel motor working principles.............................................................................................. 6-32
5.3.2 Shockless function .................................................................................................................. 6-33
5.3.3 Swivel motor parking brake .................................................................................................... 6-33
5.3.4 Make-up circuit ....................................................................................................................... 6-33
6. Travel motor............................................................................................................................................6-34
6.1 Travel motor specifications.............................................................................................................. 6-34
6.2 Travel motor hydraulic circuit .......................................................................................................... 6-36
6.3 Travel motor function and structure................................................................................................. 6-36
6.3.1 Travel motor working principles .............................................................................................. 6-36
6.3.2 Counterbalance valve ............................................................................................................. 6-36
6.3.3 Anti-cavitation valve ................................................................................................................ 6-39
6.3.4 Automatic deceleration ........................................................................................................... 6-43
6.3.5 Travel motor parking brake ..................................................................................................... 6-44
7. Hydraulic cylinder ...................................................................................................................................6-45
7.1 Hydraulic cylinder specifications ..................................................................................................... 6-45
8. Swivel joint..............................................................................................................................................6-46
8.1 Swivel joint specifications................................................................................................................ 6-46
9. Pilot control valve ...................................................................................................................................6-48
9.1 Pilot control valve specifications ..................................................................................................... 6-48
9.2 Pilot control valve performance diagram ......................................................................................... 6-49
9.3 Pilot control valve function and structure ........................................................................................ 6-49
10. Travel control valve...............................................................................................................................6-50
10.1 Travel control valve specifications................................................................................................. 6-50
10.2 Travel control valve performance diagram .................................................................................... 6-50
10.3 Travel control valve function and structure.................................................................................... 6-51
11. Unload valve .........................................................................................................................................6-52
11.1 Unload valve specifications ........................................................................................................... 6-52
11.2 Unload valve function and structure .............................................................................................. 6-53
11.2.1 Unload valve working principles............................................................................................ 6-53
12. Multi valve.............................................................................................................................................6-54
12.1 Multi valve specifications............................................................................................................... 6-54
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13. Third line valve .....................................................................................................................................6-55
13.1 Third line valve specifications ....................................................................................................... 6-55
SERVICING .....................................................................................................................................................6-57
1. Troubleshooting ......................................................................................................................................6-57
1.1 Hydraulic troubleshooting for front attachment ............................................................................... 6-57
1.2 Hydraulic troubleshooting for swivel................................................................................................ 6-59
1.3 Hydraulic troubleshooting for traveling ............................................................................................ 6-60
2.1 Service specifications for the hydraulic system............................................................................... 6-61
3. Testing ....................................................................................................................................................6-63
3.1 Measuring the hydraulic devices ..................................................................................................... 6-63
3.1.1 Measuring the boom cylinder speed ....................................................................................... 6-63
3.1.2 Measuring the arm cylinder speed.......................................................................................... 6-64
3.1.3 Measuring the bucket cylinder speed ..................................................................................... 6-64
3.1.4 Measuring the blade cylinder speed ....................................................................................... 6-64
3.1.5 Measuring the swing cylinder speed....................................................................................... 6-65
3.1.6 Measuring the swivel speed ................................................................................................... 6-65
3.1.7 Measuring the travel speed .................................................................................................... 6-66
3.1.8 Measuring the cylinder internal leakage ................................................................................. 6-66
3.1.9 Measuring the travel motor internal leakage........................................................................... 6-67
3.1.10 Measuring the swivel motor internal leakage........................................................................ 6-68
3.1.11 Testing the travel straightness............................................................................................... 6-68
3.2 Measuring the hydraulic pump ........................................................................................................ 6-70
3.2.1 Measuring the piston pump P-Q performance ........................................................................ 6-70
3.2.2 Measuring the AUX flow rate .................................................................................................. 6-73
3.3 Measuring the control valve ............................................................................................................ 6-76
3.3.1 Measuring the main relief valve pressure ............................................................................... 6-76
3.3.2 Measuring the overload relief valve ........................................................................................ 6-77
3.4 Measuring the swivel motor ............................................................................................................ 6-78
3.4.1 Measuring the swivel motor overload relief valve pressure .................................................... 6-78
3.4.2 Measuring the swivel motor drain ........................................................................................... 6-79
3.5 Measuring the travel motor ............................................................................................................. 6-80
3.5.1 Measuring the travel motor drain ............................................................................................ 6-80
3.6 Measuring the pilot control valve..................................................................................................... 6-81
3.6.1 Measuring the pilot primary pressure ..................................................................................... 6-81
3.6.2 Measuring the pilot secondary pressure ................................................................................. 6-82
4. Repairing ................................................................................................................................................6-82
4.1 Hydraulic pump ...............................................................................................................................6-82
4.1.1 Removing and installing the hydraulic pump .......................................................................... 6-82
4.1.2 Hydraulic pump components .................................................................................................. 6-84
4.1.3 Disassembling the piston pump .............................................................................................. 6-85
4.1.4 Assembling the piston pump................................................................................................... 6-89
4.1.5 Installing adapters for the hydraulic pump .............................................................................. 6-97
4.1.6 Installing the pump coupling ................................................................................................... 6-98
4.2 Control valve ...................................................................................................................................6-98
4.2.1 Removing and installing the control valve .............................................................................. 6-98
4.2.2 Control valve components .................................................................................................... 6-102
4.2.3 Disassembling and assembling the control valve ................................................................. 6-106
4.2.4 Installing adapters for the control valve ................................................................................ 6-107
4.3 Swivel motor..................................................................................................................................6-109
4.3.1 Removing and installing the swivel motor............................................................................. 6-109
4.3.2 Swivel motor components..................................................................................................... 6-110
4.3.3 Disassembling the swivel motor ........................................................................................... 6-111
4.3.4 Assembling the swivel motor ................................................................................................ 6-113
4.3.5 Installing adapters for the swivel motor ................................................................................ 6-118
4.4 Travel motor .................................................................................................................................. 6-118
4.4.1 Removing and installing the travel motor.............................................................................. 6-118
4.4.2 Travel motor components ..................................................................................................... 6-120
U30-6S ix

4.4.3 Disassembling the travel motor ............................................................................................ 6-122
4.4.4 Assembling the travel motor ................................................................................................. 6-131
4.5 Hydraulic cylinder .......................................................................................................................... 6-145
4.5.1 Boom cylinder .......................................................................................................................6-145
4.5.2 Arm, bucket, swing, and blade cylinders .............................................................................. 6-154
4.5.3 Measuring the hydraulic cylinder .......................................................................................... 6-163
4.6 Swivel joint ....................................................................................................................................6-164
4.6.1 Removing and installing the swivel joint ............................................................................... 6-164
4.6.2 Installing adapters for the swivel joint ................................................................................... 6-167
4.7 Pilot control valve ..........................................................................................................................6-168
4.7.1 Removing and installing the pilot control valve ..................................................................... 6-168
4.7.2 Pilot control valve components ............................................................................................. 6-170
4.7.3 Disassembling the pilot control valve.................................................................................... 6-170
4.7.4 Assembling the pilot control valve ........................................................................................ 6-172
4.7.5 Installing adapters for the pilot control valve......................................................................... 6-175
4.8 Travel control valve .......................................................................................................................6-176
4.8.1 Removing and installing the travel control valve................................................................... 6-176
4.8.2 Travel control valve components .......................................................................................... 6-179
4.8.3 Disassembling the travel control valve ................................................................................. 6-179
4.8.4 Assembling the travel control valve ...................................................................................... 6-182
4.8.5 Installing adapter layout for the travel control valve.............................................................. 6-186
4.9 Unload valve .................................................................................................................................6-186
4.9.1 Removing and installing the unload valve ............................................................................ 6-186
4.9.2 Unload valve components .................................................................................................... 6-187
4.9.3 Disassembling and assembling the unload valve ................................................................. 6-187
4.9.4 Installing adapters for the unload valve ................................................................................ 6-189
4.10 Multi valve ...................................................................................................................................6-189
4.10.1 Removing and installing the multi valve.............................................................................. 6-189
4.10.2 Multi valve components ...................................................................................................... 6-191
4.10.3 Installing adapters for the multi valve ................................................................................. 6-192
4.11 Third line valve ............................................................................................................................6-192
4.11.1 Removing and installing the third line valve ........................................................................ 6-192
4.11.2 Third line valve components ............................................................................................... 6-193
4.11.3 Installing adapters for the third line valve............................................................................ 6-193
4.12 Hydraulic oil tank .........................................................................................................................6-193
4.12.1 Removing and installing the hydraulic oil tank .................................................................... 6-193
4.12.2 Installing adapters for the hydraulic oil tank........................................................................ 6-195
4.13 Hydraulic hose ............................................................................................................................6-196
4.13.1 Length description of hydraulic hoses ................................................................................ 6-196
4.13.2 Metal fittings of hydraulic hoses.......................................................................................... 6-196
4.13.3 Delivery hose routing .......................................................................................................... 6-197
4.13.4 Front hose routing............................................................................................................... 6-198
4.13.5 Swivel and swing hoses routing.......................................................................................... 6-200
4.13.6 Travel and blade hoses routing........................................................................................... 6-201
4.13.7 Drain hose routing .............................................................................................................. 6-202
4.13.8 Pilot hose routing (delivery, drain)....................................................................................... 6-203
4.13.9 Pilot hose routing (operation).............................................................................................. 6-206
7. ELECTRICAL SYSTEM
MECHANISM .....................................................................................................................................................7-1
1. Electrical device........................................................................................................................................7-1
1.1 Electrical device layout...................................................................................................................... 7-1
1.2 Switch layout .....................................................................................................................................7-4
1.3 Fuse and relay layout ........................................................................................................................ 7-5
1.4 Slow blow fuse layout........................................................................................................................ 7-7
1.5 Communication port layout ............................................................................................................... 7-7
1.6 Ground wiring layout ......................................................................................................................... 7-7
2. Functional electrical circuit ....................................................................................................................... 7-9
x U30-6S

2.1 Power supply electrical circuit diagram ............................................................................................. 7-9
2.2 Accessory electrical circuit diagram ................................................................................................ 7-11
2.3 Battery charge electrical circuit diagram ......................................................................................... 7-12
2.4 Engine start electrical circuit diagram ............................................................................................. 7-13
2.5 Engine stop electrical circuit diagram.............................................................................................. 7-14
2.6 Lever lock electrical circuit diagram ................................................................................................ 7-15
2.7 Travel speed shift electrical circuit diagram .................................................................................... 7-16
2.8 Work light electrical circuit diagram................................................................................................. 7-17
2.9 AI electrical circuit diagram ............................................................................................................. 7-18
2.10 Wiper and washer motors electrical circuit diagram...................................................................... 7-19
2.11 Beacon electrical circuit diagram................................................................................................... 7-20
3. Meter panel.............................................................................................................................................7-21
3.1 Meter panel function........................................................................................................................ 7-21
3.2 Display mode ..................................................................................................................................7-22
3.3 User setting mode ........................................................................................................................... 7-22
3.3.1 Confirming operation management ........................................................................................ 7-22
3.3.2 Operating the periodic check mode ........................................................................................ 7-23
3.3.3 Operating clock setting mode ................................................................................................. 7-24
3.3.4 Operating the AUX flow rate setting mode ............................................................................. 7-25
3.3.5 Operating the various setting mode (calender and clock setting) ........................................... 7-25
3.3.6 Operating the language setting mode..................................................................................... 7-25
3.4 Hidden user setting mode ............................................................................................................... 7-26
3.4.1 Operating the crane function setting ....................................................................................... 7-26
3.4.2 Operating the arm limitation function setting .......................................................................... 7-26
3.5 Service dealer mode ....................................................................................................................... 7-27
3.5.1 Operating service dealer mode............................................................................................... 7-27
3.5.2 Service dealer mode list ......................................................................................................... 7-28
3.5.3 Operating the tester mode ...................................................................................................... 7-30
3.5.4 Reading error history .............................................................................................................. 7-33
3.5.5 Clearing error history .............................................................................................................. 7-34
3.5.6 Operating the AI setting .......................................................................................................... 7-34
3.5.7 AUX1 setting ........................................................................................................................... 7-35
3.5.8 AUX2 setting ........................................................................................................................... 7-35
3.5.9 AS settings..............................................................................................................................7-35
3.5.10 Crane settings....................................................................................................................... 7-35
3.5.11 Overload alarm setting .......................................................................................................... 7-35
3.5.12 Operating model setting........................................................................................................ 7-36
3.5.13 Other setting ......................................................................................................................... 7-38
SERVICING .....................................................................................................................................................7-45
1.1 Electrical troubleshooting ................................................................................................................ 7-45
1.2 Error warning list (Red lamp) .......................................................................................................... 7-46
1.3 Alert list (Yellow lamp) ..................................................................................................................... 7-48
1.4 Message list ....................................................................................................................................7-49
2. Handling error warning ........................................................................................................................... 7-50
2.1 Handling engine oil pressure error .................................................................................................. 7-50
2.2 Handling overheating ...................................................................................................................... 7-52
2.3 Handling battery charging error....................................................................................................... 7-53
2.4 Handling fuel level sensor error ...................................................................................................... 7-55
2.5 Handling water temperature sensor error ....................................................................................... 7-56
2.6 Handling CAN communication error (Main) .................................................................................... 7-58
2.7 Handling travel speed shift system error ......................................................................................... 7-60
2.8 Handling battery overcharging ........................................................................................................ 7-62
2.9 Handling AI system error................................................................................................................. 7-63
2.9.1 Handling AI system error (accelerator sensor) ....................................................................... 7-63
2.9.2 Handling AI system error (governor sensor) ........................................................................... 7-65
2.9.3 Handling AI system error (AI motor) ....................................................................................... 7-67
2.10 Handling lever lock system error ................................................................................................... 7-69
U30-6S xi

2.11 Handling 5 V error ......................................................................................................................... 7-71
2.12 Handling high hydraulic oil temperature warning .......................................................................... 7-73
8. AIR CONDITIONING AND HEATER SYSTEM
MECHANISM .....................................................................................................................................................8-1
1. Air conditioning device layout ................................................................................................................... 8-1
2. Air conditioning and heater system general description ........................................................................... 8-3
3. Compressor ..............................................................................................................................................8-4
3.1 Compressor specifications ................................................................................................................ 8-4
3.2 Compressor function and structure ................................................................................................... 8-5
3.2.1 Compressor working principles................................................................................................. 8-5
3.2.2 Magnetic clutch pulley .............................................................................................................. 8-5
3.2.3 Safety valve .............................................................................................................................. 8-5
3.2.4 Temperature switch................................................................................................................... 8-6
4. Air conditioning unit ..................................................................................................................................8-7
4.1 Air conditioning unit specifications .................................................................................................... 8-7
4.2 Air conditioning unit function and structure ....................................................................................... 8-9
4.2.1 Evaporator ................................................................................................................................8-9
4.2.2 Heater core ...............................................................................................................................8-9
4.2.3 Blower .......................................................................................................................................8-9
4.2.4 Blower resistor .......................................................................................................................... 8-9
4.2.5 Expansion valve...................................................................................................................... 8-10
4.2.6 Thermostat..............................................................................................................................8-10
4.2.7 Heater valve............................................................................................................................ 8-11
5. Condenser .............................................................................................................................................. 8-11
5.1 Condenser specifications ................................................................................................................ 8-11
5.2 Condenser function and structure ................................................................................................... 8-11
6. Receiver .................................................................................................................................................8-12
6.1 Receiver specifications ................................................................................................................... 8-12
6.2 Receiver function and structure ...................................................................................................... 8-12
7. Pressure switch ......................................................................................................................................8-13
7.1 Pressure switch specifications ........................................................................................................ 8-13
7.2 Pressure switch function and structure ........................................................................................... 8-13
SERVICING .....................................................................................................................................................8-15
1.1 Air conditioning troubleshooting ...................................................................................................... 8-15
2.1 Service specifications for the air conditioning system ..................................................................... 8-19
3. Testing ....................................................................................................................................................8-19
3.1 Measuring the refrigerant pressure ................................................................................................. 8-19
3.2 Checking the fan switch .................................................................................................................. 8-20
3.3 Measuring the magnetic clutch pulley air gap ................................................................................. 8-21
3.4 Checking the blower resister ........................................................................................................... 8-22
4. Repairing ................................................................................................................................................8-23
4.1 Compressor.....................................................................................................................................8-23
4.1.1 Removing and installing the compressor ................................................................................ 8-23
4.2 Air conditioning unit ......................................................................................................................... 8-25
4.2.1 Removing and installing the air conditioning unit.................................................................... 8-25
4.3 Blower resistor ................................................................................................................................8-26
4.3.1 Removing the blower resister ................................................................................................. 8-26
4.4 Heater valve ....................................................................................................................................8-27
4.4.1 Removing and installing the heater valve ............................................................................... 8-27
4.5 Condenser.......................................................................................................................................8-28
4.5.1 Removing and installing the condenser .................................................................................. 8-28
4.6 Receiver ..........................................................................................................................................8-29
4.6.1 Removing and installing the receiver ...................................................................................... 8-29
4.7 Air conditioning and heater hoses ................................................................................................... 8-31
4.7.1 Air conditioning and heater hose routing ................................................................................ 8-31
xii U30-6S

9. APPENDICES
APPENDICES ....................................................................................................................................................9-1
1. Servicing information ................................................................................................................................ 9-1
1.1 Service specifications for the machine body ..................................................................................... 9-1
1.2 Service specifications for the engine................................................................................................. 9-3
1.3 Service specifications for the hydraulic system................................................................................. 9-3
1.3.1 Piston pump P-Q performance ................................................................................................. 9-6
1.3.2 AUX P-Q performance .............................................................................................................. 9-7
1.4 Service dealer mode ......................................................................................................................... 9-9
1.4.1 Tester mode ..............................................................................................................................9-9
1.4.2 Default settings ....................................................................................................................... 9-12
2. Hydraulic circuit diagram ........................................................................................................................ 9-15
3. Wire harness ..........................................................................................................................................9-16
4. Normal mode and user setting mode flow chart ..................................................................................... 9-22
5. Service dealer mode flow chart .............................................................................................................. 9-23
U30-6S xiii

xiv U30-6S

ABBREVIATIONS
Abbreviations Definitions Abbreviations Definitions
A/C Air Conditioning ID Inner Diameter
AC Alternating Current ISO International Standards Organization
ACC Accessory J/C Joint Connector
AFS Air Flow Sensor JIS Japanese Industry Standard
AI Auto Idle LCD Liquid Crystal Display
API American Petroleum Institute LED Light Emitting Diode
Approx. Approximately LH Left Hand side
AS Auto Stop LSD Limited Slip Differential
ASSY. Assembly MAX Maximum
ASTM American Society for Testing and Materials MIL Military Standards
AUX Auxiliary MIN Minimum
C/V Control Valve NC Normally Closed
CAB Cabin NO Normally Opened
CAN Controller Area Network OD Outer Diameter
CCV Closed Crankcase Ventilation P/V Pilot Valve
Committee for European Construction Equip-

CECE P/L Pressure Limiter
ment
CNP Canopy RH Right Hand side
CRS Common Rail System RMS Root Mean Square
Deutsches Institut für Normung (German In-

DIN ROPS Roll Over Protective Structure
stitute for Standards)
DOC Diesel Oxidation Catalysts SAE Society of Automotive Engineers
DM Diagnostic Manual SBF Slow Blow Fuse
DPF Diesel Particulate Filters SCV Suction Control Valve
Système Internationale (International system

DTC Diagnostic Trouble Code SI
of units)
ECU Electronic Control Unit S/J Swivel Joint
EGR Exhaust Gas Recirculation SOL Solenoid
EN Europäische Norm (European standard) spec. Specification
Eng Engine SW Switch
FOPS Falling Object Protective Structure TEMP. Temperature
GND Ground TPSS Two Pattern Selection System
HST Hydraulic Static Transmission WSM Work Shop Manual
IAT Intake Air Temperature W/H Wire Harness
U30-6S xv

1. SAFETY

SAFE OPERATION
1. Before operating the machine 1. SAFETY
SAFE OPERATION
The best way to prevent accidents is to follow the
safety instructions and warnings in this manual,
regulations, and safe operating practices.
Read and understand this manual carefully before
operating the machine.
Every user, however experienced, should carefully read
and understand this manual and those of the
attachments and accessories before operating the
machine. The owner is obliged to inform the operators
of these instructions in detail.
Store this manual in the back of the seat.
(See OPERATOR'S MANUAL.)
1. Before operating the machine – Check for pipes and buried cables before
digging. If available, use your local utility
Familiarize yourself with the machine and be aware of
its limits. Read the operating instructions carefully service to check for such items.
before starting the machine. – Check for hidden holes, obstacles, soft
underground, and overhangs.
1.1 General
• Obey the safety labels on the machine.
• The seat belt must be inspected regularly and
replaced if frayed or damaged.
– While using the machine, do not allow any

persons within the working range.
• Do not allow other persons to use the machine
before having informed them on the exact operation
and work instructions, and make sure that they
have read and fully understood the operator's
(1) Seat belt
manual.
• Always sit in the operator's seat when starting the • Do not wear baggy, torn or oversized clothing when
engine or operating levers or controls. working with the machine as such clothing can get
• Do not operate the machine while under the caught in rotating parts or control elements which
influence of alcohol, medication, controlled can cause accidents or injuries. Wear adequate
substances or while fatigued. safety clothing, such as a safety helmet, safety
• Check the surroundings carefully before using the shoes, eye protection, ear protection, working
machine or when attachments are being attached. gloves and so on, as necessary and as prescribed
– Pay attention to overhead clearances with by law or statutes.
electric wires.
U30-6S 1-1

SAFE OPERATION
1. SAFETY 1. Before operating the machine
The OPG (top guard level I), in accordance with

ISO10262, is equivalent in definition to a falling
object protective structure (FOPS).
• Always use the seat belt when the machine is
equipped with a ROPS or OPG (top guard level I)
as this combination will reduce the risk of serious
injury or death in case of machine tip-over or
instability, or in case of falling objects.
• Do not modify any structural members of the ROPS
or OPG (top guard level I) by welding, drilling,
bending, grinding or cutting, as this may weaken
the structure.
• If any component is damaged, replace it. Do not
(1) Helmet (7) Soft hat attempt repairs.
(2) Clothing fit for work (8) Towel • If the ROPS or OPG (top guard level I) is loosened
(3) Tight seams (9) Baggy trousers or removed for any reason, make sure all parts are
(4) Good grip footwear (10) Loose cuffs of the shirt reinstalled correctly. Tighten the mounting bolts to
(5) Well fitting cuffs (11) Baggy shirt
(6) Working gloves (12) Sandals or open-toed shoes the proper torque.
• The ROPS meets the requirements of ISO 3471.
• Do not allow passengers to ride on any part of the The OPG (top guard level I) meets the
machine at any time. The operator must remain in requirements of OSHA 1926.1003 / ISO 10262.
the machine seat during operation. • Never operate the machine when the operating
• Check levers, pedals and all mechanical parts for mass including the operator exceeds the maximum
wear, and make sure that they are correctly permissible total weight indicated on the ROPS
adjusted. Replace worn or damaged parts identification plate.
immediately. Check nuts and bolts regularly to
make sure that they are tightened to the correct
torque. 2. Operating the machine
• Keep your machine clean. Heavy soiling, grease,
dust and grass can cause fires, accidents or Operator safety is a priority. Safe operation, specifically
injuries. with respect to overturning hazards, entails
• Use only Kubota authorized attachments. understanding the equipment and environmental
• Before starting the machine, be absolutely sure that conditions at the time of use. Some prohibited uses
the machine has been filled with fuel, lubricated, which can affect overturning hazards include those
greased and undergone all necessary such as traveling and turning with implements and
maintenance. loads carried too high. This manual sets forth some of
• Do not modify the machine, as it could lead to the obvious risks, but the list is not, and cannot be,
unforeseen safety problems. exhaustive. It is the operator's responsibility to be alert
• Do not operate a hydraulic hammer on anything to any equipment or environmental conditions that
that is above the operator's seat level as objects could compromise safe operation.
may fall into the operator station.
• Make sure that attachments, particularly those 2.1 Starting to operate the machine
utilizing quick attach systems, are securely
mounted. • Get into and out of the machine safely. Always face
• Install protective guards on the machine when the machine. Always use handrails and available
working in areas where objects may fall or be steps and keep yourself well balanced. Do not hold
thrown. The top guard and front guard are available any of the control levers and switches. Do not jump
for this machine. Consult your Kubota Dealer for on or off the machine, whether stationary or in
details. motion.
• Start and control the machine only from the
operator's seat. The driver should not lean out of
1.2 ROPS and OPG their seat when the engine is running.
• For your safety, a roll-over protective structure • Before starting the engine, make sure that lock
(ROPS) with a seat belt or operator protective levers are in the LOCK position, all control levers
guard, top guard level I (OPG, top guard level I) and pedals are in their neutral positions, and the
with a seat belt is installed by Kubota. seat belt is fastened correctly.
Before starting the engine, make sure that the
control levers, travel lever, pedals, and other control
1-2 U30-6S

SAFE OPERATION
2. Operating the machine 1. SAFETY
elements are not stuck and can be moved control levers or the pedals from outside the CAB
smoothly. while the engine is running.
If stuck, for example, a lever may fail to return, • Operate the machine so that it does not tip over.
possibly putting the user in danger. Keep away from steep slopes and embankments.
If anything wrong is found, immediately pinpoint the Do not swing the bucket downhill. Lower the dozer
cause and correct it. during digging. Keep the bucket as low as possible
• Make sure that the dozer blade is in front of the while driving uphill. Turn slowly on slopes (at
user (the dozer must be raised). If the levers are reduced speed). Do not place the machine near the
activated with the dozer blade at the rear, the tracks edges of trenches and banks, as the earth can give
will move in the opposite direction of the drive way due to the weight of the machine.
levers. Never cross an incline horizontally or at an angle,
as it can cause the machine to roll over. Approach
inclines head-on to avoid the loss of control.
Avoid performing any work with the machine when
it is on an incline, as this could cause the machine
to become unbalanced and roll over. Always take
care when moving the machine on an incline.
• Always pay close attention to the area to which the
machine is being moved. Watch out for any
hindrances.
• Do not change direction on steep slopes, as the
machine could roll over.
Before changing direction, be aware of people in
the work area.
• When the working light and CAB light alone do not
(A) Travel direction provide sufficient visibility, prepare additional
(B) Drive levers
(C) Front
stationary artificial lighting and observe the safety
(D) Dozer blade rules for night work.
• When towing the machine or pulling a load, the load
must be less than the strength of the towing line
2.2 Working the machine attached to the machine.
• Do not operate or idle engine in a non-ventilated Maximum drawbar pull at cou-

51 kN (5157 kgf)
area. Carbon monoxide gas is colorless, odorless, pling hook
and deadly. If you experience the initial symptoms Maximum vertical load at cou-
8.8 kN (895 kgf)
of low to moderate CO poisoning, which include pling hook
headaches, fatigue, shortness of breath, nausea, or
dizziness, stop operation, seek medical attention NOTE
– These figures are based on a machine with a CAB and steel
and contact your local Kubota Dealer. tracks.
• Keep all safety equipment and covers in place.

Replace damaged or missing safety devices. (1) Towing line
• When operating the machine, keep hands and body
inside of the ROPS or OPG (top guard level I) • The towing eye should not be used to tie down or to
protective envelope. Do not touch or depress the lift the machine.
U30-6S 1-3

SAFE OPERATION
1. SAFETY 2. Operating the machine
• When the machine is parked or left unattended on a

slope, be sure to put the bucket on the ground and
place all control levers in their neutral positions,
then brace the tracks with chocks.
– When working in groups, always let the others
know what you are going to do before you do it.
Keep others away from the machine working
area. Be sure to lock the boom swing pedal
when the boom swing function is not used.
• Details regarding the operation of the machine can
be found in a different section.
(See OPERATOR'S MANUAL.)
2.3 Important information on

excavator operation
• Do not try to crush concrete or boulders using side
swings with the bucket. Also, avoid using side
sweeps of the bucket to move earth piles.
– Excavation using the traveling power of the

machine.
• Under all circumstances, avoid the following

operations:
– Excavation using the gravitational impact of the
machine.
• Do not try to drop or shake off soil adhering to the

bucket in the manner given in the following points.
This can cause damage to the machine.
Adhering soil can be shaken off when the bucket is
being emptied by moving the bucket out to the
maximum stroke of the cylinder. Should this not
suffice, swing out the arm as far as possible and
operate the bucket back and forth.
– Compacting of gravel or soil using the dropping
action of the bucket.
1-4 U30-6S

SAFE OPERATION
2. Operating the machine 1. SAFETY
• Do not hit the dozer with the boom cylinder. • Support the machine correctly.
Make sure that the boom cylinder does not hit the When stabilizing the machine with the dozer, lower
dozer when doing deep excavations. If necessary, the dozer to engage the full width on the ground.
swivel around so that the dozer is at the back of the
machine.
• Pay attention when pulling in the bucket.

When pulling in the bucket (for driving or
transportation), avoid hitting the dozer.
• If the water or mud level reaches higher than the

top of the tracks, the swivel bearing, swivel motor
gear and ring gear may be exposed to mud, water
and other foreign objects.
• Avoid collisions with obstructions.

When moving the machine, pay attention that the
dozer does not collide with obstructions such as
boulders, and so on.
Such collisions shorten the life of the dozer and the
cylinder substantially.
U30-6S 1-5

SAFE OPERATION
1. SAFETY 2. Operating the machine
Before operating the machine in water, make sure • Stop the engine.
that the plugs, shutoff-valves and others are tight • Release the pressure from the hydraulic system.
enough. • Lock all control levers.
Also ensure that the water level is below the top of • Remove the key.
the shoe at the idler. • Lock the CAB door (if equipped).
The machine must be properly pressure washed
after each use.
– Thoroughly clean the area around the swivel
bearing, swivel motor gear and ring gear to
remove foreign objects.
– Inspect the swivel motor oil sump (if equipped)
for water contamination. If water is present,
refer to operator's manual for lubricant
replacement procedure.
– Refer to operator's manual for proper swivel
bearing, swivel motor gear and ring gear
lubrication procedures.
– Reinstall any protective coverings if removed
earlier.
– Avoid applying excessive load with cylinders
fully extended, or the machine can easily get
damaged.
– Relieve residual hydraulic pressure immediately
after the engine has stopped.
2.4 Safety for children

Tragedy can occur if the operator is not alert to the
presence of children. Children generally are attracted to
machines and the work they do.
• Never assume that children will remain where you
last saw them.
• Keep children out of the work area and under the (1) Pilot control lock lever (A) UNLOCK
watchful eye of another responsible adult. (B) LOCK
• Be alert and shut your machine down if children
enter the work area.
• Never carry children on your machine. There is no
safe place for them to ride. They may fall off and be
4. Safe loading and transport of
run over or interfere with your control of the the machine
machine.
• Observe all regulations concerning the transport of
• Never allow children to operate the machine even
machine on public roads.
under adult supervision.
• Use adequately long and robust ramps when
• Never allow children to play on the machine or on
loading on the machine.
the attachments.
(See TRANSPORTING THE MACHINE on page
• Use extra caution when backing up. Look behind
2-37)
and down to make sure the area clear before
• Do not change the running direction. To avoid
moving.
tipping over, do not try to swing the attachment
crosswise to the loading ramps.
3. After operation • Lower the attachment on the loading bed and
release the pressure from the hydraulic system.
Before leaving the machine: Then, stop the engine and remove the key.
• Park the machine on a firm, flat and level surface. If Block the tracks with blocks and chain down the
this is not possible, park across the slope. machine. After loading the machine on the vehicle,
Do not park the machine anywhere there are securely chain down the undercarriage of the
combustible materials such as dried grass or straw. machine using suitable chains, tensioners, and
• Lower the attachments and the dozer blade to the approved methods
ground.
1-6 U30-6S

SAFE OPERATION
5. Maintenance 1. SAFETY
First, loosen the cap to the first stop and allow the
system enough time to release the remaining
pressure. Then loosen the cap completely.
(1) Chain
(2) Block
• Avoid abrupt braking of the vehicle with the

machine loaded. Sudden braking causes the • To avoid short-circuiting the battery, always remove
machine to move and may cause a serious the ground cable first and attach the positive cable
accident. first.
• Do not use the hooks on the roof of the CAB for • Oil under high pressure can penetrate the skin and
lifting the machine. may be harmful to your health if not treated
immediately.
5. Maintenance • Leaking hydraulic fluid has enough pressure to
penetrate the skin and cause serious injuries.
Before doing maintenance work on the excavator, place Leakages from pin holes can be totally invisible. Do
the machine on a firm, flat and level surface, lower the not use hands for checking for leaks. Always use a
attachments to the ground, stop the engine, release piece of wood or cardboard. It is strongly
pressure trapped in the hydraulic system, lock all recommended that you use a face mask or eye
control levers and remove the key. When dismantling protection.
hydraulic parts, make sure that the hydraulic oil has In case of injuries caused by leaking hydraulic fluid,
cooled down sufficiently to avoid burns. Start contact a doctor immediately. This fluid can cause
maintenance work carefully, such as loosening the plug gangrene or serious allergic reactions.
slowly so that oil will not squirt out.
• Before doing work on the engine, the exhaust
system, the radiator and the hydraulics, let the
excavator cool down sufficiently.
• Always turn off the engine when filling the fuel tank.
Avoid spilling and over-filling of fuel.
• Smoking is prohibited while refueling or handling
the battery. Keep sparks and fire away from the fuel
tank and battery. Flammable gases escape from
the battery, especially during charging.
• Do not use or charge a refillable type battery if the
fluid level is below the [LOWER] (lower limit level)
mark. Otherwise, the battery component parts may
prematurely deteriorate, which may shorten the
battery's service life or cause an explosion. Check • To avoid environmental damage from acid and
the fluid level regularly and add distilled water as heavy metals, dispose of the battery appropriately.
required, so that the fluid level is between the • Observe all laws and regulations concerning the
[UPPER] and [LOWER] levels. disposal of used oil, coolants, solvents, hydraulic
• Read and follow the instructions when starting with fluids, battery acids and batteries.
an auxiliary battery. • To avoid fire, do not heat the hydraulic components
(See OPERATOR'S MANUAL.) (tanks, pipes, hoses, cylinders) before they have
• Keep a first aid box and a fire extinguisher handy at been drained and washed.
all times. • Use eye protection or a face mask to protect the
• Do not open the radiator cap before the radiator eyes and respiratory system against dust and other
has cooled down sufficiently. foreign particles.
U30-6S 1-7

SAFE OPERATION
1. SAFETY
• Kubota does not use components which contain

asbestos and recommends against the use of such
components.
Components containing asbestos should be
handled in accordance with applicable regulations
and industry practice.
• Fire prevention
The machine and some attachments have
components that are at high temperatures under
normal operating conditions. The primary source of
high temperatures is the engine and exhaust
system. The electrical system, if damaged or
incorrectly maintained, can be a source of arcing or
sparks.
• Securely support the excavator with stands or
The following fire prevention guidelines will help to
suitable blocking before working underneath. For
keep your equipment up and running efficiently and
your safety, do not work under any hydraulically
keep the risk of fire to a minimum.
supported devices. They can settle, suddenly leak
– Blow off all accumulated debris near hot engine
down, or be accidentally lowered.
exhaust components such as the exhaust
manifold, exhaust pipes, and muffler. Do this
more frequently when working in severe
conditions.
– Clean out all accumulated flammable debris
(such as leaves, straw, pine needles, branches,
bark, small wood chips) and any other
combustible materials from inside the machine
belly pans or lower unit structures as well as
from the area in proximity to the engine.
– Inspect all fuel lines and hydraulic hoses for
wear or for deterioration. Replace them
immediately if they begin to leak.
– Examine electrical wiring and connectors
• Do not dismantle the spring of the track tensioner. If frequently for damage. Repair any wires that
dismantling is necessary, contact your Kubota are loose or frayed before operating the
Dealer where the machine was purchased, or a machine. Clean all electrical connections and
competent service shop. The assembly must be tighten them as necessary.
done according to the Kubota work shop manual – Inspect the exhaust system daily for any signs
(WSM) for the product involved. of leakage. Check for broken pipes and muffler
• When lifting the machine itself with an attachment, and also for loose or missing bolts, nuts and
place a safety block or safety post to prevent the clamps. If any exhaust leaks or fractured parts
machine from rolling over. Keep the pilot control are found, repairs must be completed prior to
lock lever in the LOCK position. operation.
• Inspect ROPS/OPG (top guard level I) for damage – Always keep a multipurpose fire extinguisher on
and if damage is found contact your Kubota Dealer or near the machine. Be familiar with the
for repairs. operation of the fire extinguisher.
1-8 U30-6S

SAFE OPERATION
6. Safety labels 1. SAFETY
6. Safety labels
Canopy CAB
(1) Part No. RD809-5738-2 (2) Part No. RD829-5793-1

Do not forget to lock the front window.
U30-6S 1-9

SAFE OPERATION
1. SAFETY 6. Safety labels
Canopy CAB
(1) Part No. RC488-5728-1
(2) Part No. RC418-5727-4
1-10 U30-6S

SAFE OPERATION
(1) Part No. RB456-5783-1 (2) Part No. RB456-5788-1

There is a danger of a parked ma- Check overhead clearance with electric wires.
chine suddenly moving, which can
lead to being crushed or run over,
causing injury.
Before leaving the machine, lower
the attachments to the ground, set
the control levers to the lock posi-
tion, and remove the key.
(3) Part No. RB238-5736-1

Diesel fuel only No fire
U30-6S 1-11

SAFE OPERATION
(1) Part No. RC788-5727-2 (2) Part No. 69198-5739-1

Do not allow anyone within the working range.
Start engine only Do not start en-
from operator's gine by shorting
seat. across terminals.
(3) Part No. RC488-5714-1 (4) Part No. RB456-5795-1

Do not open the grease fitting completely or too quickly.
1-12 U30-6S

SAFE OPERATION
(1) Part No. RB449-5738-1 (2) Part No. RC418-5737-5

Touching the muffler or other high- There is a risk of being caught in the
temperature sections of the machine rotating section of the fan belt, caus-
during operation or after stopping ing injury.
can cause burns. When performing inspections and
Do not touch the high-temperature maintenance, completely stop the
sections of the machine. rotation.
U30-6S 1-13

SAFE OPERATION
(1) Part No. RD839-5786-1 (2) Part No. RC794-5723-1 (3) Part No. RC694-5747-1
When handling electric cables, there Opening the radiator cap when the
is a danger of electric shock. machine is at a high temperature
Read the operator's manual and can cause hot water or oil to spurt
take the correct measures. out, leading to injury.
Do not open the radiator cap before
the machine has cooled down.
1-14 U30-6S

SAFE OPERATION
Canopy CAB
(1) Part No. RC108-5796-1 (Both sides) (2) Part No. RB419-5796-2 (Both sides)
Lifting position Do not use the hook for lifting.
U30-6S 1-15

SAFE OPERATION
(1) Part No. RB456-5722-1 (Both sides) (2) Part No. RB456-5789-1 (Both sides)
Do not allow any person within the working range. Do not allow any person within the working range.
1-16 U30-6S

SAFE OPERATION
6.1 Care of safety labels

• Keep safety labels clean and free from obstructing material.
• Clean safety labels with soap and water, and dry with a soft cloth.
• Replace damaged or missing safety labels with new labels from your Kubota dealer.
• If a component with safety label(s) affixed is replaced with new part, make sure new label(s) is (are) attached in
the same location(s) as the replaced component.
• Mount new safety labels by applying on a clean dry surface and pressing any bubbles to outside edge.
U30-6S 1-17

2. GENERAL

GENERAL WORKING INSTRUCTIONS
1. General working precautions 2. GENERAL

1. General working precautions
• When servicing, observe the safety regulations in
the operator's manual and workshop manual.
• Clean the machine before maintenance.
• Before working, remove the negative (-) terminal
from the battery or turn off the battery isolator
switch.
• Disassemble the machine at a clean location.
• Whenever a special tool is required, use the special
tool that Kubota recommends. Or, craft the special
tools according to the illustrations in this manual.
• Use genuine Kubota parts to ensure safety and
machine performance.
(A) Alternately (C) Diagonally from center to

(B) Diagonally outside
3. Applying thread-locking fluid

1. Clean and dry the location where a thread-locking
fluid will be applied with a solvent to remove
moisture, oil, and dirt.
2. Apply the thread-locking fluid to the tip of the bolt.
3. If the threads are large, apply the thread-locking
fluid all around the bolt hole.
2. Tightening bolts and nuts

• Tighten the bolts and nuts to their specified torque.
NOTE
– Tighten the bolts and nuts alternately from
top to bottom and left to right so the torque
is distributed evenly.
– Gradually tighten the bolts and nuts two or
three times.
(A) Bolt hole (bolts, nuts) (B) Screw hole
4. Installing circlips
• When installing the circlip, assemble the circlip's
angular side (3) toward the side that receives force
(4) as shown in the figure.
U30-6S 2-1

2. GENERAL 5. Installing spring pins
• Tighten a grooved nut to the specified torque, align

the hole of the split pin to the tighten direction and
use an S-shaped split.
(1) Circlip (3) Angular side

(2) Rounded side
(A) Single side split (C) S-shaped split

(B) Double side split
7. Handling chain joint and split

pin
• Assemble the chain joint with its opening facing the
opposite direction of travel.
• Assemble the split pin with its opening facing the
direction of travel.
(4) Side that receives force (A) External circlip

(5) Force (B) Internal circlip
5. Installing spring pins

• When installing the spring pin, assemble the slit of
the spring pin in the direction that receives force as
shown in the figure.
(1) Chain joint (A) Direction of chain moving

(2) Split pin
8. Handling liquid gasket

• Use the specified liquid gasket.
• When using liquid gasket, fully remove the old
gasket and grease or oil.
• When applying liquid gasket, apply it on the joint
surface with a thickness of 3.0 to 5.0 mm (0.12 to
(1) Parallel movement (2) Rotational movement
0.13 in.) without making any gaps.
• When applying liquid gasket near the bolt hole (2),
6. Handling split pin apply it in the inner side.
• If there is a risk of oil leakage or if the hole goes all
• Replace split pins with new ones. Insert the split the way through when applying liquid gasket near
pins: once inserted, the two ends of the pin are bent the dowel pin (3) hole, apply it in the inner side.
apart to fix it in place.
2-2 U30-6S

9. Replacing O-rings 2. GENERAL
If there is no concern of oil leakage, apply it on the NOTE

outer side. • In cases when installing an oil seal without a
• Reassemble within 15 minutes after applying; wait press, place a wooden board on the seal
for 30 minutes or more then fill with oil. and gently tap the board with a hammer;
install the oil seal straightly and evenly.
3. Grease the seal lip and dust lip.
NOTE
• If the seal has a dust lip, grease the gap
between the lips.
• After oil seals are replaced, grease the
moving parts around the lip to prevent the
dry surfaces from wearing against each
other during engine start up.
(1) Application route (a) 3.0 to 3.5 mm (0.12 to

(2) Bolt hole 0.13 in.)
(3) Dowel pin (b) 3.0 to 5.0 mm (0.12 to
(A) Correct 0.19 in.)
(B) Incorrect
9. Replacing O-rings
1. Remove the burr and clean the O-ring groove.
2. Lubricate the O-ring. Do not apply any grease to
the floating seal.
3. Put the O-ring in the groove. (1) Packing (5) Grease
(2) Metal ring (6) Dust lip
NOTE (3) Spring (A) Air side
• Do not twist the O-ring. (4) Seal lip (B) Oil side
• Remove the burr to avoid damage on the O-
ring caused by the burr.
11. Replacing floating seals
1. Apply oil appropriately to both sides of the O-ring
and the contact surface.
2. Do not twist the O-ring when installing the floating
seal.
3. Apply oil thinly to the sliding surfaces.
4. Install the floating seal in parallel to the sliding
surfaces, O-rings, and housings.
5. After installation, rotate the floating seal for 3 times
to make an oil film on the sliding surface.
(1) O-ring groove (3) Burr

(2) O-ring
10. Replacing oil seals

1. Do not face the lip of the oil seal in the wrong
direction. Face the seal lip toward the material to be
sealed.
2. Use a press to install the oil seal until firmly fixed to
the boss.
U30-6S 2-3

2. GENERAL 12. Connecting hydraulic hoses
14. Installing elbows with male

seat
1. Clean the male seat surface and seal.
2. Loosen the lock-nut until the top end.
3. Install and tighten the elbow by hand until the male
seat touches the material surface.
(1) Sliding surface (2) O-ring
12. Connecting hydraulic hoses

1. Clean the inside of the hose fittings.
2. Tighten with the specified torque.
3. Apply pressure on the hydraulic hose to check for
oil leakage. (1) Lock-nut (3) Seal
(2) Seat
4. Adjust the direction of the elbow.

13. Wrapping thread seal tape
NOTE
1. Wrap the thread seal tape around the taper threads
• Do not loosen to more than one turn.
two or three turns.
2. Tighten the taper thread with the specified torque.
NOTE
• Do not loosen the taper thread after
tightening to avoid oil leakage.
• Do not wrap the thread seal tape on the first
and second threads to avoid contamination
in the hydraulic circuit.
5. Tighten the lock-nut with the specified torque.

NOTE
• Check for oil leakage.
(1) Thread seal tape (5) First and second threads

(2) Male thread from the screw tip
(3) Female thread
(4) Clearance
2-4 U30-6S

15. Connecting and disconnecting quick hose couplings 2. GENERAL
• Securely attach the terminal covers on the cables

when connecting the cables to the battery terminal
posts. There is a danger of short-circuiting if the tip
of the cables attached to the battery terminal post is
exposed.
• Do not allow dirt and dust to collect on the battery.
• Connect the battery terminals after removing dust,
old grease, blue rust and others.
• Apply conductive grease thinly to the battery
terminal posts to prevent corrosion.
(4) Wrench (6) Torque wrench

(5) Hose
15. Connecting and

disconnecting quick hose
couplings
1. Push the metal fittings in the direction of the arrow
mark.
(1) Battery negative (-) terminal (2) Battery positive (+) terminal
17. Handling wire harness
CAUTION
• Do not let an unprotected wire harness to come
in contact with other components.
• Do not clamp the wire harness to fuel hoses.
• If the wire harness is damaged, replace it
immediately with a new one.
• Do not alter the electrical device and wire
harness.
(1) Plastic part (2) Metal fitting
• Tighten the electrical terminals securely.
2. Pull the plastic part in the opposite direction of the
arrow mark.
3. Disconnect the quick hose coupling.
4. Push the quick hose coupling in the direction of the
arrow mark to connect.
5. Make sure that the hose is installed correctly.
16. Handling the battery
CAUTION
• When removing battery cables, disconnect
negative (-) terminal first.
• When installing battery cables, connect positive (A) Good (B) Bad: Loose bolt
(+) terminal first.
• Check the electrical terminal protection and
• Do not install any battery with a capacity (Ah) other clamping conditions before connecting the battery
than is specified. cable.
U30-6S 2-5

2. GENERAL 18. Handling fuses
(C) Covered completely with a (1) Grommet (K) Bad: poor installation
protection cover (J) Good
• Keep the wire harness away from hazardous • Clamp the wire harness securely. Do not damage
positions such as rotating parts or high-temperature the wire harness by the clamp.
sections. • Clamp the wire harness correctly. Do not slack,
twist, and pull.
(D) Hazardous position (G) Hazardous position

(E) Wiring position: bad (2) Wire harness (3) Clamp
(F) Wiring position: good
• Do not pinch the wire harness when installing parts.
• If wire harness is damaged or degraded, replace
immediately.
(4) Wire harness (L) Bad
(H) Damaged (I) Torn
• Install the grommet securely. 18. Handling fuses

• Always use fuses of the specified capacity.
• Do not use steel or copper wiring instead of fuse.
• Do not install work light or radio without auxiliary
power line.
2-6 U30-6S

19. Handling connectors 2. GENERAL
• Do not install auxiliaries to the fuses. The fuses

may blow.
(B) Good (C) Bad
• Make sure the terminal condition of the connectors

(1) Fuse (3) Slow blow fuse is not bent, rusty, and so on.
(2) Fusible link • If the terminal is rusted, remove rust with
sandpaper.
However, do not polish the terminal of the
19. Handling connectors waterproof connector or the plated terminal.
• When disconnecting the locking connectors, be
sure to disengage the lock before disconnecting.
There are two kinds of locks: one requires pressing
and the other requires pulling.
(1) Missing terminal (4) Rust

(2) Bent terminal
(3) Sandpaper
• Cover the female bullet terminals and male bullet

terminals securely with the plastic covers.
(A) Press
• Make sure that the bullet terminals are secure and
• Hold on tightly to the connectors when connected securely to the tip.
disconnecting them.
• Do not pull wire harness itself.
(D) Good (F) Bad: poor connection

(E) Bad: damaged cover
U30-6S 2-7

2. GENERAL 20. Wiring color
• Cover the female connectors and male connectors Wiring Colors Color code
securely with the plastic covers.
Black B
Brown BR, Br
Green G
Gray GY, GR, Gr
Blue L
Light green LG, Lg
Orange OR, Or
Pink P
Purple PU, Pu, V
Red R
(5) Cover (H) Bad: damaged cover Sky blue SB, Sb

(G) Good White W
Yellow Y
20. Wiring color • This symbol of "/" shows color with stripe(s).
(An example)
• Wire colors are specified in the color codes. W/R:
White with red stripe
21. Washing the machine with a

high pressure washer
Use a high pressure washer properly to avoid personal
injuries and damages to the machine.
CAUTION
• Damaged or cut the wire harness may cause
fire.
• Damaged hydraulic hoses or oil seals may
cause injury due to hydraulic oil gushing out.
(1) Wire color (2) Stripe
IMPORTANT
• Water infiltration may cause machine problems.
• Adjust the high pressure washer nozzle for a wide

spray. Do not adjust to pencil point spray.
• Spray the water at least 2 m away from the
machine.
2-8 U30-6S

22. Dispose fluids correctly 2. GENERAL
(1) Adjusting the washer power (C) Less than 2 m (80 in.)
(2) Washing distance (D) Over 2 m (80 in.)
(A) Pencil point spray
(B) Wide spray
22. Dispose fluids correctly

• Do not dispose fluids on the ground, down the
drain, into a stream, pond, or lake. Obey related
environmental protection regulations when you
dispose of oil, fuel, coolant, electrolyte, and other
dangerous materials.
U30-6S 2-9

2. GENERAL
2-10 U30-6S

PRELIMINARY WORKING INSTRUCTIONS
1. Vacuuming the hydraulic oil tank 2. GENERAL

1. Vacuuming the hydraulic oil
tank
When removing the hydraulic devices and hydraulic
hoses, vacuum the hydraulic oil tank to reduce the
hydraulic oil leakage.
1. Apply vinyl tape on the intake and exhaust ports of
the hydraulic oil tank cover to seal the hydraulic oil
tank.
2. Remove the hydraulic oil tank cap and attach the
vacuum pump mounting adapter.
3. Connect a vacuum pump to the vacuum pump
mounting adapter.
4. Connect an air hose to the vacuum pump and 2. Turn the starter switch to [RUN] without starting the
vacuum the hydraulic oil tank. engine.
(1) Hydraulic oil tank cover (C) Vacuum pump (1) Starter switch (C) [START]
(A) Vinyl tape (A) [STOP]
(B) Vacuum pump mounting (B) [RUN]
adapter
3. Lower the lever lock.
2. Releasing residual pressure

of the hydraulic circuit
1. Park the machine on the firm and level ground,
lower the bucket and blade to the ground, and stop
the engine.
(2) Lever lock (E) Lock

(D) Release
4. Operate the pilot control levers (boom, arm, bucket,

and swivel) several times in full stroke.
U30-6S 2-11

2. GENERAL 3. Removing the battery
5. Operate the travel control levers, blade control

lever, swing control pedal, and AUX control pedal
several times in full stroke.
(1) Nut ×2 (3) Battery cover

(2) Washer ×2
2. Disconnect the negative (-) terminal and the

(3) Travel control lever LH (7) Pilot control lever RH positive (+) terminal in order.
(4) Pilot control lever LH (8) Blade control lever
(5) AUX control pedal (9) Swing control pedal NOTE
(6) Travel control lever RH • Wrap insulating tape around the terminal
after removing.
6. Raise the lever lock and turn the starter switch to
[STOP]. 3. Remove the 2 nuts, stay and the clamp.
3. Removing the battery
CAUTION
• Keep fire (welding sparks, grinding sparks,
cigarettes) away from the battery. The battery
produces oxygen and hydrogen gases which
are flammable.
• Disconnect the negative (-) terminal first when
removing the battery.
• Connect the positive (+) terminal first when
connecting the battery cable.
(4) Negative (-) terminal (7) Stay
Preparing (5) Positive (+) terminal (8) Clamp
1. Remove the swivel cover RH. (6) Nut ×2
2. Open the bonnet RH 1. 4. Remove the battery.
Removing
1. Remove the 2 nuts and 2 washers to remove the
battery cover. 4. Vacuuming the refrigerant
gas
CAUTION
• Wear gloves, work clothing and eye protector to
protect your skin and eyes. Liquid refrigerant
may cause frostbite hazard due to evaporation.
• Keep fire and flammable items away from the
working area.
• Do not wash the cooling circuit with water.
Residual water in the cooling circuit may cause
corrosion.
2-12 U30-6S

5. Connecting the diagnostic connector 2. GENERAL
IMPORTANT
• The R134a refrigerant must be handled by
trained personnel when measuring, vacuuming,
or charging.
• Work at the clean and dry work space with
clean and dry tools.
• Follow the manifold gauge manufacturer's
manual when handling the manifold gauge.
• Follow the refrigerant vacuum machine
manufacturer's manual when handling the
refrigerant vacuum machine.
1. Close the high and low pressure valves of the

manifold gauge. (F) High pressure charging port (J) Refrigerant charging hose
([H] mark) (blue)
(G) Low pressure charging port
([L] mark)
(H) Refrigerant charging hose
(red)
4. Turn on the refrigerant vacuum machine.

5. Open the high and low pressure valve of the
manifold gauge to vacuum the refrigerant.
NOTE
• Vacuum the refrigerant until the cooling
circuit pressure decreases below -0.1 MPa
(-1.02 kgf/cm2).
6. Stop vacuuming, wait for 5 minutes, and make sure
(A) Manifold gauge (C) Low pressure valve
(B) High pressure valve
that cooling circuit pressure has not increased.
2. Connect the refrigerant charging hose (yellow) to NOTE

the refrigerant vacuum machine. • Vacuum the residual refrigerant in the
cooling circuit in the case that the cooling
circuit pressure has increased.
manifold gauge and disconnect the 3 charging
hoses.
NOTE
• Disconnect the charging hoses from the
charging ports quickly to prevent the
refrigerant from leaking to the atmosphere.
5. Connecting the diagnostic

(D) Refrigerant vacuum machine (E) Refrigerant charging hose connector
(yellow)
Canopy specification
3. Connect the refrigerant charging hose (red) to the 1. Open the seat support cover.
high pressure charging port and the refrigerant 2. Remove the diagnostic connector from the cap and
charging hose (blue) to the low pressure charging connect the diagnostic connector.
port.
U30-6S 2-13

2. GENERAL 6. Removing the bonnet, cover, and floor plate
(1) Diagnostic connector (1) Bolt (M10 × 25) ×2 (2) Rear bonnet
Cabin specification Removing the bonnet RH 1

1. Remove the diagnostic connector from the cap and 1. Open the bonnet RH 1.
connect the diagnostic connector. 2. Remove the 2 bolts to remove the bonnet RH 1.
(2) Diagnostic connector (3) Bolt (M10 × 25) ×2 (4) Bonnet RH 1
NOTE Removing the bonnet RH 2

• Diagnostic connector cannot be used for this 1. Open the bonnet RH 1.
machine. 2. Open the rear bonnet.
3. Remove the 4 bolts to remove the bonnet RH 2.
6. Removing the bonnet, cover,

and floor plate
Preparing
lower the front attachment and the blade to the
ground, and stop the engine.
Removing the rear bonnet
1. Open the rear bonnet.
2. Remove the 2 bolts to remove the rear bonnet.
2-14 U30-6S

2. GENERAL
(9) Rubber mat (11) Bonnet LH

(10) Bolt (M8 × 20)

3. Remove the fuel cap.
4. Remove the 3 bolts to remove the bonnet LH.
(5) Bolt (M8 × 16) ×4 (6) Bonnet RH 2
Removing the swivel cover RH

1. Remove the 2 upper bolts, and loosen the 1 lower
bolt.
2. Remove the swivel cover RH.
(11) Bonnet LH (13) Bolt (M8 × 16) ×3
(12) Fuel cap
Removing the swivel cover LH

1. Remove the 2 upper bolts, and loosen the 2 lower
bolts.
2. Remove the swivel cover LH.
(7) Bolt (M10 × 20) ×3 (8) Swivel cover RH
Removing the bonnet LH

1. Remove the rubber mat and remove the bolt.
(14) Bolt (M10 × 20) ×4 (15) Swivel cover LH
Removing the floor plate 1

1. Remove the rubber mat.
2. Remove the floor plate 1.
U30-6S 2-15

2. GENERAL 7. Jacking up the machine
Recommended jack stand
(16) Floor plate 1

(A) Jack stand
7. Jacking up the machine Dimensions
(b) 520 mm
CAUTION (c) 500 mm
• Do not work underneath when the machine is
(d) 440 mm
jacked up.
• Place the machine on jack stands securely (e) 75 mm
when lifting the machine.
Jacking up the machine
Preparing 1. Raise the front attachment.
1. Park the machine on the firm and level ground. 2. Swivel the upper structure of the machine to 180°.
2. Prepare the proper jack stands based on dimension 3. Put 2 cushions under the bucket and the blade.
(a). 4. Operate the blade to jack up the front side of the
machine.
(a) 276 mm
(B) Cushion
5. Operate the boom, the arm, and the bucket to jack

up the rear side of the machine.
2-16 U30-6S

2. GENERAL
6. Place 2 jack stands under the track frame.
(1) Track frame (C) Contact surface
7. Lower the machine and place the machine on the

jack stands.
8. Place the bucket and the blade on the ground.
U30-6S 2-17

2. GENERAL
2-18 U30-6S

CONCLUDING WORKING INSTRUCTIONS
1. Charging the refrigerant gas 2. GENERAL

1. Charging the refrigerant gas 2. Disconnect the refrigerant charging hose (yellow)
from the vacuum machine.
CAUTION
• Wear gloves, work clothing, and eye protector
to protect your skin and eyes. Liquid refrigerant
working area.
• Release the residual pressure in the manifold
gauge before connecting the refrigerant
canister to the manifold gauge. High residual
pressure causes explosion of the refrigerant
canister.
(A) Manifold gauge (C) Vacuum machine
corrosion.
(B) Refrigerant charging hose
(yellow)
IMPORTANT
• The R134a refrigerant must be handled by Charging the refrigerant from the high pressure
trained personnel when measuring, vacuuming, charging port
and charging. 1. Connect the refrigerant charging hose (yellow) to
• Work at the clean and dry work space with the refrigerant canister.
• Use the refrigerant and parts specified by
R134a. Mixing with other refrigerants or using
parts which are not specified by R134a may
cause leakage, performance decrement, and so
on.
• Keep the refrigerant canister upright while
charging the refrigerant.
• Follow the refrigerant canister manufacturer's
manual when charging and storing the
refrigerant.
manual when handling the manifold gauge.
Preparing (A) Manifold gauge (E) Low pressure valve

1. Vacuum the refrigerant from the cooling circuit. (B) Refrigerant charging hose (F) Refrigerant canister
(yellow)
IMPORTANT (D) High pressure valve
• Keep the high and low pressure valves of 2. Open the refrigerant canister valve and press the
the manifold gauge closed to prevent air air bleeding valve to release the air in the
infiltration into the cooling circuit. refrigerant charging hose (yellow) and manifold
gauge.
NOTE
• Vacuum the cooling circuit until the
pressure decreases below -0.1 MPa
(-1.02 kgf/cm2).
• Vacuum the cooling circuit for 25 minutes to
dry the inside of the circuit.
U30-6S 2-19

2. GENERAL 2. Bleeding the air from the hydraulic cylinder
Charging the remaining refrigerant from the low

pressure charging port
1. Close the high pressure valve of the manifold
gauge.
2. Open the cabin door and windows.
3. Start the engine and accelerate the engine speed to
1500 rpm.
4. Turn on the air conditioning switch and adjust the
temperature switch to the coolest level.
5. Turn the fan switch to the maximum air flow (fan
switch position [3]).
(1) Fan switch (K) Fan switch position [2]

(2) Air conditioning switch (L) Fan switch position [3]
(J) Fan switch position [1]
(A) Manifold gauge (G) Refrigerant canister valve
(D) High pressure valve (H) Air bleeding valve 6. Open the low pressure valve of the manifold gauge
(E) Low pressure valve
to charge the remaining refrigerant into the
3. Open the high pressure valve of the manifold gauge refrigerant circuit.
to charge the refrigerant. 7. Close the low pressure valve and refrigerant
canister valve to stop charging. Then stop the
NOTE engine, and disconnect the charging hoses (blue).
• Soak the refrigerant canister in 40 ℃ water if
the refrigerant canister is frosting. NOTE
• Check for refrigerant leakage with a gas leak • Disconnect the charging hoses from the
tester. charging ports quickly to avoid refrigerant
• Vacuum the refrigerant and repair or replace leaking to the atmosphere.
the damaged parts in case of leakage.
• If the refrigerant canister was replaced
during charge, press the air bleeding valve 2. Bleeding the air from the
to release the air in the refrigerant charging
hose (yellow) and manifold gauge. hydraulic cylinder
• Charge the remaining refrigerant from the Bleed air from the hydraulic cylinder after removing and
low pressure charging port if the specified disassembling the hydraulic cylinder to prevent
volume of the refrigerant cannot be charged. cavitation and seizure of the internal parts.
1. Set the engine speed to less than 1500 rpm.
Service specification
IMPORTANT
Refrigerant amount 880 to 930 g
• If the engine speed is more than 1500 rpm,
4. Close the high pressure valve and refrigerant the seals and bushings may be damaged.
canister valve to stop charging, and disconnect the 2. Compress and extend the hydraulic cylinder slowly
charging hoses (red). to bleed air.
NOTE IMPORTANT
• Disconnect the charging hoses from the • Do not relieve the main relief valve of the
charging ports quickly to avoid refrigerant hydraulic cylinder at the end of stroke.
leaking to the atmosphere.
2-20 U30-6S

3. Bleeding the air from the hydraulic pump 2. GENERAL
When the cylinder is fully retracted 2. Remove the bonnet LH.

3. Open the bonnet RH 1.
Bleeding
1. Remove the hydraulic oil tank cap.
2. Disconnect the 3 clamps to disconnect the air bleed
hose.
3. Push the plug on the air bleed hose and the quick
coupler.
4. Hold the quick coupler, and pull out the plug on the
air bleed hose.
NOTE
• Be careful not to splash the hydraulic oil
when pulling out the plug.
When the cylinder is fully extended
(1) Clamp ×3 (4) Quick coupler

(2) Air bleed hose
When the cylinder is in mid-stroke (3) Plug
5. Leave the air bleed hose for 30 seconds.
3. Bleeding the air from the 6. Install the plug to the air bleed hose.
7. Install the air bleed hose to the clamp.
hydraulic pump 8. Start the engine in idling speed, and check for
Bleed air from the hydraulic pump after removing and cavitation noise.
disassembling the hydraulic components, replacing the NOTE
hydraulic oil, or vacuuming the hydraulic oil tank to • If cavitation noise is heard, stop the engine
prevent cavitation and seizure of the hydraulic pump. and repeat bleeding the air from the
Preparing beginning until cavitation noise is not heard.
lower the front attachment and blade to the ground, 9. Raise the engine speed to approximately 1500 rpm,
and stop the engine. slowly operate the front attachment without
U30-6S 2-21

2. GENERAL
relieving the relief valves, and check for cavitation

noise.
NOTE
• If cavitation noise is heard, stop the engine
and repeat bleeding the air from the
beginning until cavitation noise is not heard.
10. Raise the engine speed to approximately 2000 rpm,
slowly operate the front attachment without
relieving the relief valves, and check for cavitation
noise.
NOTE
11. Raise the engine speed to the maximum, slowly
operate the front attachment without relieving the
relief valves, and check for cavitation noise.
NOTE
2-22 U30-6S

TIGHTENING TORQUES
1. Bolts and nuts tightening torque 2. GENERAL
TIGHTENING TORQUES
1. Bolts and nuts tightening torque

NOTE
• Screws, bolts and nuts which tightening torques are not specified in this workshop manual should be
tightened according to the table below.
Mark
on top
of bolt No grade or 4T 7T 9T
Mark
on top
of nut No grade or 4T 6T
Materi-
Steel Aluminum Steel Aluminum Steel
al
Units N⋅m kgf⋅m lbf⋅ft N⋅m kgf⋅m lbf⋅ft N⋅m kgf⋅m lbf⋅ft N⋅m kgf⋅m lbf⋅ft N⋅m kgf⋅m lbf⋅ft
7.9 to 0.80 to 5.8 to 7.9 to 0.80 to 5.8 to 9.81 to 1.00 to 7.24 to 7.9 to 0.80 to 5.8 to 12.3 to 1.25 to 9.05 to
M6
9.3 0.95 6.8 8.8 0.90 6.5 11.2 1.15 8.31 8.8 0.90 6.5 14.2 1.45 10.4
1.8 to 1.7 to 2.4 to 1.8 to 3.0 to
M8 18 to 20 13 to 15 17 to 19 13 to 14 24 to 27 18 to 20 18 to 20 13 to 15 30 to 34 22 to 25
2.1 2.0 2.8 2.1 3.5
4.0 to 3.2 to 4.9 to 4.0 to 6.2 to
M10 40 to 45 29 to 33 32 to 34 24 to 25 48 to 55 36 to 41 40 to 44 29 to 32 61 to 70 45 to 52
4.6 3.5 5.7 4.5 7.2
6.4 to 7.9 to 6.4 to 103 to 10.5 to 76.0 to
M12 63 to 72 47 to 53 - - - 78 to 90 58 to 66 63 to 72 47 to 53
7.4 9.2 7.4 117 12.0 86.7
108 to 11.0 to 79.6 to 124 to 12.6 to 91.2 to 167 to 17.0 to 123 to
M14 - - - - - -
125 12.8 92.5 147 15.0 108 196 20.0 144
167 to 17.0 to 123 to 197 to 20.0 to 145 to 260 to 26.5 to 192 to
M16 - - - - - -
191 19.5 141 225 23.0 166 304 31.0 224
M18 - - - - - -
284 29.0 209 318 32.5 235 402 41.0 296
M20 - - - - - -
392 40.0 289 431 44.0 318 568 58.0 419
2. Stud bolts tightening torque

Material Steel Aluminum
Units N⋅m kgf⋅m lbf⋅ft N⋅m kgf⋅m lbf⋅ft
M8 12 to 15 1.2 to 1.6 8.7 to 11 8.9 to 11 0.90 to 1.2 6.5 to 8.6
M10 25 to 31 2.5 to 3.2 18 to 23 20 to 25 2.0 to 2.6 15 to 18
M12 30 to 49 3.0 to 5.0 22 to 36 31 3.2 23
M14 62 to 73 6.3 to 7.5 46 to 54 - - -
M16 98.1 to 112 10.0 to 11.5 72.4 to 83.1 - - -
M18 172 to 201 17.5 to 20.5 127 to 148 - - -
U30-6S 2-23

TIGHTENING TORQUES
2. GENERAL 3. Hydraulic hose fitting tightening torque
3. Hydraulic hose fitting 4. Hydraulic hoses tightening

tightening torque torque (taper thread)
(1) Union nut (1) Taper thread
Units N⋅m kgf⋅m lbf⋅ft Units N⋅m kgf⋅m lbf⋅ft
1/8 7.8 to 11.8 0.8 to 1.2 5.8 to 8.7 1/8 19.6 to 29.4 2.0 to 3.0 14.5 to 21.6
1/4 24.5 to 29.2 2.5 to 3.0 18.1 to 21.5 1/4 36.6 to 44.1 3.7 to 4.5 27.0 to 32.5
3/8 37.2 to 42.1 3.8 to 4.3 27.5 to 31.0 3/8 68.6 to 73.5 7.0 to 7.5 50.6 to 54.2
1/2 58.8 to 63.7 6.0 to 6.5 43.4 to 46.9 1/2 83.4 to 88.3 8.5 to 9.0 61.6 to 65.1
3/4 117.6 to 127.4 12.0 to 13.0 86.7 to 94.0 3/4 166.6 to 181.3 17.0 to 18.5 122.9 to 133.7
1 181.3 to 191.1 18.5 to 19.5 133.8 to 140.9
1-1/4 220.5 to 230.3 22.5 to 23.5 162.8 to 170.0

5. Locknuts of adapters with O-
Units N⋅m kgf⋅m lbf⋅ft ring tightening torque (straight
9/16-18
35.2 to 43.1 3.6 to 4.4 26.0 to 31.8
thread)
(ORS type)
11/16-16
60.0 to 73.5 6.0 to 7.5 44.3 to 54.2
(ORS type)
13/16-16
70.6 to 86.2 7.2 to 8.8 52.1 to 63.6
(ORS type)
1-14 (ORS
105.8 to 129.4 10.8 to 13.2 78.0 to 98.4
type)
(1) Locknut (3) Seal (O-ring)

(2) Seat
2-24 U30-6S

TIGHTENING TORQUES
6. Adapters tightening torque (taper thread) 2. GENERAL
Units N⋅m kgf⋅m lbf⋅ft 7. Hose clamps tightening

1/8 15.0 to 16.5 1.5 to 1.7 11.1 to 12.1 torque
1/4 24.5 to 29.4 2.5 to 3.0 18.1 to 21.5 Steel band type
3/8 49.0 to 53.9 5.0 to 5.5 36.2 to 39.7
1/2 58.8 to 63.7 6.0 to 6.5 43.4 to 46.9
3/4, 1 117.6 to 127.4 12.0 to 13.0 86.74 to 93.96
1-1/4 220.5 to 230.3 22.5 to 23.5 162.7 to 169.8
6. Adapters tightening torque

(taper thread)
Units N⋅m kgf⋅m lbf⋅ft
ϕ13-ϕ20 2.5 to 3.4 0.3 to 0.4 1.9 to 2.5
ϕ15-ϕ25
ϕ19-ϕ28
ϕ22-ϕ32
ϕ26-ϕ38
ϕ32-ϕ44
(1) Taper thread
ϕ44-ϕ56 4.9 to 5.9 0.5 to 0.6 3.7 to 4.3
Units N⋅m kgf⋅m lbf⋅ft ϕ50-ϕ65
1/8 19.6 to 29.4 2.0 to 3.0 14.5 to 21.6 ϕ58-ϕ75
1/4 36.3 to 44.1 3.7 to 4.5 27.0 to 32.5 ϕ60-ϕ80
3/8 68.6 to 73.5 7.0 to 7.5 50.6 to 54.2 ϕ68-ϕ85
1/2 83.4 to 88.3 8.5 to 9.0 61.6 to 65.1 ϕ77-ϕ95
3/4 166.6 to 181.3 17.0 to 18.5 122.9 to 133.7
Wire band type
ϕ10-ϕ14 2.5 to 3.4 0.3 to 0.4 1.9 to 2.5

(Continued)
U30-6S 2-25

TIGHTENING TORQUES
2. GENERAL
ϕ12-ϕ16
ϕ19-ϕ25
2.5 to 3.4 0.3 to 0.4 1.9 to 2.5
ϕ31-ϕ40
ϕ36-ϕ46
ϕ44-ϕ53
3.9 to 4.9 0.4 to 0.5 2.9 to 3.6
ϕ51-ϕ59
ϕ86-ϕ96 2.5 to 3.4 0.3 to 0.4 1.9 to 2.5
2-26 U30-6S

GENERAL MACHINE INFORMATION
1. Machine model identification 2. GENERAL

1. Machine model identification
IMPORTANT
• Before contacting customer support, take notes
of the excavator model, serial number, engine
type, engine serial number, and hour meter.
(B) Product identification num- (D) Serial number (5 digits)

ber [PIN] (17 digits)
2. Engine model identification

IMPORTANT
• Before contacting customer support, take notes
of the excavator model, serial number, engine
type, engine serial number, and hour meter.
(A) Engine model and serial

number
(A) Model
(B) Product identification number [PIN] (17 digits)
(C) Engine number
(B) Engine model (E) Production month

(C) Engine series (F) Sequence number
(D) Production year (G) Engine serial number
Engine serial number

The engine serial number identifies the engine series,
production year, production month, and sequence
number.
U30-6S 2-27

2. GENERAL
Engine series Letter Month

Number or letter Series U or V October
1 05 (include: WG) W or X November
2 V3 Y or Z December
3 08 * Alphabetical letters "I" and "O" are not used.
4 SM (include: WG) Sequence number
5 Air-cooled gasoline
Sequence number
6 GZ, OC, AC, EA, E
0001 to 9999 or A001 to Z999
7 03 * Alphabetical letters "I" and "O" are not used.
8 07
A EA, RK
B 03 (KET production)
Production year
Number Number
Year Year
or letter or letter
1 2001 F 2015
2 2002 G 2016
3 2003 H 2017
4 2004 J 2018
5 2005 K 2019
6 2006 L 2020
7 2007 M 2021
8 2008 N 2022
9 2009 P 2023
A 2010 Q 2024
B 2011 R 2025
C 2012 S 2026
D 2013 T 2027
E 2014 - -
* Alphabetical letters "I" and "O" are not used.
Production month
Letter Month
A or B January
C or D February
E or F March
G or H April
J or K May
L or M June
N or P July
Q or R August
S or T September
(Continued)
2-28 U30-6S

3. Specifications 2. GENERAL
3. Specifications
Model U30-6S
Type Canopy Cabin
Crawler Rubber tracks Steel tracks Rubber tracks Steel tracks
Machine weight 3095 kg 3210 kg 3250 kg 3365 kg
Operating weight* 3170 kg 3285 kg 3325 kg 3440 kg
Capacity (CECE) 0.09 m3
Bucket
Width with teeth 524 mm
Type Water cooled 4 cycle diesel engine with 3 cylinder
Model name D1803-M-DI-E2-BH-TH1 D1803-M-DI-E2-BH-TH2
Total displacement 1826 cm3
Net
19.7 kW / 2200 min-1(rpm)
SAE J1349
Net
20.5 kW / 2200 min-1(rpm)
Engine Rated output / ISO 8178
Speed Net
20.5 kW / 2200 min-1(rpm)
ISO 9249
Gross
20.5 kW / 2200 min-1(rpm)
SAE J1995
Rated engine speed 2200 min-1(rpm)
Idling engine speed 1150 min-1(rpm) 1300 min-1(rpm)
Swivel speed 8.6 min-1(rpm)
Low speed 2.6 km/h 2.5 km/h 2.6 km/h 2.5 km/h
Travel speed
High speed 4.5 km/h 4.4 km/h 4.5 km/h 4.4 km/h
Performance
28.4 kPa 29.4 kPa 29.8 kPa 30.8 kPa
Ground pressure (without operator)
0.287 kgf/cm2 0.300 kgf/cm2 0.304 kgf/cm2 0.314 kgf/cm2
58%
Climbing performance
30°
Blade Width (extended) × Height 1550 × 340 mm
LH 70°
Boom swing angle
RH 48°
Maximum flow rate (theoretical) 50.0 L/min
AUX 20.6 MPa
Maximum pressure
210 kgf/cm2
Fuel tank capacity 41.5 L
Pulling capacity at the towing eyes 46599 N 48290 N 48878 N 50568 N
Vertical load at the towing eyes 8092 N 8385 N 8487 N 8781 N
LpA 81.2 dB (A) 80.3 dB (A)
Noise level LwA
95.4 dB (A) 95.4 dB (A)
(2000 / 14 / EC)
* Machine weight including operator's weight (75 kg)
NOTE
• Specifications are based on the machine with the standard bucket.
• Specifications are subject to change without prior notice.
• Climbing ability and angle are based on the condition below. Worse condition or heavier attachment will
decrease the climbing performance.
– Machine with an unloaded bucket
– Firm and compacted soil
U30-6S 2-29

2. GENERAL 4. Machine dimensions
4. Machine dimensions
(a) (b) (c) (d) (e) (f) (g) (h) (i)
4265 mm*1 2880 mm*1 2805 mm*1 2275 mm*1

600 mm 600 mm 1550 mm 790 mm 3500 mm
4250 mm*2 2865 mm*2 2820 mm*2 2290 mm*2
(j) (k) (m) (n) (p) (r) (s) (t) (u)
360 mm*1 335 mm*1 2485mm*1 4545 mm*1

4905 mm 1550 mm 4780 mm 1250 mm 2290 mm
350 mm*2 345 mm*2 2470 mm*2 4530 mm*2
*1: Steel tracks specification

*2: Rubber tracks specification
NOTE
• Specifications are subject to change without prior notice.
2-30 U30-6S

5. Machine mass table 2. GENERAL
5. Machine mass table

NOTE
• Mass values described here are reference values based on actual measured values (marked with @) and
drawing values.
Mass Remarks
Boom 113 kg -
Boom cylinder 32 kg -
Arm 67 kg -
Arm cylinder 31 kg -
Front attachment
Bucket 64 kg -
Bucket cylinder 22 kg -
Swing bracket 71 kg -
Swing cylinder 23 kg -
Canopy 62 kg -
Cabin 216 kg -
Counterweight 400 kg -
Seat assembly 14 kg -
Seat support 38 kg -
Arch frame 44 kg -
Engine 163 kg -
Alternator 4.0 kg -
Starter motor 4.0 kg -

Upper structure
Radiator 3.0 kg -
Muffler 7.0 kg -
Fuel tank 5.0 kg -
Hydraulic pump 31 kg -
Control valve assembly 59 kg @
Hydraulic oil tank 19 kg -
Swivel motor 33 kg -
Swivel joint 14 kg -
Swivel bearing 37 kg -
Rubber track 131 kg -
Steel track 175 kg -
Front idler 28 kg -
Tension spring assembly 10 kg -

Undercarriage
Grease cylinder 7.0 kg -
Track roller 8.0 kg -
Carrier roller 3.0 kg -
Blade 114 kg -
(Continued)
U30-6S 2-31

2. GENERAL
Mass Remarks
Blade cylinder 20 kg -
Undercarriage
Travel motor 41 kg With the sprocket
2-32 U30-6S

GENERAL ELECTRICAL INFORMATION
1. Electrical circuit general description 2. GENERAL

1. Electrical circuit general description
1.1 Electrical circuit diagram description
(a) Part name (c) Electrical wiring size (e) Unit symbol (g) Pin number
(b) Specification code (d) Wiring color coding (f) Pin name
1.2 Electrical circuit diagram unit symbol
(1) Variable (11) Heating element (22) Auto-resetting NC (normally (31) Starter switch
(2) Nonlinear variable (12) Capacitor closed) (32) STOP
(3) Fixed setting (13) Electrolytic capacitor (23) Auto-resetting NO (normally (33) RUN
(4) Step variable (14) Magnetic core inductance open) (34) START
(5) Non-ionizing radiation (NIR) (15) PNP transistor (24) Relay coil
(6) Body GND (16) NPN transistor (25) Fuse
(7) Thermistor (17) Semiconductor diode (26) Lamp
(8) Resistor (18) Light-emitting diode (LED) (27) Buzzer
(9) Variable resistor (19) Two-way breakdown diode (28) Horn
(10) Potentiometer with sliding (20) Coil (29) Speaker
contact (21) NO (normally open) (30) AC voltage source
U30-6S 2-33

2. GENERAL 1. Electrical circuit general description
1.3 Electrical wiring color coding

Wiring color Color code Wiring color Color code
Black B Blue/Green L/G
Green G Blue/Orange L/O
Blue L Blue/Red L/R
Pink P Blue/White L/W
Red R Blue/Yellow L/Y
Yellowish
White W LG/L
green/Blue
Yellowish
Yellow Y LG/R
green/Red (a) Electric wiring size (mm2) (c) Stripe color
(b) Base color
Yellowish
Brown BR LG/W
green/White • 1.25-Y/R
Yellowish 1.25 mm2 (electric wiring size)
Gray GR LG/Y Y: Yellow (base color)
green/Yellow
R: Red (stripe color)
Yellowish
LG Orange/White O/W
green
Orange O Pink/White P/W 1.4 Electrical wiring clamp

Light blue SB Pink/Blue P/L
Black/Green B/G Red/Black R/B
Black/Blue B/L Red/Green R/G
Black/Pink B/P Red/Blue R/L
Black/Violet B/V Red/White R/W
Black/Red B/R Red/Yellow R/Y
Black/White B/W Violet/White V/W
Black/Yellow B/Y White/Black W/B
Brown/Black BR/B White/Green W/G
Brown/Yellow BR/Y White/Blue W/L

(1) Anchor type (insert to the an- (4) Plug-in type (insert until it
Brown/Red BR/R White/Red W/R
chor) locks)
Green/Black G/B White/Yellow W/Y (2) Screw type (insert to the (A) Wire harness
screw end)
Green/Blue G/L Yellow/Black Y/B (3) Plug-in type (insert until it
locks)
Green/Red G/R Yellow/Green Y/G
Green/White G/W Yellow/Blue Y/L
Green/Yellow G/Y Yellow/Red Y/R
Blue/Black L/B
2-34 U30-6S

1. Electrical circuit general description 2. GENERAL
1.5 Bus description 2. Connector

Bus simplifies complex circuits with many branches. 2.1 Connector handling precaution
IMPORTANT
• When disconnecting a connector, grasp the
connector to pull it out. Do not pull the wiring.
• When disconnecting a locking type connector,
release the lock and pull it out.
• When removing the waterproof plastic cover of
the connector, do not allow water to enter the
connector.
• Repair any connector terminal deformations.
Ensure that there is no protruding, loose, or
rusty wiring.
• Ensure that the locking type connector is
locked when inserted.
2.2 Connector diagram description

Fewer than 10 pins
Female
(A) Diagram with bus (B) Diagram without bus
1.6 Composite terminal description

Connects 2 or more terminals together to a device.
(1) Non-waterproof (2) Waterproof
• Numbers are arranged from the top right.

• Number 1 is located on the top right.
Male
(3) Non-waterproof (4) Waterproofed
• Numbers are arranged from the top left.

• Number 1 is located on the top left.
U30-6S 2-35

2. GENERAL 2. Connector
More than 11 pins

Female
(1) Main ECU connector (fe-

male)
2-36 U30-6S

TRANSPORTING THE MACHINE
1. Loading and unloading the machine on a truck 2. GENERAL

1. Loading and unloading the
machine on a truck
DANGER
• Make sure that the loading ramp has sufficient
load capacity and is securely connected to the
truck.
• Do not use a wet loading ramp. The machine
may fall from the loading ramp.
• Do not change the machine direction on the
loading ramp. To change the direction, move
the machine off the loading ramp, and turn the
machine on the ground. (A) Wheel stopper
• When driving the machine on or off the truck, or
Loading
swinging the upper structure, take care not to
1. Set a loading ramp securely.
damage the cab and gate of the truck.
2. Set a support block under the loading ramp to
• Do not operate the front attachment, or turn or
prevent the front side of truck from lifting by the
steer the machine while loading or unloading
machine weight.
the machine.
3. Start the engine.
• Do not operate the machine with high speed
4. Completely align the loading ramp and the tracks,
while loading or unloading the machine.
and drive the machine onto the truck bed with low
• Once the machine reaches the connecting point
speed.
between the loading ramp and truck bed, halt
the machine, and then drive carefully until the NOTE
machine posture becomes horizontal. • Make sure to position the bucket not to hit
the ground or loading ramp.
• Turn off the AI switch.
• Set the travel speed shift switch to low
speed.
• When loading the machine onto the truck,
place the bucket at a height of 200 to
400 mm from the loading ramp, with the arm
perpendicular to the loading ramp or slightly
retracted.
• Pull in the arm completely before loading the

machine onto the truck.
• Do not jack up the machine using its boom to
load or unload the machine from the truck.
Preparing
1. Park the truck on the firm and level ground and stop
the engine.
2. Apply the parking brake of the truck and block the
drive wheels from both sides.
U30-6S 2-37

2. GENERAL 2. Towing the inoperable machine
(B) Loading ramp (a) 4 × (D) or more (G) Tie down point
(C) Support block (b) 200 to 400 mm
(D) Track bed height Unloading
5. After ensuring that the tracks are completely on the 1. Start the engine.
truck bed, swivel the machine 180° and place the 2. Operate the machine with low speed to unload the
bucket on the truck bed. machine.
6. Lower the blade onto the truck bed.
NOTE
7. Pull in the bucket and the arm completely and then
• Make sure to position the bucket not to hit
lower the boom.
the ground or loading ramp.
8. Stop the engine, release the pressure trapped in
• Turn off the AI switch.
the hydraulic system, and remove the key.
• Set the travel speed shift switch to low
9. Lower the lever lock to the lock position.
speed.
10. Securely secure the machine to the truck bed with
support blocks and chains.
NOTE 2. Towing the inoperable
• Drive the truck carefully to prevent the
machine from moving while transporting.
machine
IMPORTANT
• Towing is only allowed in situations such as the
machine is stuck in mud.
• When towing the machine or pulling a load, the
load must be less than the strength of the
towing line attached to the machine. Do not use
towing lines for tying down or lifting the
machine.
• Do not tow for a long distance.
• Tow at walking speed.
• Use a chain or rope that is capable of towing an
object 1.5 times heavier than the machine.
• Towing should only be carried out by trained or
licensed personnel.
(E) Support block (F) Chain • During towing, operator must be seated on the
operator seat.
1. Attach chain or rope to the towing point.
2-38 U30-6S

2. GENERAL
(A) Towing point (B) Chain or rope
2. Tow the machine at walking speed with a truck.
U30-6S 2-39

2. GENERAL
2-40 U30-6S

SPECIAL JIGS AND TOOLS
1. Special tools for the engine section 2. GENERAL

1. Special tools for the engine Nozzle tester
section
1.1 Engine compression pressure
measuring kit
Diesel engine compression tester
(A) Support (D) Nut (M12) ×2

(B) Pipe fitting (M12-G1/4) (E) Test hose
(C) Bolt (M10 × 35) ×2
Support
(A) Pressure gauge (C) Adapter K (07909-31301)

(B) Hose assembly
2. Special tools for the hydraulic

section
2.1 Overload relief valve measuring
kit
CAUTION
• When measuring overload relief pressure, use a
test hose which has enough pressure Dimension
endurance.
(a) 100 mm
(b) 50 mm
(c) 2.3 mm
(d) 70 mm
(e) 15 mm
(f) 600 mm
(g) 11 mm
U30-6S 2-41

2. GENERAL 2. Special tools for the hydraulic section
Pipe fitting (M12-G1/4) 2.2 Travel motor special jigs
(A) Floating seal installation jig (D) Cover removal jig

Dimension (for housing) (E) Ring nut tightening jig
(B) Floating seal installation jig (F) Removal bolt
(a) 47 mm (pusher) (G) Oil seal installation jig
(C) Floating seal installation jig
(b) 12 mm
(plunger holder)
(c) 15 mm
Floating seal installation jig (for housing)
(d) 20 mm
(e) 10 mm
(f) 12 mm
(g) ϕ8 mm
(h) ϕ3 mm
(i) ϕ18 mm
(j) ϕ9±0.2 mm
(k) 19 mm
(m) 21.9 mm
(n) M12 × 1.5
(p) G1/4
(r) 30° Dimension
(a) 17 mm
(b) 12 mm
(c) 5 mm
(d) 15°
(e) ϕ198 mm
(f) ϕ179.6 mm
(g) ϕ170.5 mm
C1 Chamfer 1 mm
a Ra = 6.3a
2-42 U30-6S

2. Special tools for the hydraulic section 2. GENERAL
Floating seal installation jig (pusher) Dimension
(a) 20 mm
(b) 3 mm
(c) 17 mm
(d) 15°
(e) ϕ198 mm
(f) ϕ179.4 mm
(g) ϕ170.5 mm
C1 Chamfer 1 mm
a Ra = 6.3a
Cover removal jig

Dimension
(a) 22 mm
(b) 17 mm
(c) 5 mm
(d) ϕ170.3 mm
(e) ϕ168.5 mm
(f) 7.0 mm
(g) ϕ156 mm
(h) ϕ208 mm
C1 Chamfer 1 mm
a Ra = 6.3a
Floating seal installation jig (plunger holder)
(H) Hardening
Dimension
(a) 80 mm
(b) ϕ13 mm
(c) ϕ60 mm
(d) R3/8
(e) ϕ12.5 mm
(f) M12 × P1.25
(g) 25 mm
(h) 315 mm
C2 Chamfer 2 mm
C5 Chamfer 5 mm
U30-6S 2-43

Ring nut tightening jig Oil seal installation jig
(J) Welding
Dimension
Dimension
(a) 110 mm
(a) 12.7 mm
(b) 12 mm
(b) ϕ152 mm
(c) 12 mm
(c) ϕ146 mm
(d) 11 mm
(d) 8 to16 mm
(e) 2 mm
(e) 90 mm
(f) ϕ42.0 mm
(f) 14 mm
(g) ϕ34.8 mm
(g) 56 mm
(h) ϕ19.8 mm
(h) 9 mm
(i) 30°
Removal bolt (j) ϕ16.0 mm
(k) ϕ30 mm
Dimension
(a) M14 × P2.0
(b) M14 nut
(c) 250 mm
(d) 5 mm
2-44 U30-6S

2.3 Universal joint tightening jig Dimension
Universal joint tightening jig 1 (a) ϕ29 mm
(b) ϕ26.5 mm
(c) 23.5 mm
(d) ϕ19 mm
(e) Less than 13 mm
(f) Less than 69 mm
(g) 54 mm
(h) 50 mm
(i) 46 mm
(j) 25 mm
(k) 17 mm
(m) ϕ23 mm
(n) ϕ27 mm
(p) ϕ31 mm
(r) H6 mm
(s) N6 mm
(t) ϕ16 mm
Universal joint tightening jig 2
(B) Universal joint tightening jig

(A) Universal joint tightening jig 2 detailed view
1 detail view
Dimension
(u) 15.5 mm
(v) 0.5 × 15 mm
(w) 12.5 mm
(x) 9.5 mm
(y) Less than 11.6 mm
(z) Less than 6.5 mm
C1 Chamfer 0.5 mm
R1 R13 mm
R2 R5.8 mm
U30-6S 2-45

2.4 Hydraulic cylinder special jigs U-ring installation jig 1
IMPORTANT
• Process the jigs so that roughness of their
surfaces is less than 3.2a to protect the seal
from damage.
Bushing installation jig
Dimension
(a) Rod diameter
(b) 40 mm
(c) 50 mm
Material S45C
U-ring installation jig 2
Dimension
(a) Rod diameter +3 mm
(b) Rod diameter -0.1 mm
(c) Rod diameter +1 mm
(d) 40 mm
(e) 15 mm
(f) 25 mm
Material S45C
Dimension
(b) 15 mm
(c) 25 mm
(d) 75 mm
Material MC nylon
2-46 U30-6S

Wiper ring installation jig Seal ring installation jig 2
Dimension
(b) Rod diameter +8 mm

Dimension
(c) 45 mm
(a) Piston diameter +2 mm
(d) 10 mm
(b) Piston diameter
(e) 15 mm
(c) Piston diameter -15 mm
(f) 20 mm
(d) Piston diameter -10 mm
Material S45C
(e) 20 mm
Seal ring installation jig 1 (f) 72 mm
Material S45C
Seal ring correction jig
Dimension
(a) Piston diameter +2 mm
(b) Piston diameter -5 mm
(c) Piston diameter -2 mm
(d) 10 mm
(e) 72 mm
Material MC nylon
U30-6S 2-47

2. GENERAL 3. Special tools for the air conditioning section
Dimension 3. Special tools for the air

(a) Piston diameter +10 mm conditioning section
(b) Piston diameter +3.0 mm
3.1 Manifold gauge
(c) Piston diameter
Three functions for measuring the high and low
(d) Piston diameter +6.3 mm pressure, vacuuming the refrigerant gas from the
(e) 78 mm cooling circuit with a refrigerant gas vacuuming
machine, and charging the refrigerant gas into the
(f) 23 mm
cooling circuit with a refrigerant gas canister.
(g) 30 mm
NOTE
(h) 15° • Follow the manifold gauge manufacturer's
(i) 6°
manual for details when handling the manifold
gauge.
Material S45C
Seal ring correction jig
(1) Low pressure gauge (4) Air bleeding valve

(2) High pressure gauge (5) Low pressure valve
(3) High pressure valve
Dimension
(a) Piston diameter +10 mm 3.2 Charging hoses

(b) Piston diameter Three hoses which connect a manifold gauge to the
(c) 30 mm cooling circuit, refrigerant gas vacuum machine or
refrigerant gas canister.
(d) More than 24 mm
(e) 3°
Material S45C
Piston and rod diameter
Cylinder Piston diameter Rod diameter
Boom cylinder 80 mm 45 mm
Arm cylinder 75 mm 45 mm
Bucket cylinder 65 mm 40 mm
Swing cylinder 80 mm 40 mm
Blade cylinder 80 mm 45 mm (1) Red charging hose (to high (4) Blue charging hose (to low
pressure charging port) pressure charging port)
(2) Quick coupler
(3) Yellow charging hose (to re-
frigerant gas vacuum ma-
chine or refrigerant gas can-
ister)
2-48 U30-6S

3. Special tools for the air conditioning section 2. GENERAL
3.3 Refrigerant gas vacuum machine

Vacuums the refrigerant gas from the cooling circuit.
IMPORTANT
• Follow the refrigerant gas vacuum machine
manufacturer's manual for details when
handling the refrigerant gas vacuum machine.
(1) Refrigerant gas canister
(1) Refrigerant gas vacuum ma-

chine
3.4 Refrigerant gas leak tester

Detects the leakage of the refrigerant gas.
NOTE
• Follow the gas leak tester manufacturer's
manual for details when handling the refrigerant
gas leak tester.
(1) Refrigerant gas leak tester
3.5 Refrigerant gas canister

Charges refrigerant gas into the cooling circuit.
NOTE
• Follow the refrigerant gas canister
manufacturer's manual when charging and
storing.
U30-6S 2-49

3. MAINTENANCE

MAINTENANCE INTERVALS TABLE
3. MAINTENANCE
MAINTENANCE INTERVALS TABLE

Hour meter indication
1 1 2 2 3 3 4 4 Refer-
No. Check point Measure 5 Interval Remarks
0 5 0 5 0 5 0 5 ence
0
0 0 0 0 0 0 0 0
1 Coolant level Check Daily check - 3-11
2 Fuel level Check Daily check - 3-11
3 Engine oil level Check Daily check - 3-12
4 Hydraulic oil level Check Daily check - 3-12
5 Fan belt Check Daily check - 3-13
Radiator, hydraulic oil cooler, and fuel

6 Check Daily check - 3-13
cooler
7 Engine and electrical wiring Check Daily check - 3-14
8 Lubrication points Grease Daily check - 3-15
9 Fuel tank Drain ○ ○ ○ ○ ○ ○ ○ ○ ○ Every 50 h 3-17
Drain ○ ○ ○ ○ ○ ○ ○ ○ ○ Every 50 h
10 Water separator 3-17
Clean ○ ○ ○ ○ ○ ○ ○ ○ ○ Every 50 h
11 Battery Check ○ ○ ○ ○ ○ ○ ○ ○ ○ Every 50 h 3-18
12 Swivel gear Grease ○ ○ ○ ○ ○ ○ ○ ○ ○ Every 50 h 3-19
13 Fan belt Adjust ○ ○ Every 200 h 3-21
14 Radiator hoses and clamps Check ○ ○ Every 200 h 3-22
15 Swivel bearing Grease ○ ○ Every 200 h 3-22
Engine air clean- Check ○ ○ Every 200 h @

16 Outer element 3-23
er elements*1 Clean ○ ○ Every 200 h @
17 Fuel line and intake air line Check ○ ○ Every 200 h @ 3-24
Every 250 h
18 Engine oil Replace ○ or every 3-25
6 months
Every 250 h
19 Engine oil filter Replace ○ or every 3-25
6 months
20 Travel motor gear oil Replace ● Every 500 h 3-27
21 Fuel filter Replace Every 500 h @ 3-27
22 Return filter*2 Replace ● Every 500 h 3-28
23 Fan belt Replace Every 500 h 3-29
24 Pilot filter Replace Every 1000 h 3-31
25 Hydraulic oil and suction filter*2 Replace Every 1000 h 3-31
Engine air clean- Outer element Replace Every 1000 h @

26 3-33
er elements*1 Inner element Replace Every 1000 h @
27 Injection nozzles*3 Check Every 1500 h @ 3-35

(Continued)
U30-6S 3-1

3. MAINTENANCE
1 1 2 2 3 3 4 4 Refer-
0 5 0 5 0 5 0 5 ence
0
0 0 0 0 0 0 0 0
28 Engine oil in the front idler and track roller Replace Every 2000 h 3-37
29 Alternator Check Every 2000 h 3-38
30 Starter motor Check Every 2000 h 3-39
31 Fuel injection pump*3 Check Every 3000 h @ 3-41
32 Electrical wiring and fuses Check Every 1 year 3-43
Every
33 Radiator hoses and clamps Replace 3-45
2 years
Every
34 Coolant Replace 3-46
2 years
Every
35 Fuel line and intake air line*4 Replace @ 3-47
2 years
* 500 through 1000 continues to the following table.
3-2 U30-6S

3. MAINTENANCE
1
No. Check point Measure 5 5 6 6 7 7 8 Interval Remarks Reference
0
0 5 0 5 0 5 0
0
0 0 0 0 0 0 0
0
1 Coolant level Check Daily check - 3-11
2 Fuel level Check Daily check - 3-11
3 Engine oil level Check Daily check - 3-12
4 Hydraulic oil level Check Daily check - 3-12
5 Fan belt Check Daily check - 3-13
Radiator, hydraulic oil cooler, and fuel cool-

6 Check Daily check - 3-13
er
7 Engine and electrical wiring Check Daily check - 3-14
8 Lubrication points Grease Daily check - 3-15
9 Fuel tank Drain ○ ○ ○ ○ ○ ○ ○ ○ Every 50 h 3-17
Drain ○ ○ ○ ○ ○ ○ ○ ○ Every 50 h
10 Water separator 3-17
Clean ○ ○ ○ ○ ○ ○ ○ ○ Every 50 h
11 Battery Check ○ ○ ○ ○ ○ ○ ○ ○ Every 50 h 3-18
12 Swivel gear Grease ○ ○ ○ ○ ○ ○ ○ ○ Every 50 h 3-19
13 Fan belt Adjust ○ ○ ○ Every 200 h 3-21
14 Radiator hoses and clamps Check ○ ○ ○ Every 200 h 3-22
15 Swivel bearing Grease ○ ○ ○ Every 200 h 3-22
Engine air clean- Check ○ ○ ○ Every 200 h @

16 Outer element 3-23
er elements*1 Clean ○ ○ ○ Every 200 h @
17 Fuel line and intake air line Check ○ ○ ○ Every 200 h @ 3-24
Every 250 h
18 Engine oil Replace ○ ○ ○ or every 3-25
6 months
Every 250 h
19 Engine oil filter Replace ○ ○ ○ or every 3-25
6 months
20 Travel motor gear oil Replace ○ ○ Every 500 h 3-27
21 Fuel filter Replace ○ ○ Every 500 h @ 3-27
22 Return filter*3 Replace ○ Every 500 h 3-28
23 Fan belt Replace ○ ○ Every 500 h 3-29
24 Pilot filter Replace ○ Every 1000 h 3-31
25 Hydraulic oil and suction filter*2 Replace ○ Every 1000 h 3-31
Engine air clean- Outer element Replace ○ Every 1000 h @

26 3-33
er elements*1 Inner element Replace ○ Every 1000 h @
27 Injection nozzles*3 Check Every 1500 h @ 3-35
28 Engine oil in the front idler and track roller Replace Every 2000 h 3-37
29 Alternator Check Every 2000 h 3-38
30 Starter motor Check Every 2000 h 3-39

(Continued)
U30-6S 3-3

3. MAINTENANCE
1
0
0 5 0 5 0 5 0
0
0 0 0 0 0 0 0
0
31 Fuel injection pump*3 Check Every 3000 h @ 3-41
32 Electrical wiring and fuses Check Every 1 year 3-43
33 Radiator hoses and clamps Replace Every 2 years 3-45
34 Coolant Replace Every 2 years 3-46
35 Fuel line and intake air line*4 Replace Every 2 years @ 3-47
* Servicings marked with ● must be carried out once the specified hours of operation after initial commissioning have
been reached.
*1 Clean or replace the engine air cleaner elements more frequently if used under dusty conditions. If the elements
are very dirty due to dusty conditions, replace the elements.
*2 If using a hydraulic breaker, change the hydraulic oil and the return filter according to the table on the operator's
manual.
*3 Consult your local Kubota dealer for this service.
*4 Replace only if necessary.
IMPORTANT
• The items listed above (marked with @) are registered as emission-related critical parts by kubota in the
U.S.EPA non-road emission regulation. As the engine owner, you are responsible for the performance of
the required maintenance on the engine according to the above instruction. Please refer to the warranty
statement for detail.
Maintenance for cabin specification
1 1 2 2 3 3 4 4 Refer-
0 5 0 5 0 5 0 5 ence
0
0 0 0 0 0 0 0 0
1 Washer liquid level Check Daily check - 3-49
2 Air conditioning belt Check ○ ○ Every 200 h 3-49
3 Air conditioning filter *5 Clean ○ ○ Every 200 h 3-50
4 Condenser Clean ○ ○ Every 200 h 3-50
5 Air conditioning belt Replace Every 500 h 3-51
6 Air conditioning filter *5 Replace Every 1000 h 3-52
Check Every 1 year 3-52

7 Air conditioning and heater hoses Every
Replace 3-53
2 years
Perform
8 Refrigerant Check maintenance 3-55
as required
* 500 through 1000 continues to the following table.
3-4 U30-6S

3. MAINTENANCE
1
0
0 5 0 5 0 5 0
0
0 0 0 0 0 0 0
0
1 Washer liquid level Check Daily check - 3-49
2 Air conditioning belt Check ○ ○ ○ Every 200 h 3-49
3 Air conditioning filter *5 Clean ○ ○ ○ Every 200 h 3-50
4 Condenser Clean ○ ○ ○ Every 200 h 3-50
5 Air conditioning belt Replace ○ ○ Every 500 h 3-51
6 Air conditioning filter *5 Replace ○ Every 1000 h 3-52
Check Every 1 year 3-52

7 Air conditioning and heater hoses
Replace Every 2 years 3-53
Perform
8 Refrigerant Check maintenance 3-55
as required
*5 Clean or replace the air conditioning filter more frequently if used under dusty conditions. If the filters are very dirty
due to dusty conditions, replace the filters.
U30-6S 3-5

3. MAINTENANCE
3-6 U30-6S

LUBRICANT QUANTITY
3. MAINTENANCE
LUBRICANT QUANTITY
Quantity Remarks
Engine 7.0 L Including the engine oil filter
Engine oil Front idler 80 ml -
Track roller 80 ml -
Total capacity 5.0 L Canopy specification
Coolant (Including reserve tank) 5.3 L Cabin specification
Reserve tank 0.85 L At the [FULL] mark
All hydraulic system 39.5 L -

Hydraulic oil
Hydraulic oil tank 14.5 L At the center of the gauge
Fuel Fuel tank 41.5 L -
Gear oil Travel motor 0.9 L -
Refrigerant Air conditioning system 880 to 980 g -
U30-6S 3-7

3. MAINTENANCE
3-8 U30-6S

RECOMMENDED LUBRICANTS
3. MAINTENANCE
RECOMMENDED LUBRICANTS
Recommendation
Ambient
tempera- Quality Note
Viscosity Mil standard Brand Type
ture con- standard
dition
In winter Rotella T10W

SAE 10W - Shell
or in low Rimula 10W
tempera- Rotella T20W-2
tures SAE 20W - Shell
Rimula 20W-2
Rotella T30
In summ- SAE 30 - Shell
MIL -L-2104C Rimula 30
Engine oil er or in -
high am- MIL -L-2104D Rotella T40
SAE 40 - Shell
bient tem- Rimula 40
peratures
SAE 50 - Shell Rimula 50
All-sea-
son en- Multipurpose - Shell Rotella T15W-40
gine oil
• Always use distilled

water to dilute anti-
freeze.
SAE J1034
• Always follow the rec-
MB 325.0 Kubo-
Coolant - - - LLC-N-50F ommendations of the
ASTM D3306 ta
coolant manufacturer
ASTM D4985
for mixing ratio. Do
not mix with other
coolants.
Grease - - - - Shell Alvania EP2 -
In winter
or in low Tellus S2M32
ISO 32 - Shell
tempera- Tellus S2MX32
tures
Hydraulic
In summ- - Tellus S2M46 -
oil ISO 46 - Shell
er or in Tellus S2MX46
high am-
bient tem- Tellus S2M68
ISO 68 - Shell
peratures Tellus S2MX68
In winter SAE 75 - Shell Oil S8643

or in low
tempera- SAE 80 - Shell Spirax HD80W
tures
In summ- SAE 90 - Shell Spirax HD90

er or in
Gear oil MIL -L-2105C -
high am-
bient tem- SAE 140 - Shell Spirax HD140
peratures
All-sea-
son gear Multipurpose - Shell Spirax HD85W
oil
Above No.2-D diesel

Fuel ASTM D975 - - - -
-5 ℃ fuel
(Continued)
U30-6S 3-9

3. MAINTENANCE
Recommendation
Ambient
tempera- Quality Note
Viscosity Mil standard Brand Type
ture con- standard
dition
Below No.1-D diesel

Fuel ASTM D975 - - - -
-5 ℃ fuel
HFC-134a HFC-134a
Refrigerant - - - - -
(R134a) (R134a)
NOTE
• Before delivery, the hydraulic oil used was Shell Tellus S2M46.
• Use engine oil API service classification CF/CF-4 or better and SAE 10W-30.
• Use SAE 90 (API, GL-4/GL-5) as drive unit oil for all seasons.
• To change the engine oil, hydraulic oil, gear oil or the like, drain all of the oil and replace it with fresh oil.
When adding oil, use the same brand and same type of oil.
• Other than the oil mentioned below, JCMAS HK certified oil and GK certified grease can also be used.
Check the Japan Lubricating Oil Society (JALOS) website for more details.
3-10 U30-6S

DAILY CHECK
1. Checking the coolant level 3. MAINTENANCE
DAILY CHECK
1. Checking the coolant level IMPORTANT
• If the fuel is empty, do not start the engine to
Preparing avoid mixing of the air into the fuel system.
1. Park the machine on the firm and level ground, • Fully replenish the fuel into the fuel tank before
lower the front attachment and blade to the ground, parking overnight to prevent condensation in
and stop the engine. the fuel tank.
Checking Preparing
1. Check that the coolant level is in between [FULL] 1. Park the machine on the firm and level ground,
and [LOW]. lower the front attachment and blade to the ground,
and stop the engine.
NOTE
Checking
• Check the coolant level in the reserve tank
1. Turn the starter switch to [RUN].
after the engine has cooled down.
NOTE
• Even without inserting the starter key, the
hour meter, fuel gauge, water temperature
gauge, and clock can be displayed for
10 seconds. To do so, press the user setting
switch (SW1) or the display switch (SW5) on
the meter panel.
(1) Reserve tank (B) [LOW]

(A) [FULL]
2. Replenish the coolant into the reserve tank if

necessary.
IMPORTANT
• Do not replenish the coolant exceeding
[FULL]. (1) User setting switch (SW1) (2) Display switch (SW5)
• Do not mix the coolant with dirty or salt
water. 2. Check the fuel level on the meter panel.
• In the case that the coolant level decreases
soon after replenishing, there is a possibility
of cooling system leakage. Repair the
cooling system before starting the engine.
2. Checking the fuel level
WARNING
working area.
U30-6S 3-11

DAILY CHECK
3. MAINTENANCE 3. Checking the engine oil level
(3) Fuel gauge (B) Full (1) Dipstick (A) Correct oil level range
(A) Empty (2) Oil filler port
3. Replenish the fuel if necessary. 4. Replenish the engine oil if necessary.

Recommended fuel Recommended oil
Above -5 ℃ ASTM D975 No.2-D diesel fuel In winter or in low SAE 10W
Diesel fuel temperatures SAE 20W
Below -5 ℃ ASTM D975 No.1-D diesel fuel
In summer or in SAE 30
Engine oil
high ambient tem- SAE 40
peratures SAE 50
3. Checking the engine oil level All-season gear oil Multipurpose
IMPORTANT
• If the oil level is too high or too low, the engine
may be damaged during operation. 4. Checking the hydraulic oil
Preparing level
1. Park the machine on the firm and level ground, Preparing
lower the front attachment and blade to the ground, 1. Park the machine on the firm and level ground.
and stop the engine. 2. Operate the machine to the hydraulic oil checking
2. Open the rear bonnet. position as follows.
Checking • Boom: Half-extended
1. Pull the dipstick out of the engine and wipe the • Arm: Half-extended
engine oil off. • Bucket: Half-extended
• Blade: Lowered to the ground
NOTE • Swing mechanism: Swing center
• Check the engine oil level 5 minutes after
the engine has stopped.
2. Fully insert the dipstick into the dipstick port.
3. Pull the dipstick out of the engine again and check
the engine oil level.
Checking
1. Check the hydraulic oil level with the level gauge
while the temperature of the hydraulic oil is from 20
to 30 ℃.
3-12 U30-6S

DAILY CHECK
5. Checking the fan belt 3. MAINTENANCE
NOTE
• Make sure that the oil level is in between
half and three-quarters on the level gauge.
(1) Clamp ×2 (3) Fan cover

(2) Bolt (M8 × 16) ×2
Checking
1. Check the fan belt for crack and damage, and
(1) Hydraulic oil gauge (B) Lower limit
(A) Upper limit replace it if necessary.
2. Push the position (a) to check the fan belt tension.
2. Replenish the hydraulic oil if necessary.
IMPORTANT
• Clean the surface of the hydraulic oil tank
around the oil filler port before replenishing
the hydraulic oil to avoid dust
contamination.
• Do not use or mix different oil.
Recommended oil
In winter or in low
ISO 32
temperatures
Hydraulic oil In summer or in
ISO 46
high ambient tem-
ISO 68
peratures (4) Fan belt (9) Tension pulley nut
(5) Alternator (10) Adjusting bolt
(6) Crankshaft pulley (11) Tension pulley
(7) Fan pulley
5. Checking the fan belt (8) Locknut
CAUTION
Push with 58.8 to 68.6 N
• Stop the engine, remove the key, and hang a DO (a) 9 to 11 mm
Push with 6.0 to 7.0 kgf
NOT OPERATE tag near the operator's seat
when checking the fan belt. 3. Adjust the fan belt tension if necessary.
Preparing
1. Park the machine on the firm and level ground, 6. Checking the radiator,
lower the front attachment and blade to the ground,
hydraulic oil cooler, and fuel
2. Open the rear bonnet. cooler
3. Remove the 2 clamps to disconnect the wire
harness.
4. Remove the 2 bolts to remove the fan cover. CAUTION
• Do not work soon after the engine has stopped.
– Engine, coolant, oil, and fuel are extremely
hot.
• Wear an eye protector when cleaning the
radiator, hydraulic oil cooler, and fuel cooler
with compressed air.
U30-6S 3-13

DAILY CHECK
3. MAINTENANCE 7. Checking the engine and electrical wiring
• Do not touch the hot radiators. There is a risk of

burn.
Preparing
4. Remove the bonnet RH 2.
Checking
1. Check if the fins and ribs of the radiator, hydraulic
oil cooler and fuel cooler are clogged.
2. Remove dirt with compressed air if necessary. (6) Bolt (M10 × 20) ×4 (7) Cover
IMPORTANT 7. Check for coolant leakage from the lower hose.

• Pressure of compressed air must be under 8. Check the tightness of the 2 clamps.
205 kPa (2.1 kgf/cm2).
3. Check the radiator, hydraulic oil cooler, and fuel
cooler for damage and replace them if necessary.
(1) Radiator (3) Fuel cooler

(2) Hydraulic oil cooler
4. Check for coolant leakage from the upper hose.

5. Check the tightness of the 2 clamps.
(8) Lower hose (9) Clamp ×2
7. Checking the engine and

electrical wiring
WARNING
(4) Upper hose (5) Clamp ×2
• Always stop the engine and remove the key
6. Remove the 4 bolts to remove the cover. before cleaning the wiring, cables and engine.
• Be sure to check the wire harness and battery
cords for any damage. If they are damaged, a
short circuit may result.
3-14 U30-6S

DAILY CHECK
8. Greasing the lubrication points 3. MAINTENANCE
• Be sure to check if there is any dust or fuel on Front attachment

the battery, wiring, muffler, or peripheral parts
of the engine. If such substances are adhering,
a fire may result.
Preparing
Checking
1. Check that each switch works properly.
2. Check the tightness and condition of all accessible
electrical wirings and connectors.
3. Repair or replace the damaged parts if any is
present.
4. Check for rust and dirt on the fuses and clean if Swing bracket
necessary.
8. Greasing the lubrication

points
IMPORTANT
• Grease the machine before operation.
• In the case of operating the machine in water,
grease again after finishing operation.
Preparing
Greasing
1. Grease each grease fitting.
NOTE
• Clean around the grease fittings before and
after greasing.
• Greasing of the swivel gear and swivel
bearing are not necessary for daily check.
Bucket and bucket linkage
U30-6S 3-15

DAILY CHECK
3. MAINTENANCE
Swing cylinder pin
Blade
3-16 U30-6S

EVERY 50 HOURS
1. Draining the water from the fuel tank 3. MAINTENANCE
EVERY 50 HOURS
1. Draining the water from the Preparing
fuel tank lower the front attachment and blade to the ground,
WARNING
• Keep fire and flammable items away from the Draining
working area. 1. Turn the water separator lever to [CLOSE].
2. Put a tray under the water separator.
Preparing 3. Loosen the retainer ring on the top of the cup and
1. Park the machine on the firm and level ground, remove the cup.
lower the front attachment and blade to the ground, 4. Remove the water-mixed fuel from the cup.
and stop the engine. 5. Check the element for clogging, and if it is clogged,
Draining the fuel tank clean it.
1. Open the cover. NOTE
2. Put a tray under the drain valve to receive the • Cleaning should be done with diesel fuel or
water-mixed fuel. cleaning oil.
3. Open the drain valve and drain the water-mixed • If cleaning does not improve the clogging,
fuel. replace the element.
(1) Cover (2) Drain valve

(1) Water separator (7) Element
4. Close the drain valve. (2) Water separator lever (A) Loosen
(3) Retainer ring (B) Tighten
(4) Cup (C) [OPEN]
2. Draining the water separator (5)
(6)
Line
Float
(D) [CLOSE]
6. Install the cup by hand tightening.

WARNING 7. Turn the water separator lever to [OPEN].
• Keep fire and flammable items away from the 8. Bleed the air from the fuel line.
working area.
NOTE
• Bleed the air for about 60 seconds after
CAUTION turning the starter switch to [RUN].
– Engine, fuel, and oil are extremely hot.
• Keep dust away from the working area.
• Do not reuse removed O-rings for assembly to
avoid oil leakage.
U30-6S 3-17

EVERY 50 HOURS
3. MAINTENANCE 3. Checking the battery
3. Checking the battery Checking the electrolyte level

1. Check that the electrolyte level is between the
upper and lower level lines.
DANGER 2. Replenish distilled water if necessary.
• In the case that the electrolyte level is below the
IMPORTANT
lower level line, do not use or charge the battery
• Do not replenish distilled water exceeding
to avoid battery explosion.
the upper level line.
WARNING
• Do not remove the vent caps while the engine is
running.
• Keep electrolyte away from your eyes, hands
and clothing. Sulfuric acid in battery electrolyte
is poisonous, and it can burn your skin and
clothing or cause blindness. In case that you
spill electrolyte on yourself, rinse with water
and get medical aid immediately.
• Do not use metal tools when cleaning battery
terminals. It may cause short circuit.
CAUTION (A) Upper level line (B) Lower level line

• Keep a fire (welding sparks, grinding sparks,
cigarettes) away from the battery. The battery Checking the electrolyte density
produces oxygen and hydrogen gas which are
flammable. CAUTION
• Disconnect the negative (-) terminal first when • Wear protective gloves, work clothing and eye
removing the battery cable. protector to protect your skin and eyes from
• Connect the positive (+) terminal first when sulfuric acid in battery electrolyte.
connecting the battery cable.
1. Remove the vent caps from the battery.
Preparing 2. Measure the density of electrolyte with the
1. Park the machine on the firm and level ground, refractometer and charge the battery if necessary.
Checking the battery terminal
1. Check the condition of the battery terminal.
(1) Positive (+) terminal (3) Battery

(2) Negative (-) terminal
2. Clean the battery terminal and grease with

petroleum jelly if necessary.
3-18 U30-6S

EVERY 50 HOURS
4. Greasing the swivel gear 3. MAINTENANCE
Charging the battery
CAUTION
• Wear protective gloves, work clothing and eye
protector to protect your skin and eyes from
sulfuric acid in battery electrolyte.
• In the case of working indoors, ventilate the
work area during work.
1. Check the electrolyte level and replenish distilled

water if necessary.
2. Disconnect the battery cables from the battery.
3. Remove the vent caps.
4. Connect the battery to the charger.
NOTE
• When charging the battery, follow the
battery charger manufacturer's manual for
details.
5. Charge the battery.
IMPORTANT
• Charge the battery in normal speed.
• Charge the battery in fast speed only for
emergencies because the fast speed charge
may shorten the battery life.
(C) Electrolyte density (F) Charging is necessary

6. Check the electrolyte level after charging and
(D) Discharge replenish distilled water if necessary.
(E) Normal 7. Install the vent caps.
8. Connect the battery cables.
Normal More than 1.20
Charging is necessary Less than 1.20

4. Greasing the swivel gear
3. Install the vent caps.
Checking the battery voltage CAUTION
1. Check the battery voltage with a voltage tester. • Keep any persons or objects away from the
swivel range.
Preparing
Greasing
1. Grease the swivel gear from the grease fitting.
2. Swivel the upper structure of the machine 90° for 4
times to grease the gear.
NOTE
• The grease amount should be approximately
50 g (20 to 30 pumps with a grease gun) at
(1) Positive (+) terminal (2) Negative (-) terminal each position.
Battery voltage Higher than 12 V
2. Check the electrolyte density in the case that the

battery voltage is lower than the service
specification.
U30-6S 3-19

EVERY 50 HOURS
3. MAINTENANCE
(1) Grease fitting (for swivel

gear)
3. Swivel the upper structure of the machine 360°

several times to distribute the grease evenly.
3-20 U30-6S

EVERY 200 HOURS
1. Checking and adjusting the fan belt 3. MAINTENANCE
EVERY 200 HOURS

1. Checking and adjusting the
fan belt
CAUTION
• Stop the engine, remove the key, and hang a DO
NOT OPERATE tag near the operator's seat
when checking and adjusting the fan belt.
Preparing
2. Open the rear bonnet. (4) Fan belt (9) Tension pulley nut
3. Remove the 2 clamps to disconnect the wire (5) Alternator (10) Adjusting bolt
harness. (7) Fan pulley
4. Remove the 2 bolts to remove the fan cover. (8) Locknut
(a) 9 to 11 mm
3. Adjust the fan belt tension if necessary.

Adjusting the fan belt
1. Loosen the tension pulley nut and locknut.
2. Rotate the adjusting bolt to adjust the fan belt
tension.
NOTE
• Rotate the adjusting bolt counterclockwise
to tighten the fan belt.
(2) Bolt (M8 × 16) ×2 3. Push the position (a) to check the fan belt tension.
Checking
1. Check the fan belt for crack and damage, and
replace it if necessary.
(4) Fan belt (9) Tension pulley nut

(7) Fan pulley
(8) Locknut
U30-6S 3-21

EVERY 200 HOURS
3. MAINTENANCE 2. Checking the radiator hoses and clamps
(a) 9 to 11 mm
4. Tighten the tension pulley nut and locknut.

5. Start the engine and check for slip of the fan belt.
NOTE
• If the engine is running with a loose belt, the
warning lamp lights up.
2. Checking the radiator hoses

and clamps (3) Bolt (M10 × 20) ×4 (4) Cover
4. Check for coolant leakage from the lower hose.

CAUTION 5. Check the tightness of the 2 clamps.
• Do not work soon after the engine has stopped. NOTE
– Coolant is extremely hot. • Replace the lower hose if necessary.
Preparing • Tighten or replace the clamps if necessary.
Checking
1. Check for coolant leakage from the upper hose.
2. Check the tightness of the 2 clamps.
NOTE
• Replace the upper hose if necessary.
• Tighten or replace the clamps if necessary.
(1) Upper hose (2) Clamp ×2 (5) Lower hose (6) Clamp ×2
3. Remove the 4 bolts to remove the cover.
3. Greasing the swivel bearing
CAUTION
• Keep any persons or objects away from the
swivel range.
3-22 U30-6S

EVERY 200 HOURS
4. Checking and cleaning the engine air cleaner elements 3. MAINTENANCE
Preparing
Greasing
1. Grease the swivel bearing from the grease fitting.
2. Swivel the upper structure of the machine 90° for 4
times to grease the swivel bearing balls.
NOTE
• The amount of grease should be 5 pumps of
a grease gun for each position.
(1) Inner element (5) Dust valve

(2) Outer element (6) Engine air cleaner case
(3) Clip ×2
(4) Cover
2. Remove the outer element from the engine air

cleaner case.
3. Check the outer element for damage and dirt and
replace it if necessary.
4. Clean the outer element with compressed air.
IMPORTANT
• Pressure of the compressed air must be
under 205 kPa (2.1 kgf/cm2).
• Blow compressed air from the inside of the
(1) Grease fitting (for swivel
bearing) element to the outside.
• Do not clean the outer element with fluids.
3. Swivel the upper structure of the machine 360°
several times to distribute the grease evenly.
4. Checking and cleaning the

engine air cleaner elements
CAUTION
• Wear an eye protector when cleaning the outer
element with compressed air.
IMPORTANT
• If using the machine in extremely dusty
conditions, check and clean or replace the outer
5. Clean the engine air cleaner case and cover
element more frequently.
without removing the inner element.
• Do not start the engine without installing the
6. Clean the dust valve.
filter elements.
7. Install the outer element and cover.
Preparing
IMPORTANT
• Install the cover so that the top mark faces
upwards.
Checking and cleaning
1. Open the 2 clips and remove the cover.
U30-6S 3-23

EVERY 200 HOURS
3. MAINTENANCE 5. Checking the fuel line and intake air line
5. Checking the fuel line and

intake air line
WARNING
working area.
CAUTION
– Engine, fuel, muffler, and oil are extremely
hot.
– Pressure in the fuel line is high.
(1) Fuel hose (2) Clamp
Preparing
1. Park the machine on the firm and level ground, 3. Check damage for the 2 intake air hoses.
lower the front attachment and blade to the ground, 4. Check the bolts that fix the 3 clamps for any
and stop the engine. looseness and tighten them if necessary.
Checking
1. Check damage for the fuel hoses and replace them
if necessary.
2. Check the tightness of the clamps and tighten them
if necessary.
(3) Intake air hose (5) Clamp ×3

(4) Intake air hose
3-24 U30-6S

EVERY 250 HOURS
1. Replacing the engine oil 3. MAINTENANCE
EVERY 250 HOURS

1. Replacing the engine oil
CAUTION
hot.
– Pressure in the engine oil line is high.
Preparing
2. Open the rear bonnet. (2) Dipstick (A) Correct oil level range
Replacing (3) Oil filler port
1. Put a tray under the drain plug to receive the
engine oil. Recommended oil
2. Remove the drain plug and drain all of the engine In winter or in low SAE 10W
oil. temperatures SAE 20W
NOTE Engine oil 7.0 L
• Remove the filler cap to drain the engine oil peratures SAE 50
faster.
All-season gear oil Multipurpose
5. Start the engine in idling speed and leave it for

5 minutes.
6. Stop the engine, and check the engine oil level with
the dipstick.
7. Replenish the engine oil if necessary.
2. Replacing the engine oil filter
CAUTION
(1) Drain plug hot.
– Pressure in the engine oil line is high.
3. Install the drain plug with a new washer.
4. Fill the engine oil from the oil filler port up to the NOTE
maximum level of the dipstick. • When replacing the engine oil filter, replace the
engine oil at the same time.
Preparing
Replacing
1. Put a tray under the engine oil filter to receive the
engine oil.
U30-6S 3-25

EVERY 250 HOURS
3. MAINTENANCE
2. Remove the engine oil filter with a filter wrench.
(1) Engine oil filter
3. Apply engine oil to the O-ring of the new engine oil

filter.
4. Install a new engine oil filter by hand tightening.
NOTE
• Do not tighten the engine oil filter strongly
with a filter wrench.
5. Fill the engine oil from the oil filler port up to the
maximum level of the dipstick.
(2) Dipstick (A) Correct oil level range

(3) Oil filler port
Recommended oil
In winter or in low SAE 10W
temperatures SAE 20W
Engine oil 7.0 L
peratures SAE 50
All-season gear oil Multipurpose
6. Start the engine in idling speed and leave it for

5 minutes.
7. Stop the engine, and check the engine oil level with
the dipstick.
8. Replenish the engine oil if necessary.
3-26 U30-6S

EVERY 500 HOURS
1. Replacing the travel motor gear oil 3. MAINTENANCE
EVERY 500 HOURS

1. Replacing the travel motor – Engine, fuel, and oil are extremely hot.
gear oil Preparing

Preparing
1. On the firm and level ground, move the machine so
that the drain port is at the bottom position.
Replacing
1. Turn the water separator lever to [CLOSE].
(1) Oil check port (3) Drain port

(2) Oil filler port
2. Lower the front attachment and the blade to the

(1) Water separator (B) [CLOSE]
(2) Water separator lever
Replacing (A) [OPEN]
1. Put a tray under the drain port to receive the gear 2. Remove the fuel filter with a filter wrench.
oil.
2. Remove the oil filler plug.
3. Remove the oil check plug.
4. Remove the drain plug and drain all gear oil.
5. Install the drain plug with a new O-ring.
6. Replenish gear oil from the oil filler port.
Recommended oil
SAE #90
Gear oil 0.9 L
APL GL-4
7. Check the oil level from the oil check port.

8. Install the oil filler plug and oil check plug with a
new O-ring.
(3) Fuel filter
2. Replacing the fuel filter 3. Apply fuel to the O-ring of a new fuel filter.
4. Install the new fuel filter by hand tightening.
WARNING IMPORTANT
• Keep fire and flammable items away from the • Do not tighten the filter strongly with a filter
working area. wrench.
5. Turn the water separator lever to [OPEN].
6. Turn the starter switch to [RUN] to bleed the air
CAUTION
from the fuel line.
U30-6S 3-27

EVERY 500 HOURS
3. MAINTENANCE 3. Replacing the return filter
IMPORTANT
• Check for fuel leakage from the fuel filter. If
there is any leakage, tighten the filter
slightly with a filter wrench.
3. Replacing the return filter
CAUTION
• The hydraulic devices and oil are extremely hot.
Handle with care before preparation,
measurement, and restoration.
• Replacement of the return filter can only be (3) Hydraulic oil tank cover (6) Return filter
carried out after the hydraulic oil has cooled (5) Set bolt
down. Before replacement, release the pressure 6. Install a new return filter to the hydraulic oil tank
of the hydraulic oil tank. cover, and install the set bolt.
IMPORTANT Tightening torque

• Keep dust away from the working area. 68.6 to 78.4 N⋅m
(6) Return filter -
• Do not reuse removed O-rings for assembly to 7.0 to 8.0 kgf⋅m
avoid contamination.
7. Install a new O-ring to the hydraulic oil tank.
Preparing
NOTE
• Apply hydraulic oil to the new O-ring.
and stop the engine. 8. While fitting the pin of the hydraulic oil tank cover
2. Open the bonnet RH 1. into the guide holder of the suction filter, install the
hydraulic oil tank and tighten with 6 bolts.
Replacing
1. Loosen the clamp to disconnect the return hose NOTE
from the hydraulic oil tank cover. • A spring is incorporated in the guide holder
2. Loosen the clamp to disconnect the hydraulic oil of the suction filter.
cooler hose from the hydraulic oil tank cover.
3. Remove the 6 bolts.
(3) Hydraulic oil tank cover (9) Guide holder

(7) Suction filter (10) Spring
(8) Pin
(1) Return hose (4) Bolt (M10 × 16) ×6
(2) Hydraulic oil cooler hose Tightening torque
(3) Hydraulic oil tank cover
48.1 to 55.9 N⋅m
(4) Bolt -
4. Remove the hydraulic oil tank cover and return filter 4.9 to 5.7 kgf⋅m
from the hydraulic oil tank.
5. Remove the set bolt to remove the return filter from 9. Connect the hydraulic oil cooler hose to the
the hydraulic oil tank cover. hydraulic oil tank cover and tighten with a clamp.
10. Connect the return hose to the hydraulic oil tank
cover and tighten with a clamp.
3-28 U30-6S

EVERY 500 HOURS
4. Replacing the fan belt 3. MAINTENANCE
11. Operate the machine to the hydraulic oil level check

position.
12. Check the hydraulic oil level and replenish if
necessary.
Recommended oil
In winter or in low
ISO 32
temperatures
Hydraulic oil In summer or in
ISO 46
high ambient tem-
ISO 68
peratures
4. Replacing the fan belt (4) Fan belt (9) Tension pulley nut
CAUTION (7) Fan pulley
(8) Locknut
NOT OPERATE tag near the operator's seat Service specification
when replacing the fan belt.
(a) 9 to 11 mm
Preparing Push with 6.0 to 7.0 kgf
6. Tighten the tension pulley nut and locknut.
7. Start the engine and check for slip of the fan belt.
2. Open the rear bonnet. NOTE
3. Remove the 2 clamps to disconnect the wire • If the engine is running with a loose belt, the
harness. warning lamp lights up.
4. Remove the 2 bolts to remove the fan cover.

(2) Bolt (M8 × 16) ×2
5. Remove the air conditioning belt (cabin

specification).
Replacing the fan belt
1. Loosen the tension pulley nut and locknut.
2. Rotate the adjusting bolt clockwise to loosen the
fan belt.
3. Replace the fan belt.
4. Rotate the adjusting bolt to adjust the fan belt
tension.
U30-6S 3-29

EVERY 500 HOURS
3. MAINTENANCE
3-30 U30-6S

EVERY 1000 HOURS
1. Replacing the pilot filter 3. MAINTENANCE
EVERY 1000 HOURS

1. Replacing the pilot filter Recommended oil
In winter or in low
ISO 32
temperatures
CAUTION Hydraulic oil In summer or in
• The hydraulic devices and oil are extremely hot. high ambient tem-
ISO 46
Handle with care before preparation, ISO 68
peratures
• Release the residual pressure of the hydraulic
circuit.
2. Replacing the hydraulic oil
IMPORTANT and suction filter
avoid oil leakage.
CAUTION
Preparing • The hydraulic devices and oil are extremely hot.
1. Park the machine on the firm and level ground, Handle with care before preparation,
lower the bucket and blade to the ground, and stop measurement, and restoration.
the engine. • Replacement of the hydraulic oil and suction
2. Release the residual pressure. filter can only be carried out after the hydraulic
3. Vacuum the hydraulic oil tank. oil has cooled down. Before replacement,
4. Open the rear bonnet. release the pressure of the hydraulic oil tank.
5. Remove the bonnet LH.
Replacing IMPORTANT
1. Remove the pilot filter case from the head cover. • Keep dust away from the working area.
NOTE avoid oil leakage.
• Put waste cloths under the pilot filter.
2. Replace the element, apply hydraulic oil to the new NOTE
O-ring, and install the case by hand tightening. • The suction filter must be replaced along with
the hydraulic oil.
• Replace the return filter at the same time.
Preparing
2. Make the machine posture to the hydraulic oil level
checking posture by extending each cylinder rod to
the approximate middle and grounding the bucket
and blade.
(1) Head cover (4) Pilot filter case

(2) Element
(3) O-ring
3. Start the engine in idle speed and leave it for

3 minutes.
4. Operate the machine to the hydraulic oil level check
position.
5. Stop the engine, and check the hydraulic oil level.
U30-6S 3-31

EVERY 1000 HOURS
3. MAINTENANCE
6. Remove the hydraulic oil tank cover and return filter

from the hydraulic oil tank.
7. Remove the suction filter, and replace with a new
one.
NOTE
• Clean the inside of the hydraulic oil tank if
necessary.

Replacing
1. Put a tray under the drain plug.
2. Remove the drain plug and drain all of the hydraulic
oil.
(4) Hydraulic oil tank cover (7) Suction filter

(6) Return filter
8. Install a new O-ring to the hydraulic oil tank.

NOTE
• Apply hydraulic oil to the new O-ring.
9. While fitting the pin of the hydraulic oil tank cover
into the guide holder of the suction filter, install the
hydraulic oil tank and tighten with 6 bolts.
NOTE
(1) Drain plug • A spring is incorporated in the guide holder
3. Loosen the clamp to disconnect the return hose of the suction filter.
from the hydraulic oil tank cover.
4. Loosen the clamp to disconnect the hydraulic oil
cooler hose from the hydraulic oil tank cover.
(4) Hydraulic oil tank cover (9) Guide holder

(7) Suction filter (10) Spring
(8) Pin
Tightening torque
(2) Return hose (5) Bolt (M10 × 16) ×6 48.1 to 55.9 N⋅m
(5) Bolt -
(3) Hydraulic oil cooler hose 4.9 to 5.7 kgf⋅m
(4) Hydraulic oil tank cover
10. Connect the hydraulic oil cooler hose to the
hydraulic oil tank cover and tighten with a clamp.
3-32 U30-6S

EVERY 1000 HOURS
3. Replacing the engine air cleaner elements 3. MAINTENANCE
11. Connect the return hose to the hydraulic oil tank 2. Remove the outer element from the engine air
cover and tighten with a clamp. cleaner case.
12. Install the drain plug securely. 3. Clean the engine air cleaner case and cover
13. Fill the hydraulic oil from the filling port up to the without removing the inner element.
center of the gauge. 4. Clean the dust valve.
5. Replace the inner element.
Recommended oil
6. Install the new outer element.
All hydraulic
39.5 L
ISO 32 7. Install the cover.
system (In winter or in
low tempera- IMPORTANT
tures) • Install the cover so that the top mark faces
ISO 46
Hydraulic oil
ISO 68 upwards.
Hydraulic oil
14.5 L (In summer or
tank
in high ambi-
ent tempera-
tures)
14. Start the engine, and move the control lever to the
end and hold it for approximately 5 minutes to bleed
air in the hydraulic circuit.
15. Stop the engine, and check the hydraulic oil level.
3. Replacing the engine air

cleaner elements
IMPORTANT
conditions, check and clean or replace the air
filter element more frequently.
• Do not start the engine without installing the
filter elements.
Preparing
Replacing
1. Open the 2 clips and remove the cover.
(1) Inner element (5) Dust valve

(2) Outer element (6) Engine air cleaner case
(3) Clip ×2
(4) Cover
U30-6S 3-33

EVERY 1000 HOURS
3. MAINTENANCE
3-34 U30-6S

EVERY 1500 HOURS
1. Checking the injection nozzles 3. MAINTENANCE
EVERY 1500 HOURS

1. Checking the injection
nozzles
WARNING
working area.
CAUTION
• Make sure that there is no person in the
injecting direction.
Preparing (B) Normal (C) Needs to be replaced

5. Replace the injection nozzle if necessary.
3. Remove the injection nozzle.
Checking
1. Set the injection nozzle to the nozzle tester.
2. Operate the lever of the nozzle tester slowly until
injection from the tip of the injection nozzle starts.
3. Measure the injection pressure.
(1) Injection nozzle (A) Nozzle tester
18.7 to 20.1 MPa

Fuel injection pressure
190.7 to 205.0 kgf/cm2
4. Check the condition of injection.
U30-6S 3-35

EVERY 1500 HOURS
3. MAINTENANCE
3-36 U30-6S

EVERY 2000 HOURS
1. Replacing the engine oil in the front idler and track roller 3. MAINTENANCE
EVERY 2000 HOURS

1. Replacing the engine oil in
the front idler and track roller
CAUTION
• Place the machine on jack stands securely
jacked up.
• Keep hands and body away from the rotating
track.
• To avoid a direct high pressure release of the
grease,
– Do not stand in front of the grease fitting. Recommended lubricant
– Loosen the grease fitting slowly.
SAE 30
Engine oil in the front idler Approximately 80 ml
Preparing API CD
1. Jack up the machine and set jack stands under the
4. Tighten the plug and install the front idler to the
machine.
machine.
2. Lower the front attachment and blade to the
ground, and stop the engine. Tightening torque
3. Remove the 2 tracks.
10 N⋅m Thread lock
4. Remove the front idler from each side of the (1) Plug (R1/8)
1.0 kgf⋅m (Loctite® 503)
machine.
5. Remove the 4 track rollers from each side of the Changing the engine oil in the track roller
machine. 1. Remove the plug (R1/8).
Replacing the engine oil in the front idler
1. Remove the plug (R1/8).
(2) Plug (R1/8)
2. Drain the gear oil from the track roller.

(1) Plug (R1/8)
3. Fill new gear oil up to the specified volume.
2. Drain the engine oil from the front idler.
3. Fill new engine oil up to the specified volume.
U30-6S 3-37

EVERY 2000 HOURS
3. MAINTENANCE 2. Checking the alternator
(1) Bolt (M6 × 20) ×5 (2) Center cover

Recommended lubricant
2. Check the connection of the battery terminals.
SAE 30 3. Check the connection of the alternator wiring.
Engine oil in the track roller Approximately 80 ml
API CD
4. Check for rust and dirt on the slow blow fuse.
4. Tighten the plug and install the track rollers to the 5. Check the fan belt tension.
machine. 6. Start the engine.
7. Check if abnormal noise is heard from the
Tightening torque alternator.
9.8 N⋅m Thread lock
(2) Plug NOTE
• If abnormal noise is heard from the
alternator, there is a possibility of bearing
deterioration, looseness or damage of the
2. Checking the alternator fan belt, or wear of the pulley.
8. Measure the voltage of the alternator between the
WARNING terminal B and body ground.
• Keep hands, body, tools, and waste clothes
away from the rotating fan and fan belt.
• Do not clamp electrical wiring to fuel hoses.
CAUTION
• Do not make an unprotected electrical wiring
contact other components.
• Do not alter the electrical device and wiring.
Preparing
4. Tilt the seat.
Checking
1. Remove the 5 bolts to remove the center cover.
3-38 U30-6S

EVERY 2000 HOURS
3. Checking the starter motor 3. MAINTENANCE
Checking the starter motor

1. Connect the terminal C and starter motor body to
the positive (+) and negative (-) terminals of the
battery each.
IMPORTANT
• Fix the starter motor when testing.
NOTE
• If the starter motor does not operate, starter
motor is damaged. Repair or replace the
starter motor following the engine WSM.
(1) Terminal C (3) Negative (-) terminal

(3) Alternator (4) Terminal B (2) Positive (+) terminal
Engine is stopped 12 V
Checking the magnetic switch
Normal 1. Connect the terminal S and the starter motor body
Engine is running Approximately 14 V to the positive (+) and negative (-) terminals of the
battery each.
NOTE
NOTE
• If any abnormality is found on voltage of the
• If the pinion gear does not come out, the
alternator, inspect the alternator according
magnetic switch is damaged. Repair or
to the engine WSM.
replace the starter motor following the
engine WSM.
3. Checking the starter motor
WARNING
• Do not clamp the electrical wiring to fuel hoses.
CAUTION
• Do not alter the electrical device and wiring.
Preparing
2. Open the rear bonnet. (2) Positive (+) terminal (4) Terminal S
3. Open the bonnet RH 1. (3) Negative (-) terminal
4. Disconnect the battery cable from the negative (-)
terminal.
5. Remove the starter motor.
U30-6S 3-39

EVERY 2000 HOURS
3. MAINTENANCE
Checking the conduction of the magnetic clutch

1. Push in the plunger and check the conduction
between the terminal C and terminal B with a circuit
tester.
NOTE
• If there is no conduction, the magnetic
clutch is damaged. Replace the starter
motor following the engine WSM.
(1) Terminal C (5) Terminal B
3-40 U30-6S

EVERY 3000 HOURS
1. Checking the fuel injection pump 3. MAINTENANCE
EVERY 3000 HOURS

1. Checking the fuel injection 6. If the measurement pressure is not within the
specified values, replace the fuel injection pump
pump following the engine WSM.
IMPORTANT
WARNING • Do not disassemble the fuel injection pump
• Keep fire and flammable items away from the assembly.
working area.
CAUTION
Preparing
1. Park the machine on firm and level ground, lower
the bucket and blade to the ground, and stop the
engine.
3. Remove the injection nozzle.
Checking
1. Remove the engine stop solenoid.
2. Install the pressure tester to the fuel injection pump.
(1) Injection nozzle (B) Protection cover

(A) Fuel injection pump pressure
tester
3. Install the injection nozzle to fuel injection pump

pressure tester joint.
4. Set the speed control lever to the maximum speed
position.
5. Crank the engine with the starter and measure the
pressure.
18.7 to 20.1 MPa

190.7 to 205.0 kgf/cm2
U30-6S 3-41

EVERY 3000 HOURS
3. MAINTENANCE
3-42 U30-6S

EVERY 1 YEAR
1. Checking the electrical wiring and fuses 3. MAINTENANCE
EVERY 1 YEAR
1. Checking the electrical wiring
and fuses
WARNING
• If the wire harness or battery cord is damaged,
it will cause a short circuit, so be sure to check
it.
• Check and clean the battery, wiring, muffler, and
peripheral parts of the engine as dust or fuel
may cause a fire.
Preparing
1. Park the machine on the firm and level ground, (1) Slow blow fuse box (4) Slow blow fuse (50 A) (cabin
lower the front attachment and the blade to the (2) Slow blow fuse (80 A) specification)
(3) Slow blow fuse (50 A)
terminal.
Checking
1. Check the electrical wire harness for short circuits
and loose terminals.
2. If the electrical wire harness is damaged, repair it
with an insulating tape or rat-proof tape, or replace
the wire harness with a new one.
IMPORTANT
• Use the proper protective equipment.
NOTE
(5) Fuse box
• Loosening of the terminals of wiring may
cause poor connection. In addition, if wiring 4. Clean the fuse boxes, fuses and relays if
is damaged, unexpected accidents such as necessary.
short circuit, electric leakage, or burning
may result, in addition to performance
impairment of electrical parts. If any damage
is found on wiring, repair or replace the
damaged part as soon as possible.
3. Check the slow blow fuse, and relays and fuses in
the fuse box for rust and dirt.
U30-6S 3-43

EVERY 1 YEAR
3. MAINTENANCE
3-44 U30-6S

EVERY 2 YEARS
1. Replacing the radiator hoses and clamps 3. MAINTENANCE
EVERY 2 YEARS
1. Replacing the radiator hoses
and clamps
WARNING
• Do not open the radiator cap soon after the
engine has stopped. There is a possibility of
serious burn injury due to the coolant blowing
out from the radiator.
CAUTION
– Engine, fuel, and oil are extremely hot. (3) Upper hose (4) Clamp ×2

NOTE
• When replacing the coolant, replace the radiator
hoses and hose clamps at the same time.
Preparing
5. Drain the coolant.
6. Tilt the seat.
Replacing
1. Remove the 5 bolts to remove the center cover. (5) Bolt (M10 × 20) ×4 (6) Cover
4. Replace the lower hose and 2 clamps.
2. Replace the upper hose and 2 clamps.
U30-6S 3-45

EVERY 2 YEARS
3. MAINTENANCE 2. Replacing the coolant
CAUTION
NOTE
• When replacing the coolant, replace the radiator
hoses and hose clamps at the same time.
Preparing
Replacing
1. Put a tray under the drain plug.
2. Loosen the radiator cap and remove the drain plug
to drain the coolant completely.
(7) Lower hose (8) Clamp ×2
5. Replenish the new coolant.

Coolant quantity
Canopy specifi-
Total capacity 5.0 L
cation
(Including re-
serve tank) Cabin specifica- 50% anti-
5.3 L
tion freeze
At the [FULL]
Reserve tank 0.85 L
mark

5 minutes.
NOTE
• Activate the heater (cabin specification).
7. Stop the engine, and check for coolant leakage.
8. Check the coolant level and replenish the coolant if
necessary.
2. Replacing the coolant

(1) Radiator cap (2) Drain plug
3. Dispose of the coolant in the reserve tank.

WARNING
• Do not open the radiator cap soon after the
engine has stopped. There is a possibility of
serious burn injury due to the coolant blowing
out from the radiator.
3-46 U30-6S

EVERY 2 YEARS
3. Replacing the fuel line and intake air line 3. MAINTENANCE
NOTE
• Activate the heater (cabin specification).
12. Stop the engine, and check for coolant leakage.
13. Check the coolant level and replenish the coolant if
necessary.
3. Replacing the fuel line and

intake air line
WARNING
(3) Reserve tank
working area.
4. Clean the inside of the radiator with coolant.
IMPORTANT CAUTION
• Do not apply excessive pressure to the • Do not work soon after the engine has stopped.
radiator to avoid burst of the radiator. The – Engine, fuel, muffler, and oil are extremely
coolant pressure inside the radiator must be hot.
below 88 kPa (0.9 kgf/cm2). – Pressure in the fuel line is high.
5. Close the drain plug and fill up the radiator with
coolant for flushing. Preparing
6. Install the radiator cap. 1. Park the machine on the firm and level ground,
7. Start the engine and keep it idle to flush the coolant lower the front attachment and blade to the ground,
circuit. and stop the engine.
NOTE 3. Open the bonnet RH 1.
• Warm up the coolant until the thermostat 4. Remove the bonnet RH 2.
opens.
Replacing
• Activate the heater for flushing (cabin
1. Replace all of the fuel hoses and clamps.
specification).
8. Drain the coolant, fill the radiator with new coolant,
and then flush again.
9. Repeat flushing several times until the drained
coolant becomes clean.
10. Close the drain plug and fill up the radiator with new
coolant.
IMPORTANT
• Do not fill the reserve tank with the coolant
exceeding the [FULL] level.
• Do not mix the coolant with dirty or salt
water.
• Do not operate the machine without coolant.
Coolant quantity
Canopy specifi-
Total capacity 5.0 L
cation
(Including re-
serve tank) Cabin specifica- 50% anti-
5.3 L
tion freeze
At the [FULL]
Reserve tank 0.85 L
mark

5 minutes.
U30-6S 3-47

EVERY 2 YEARS
3. MAINTENANCE
(1) Fuel hose (2) Clamp
2. Turn the starter switch to [RUN] to bleed the air

from the fuel line.
IMPORTANT
• Check for fuel leakage from the fuel hoses.
3. Replace the 2 intake air hoses and 3 clamps.
(3) Intake air hose (5) Clamp ×3

(4) Intake air hose
3-48 U30-6S

MAINTENANCE FOR CABIN SPECIFICATION
1. Daily check 3. MAINTENANCE

1. Daily check
1.1 Checking the washer liquid level
Preparing
Checking
1. Check the washer liquid level.
IMPORTANT
• Do not turn on the washer motor when the
washer tank is empty to avoid damaging the
washer motor. (2) Bolt (M8 × 16) ×2
Checking
1. Check the air conditioning belt for crack and
damage, and replace it if necessary.
2. Push the position (a) to check the air conditioning
belt tension.
(1) Washer tank
2. Replenish the washer tank if necessary.
2. Every 200 hours

2.1 Checking and adjusting the air (4) Air conditioning belt (8) Locknut (M8)
conditioning belt (5) Tension pulley (9) Adjusting bolt (M8 × 100)
(6) Compressor
(7) Crankshaft pulley
CAUTION
• Stop the engine, remove the key, and hang a DO Service specification
NOT OPERATE tag near the operator's seat Push with 58.8 to 68.6 N
(a) 12.0 to 15.0 mm
when checking or adjusting the air conditioning Push with 6.0 to 7.0 kgf
belt.
3. Adjust the air conditioning belt tension if necessary.
Preparing Adjusting
1. Park the machine on the firm and level ground, 1. Loosen the locknut.
lower the front attachment and blade to the ground, 2. Rotate the adjusting bolt to adjust the air
and stop the engine. conditioning belt tension.
3. Remove the 2 clamps to disconnect the wire NOTE
harness. • Rotate the adjusting bolt clockwise to
4. Remove the 2 bolts to remove the fan cover. tighten the air conditioning belt.
U30-6S 3-49

3. MAINTENANCE 2. Every 200 hours

belt tension.
(1) Rubber mat (3) Air conditioning filter

(2) Seat support cover
(4) Air conditioning belt (8) Locknut (M8) 4. Check the air conditioning filter for contamination
(5) Tension pulley (9) Adjusting bolt (M8 × 100) and damage. In case of heavy contamination,
(6) Compressor replace the air conditioning filter.
(7) Crankshaft pulley
5. Clean the air conditioning filter with compressed air
from the direction opposite of the intake air flow.
IMPORTANT
(a) 12.0 to 15.0 mm • Pressure of the compressed air must be
under 205 kPa (2.1 kgf/cm2).
4. Tighten the locknut.
Tightening torque
17.7 to 20.6 N⋅m
(8) Locknut -
1.8 to 2.1 kgf⋅m
5. Start the engine and check for slip of the air

conditioning belt.
2.2 Cleaning the air conditioning

filter
CAUTION
• Wear an eye protector when cleaning the air (A) Intake air flow
conditioning filter with compressed air.
6. Install the air conditioning filter.
IMPORTANT 7. Close the seat support cover and install the rubber
• If using the machine in extremely dusty mat.
conditioning filter more frequently. 2.3 Cleaning the condenser
Preparing
1. Park the machine on the firm and level ground, CAUTION
lower the front attachment and blade to the ground, • Be sure to stop the engine before cleaning the
and stop the engine. condenser.
Cleaning • Wear an eye protector when cleaning the
1. Remove the rubber mat. condenser with compressed air.
2. Remove the seat support cover.
3. Remove the air conditioning filter. Preparing
3-50 U30-6S

3. Every 500 hours 3. MAINTENANCE
Cleaning 4. Remove the 2 bolts to remove the fan cover.

1. Remove the 4 bolts to remove the condenser cover.

(1) Bolt (M8 × 20) ×4 (2) Condenser cover (2) Bolt (M8 × 16) ×2
2. Check if the fins and ribs of the condenser are Replacing

clogged. 1. Loosen the locknut.
3. Remove dirt with compressed air if necessary. 2. Rotate the adjusting bolt counterclockwise to
loosen the air conditioning belt.
IMPORTANT
3. Replace the air conditioning belt.
• Pressure of compressed air must be under
4. Rotate the adjusting bolt to adjust the air
205 kPa (2.1 kgf/cm2).
conditioning belt tension.
belt tension.
(3) Condenser
3. Every 500 hours (4)

(5)
Air conditioning belt
Tension pulley
(8) Locknut (M8)
(9) Adjusting bolt (M8 × 100)
(6) Compressor
3.1 Replacing the air conditioning (7) Crankshaft pulley
belt
CAUTION (a) 12.0 to 15.0 mm
NOT OPERATE tag near the operator's seat 6. Tighten the locknut.
when replacing the air conditioning belt.
Tightening torque
Preparing 17.7 to 20.6 N⋅m
(8) Locknut -
1. Park the machine on the firm and level ground, 1.8 to 2.1 kgf⋅m
and stop the engine. 7. Start the engine and check for slip of the air
2. Open the rear bonnet. conditioning belt.
3. Remove the 2 clamps to disconnect the wire
harness.
U30-6S 3-51

3. MAINTENANCE 4. Every 1000 hours
4. Every 1000 hours 2.

3.
Open the rear bonnet.
Open the bonnet RH 1.
4.1 Replacing the air conditioning 4. Remove the bonnet RH 2.
filter 5. Tilt the seat.
Checking
IMPORTANT 1. Remove the 5 bolts to remove the center cover.
conditioning filter more frequently.
Preparing
Replacing
1. Remove the rubber mat.
2. Remove the seat support cover.
3. Replace the air conditioning filter with a new one.
NOTE
• Do not damage the air conditioning filter to (1) Bolt (M6 × 20) ×5 (2) Center cover
avoid dust contamination which may cause
damage and malfunction of the air
conditioning system.
(3) Bolt (M10 × 20) ×4 (4) Cover
(1) Rubber mat. (3) Air conditioning filter

3. Check the air conditioning hoses for damage.
(2) Seat support cover. 4. Replace the air conditioning hoses if necessary.
4. Close the seat support cover and install the rubber
mat.
5. Every 1 year
5.1 Checking the air conditioning
and heater hoses
WARNING
– The coolant hoses and heater hoses are
extremely hot.
Preparing
3-52 U30-6S

6. Every 2 years 3. MAINTENANCE
– The coolant hoses and heater hoses are

extremely hot.
CAUTION
working area.
corrosion.
IMPORTANT
and charging.
• Install plugs to the disconnected hoses, pipes,
and devices to avoid water infiltration and dust
contamination.
(5) Liquid hose 2 (9) Suction hose on.
(6) Discharge hose 2 (10) Liquid pipe
(7) Discharge hose 3 (11) Liquid hose 1
• Apply compressor oil to every O-ring to avoid
(8) Discharge hose 1 damage when installing.
5. Check the heater hoses for damage. Preparing
6. Replace the heater hoses if necessary. 1. Park the machine on the firm and level ground,
2. Remove the rear bonnet.
5. Vacuum the refrigerant from the cooling circuit.
7. Remove the cabin.
8. Remove the seat.
9. Remove the seat support.
Replacing
(12) Heater hose (inlet) (13) Heater hose (outlet)
6. Every 2 years
6.1 Replacing the air conditioning
and heater hoses
WARNING
U30-6S 3-53

3. MAINTENANCE 6. Every 2 years
(1) Bolt (M10 × 30) ×2 (2) Cover (8) Bolt (M8 × 100) ×2 (11) Grommet
(9) Bolt (M8 × 20) ×2
2. Remove the 4 bolts to remove the cover. (10) Plate
(3) Bolt (M8 × 25) (5) Cover

(4) Bolt (M8 × 16) ×3
(12) Bolt (M10 × 20) ×4 (13) Cover
3. Remove the 4 bolts to remove the center bonnet.
6. Replace the air conditioning hoses with new ones.
(6) Bolt (M10 × 20) ×4 (7) Center bonnet
4. Remove the 4 bolts to remove the plate and

grommet.
3-54 U30-6S

7. Service as required 3. MAINTENANCE
7. Service as required
7.1 Checking the refrigerant
CAUTION
• Use protective gloves and eye protector when
removing the hose from the charging valve.
IMPORTANT
and charging.
NOTE
• Always use the R134a refrigerant and the
compressor oil for the R134a refrigerant.
Preparing
Checking
1. Start the engine, and turn on the air conditioning.
2. Set the engine speed to 1500 rpm, and set an air
flow of the air conditioner to the maximum.
3. Check the flow of the refrigerant from the sight
(14) Liquid hose 2 (18) Suction hose
glass.
(15) Discharge hose 2 (19) Liquid pipe
(16) Discharge hose 3 (20) Liquid hose 1
(17) Discharge hose 1
7. Replace the heater hoses with new ones.
(21) Heater hose (inlet) (22) Heater hose (outlet)
Concluding
1. Charge the cooling circuit with refrigerant.
2. Refill the radiator with coolant.
(1) Sight glass
U30-6S 3-55

3. MAINTENANCE 7. Service as required
Almost no air bubbles in the

flow. If the engine speed is
raised gradually from idle to
(A) Suitable charge
1500 rpm, the air bubbles disap-
pear and the flow becomes
transparent.
(B) Undercharged Air bubbles flow past constantly.
No air bubbles at all in the flow.

Both high and low pressure
(C) Overcharged
sides are at high pressure and
the cooling is ineffective.
4. If refrigerant is low, charge the refrigerant gas.

NOTE
• If the amount of refrigerant is low, check for
gas leaks and repair if necessary.
3-56 U30-6S

4. MACHINE BODY

MECHANISM
1. Machine device layout 4. MACHINE BODY
MECHANISM
1. Machine device layout
(1) Arm (5) Bucket (9) Canopy (13) Rubber track

(2) Bucket link 2 (6) Swing bracket (10) Seat (14) Steel track
(3) Bucket link 3 (7) Blade (11) Carrier roller (15) Track roller
(4) Bucket link 1 (8) Boom (12) Sprocket (16) Front idler
U30-6S 4-1

MECHANISM
4. MACHINE BODY
(17) Cabin
(18) Travel control lever LH (20) Pilot control lever LH (22) Swing control pedal (24) Pilot control lever RH
(19) Lever lock (21) AUX control pedal (23) Travel control lever RH (25) Blade control lever
4-2 U30-6S

MECHANISM
2. Bucket 4. MACHINE BODY
2. Bucket
2.1 Bucket dimensions
Dimension Dimension
(a) 480 mm (e) ϕ40.05 to 40.10 mm
(b) 462 mm (f) 603 mm
(c) 12 mm (g) 185.5 to 186.5 mm
(d) 178 to 179 mm (h) 195.0 to 195.5 mm
U30-6S 4-3

MECHANISM
4. MACHINE BODY 3. Arm
3. Arm
3.1 Arm dimensions
Arm
NOTE
• (k), (m) and (s) show inner dimensions with bushings installed.
Dimension Dimension
(a) 174 to 176 mm (k) ϕ40.17 to 40.20 mm
(b) 1163 to 1167 mm (m) ϕ40.17 to 40.20 mm
(c) 277 to 279 mm (n) ϕ40.05 to 40.10 mm
(d) 191 to 193 mm (p) 56 to 57 mm
(e) 1221 to 1225 mm (r) 156 to 157 mm
(f) 220 mm (s) ϕ40.10 to 40.13 mm
(g) 287 to 291 mm (t) 144.6 to 144.9 mm
(h) 9 to 11 mm (u) ϕ48 mm
(i) 133.4 to 133.7 mm (v) 61 to 62 mm
(j) 133.4 to 133.7 mm (w) 156 mm
4-4 U30-6S

MECHANISM
3. Arm 4. MACHINE BODY
Bucket link
(1) Bucket link 1 (2) Bucket link 2, 3
NOTE
• (b) and (c) show inner dimensions with bushings installed.
Dimension Dimension
(a) 133.4 to 133.7 mm (g) 133.4 to 133.7 mm
(b) ϕ40 mm (h) 309 to 311 mm
(c) ϕ40 mm (i) 309.8 to 310.2 mm
(d) 41.2 to 41.5 mm (j) ϕ40 mm
(e) 51 mm (k) ϕ40 mm
(f) 41.2 to 41.5 mm - -
U30-6S 4-5

MECHANISM
4. MACHINE BODY 4. Boom
4. Boom
4.1 Boom dimensions
NOTE
• (j) shows the inner dimension with the bushing installed.
Dimension Dimension
(a) 1221 to 1213 mm (k) 60 mm
(b) 920 to 926 mm (m) 75 mm
(c) 1043 mm (n) 194.5 to 195.0 mm
(d) 1207 to 1209 mm (p) 61 to 62 mm
(e) 1149 to 1155 mm (r) 169 mm
(f) 2192 to 2198 mm (s) ϕ48 mm
(g) 39 mm (t) 61 to 62 mm
(h) 145.3 to 145.8 mm (u) 169 mm

(Continued)
4-6 U30-6S

MECHANISM
4. Boom 4. MACHINE BODY
Dimension Dimension
(i) 223 mm (v) ϕ48 mm
(j) ϕ50.10 to 50.13 mm - -
U30-6S 4-7

MECHANISM
4. MACHINE BODY 5. Blade
5. Blade 7. Steel track

5.1 Blade dimensions 7.1 Steel track dimensions
Dimension
(a) 1550 mm
(b) 344.5 mm
(c) 1112 mm
(d) 65 mm
(e) 483 mm
(f) ϕ45.1 to 45.3 mm
(g) ϕ45.1 to 45.3 mm
6. Rubber track
6.1 Rubber track dimensions
(1) Steel track (3) Master pin

(2) Bushing (4) Pin
Dimension
(a) Link length 406.4 mm
(b) Height 68 mm
(c) Grouser height 16.5 mm
(d) Bushing length 54.8 to 55.0 mm
(e) Bushing inner diameter ϕ17.40 to 17.55 mm
(f) Bushing outer diameter ϕ27.96 to 28.00 mm

Dimension (g) Master pin length 96.5 mm
(a) Lug height 22 mm (h) Master pin outer diameter ϕ16.97 to 17.00 mm
(b) Link height 23.5 mm (i) Pin length 96.5 to 97.5 mm
(c) Width 295 mm (j) Pin outer diameter ϕ17.17 to 17.23 mm
(d) Height 75 mm (k) Track tension dimension 75 to 80 mm
(m) Width 300 mm
Number of links 42
4-8 U30-6S

MECHANISM
8. Front idler 4. MACHINE BODY
8. Front idler 10. Track roller

8.1 Front idler dimensions 10.1 Track roller dimensions
Dimension Dimension
(a) Idler outer diameter ϕ292 to 294 mm (a) Guide diameter ϕ78 to 80 mm
(b) Idler width 72 mm (b) Outer diameter ϕ124.0 to 124.5 mm
(c) Guide width 30 mm (c) Roller width 175.0 to 175.4 mm
(d) Shaft outer diameter ϕ35 mm (d) Guide inner width 81 mm
(e) Bushing inner diameter ϕ35 mm
11. Carrier roller

9. Sprocket 11.1 Carrier roller dimensions
9.1 Sprocket dimensions
Dimension
(a) Roller diameter ϕ76.3 mm
(b) Shaft inner diameter ϕ30 mm

Dimension
(a) Sprocket outer diameter ϕ359 to 362 mm
(b) Sprocket inner diameter ϕ184 mm
(c) Sprocket width 18 mm
(d) Gear height 87.5 to 89.0 mm
U30-6S 4-9

MECHANISM
4. MACHINE BODY 12. Pins, bushings, and shims
12. Pins, bushings, and shims

12.1 Pin, bushing, and shim dimensions
4-10 U30-6S

MECHANISM
12. Pins, bushings, and shims 4. MACHINE BODY
(A) Swing bracket (upper side) - (E) Swing bracket - Boom (K) Arm - Arm cylinder (rod side) (R) Blade - Blade cylinder (bottom
Swivel frame (F) Boom cylinder (bottom side) - (L) Arm - Bucket cylinder (bottom side)
(B) Swing bracket (lower side) - Swing bracket side) (S) Track frame - Blade cylinder
Swivel frame (G) Boom cylinder (rod side) - (M) Bucket link (2.3) - Arm (rod side)
(C) Swing cylinder (rod side) - Boom (N) Bucket link (1.2.3) - Bucket (T) Blade - Track frame
Swing bracket (H) Boom - Arm cylinder (rod side)
(D) Swing cylinder (bottom side) - (J) Boom - Arm cylinder (bottom (P) Arm - Bucket
Swivel frame side) (Q) Bucket link (1) - Bucket
IMPORTANT
• Dimensions of pins and bushings correspond to new and unused parts.
U30-6S 4-11

MECHANISM
4. MACHINE BODY 12. Pins, bushings, and shims
• Bushing dimensions are based on the values while not being assembled. Generally, bushings slightly
shrink after assembly.
Dimensions table
[1] Bushing [3] Thrust [4] Cylinder
Pin Shim [5] Dust seal
[2] Bushing collar bushing
No.
Diameter × Diameter ID × OD × Bushing ID ID × OD × ID × OD × ID × OD × ID × OD ×
length tolerance length tolerance thickness thickness length thickness
[1] ϕ70 × ϕ82

-0.05 × 41 +0.12 [3] ϕ71 ×
(A) ϕ70 × 147 - - -
-0.08 [2] ϕ70 × ϕ82 +0.09 ϕ120 × 3.5
× 34
[1] ϕ70 × ϕ82

[3] ϕ71 ×
-0.05 × 34 +0.12
(B) ϕ70 × 123 ϕ120 × (3.5 - - -
-0.08 [2] ϕ70 × ϕ82 +0.09
or 4.0)
× 27
-0.05 [1] ϕ40 × ϕ50 +0.12 ϕ41 × ϕ75 × [4] ϕ40 × ϕ50
(C) ϕ40 × 107 - -
-0.08 × 25 +0.09 (0.5 or 1.0) × 50
-0.05 ϕ41 × ϕ75 × [4] ϕ40 × ϕ50

(D) ϕ40 × 132 - - - -
-0.08 (0.5 or 1.0) × 50
[1] ϕ50 × ϕ60 +0.13

-0.05 × 60 +0.10 ϕ52.5 × ϕ98
(E) ϕ50 × 286 - - -
-0.08 [2] ϕ50 × ϕ60 +0.12 × (0.5 or 1.0)
× 42 +0.09
-0.05 [1] ϕ45 × ϕ55 +0.07 ϕ47 × ϕ80 × [4] ϕ45 × ϕ55
(F) ϕ45 × 157 - -
-0.08 × 45 +0.05 (0.5 or 1.0) × 60
-0.05 ϕ47 × ϕ80 × [4] ϕ45 × ϕ55

(G) ϕ45 × 185 - - - -
-0.08 (0.5 or 1.0) × 60
-0.05 [1] ϕ40 × ϕ50 +0.13 ϕ41 × ϕ75 ×

(H) ϕ40 × 230 - - -
-0.08 × 60 +0.10 (0.5 or 1.0)
-0.05 ϕ47 × ϕ80 × [4] ϕ45 × ϕ55

(J) ϕ45 × 185 - - - -
-0.08 (0.5 or 1.0) × 60
-0.05 ϕ46 × ϕ85 × [4] ϕ45 × ϕ55

(K) ϕ45 × 162 - - - -
-0.08 (0.5 or 1.0) × 60
-0.05 ϕ41 × ϕ75 × [4] ϕ40 × ϕ50

(L) ϕ40 × 162 - - - -
-0.08 (0.5 or 1.0) × 55
-0.05 [1] ϕ40 × ϕ50 +0.20 [5] ϕ40 × ϕ50

(M) ϕ40 × 193 - - -
-0.08 × 40 +0.17 × 4.0
-0.05 [1] ϕ40 × ϕ50 +0.12 ϕ41 × ϕ75 × [4] ϕ40 × ϕ50 [5] ϕ40 × ϕ50
(N) ϕ40 × 193 -
-0.08 × 32 +0.09 (0.5 or 1.0) × 40 × 4.0
-0.05 [1] ϕ40 × ϕ50 +0.20 ϕ41 × ϕ65 × [5] ϕ40 × ϕ50
(P) ϕ40 × 209 - -
-0.08 × 40 +0.17 (0.5 or 1.0) × 4.0
-0.05 [1] ϕ40 × ϕ50 +0.20 ϕ41 × ϕ65 × [5] ϕ40 × ϕ50
(Q) ϕ40 × 209 - -
-0.08 × 40 +0.17 (0.5 or 1.0) × 4.0
-0.05 [4] ϕ45 × ϕ55

(R) ϕ45 × 101 - - - - -
-0.08 × 50
-0.05 [4] ϕ45 × ϕ55

(S) ϕ45 × 101 - - - - -
-0.08 × 50
-0.05
(T) ϕ40 × 161 - - - - - -
-0.08
4-12 U30-6S

SERVICING
1. Service specifications 4. MACHINE BODY
SERVICING
1. Service specifications
1.1 Service specifications for the machine body

• Standard measurement condition is as follows:
– Engine speed: Maximum
Service specification Service limit

Unit
Value Tolerance Value
1 mm of wear on the
Pin - - -
pin outer diameter
Wear 1 mm of wear on the
Bushing - - - bushing inner diam-
eter
Swivel bearing (vertical play) mm Less than 1.04 - Less than 2.08
Play
Front attachment mm Less than 70 - Less than 140
Swing bracket (vertical clearance) mm 0.45 ±0.35 -

Clearance
Front attachment (each pin) mm 0.6 - -
N 11 ±5.0
Forward -
kgf 1.1 ±0.51
Pilot control N 10 ±5.0

Backward -
lever kgf 1.0 ±0.51
N 7 ±5.0
RH and LH -
kgf 0.7 ±0.51
N 19 ±5.0
Forward -
Travel con- kgf 1.9 ±0.51
trol lever N 19 ±5.0
Control lever Backward -
kgf 1.9 ±0.51
N 25 ±5.0
Forward -
Blade control kgf 2.5 ±0.51
lever N 24 ±5.0
Force Backward -
kgf 2.4 ±0.51
N 69 ±14.5
Raising -
kgf 7.0 ±1.48
Lever lock
N 69 ±9.5
Lowering -
kgf 7.0 ±0.97
N 56 ±10.0
RH -
Swing con- kgf 5.7 ±1.02
trol pedal N 63 ±10.0
LH -
kgf 6.4 ±1.02
Control pedal
N 73 ±10.0
Forward -
AUX control kgf 7.4 ±1.02
pedal N 76 ±10.0
Backward -
kgf 7.8 ±1.02
(Continued)
U30-6S 4-13

SERVICING
4. MACHINE BODY 1. Service specifications

Unit
Width mm 300 - -
Link length mm 406.4 - 416.4
Height mm 68 - 63
Grouser height mm 16.5 - 8.0
Bushing length mm 55 -0.2 -
Bushing inner +0.40

mm ϕ17 ϕ19.6
diameter +0.55
Bushing outer
mm ϕ28 -0.04 ϕ25.4
diameter
Steel track Master pin
mm 96.5 - -
length
Master pin out-

mm ϕ17 -0.03 -
er diameter
Track
Pin length mm 97 ±0.5 -
Pin outer di- +0.17

mm ϕ17 ϕ13
ameter +0.23
Number of
- 42 - -
links
Tension di-
mm 77.5 ±2.5 -
mension
Lug height mm 22 - -
Link height mm 23.5 - -

Dimension
Width mm 295 - -
Rubber track
Height mm 75 - -
Tension di-
mm 12.5 ±2.5 -
mension
Carrier roller Outer diameter mm ϕ76.3 - ϕ72.3
Outer diameter mm ϕ292 +2.0 ϕ286
Front idler Guide width mm 30 - 24
Idler width mm 72 - -
-2.0
Outer diameter mm ϕ361 ϕ355
+1.0
Sprocket Inner diameter mm ϕ184 - -
Sprocket width mm 18 - 12
Gear height mm 88.25 ±0.75 85.25
Spring dimen-
Steel track mm 251 ±1.0 -
sion
Tension spring
Spring dimen-
Rubber track mm 242 ±1.0 -
sion
Guide diameter mm ϕ80 -2.0 ϕ74
Guide width mm 81 - 87
Track roller
Roller width mm 175 +0.4 -
4-14 U30-6S

SERVICING
2. Testing 4. MACHINE BODY
2. Testing
2.1 Measuring the front attachment
horizontal play
Measure the horizontal play of the front attachment to
check the wear condition of the pins and bushings.
IMPORTANT
• Measured value is the sum of all clearances of
pins and bushings used in the connections of
the front attachment.
• When adjusting clearance of pin connections,
start with the one that has the largest play.
• Consider the swivel gear backlash when (B) 50 N (5 kgf) (D) Play
measuring the front attachment play. (C) 300 N (31 kgf)
3. Measure 3 times to calculate the average.

Preparing
4. Measure in the opposite direction as well.
1. Dump the arm and the bucket to the stroke end.
2. Make the line which connects the boom support pin Service specification
and the bucket pin horizontal to the ground.
Play Less than 70 mm
Service limit
Play 140 mm
Adjusting
1. Install designated shims to each pin to reduce
clearance.
IMPORTANT
• Install the designated shims to both sides
equally to reduce the clearance.
(A) Boom support pin height Clearance 0.6 mm
3. Stop the engine.
Measuring
1. Press the bucket to the right side by 50 N (5 kgf) to 2.2 Measuring the swivel bearing
set the zero point. vertical play
NOTE Measure the vertical play of the swivel bearing to check
• Set a pole or put a mark on the ground to the wear condition of the balls, inner ring, and outer
recognize the zero point. ring.
Preparing
2. Press the bucket to the left side by 300 N (31 kgf)
1. Fix a dial gauge to the track frame with a magnet
and measure the value of play.
and make the tip of the dial gauge contact the
NOTE swivel frame.
• Measure the distance from the zero point to
the stroke end with a scale or measuring
tape.
U30-6S 4-15

SERVICING
4. MACHINE BODY 2. Testing
Service limit
Play Less than 2.08 mm
2.3 Measuring the swing bracket

vertical clearance
Measure the vertical clearance of the swing bracket to
check the wear condition of the thrust collar, swing
bracket, and track frame.
Preparing
1. Release the residual pressure.
2. Vacuum the hydraulic oil tank.
(a) 125 mm 3. Remove the front attachment.
2. Dump the arm and bucket to the stroke end. Measuring
3. Make the line which connects the boom support pin 1. Measure the clearance between the lower side of
and the bucket pin horizontal to the ground. the swing bracket and the track frame with a feeler
gauge.
(A) Boom support pin height
4. Set the dial gauge to zero. (1) Upper thrust collar (2) Lower thrust collar
Measuring Service specification

1. Jack up the machine with the front attachment and
(a) 0.1 to 0.8 mm
measure the vertical play of the swivel bearing with
the dial gauge.
Adjusting
1. Replace the upper thrust collar.
NOTE
• To adjust the clearance, select a proper
thickness of the thrust collar.
• Grease the thrust collar.
2. Replace the lower thrust collar.
NOTE
• To adjust the clearance, select a proper
thickness of the thrust collar.
Play Less than 1.04 mm
4-16 U30-6S

SERVICING
2. Testing 4. MACHINE BODY
2.4 Measuring the operating force for Service specification

levers and pedals Service specification
Measure the operating forces for levers and pedals to Value Tolerance
check the wear or fixation condition of their internal 11 N ±5.0 N
Forward
parts. 1.1 kgf ±0.51 kgf
Pilot con- 10 N ±5.0 N

CAUTION Backward
trol lever 1.0 kgf ±0.51 kgf
• Make sure that the lever lock is raised before RH and 7N ±5.0 N
the measurement. LH 0.7 kgf ±0.51 kgf
Measuring 19 N ±5.0 N
Travel Forward
1.9 kgf ±0.51 kgf
1. Start the engine and accelerate the engine to control
maximum speed. lever Backward
19 N ±5.0 N
2. Set an operating force measuring device to the 1.9 kgf ±0.51 kgf
lever or pedal. 25 N ±5.0 N
Forward
• Blade control lever: 10 mm below the grip edge Blade con- 2.5 kgf ±0.51 kgf
• Travel control lever: 15 mm below the grip edge Operating trol lever 24 N ±5.0 N
• Other control lever: 20 mm below the grip edge Backward
force 2.4 kgf ±0.51 kgf
• Control pedal: At the edge of the pedal
69 N ±14.5 N
Raising
7.0 kgf ±1.48 kgf
Lever lock
69 N ±9.5 N
Lowering
7.0 kgf ±0.97 kgf
56 N ±10.0 N
Swing RH
5.7 kgf ±1.02 kgf
control
pedal 63 N ±10.0 N
LH
6.4 kgf ±1.02 kgf
73 N ±10.0 N
Forward
AUX con- 7.4 kgf ±1.02 kgf
trol pedal 76 N ±10.0 N
Backward
7.8 kgf ±1.02 kgf
3. Repairing
3.1 Bucket
3.1.1 Removing the bucket
CAUTION
• Do not put your finger into the pinhole,
especially when adjusting the hole position.
Preparing
1. Lower the front attachment to the ground, and stop
the engine.
3. Operate the lever or pedal and measure the force Removing
right before the lever or pedal reaches the end. 1. Remove the 2 bolts.
U30-6S 4-17

SERVICING
4. MACHINE BODY 3. Repairing
IMPORTANT
• Install plugs to the removed hydraulic hoses
and adapters to avoid oil leakage and dust
contamination.
Preparing
1. Remove the bucket.
2. Dump the bucket to the stroke end and lower the
arm to the ground.
Removing
1. Remove the pin-fixing bolt on the rod side of the
(1) Pin (3) Bolt (M12 × 25) ×2 bucket cylinder.
(2) Pin
2. Hit the pin with a hammer and round bar to remove
2. Remove the O-ring from the groove. the link 1, link 2, and link 3.
(4) Bucket (7) Dust seal (1) Bolt (M16 × P1.5 × 30) (4) Link 2
(5) O-ring (8) Shim (2) Pin (5) Link 3
(6) Arm (3) Link 1
3. Hit the 2 pins with a hammer and a round bar to

remove. NOTE
4. Start the engine to lift the boom carefully. The • Apply Loctite® 263 to the pin-fixing bolt on
bucket will be removed. the rod side of the bucket cylinder.
Mass 3. Remove the bolt and clamp.
(4) Bucket Approximately 64 kg
3.2 Arm
3.2.1 Removing the arm
CAUTION
• Before disconnecting the hydraulic hoses,
release the residual pressure first.
• Do not put your finger into the pinhole, (6) Clamp (7) Bolt (M8 × 16)
4. Disconnect all of the hydraulic hoses from the
bucket cylinder.
5. Attach 2 nylon slings to the bucket cylinder and
hoist for support.
4-18 U30-6S

SERVICING
3. Repairing 4. MACHINE BODY
6. Remove the pin-fixing bolt and nut on the bottom

side of the bucket cylinder.
the bucket cylinder.
(13) Arm cylinder (17) Arm

(14) Bolt (M12 × 100) (A) Nylon sling
(15) Pin (B) Supporting block
(16) Nut (M12)
(8) Bucket cylinder (11) Pin Mass

(9) Bolt (M12 × 95) (A) Nylon sling ×2
(10) Nut (M12) (13) Arm cylinder Approximately 31 kg
Mass NOTE
(8) Bucket cylinder Approximately 22 kg
• This value does not include the mass of
hydraulic oil.
NOTE 13. Attach 2 nylon slings to the arm and hoist for
• This value does not include the mass of the support.
hydraulic oil. 14. Remove the pin-fixing bolt on the bottom side of the
arm.
8. Disconnect the AUX hoses. 15. Hit the pin with a hammer and round bar to remove
the arm.
(12) AUX hose
9. Place a supporting block under the arm cylinder for (17) Arm (A) Nylon sling ×2
support. (18) Bolt (M12 × P1.25 × 30)
(19) Pin
10. Attach a nylon sling to the arm cylinder and hoist for
support. Mass
11. Remove the pin-fixing bolt and nut on the rod side
of the arm cylinder. (17) Arm Approximately 67 kg
the rod side of the arm cylinder from the arm. NOTE
• Apply Loctite® 263 to the pin-fixing bolt on
the bottom side of the arm.
U30-6S 4-19

SERVICING
3.3 Boom 5. Remove the bolt to remove the boom cylinder

cover.
3.3.1 Removing the boom
CAUTION
IMPORTANT
• Install plugs to removed hydraulic hoses and
adapters to avoid oil leakage and dust (5) Boom cylinder cover (6) Bolt (M12 × 30)
contamination.
6. Disconnect the work light wire harness.
Preparing
4. Remove the arm.
5. Lower the boom to the ground.
Removing
1. Disconnect all of the hydraulic hoses from the arm
cylinder.
2. Attach 2 nylon slings to the arm cylinder and hoist
for support.
side of the arm cylinder.
4. Hit the pin with a hammer and round bar to remove (7) Work light (8) Work light wire harness
the arm cylinder.
7. Disconnect the 8 hydraulic hoses and work light
wire harness from the boom.
(1) Arm cylinder (4) Nut (M12)

(3) Pin (8) Work light wire harness (9) Hydraulic hose ×8
8. Attach a nylon sling to the boom cylinder and hoist

Mass for support.
(1) Arm cylinder Approximately 31 kg 9. Remove the pin-fixing bolt and nut on the rod side
of the boom cylinder.
NOTE 10. Hit the pin with a hammer and round bar to remove
• This value does not include the mass of the rod side of the boom cylinder from the boom.
hydraulic oil.
4-20 U30-6S

SERVICING
(10) Boom cylinder (14) Nut (M12) (17) Bolt (M8 × 16) (18) Clamp
(11) Boom (A) Nylon sling
(12) Bolt (M12 × 95) 15. Remove the 4 bolts to remove the left and right
(13) Pin guides.
Mass
(10) Boom cylinder Approximately 32 kg
NOTE
hydraulic oil.
11. Attach 2 shackles and a nylon sling to the boom
and hoist for support.
12. Remove the pin-fixing bolt on the bottom side of the
boom.
the boom.
(19) Guide ×2 (20) Bolt (M10 × 25) ×4
16. Disconnect all of the hydraulic hoses from the boom

cylinder.
17. Attach 2 nylon slings to the boom cylinder and hoist
for support.
side of the boom cylinder.
the boom cylinder.
(11) Boom (A) Nylon sling

(15) Bolt (M16 × P1.5 × 35) (B) Shackle ×2
(16) Pin
Mass
(11) Boom Approximately 113 kg
NOTE
• Apply Loctite® 263 to the pin-fixing bolt on
the bottom side of the boom. (10) Boom cylinder (23) Nut (M12)
14. Remove the bolt to remove the clamp. (22) Pin
U30-6S 4-21

SERVICING
Mass 5. Attach 3 nylon slings on the blade and hoist for

support.
(10) Boom cylinder Approximately 32 kg
NOTE
hydraulic oil.
3.4 Blade
3.4.1 Removing the blade
CAUTION
(B) Shackle ×2 (C) Nylon sling ×3
especially when adjusting the hole position. 6. Remove the 2 pin-fixing bolts of the blade.
7. Hit the 2 pins with a hammer and round bar to
Preparing remove the blade from the track frame.
1. Swivel the upper structure 180° against the blade.
the engine.
Removing
1. Place a supporting block under the blade cylinder
for support.
2. Remove the pin-fixing bolt on the bottom side of the
blade cylinder.
the blade cylinder bottom side of the blade cylinder
from the blade.
(1) Blade (7) Track frame

(5) Pin ×2
(6) Bolt (M12 × 75) ×2
Mass
(1) Blade Approximately 114 kg
3.5 Swing bracket

3.5.1 Removing the swing bracket
(1) Blade (4) Bolt (M12 × 25)

(2) Blade cylinder (A) Supporting block
CAUTION
(3) Pin • The hydraulic devices and oil are extremely hot.
Mass measurement, and restoration.
(2) Blade cylinder Approximately 20 kg
NOTE especially when adjusting the hole position.
hydraulic oil.
4. Attach 2 shackles to the blade.
4-22 U30-6S

SERVICING
IMPORTANT
adapters to avoid oil leakage and dust
contamination.
Preparing
4. Remove the arm.
6. Remove the boom.
Removing
1. Remove the 2 bolts to remove the clamp. (6) Swing bracket (A) Nylon sling ×2
5. Remove the snap pin, washer and pin to remove

the pin.
(1) Bolt (M10 × 25) ×2 (2) Clamp
2. Remove the pin-fixing bolt on the rod side of the

swing cylinder. (7) Snap pin (10) Pin
(8) Washer
3. Hit the pin with a hammer and round bar to remove (9) Pin
the rod side of the swing cylinder.
6. Remove the bolt and pin to remove the swing
bracket.
(3) Bolt (M12 × 30) (5) Swing bracket

(4) Pin
(6) Swing bracket (12) Pin
4. Attach 2 nylon slings on the swing bracket and hoist (11) Bolt (M12 × 30)
for support.
Mass
(6) Swing bracket Approximately 71 kg
7. Remove the 2 thrust collars from the swing bracket.
U30-6S 4-23

SERVICING
3.6 Counterweight
3.6.1 Removing and installing the
counterweight
Preparing
1. Lower the bucket and blade to the ground and stop
the engine.
Removing
1. Remove the 2 bolts to remove the partition plate. (5) Counterweight (B) Eye bolt ×2
(6) Bolt (M20 × P2.5 × 90) ×3
(A) Nylon sling ×2
Mass
(5) Counterweight Approximately 400 kg
Installing
IMPORTANT
• Install a shim between the swivel frame and
counterweight.
(1) Partition plate (2) Bolt (M10 × 16) ×2
2. Remove the 2 bolts to remove the bracket.
(5) Counterweight (7) Swivel frame

(6) Bolt (M20 × P2.5 × 90) ×3 (8) Shim
Tightening torque
367.7 to 431.5 N⋅m Thread lock
(6) Bolt
(3) Bracket (4) Bolt (M10 × 20) ×2 37.5 to 44.0 kgf⋅m (Loctite® 263)
3. Install 2 eye bolts to the counterweight.

4. Attach 2 nylon slings to the eye bolts and hoist for
3.7 Seat
support. 3.7.1 Removing the seat
6. Remove the counterweight carefully. Preparing
the engine.
Removing
1. Remove the 2 snap pins.
2. Remove the pin to remove the seat.
4-24 U30-6S

SERVICING
(1) Snap pin ×2 (3) Seat (3) Canopy (B) Nylon sling
(2) Pin (A) Shackle ×2
4. Remove the 6 bolts to remove the canopy

Mass
(3) Seat Approximately 14 kg
3.8 Canopy
3.8.1 Removing and installing the canopy
Preparing
the engine.
2. Tilt the seat.
Removing
1. Remove the 2 bolts to remove the handrail.
(3) Canopy (4) Bolt (M16 × P1.5 × 50) ×6
Mass
(3) Canopy Approximately 62 kg
Installing
Tightening torque
(4) Bolt
20.0 to 23.0 kgf⋅m (Loctite® 263)
3.9 Cabin
(1) Bolt (M10 × 30) ×2 (2) Handrail 3.9.1 Removing and installing the cabin
2. Install the 2 shackles to the canopy.
3. Attach a nylon sling to the shackle and hoist for IMPORTANT
support. • The R134a refrigerant must be handled by
and charging.
Preparing
the engine.
U30-6S 4-25

SERVICING
Removing
(12) Screw ×2 (14) Cabin

(13) Air conditioning panel
(1) Bolt (M6 × 12) ×4 (2) Cover 7. Disconnect the cabin harness connector and cabin
wiper harness connector.
2. Remove the 3 bolts to remove the plate.
(15) Cabin harness connector (16) Cabin wiper harness con-

(3) Bolt (M6 × 12) ×3 (4) Plate nector
3. Remove the nut to disconnect the liquid pipe and 8. Remove the 5 screws to remove the rear cover.
liquid hose 2.
4. Remove the nut to disconnect the discharge hose 2
and discharge hose 3.
5. Disconnect the junction connector.
(17) Screw ×5 (18) Rear cover
9. Install the 2 shackles to the cabin.

10. Attach a nylon sling to the cabin and hoist for
support.
(5) Liquid pipe (9) Discharge hose 2
(6) Nut (M16) (10) Nut (M22)
(7) Liquid hose 2 (11) Discharge hose 3
(8) Junction connector
6. Remove the 2 screws to remove the air

conditioning panel from the cabin.
4-26 U30-6S

SERVICING
Installing
Tightening torque
11.6 to 14.7 N⋅m
(6) Nut -
1.20 to 1.50 kgf⋅m
19.6 to 24.5 N⋅m

(10) Nut -
2.00 to 2.50 kgf⋅m
107.9 to 127.4 N⋅m

(19) Nut -
11.0 to 13.0 kgf⋅m

(20) (21) Stud bolt
8.0 to 13.0 kgf⋅m (Loctite® 271)
3.10 Seat support

(14) Cabin (B) Shackle ×2
(A) Nylon sling 3.10.1 Removing and installing the seat
11. Remove the 4 nuts to remove the cabin. support
IMPORTANT
and charging (cabin specification).
Preparing
the engine.
3. Remove the canopy (canopy specification).
4. Vacuum the refrigerant from the cooling circuit
(cabin specification).
5. Remove the cabin (cabin specification).
6. Remove the seat.
Removing
1. Remove the 2 screws to remove the under cover.
(14) Cabin (C) Front

(19) Nut (M16) ×4 (D) Rear
(20) Front stud bolt (M16 × P1.5)
×2
(21) Rear stud bolt (M16 × P1.5)
×2
Mass
(14) Cabin Approximately 216 kg
U30-6S 4-27

SERVICING
(5) Lever lock switch connector (6) Wire harness
4. Remove the 3 bolts to remove the pilot control

valve LH.
(1) Screw ×2 (2) Under cover
2. Remove the screw to remove the upper cover.
(7) Bolt ×3 (8) Pilot control valve LH
5. Remove the 5 clips to remove the cover.
(3) Screw (4) Upper cover
3. Disconnect the lever lock switch connector to

disconnect the wire harness.
(9) Clip ×5 (10) Cover
6. Remove the 3 grills, 2 bolts and 3 screws to remove

the cover (cabin specification).
4-28 U30-6S

SERVICING
(11) Screw ×3 (14) Grill ×3 (19) AI console connector (22) Work light switch connector
(12) Cover (20) Starter switch connector
(13) Bolt (M6 × 13.5) ×2 (21) Antenna connector
7. Remove the bolt to remove the duct (cabin 10. Remove the 2 screws and bolt to remove the cover.
specification).
(23) Bolt (M6 × 13.5) (25) Cover

(15) Bolt (M6 × 13.5) (16) Duct (24) Screw ×2
8. Remove the 4 screws to remove the cover (canopy 11. Disconnect the meter panel connector and
specification). electronic buzzer connector.
(17) Screw ×4 (18) Cover (26) Meter panel connector (27) Electronic buzzer connector
9. Disconnect the starter switch connector, work light 12. Remove the bolt, loosen the 2 locknuts to remove
switch connector, AI console connector and the blade control cable.
antenna connector.
U30-6S 4-29

SERVICING
(28) Bolt (M6 × 16) (30) Locknut ×2 (36) Seat support cover (38) Snap pin
(29) Blade control cable (37) Washer
13. Disconnect the horn switch connector. 17. Remove the 3 bolts to remove the duct (cabin
14. Remove the 3 bolts to remove the pilot control specification).
valve RH.
(39) Bolt (M10 × 20) ×2 (41) Duct

(31) Pilot control valve RH (33) Bolt ×3 (40) Bolt (M8 × 16)
(32) Horn switch connector
18. Remove the fuse box from the seat support.
15. Remove the 4 bolts to remove the seat support
cover (cabin specification).
(42) Fuse box
19. Disconnect the blower resister connector (cabin

(34) Bolt (M8 × 16) ×4 (35) Seat support cover
specification).
16. Remove the snap pin and washer to remove the
seat support cover (canopy specification).
4-30 U30-6S

SERVICING
(43) Blower resister connector (46) Seat support (47) Bolt (M10 × 25) ×5
20. Remove the 2 bolts to remove the ECU bracket.

Mass
(46) Seat support Approximately 38 kg
Installing
(44) Bolt (M6 × 50) ×2 (45) ECU bracket
21. Attach 2 nylon slings to the seat support and hoist

for support.
(46) Seat support (A) Nylon sling ×2 (29) Blade control cable (49) Grip
(48) Blade control lever
22. Remove the all wire harnesses and hydraulic hoses
from the seat support. Adjusting dimension
23. Remove the 5 bolts to remove the seat support.
(a) 10 mm
(b) 12 mm
(c) 139 mm
(d) 90°
(e) 66.2 mm
U30-6S 4-31

SERVICING
IMPORTANT
• (B) : Set the stopper bolt at the spool end
position of the control valve.
• (C) : Secure the end of the rod so that the cable
does not twist.
• (D) : Secure the cable so that it stands upright.
3.11 Lever lock

3.11.1 Removing and installing the lever
lock
Preparing
(3) Screw (4) Upper cover
the engine.
3. Disconnect the lever lock switch connector and wire
Removing
harness.
1. Remove the 2 screws to remove the under cover.
(5) Lever lock switch connector (6) Wire harness
4. Remove the 2 screws to remove the lever lock

switch.
(1) Screw ×2 (2) Under cover
2. Remove the screw to remove the upper cover.
(7) Screw ×2 (8) Lever lock switch
5. Remove the 2 snap pins and 2 washers to remove

the damper.
4-32 U30-6S

SERVICING
(13) Split pin (14) Washer
8. Remove the 2 bolts to remove the lever lock.
(9) Snap pin ×2 (11) Damper

(10) Washer ×2
6. Remove the spring.

(15) Bolt (M12 × 18.5) ×2 (16) Lever lock
CAUTION Installing
• The spring may pop out rapidly when
removing.
(7) Screw ×2 (12) Spring

(8) Lever lock switch (16) Lever lock
(11) Damper
(12) Spring
NOTE
7. Remove the split pin and washer. • (A) : Lower the lever lock, and check that the
clearance is 0 mm.
Tightening torque
Thread lock
3.9 to 4.9 N⋅m
(7) Screw (ThreeBond®
0.4 to 0.5 kgf⋅m
TB1401B)
U30-6S 4-33

SERVICING
Adjusting dimension
(a) 20 mm
3.12 Blade control lever

3.12.1 Removing and installing the blade
control lever
IMPORTANT
Preparing (3) Screw ×3 (6) Grill ×3

1. Lower the front attachment to the ground, and stop (4) Cover
the engine. (5) Bolt (M6 × 13.5) ×2
2. Remove the floor plate 1. 3. Remove the bolt to remove the duct (cabin
3. Remove the canopy (canopy specification). specification).
6. Remove the seat.
Removing
1. Remove the 5 clips to remove the cover.
(7) Bolt (M6 × 13.5) (8) Duct
4. Remove the 4 screws to remove the cover (canopy

specification).

the cover (cabin specification).
(9) Screw ×4 (10) Cover
5. Disconnect the starter switch connector, work light

switch connector, AI console connector and
antenna connector.
4-34 U30-6S

SERVICING
(11) AI console connector (14) Work light switch connector (20) Blade control lever (22) Washer
(12) Starter switch connector (21) Snap pin
(13) Antenna connector
9. Loosen the 2 locknuts to remove the blade control
6. Remove the 2 screws and bolt to remove the cover. cable.
(15) Bolt (17) Cover (19) Blade control cable (23) Locknut ×2
(16) Screw ×2
10. Remove the seat support (see 4-27).
7. Remove the bolt to separate the blade control 11. Remove the snap pin and washer to separate the
cable. blade control cable.
(18) Bolt (M6 × 16) (19) Blade control cable

(19) Blade control cable (25) Washer
8. Remove the snap pin and washer to remove the (24) Snap pin
blade control lever. 12. Loosen the 2 locknuts to remove the blade control
cable.
U30-6S 4-35

SERVICING
Adjusting dimension
(a) 10 mm
(b) 12 mm
(c) 139 mm
(d) 90°
(e) 66.2 mm
3.13 Swing control pedal

3.13.1 Removing and installing the swing
control pedal
(19) Blade control cable (26) Locknut ×2
IMPORTANT
Installing • The R134a refrigerant must be handled by
Preparing
the engine.
6. Remove the seat.
Removing
1. Remove the 2 bolts to remove the swing control
pedal.
(19) Blade control cable (27) Grip

(20) Blade control lever
(1) Bolt (M8 × 20) ×2 (2) Swing control pedal
IMPORTANT
• (A) : Set the stopper bolt at the spool end 2. Remove the snap pin and washer to separate the
position of the control valve. swing control cable.
• (B) : Secure the end of the rod so that the cable
does not twist.
• (C) : Secure the cable so that it stands upright.
4-36 U30-6S

SERVICING
(3) Snap pin (5) Swing control cable (5) Swing control cable (9) Locknut ×2
(4) Washer
3. Loosen the 2 locknuts to remove the swing control Installing

cable.
(2) Swing control pedal (11) Bracket (swing control cable)

(5) Swing control cable (12) Cover
(5) Swing control cable (6) Locknut ×2 (10) Swing control pedal bracket (13) Snap pin
assembly
4. Remove the snap pin and washer to separate the
swing control cable. IMPORTANT
• (A) : Install so that the notches face toward the
front of the machine.
3.14 AUX control pedal

3.14.1 Removing and installing the AUX
control pedal
IMPORTANT
Preparing
(5) Swing control cable (8) Washer 1. Lower the front attachment to the ground, and stop
(7) Snap pin
the engine.
5. Loosen the 2 locknuts to remove the swing control 2. Remove the swivel cover LH.
cable. 3. Remove the floor plate 1.
7. Remove the seat.
U30-6S 4-37

SERVICING

Removing
1. Remove the 2 bolts to remove the AUX control
pedal.
(5) AUX control cable (8) Washer

(7) Snap pin
5. Loosen the 2 locknuts to remove the AUX control

cable.
(1) Bolt (M8 × 20) ×2 (2) AUX control pedal

AUX control cable.
(5) AUX control cable (9) Locknut ×2
Installing
(3) Washer (5) AUX control cable

(4) Snap pin
3. Loosen the 2 locknuts to remove the AUX control

cable.
(2) AUX control pedal (11) Step 4

(5) AUX control cable (12) Step 1
(10) AUX control pedal cover (13) AUX rod assembly
IMPORTANT
• (A) : Install so that the notches face toward the
(5) AUX control cable (6) Locknut ×2 left of the machine.
• (B) : Apply grease to the grease fitting.
AUX control cable.
4-38 U30-6S

SERVICING
Adjusting dimension
(a) 65 to 67 mm
3.15 Hydraulic lock cylinder

3.15.1 Removing the hydraulic lock
cylinder
IMPORTANT
Preparing (4) Screw ×2 (7) Grill ×3

1. Lower the front attachment to the ground, and stop (5) Duct cover
the engine. (6) Bolt (M6 × 14.5) ×3
2. Remove the floor plate 1. 3. Remove the bolt to remove the duct (cabin
3. Remove the canopy (canopy specification). specification).
Removing
1. Remove the 4 bolts to remove the partition cover.
(8) Bolt (M6 × 14.5) (9) Duct
4. Remove the 5 bolts to remove the SPT support and

stay.
(1) Bolt (M8 × 25) (3) Partition cover

(2) Bolt (M8 × 16) ×3

the duct cover (cabin specification).
(10) Bolt (M10 × 25) ×4 (13) Stay

(11) Bolt (M10 × 20)
(12) SPT support
5. Remove the 4 bolts to remove the seat support

cover (cabin specification).
U30-6S 4-39

SERVICING
(14) Bolt (M8 × 16) ×4 (15) Seat support cover (20) Bolt (M8 × 16) ×4 (21) Hydraulic lock cylinder
6. Remove the 3 bolts to remove the duct (cabin

specification). 3.16 Swivel bearing
3.16.1 Removing and installing the swivel
bearing
CAUTION
(16) Bolt (M10 × 20) ×2 (18) Duct

IMPORTANT
(17) Bolt (M8 × 16) • Install plugs to the removed hydraulic hoses
7. Disconnect the hydraulic hose.
contamination.
Preparing
4. Remove the arm.
6. Remove the boom.
(19) Hydraulic hose
8. Remove the 4 bolts to remove the hydraulic lock 11. Remove the bonnet LH.
cylinder. 12. Remove the swivel cover LH.
17. Remove the seat.
4-40 U30-6S

SERVICING
19. Remove the counterweight. Mass

20. Remove the air conditioning unit (cabin
(3) Upper structure Approximately 670 kg
specification).
21. Remove the engine. 4. Remove the 18 bolts, 18 spring washers, and 2
22. Remove the fuel tank. grease fittings.
23. Remove the swivel motor.
Removing
1. Disconnect the hydraulic hoses on the swivel frame
side of the swivel joint.
2. Remove the 2 bolts to remove the drain.
(4) Bolt (M16 × P1.5 × 45) ×18 (7) Swivel bearing

(5) Spring washer ×18
(6) Grease fitting ×2
5. Remove the upper structure.

6. Remove the 16 bolts and 16 spring washers.
(1) Bolt (M10 × 20) ×2 (2) Drain
3. Attach 3 nylon slings and 2 lever blocks on the

upper structure, and hoist for support.
(7) Swivel bearing (9) Bolt (M16 × P1.5 × 45) ×16

(8) Spring washer ×16
7. Install the 2 shackles to the swivel bearing and

attach a nylon sling.
8. Remove the swivel bearing.
(3) Upper structure (B) Nylon sling ×3

(A) Lever block ×2
U30-6S 4-41

SERVICING
IMPORTANT
• Install the swivel bearing's inner ring so that the
[S]-mark on the swivel bearing faces the RH
side of the machine.
• Tighten bolts alternately in a crosswise pattern
so that the torque is distributed evenly.
• Secure bolts and nuts by tightening 2 to 3
times.
Tightening torque
(4), (9) Bolt
26.5 to 31.0 kgf⋅m (Loctite® 263)
(7) Swivel bearing (D) Eye bolt ×2

(B) Nylon sling 3.17 Rubber track
(C) Shackle ×2
3.17.1 Removing and installing the rubber
Mass track
(7) Swivel bearing Approximately 37 kg
CAUTION
Installing • Place the machine on jack stands securely
jacked up.
track.
grease,
– Do not stand in front of the grease fitting.
IMPORTANT
• Be sure to install the rubber track in the correct
direction.
• If you are going to install rubber tracks in a
steel track specification machine, adjust the
dimension of the tension spring and position of
the second track roller, and remove the guide
plate and slide plate.
Preparing
1. Jack up the machine, and secure the machine on
jack stands.
Removing
1. Remove the bolt to remove the cover.
2. Use a socket wrench to remove the grease fitting
slowly.
(4) Bolt (M16 × P1.5 × 45) ×18 (E) Grease filler hole for ball
(5) Spring washer ×18 bearing
(6) Grease fitting ×2 (F) Grease filler hole for bearing
(7) Swivel bearing teeth
(8) Spring washer ×16 (G) [S]-mark
(9) Bolt (M16 × P1.5 × 45) ×16 (H) Ball insertion hole (outer ring
(10) Grease tube ×2 soft zone)
4-42 U30-6S

SERVICING
5. Slide the rubber track to the direction A to mesh the

rubber track mesh with the idler.
(1) Cover (3) Grease fitting

(2) Bolt (M10 × 20)
3. Remove the grease from the grease cylinder 6. Remove the pipes.
completely. 7. Align the match mark right over the carrier roller.
NOTE 8. Inject grease into the grease fitting to extend the
• The grease comes out by own weight of the grease cylinder.
track. 9. Adjust the distance between the rubber track and
the track roller in range.
4. Tighten the grease fitting. 10. After adjustment, rotate the rubber track 2
Tightening torque revolutions to check the distance.
98.0 to 107.8 N⋅m
(3) Grease fitting -
10.0 to 11.0 kgf⋅m
5. Insert 3 or 4 steel pipes between the rubber track

links.
6. Slowly rotate the travel motor until the rubber track
derails from the idler.
7. Remove the rubber track.
(a) Tension dimension (A) Match mark
Mass Service specification

Rubber track Approximately 131 kg
(a) 10 to 15 mm
Installing
1. Jack up the machine and set the rubber track on
the sprocket.
2. Insert 3 or 4 steel pipes into the lower side of the
rubber track.
3. Slowly rotate the travel motor forwards until the
pipes comes between the idler and rubber track.
4. Stop the travel motor.
U30-6S 4-43

SERVICING
3.18 Steel track Tightening torque

98.0 to 107.8 N⋅m
3.18.1 Removing and installing the steel (3) Grease fitting
10.0 to 11.0 kgf⋅m
-
track
5. Slowly rotate the travel motor until the master pin is
in front of the front idler.
CAUTION 6. Remove the locking pin from the master pin.
jacked up.
track.
grease,
IMPORTANT
• Be sure to install the steel track in the correct
direction.
• If you are going to install steel tracks in a
rubber track specification machine, adjust the
dimension of the tension spring and position of
the second track roller, and install the guide
plate and slide plate.
Preparing
1. Jack up the machine, and secure the machine on (4) Guide plate (7) Master link
jack stands. (5) Slide plate (8) Locking pin
(6) Master pin
Removing
1. Remove the bolt to remove the cover. 7. Place the support block under the track and remove
2. Use a socket wrench to remove the grease fitting the master pin with a hammer and jig.
slowly.
(A) Hammer (C) Support block

(B) Jig
(2) Bolt (M10 × 20) 8. Slowly rotate the travel motor backwards to remove
3. Remove the grease from the grease cylinder the steel track.
completely.
NOTE
• The grease comes out by own weight of the
track.
4. Tighten the grease fitting.
4-44 U30-6S

SERVICING
Dimension
(b) Height 68 mm
(d) Bushing length 54.8 to 55.0 mm
(e) Bushing inner diameter ϕ17.40 to 17.55 mm
(f) Bushing outer diameter ϕ27.96 to 28.00 mm
(g) Master pin length 96.5 mm
(h) Master pin outer diameter ϕ16.97 to 17.00 mm

(9) Steel track
(i) Pin length 96.5 to 97.5 mm
Mass (j) Pin outer diameter ϕ17.17 to 17.23 mm
(9) Steel track Approximately 175 kg (k) Track tension dimension 75 to 80 mm
(m) Width 300 mm

Measuring
1. Check the steel track dimensions.
Service limit
Dimension
(b) Height 63 mm
(d) Bushing length -
(e) Bushing inner diameter ϕ19.6 mm
(f) Bushing outer diameter ϕ25.4 mm
(g) Master pin length -
(h) Master pin outer diameter -
(i) Pin length -
(j) Pin outer diameter ϕ13 mm
(k) Track tension dimension -
(m) Width -
Installing
1. Put the steel track under the track roller so that it
protrudes a little from the sprocket.
(6) Master pin (11) Pin

(9) Steel track
(10) Bushing (7) Master link (E) Front idler side
(D) Sprocket side
U30-6S 4-45

SERVICING
2. Hoist the steel track with a crane and install the Service specification
steel track on the sprocket.
(k) 75 to 80 mm
3.19 Front idler

3.19.1 Removing the front idler
CAUTION
jacked up.
(12) Sprocket • Keep hands and body away from the rotating
track.
3. Slowly rotate the travel motor forwards to make it
mesh with the steel track.
grease,
4. Make the travel motor mesh with the steel track in a
full circle, and stop the travel motor.
5. Set a support block under the track.
Preparing
jack stands.
2. Remove the track.
Removing
1. Use a crowbar to separate the front idler from the
track frame.
(13) Idler (C) Support block

(14) Track
6. Adjust the hole position and install the master pin

and locking pin.
7. Bend the tip of the locking pin.
8. Inject grease into the grease fitting to extend the
grease cylinder.
9. Adjust the distance between the steel track and
track roller in range.
10. After adjustment, rotate the steel track 2 revolutions
and check the distance. (1) Front idler (A) Crowbar
(2) Track frame
2. Attach a nylon sling to the front idler and hoist for

support.
3. Remove the front idler.
(k) Track tension dimension
4-46 U30-6S

SERVICING
3.19.2 Front idler components
(1) Front idler (B) Nylon sling
Mass (1) Bracket LH (7) Idler

(2) Spring pin (8) Bracket RH
(1) Front idler Approximately 28 kg (3) Floating seal (9) External circlip
(4) O-ring (10) Plug (R1/8)
(5) Shaft (11) Plate
Measuring (6) Bushing (12) Bolt (M12 × P1.25 × 45) ×4
1. Check the front idler dimensions.
3.19.3 Disassembling the front idler

1. Remove the 4 bolts and plate.
Dimension
(a) Idler outer diameter ϕ292 to 294 mm

(1) Bolt (M12 × P1.25 × 45) ×4 (2) Plate
(b) Idler width 72 mm
2. Remove the plug from the bracket RH and drain the
(c) Guide width 30 mm oil.
(d) Shaft outer diameter ϕ35 mm 3. Remove the spring pin with a pin punch and
remove the bracket LH.
Service limit
Dimension
(a) Idler outer diameter ϕ286 mm
(b) Idler width -
(c) Guide width 24 mm
(d) Shaft outer diameter ϕ34 mm
U30-6S 4-47

SERVICING
• After assembling, rotate the front idler 3

revolutions to make an oil film on the sliding
surface.
1. Install the O-ring to the shaft.

NOTE
• Lubricate the O-ring.
(3) Spring pin (4) Bracket LH
4. Remove the floating seal.
(1) Shaft (2) O-ring
2. Install the shaft to the bracket RH and attach the

external circlip.
(5) Floating seal
5. Remove the shaft and bracket RH from the idler.
(1) Shaft (4) External circlip

(3) Bracket RH
3. Install a floating seal to the bracket RH.

4. After installing a floating seal to the bracket, mount
the shaft and fix it in place with a spring pin.
(6) Shaft (8) Bracket RH

(7) Idler
3.19.4 Assembling the front idler

IMPORTANT
• Clean the O-ring and its installing location.
• Lubricate the sliding surfaces of the floating
seal.
• Do not twist the floating seal or O-ring.
4-48 U30-6S

SERVICING
(1) Shaft (A) Sliding surface

(3) Bracket RH
(5) Floating seal (8) Spring pin (B) Clamp
5. Install a floating seal to the idler. 9. Install the yoke with 4 bolts.
(1) Shaft (6) Idler (9) Plate (10) Bolt (M14 × P1.25 × 45) ×4
(3) Bracket RH
(5) Floating seal 10. Fill engine oil from the plug hole.
6. Install a floating seal on the idler and bracket LH.
(11) Front idler (12) Plug (R1/8)

(5) Floating seal (7) Bracket LH
(6) Idler Recommended lubricant
7. Align the shaft hole and bracket LH hole and fix Engine oil
Approximately
(11) Front idler SAE 30
with a clamp. 80 ml
API CD
8. Insert the spring pin.
U30-6S 4-49

SERVICING
Tightening torque Installing
(10) Bolt
77.4 to 90.2 N⋅m Thread lock Rubber track specification
7.89 to 9.20 kgf⋅m (Loctite® 271)
10 N⋅m Thread lock

(12) Plug (R1/8)
3.20 Tension spring

3.20.1 Removing and installing the tension
spring
CAUTION
• Place the machine on the jack stands securely
(3) Bolt (6) Slotted nut
jacked up. (4) Tension spring (7) Split pin
• Keep hands and body away from the rotating (5) Spring retainer
track.
• To avoid a direct high pressure release of the NOTE
grease, • (A) : Install and bend the split pin to the groove
– Do not stand in front of the grease fitting. of slotted nut after adjusting.
– Loosen the grease fitting slowly. • (B) : Set position for the steel track
specification.
Preparing
1. Jack up the machine, and secure the machine on Service specification
jack stands.
(a) 242 mm
3. Remove the front idler assembly. Steel track specification
Removing
1. Remove the tension spring from the track frame.
(3) Bolt (6) Slotted nut

(4) Tension spring (7) Split pin
(5) Spring retainer
(1) Tension spring (2) Track frame
NOTE
Mass • (C) : Install and bend the split pin to the groove
of slotted nut after adjusting.
(1) Tension spring Approximately 10 kg
• (D) : Set position for the rubber track
specification.
(b) 251 mm
4-50 U30-6S

SERVICING
3.21 Grease cylinder • To avoid a direct high pressure release of the

grease,
3.21.1 Removing the grease cylinder – Do not stand in front of the grease fitting.
CAUTION Preparing
• Place the machine on the jack stands securely 1. Jack up the machine, and secure the machine on
when lifting the machine. jack stands.
Removing
jacked up.
track.
slowly. Wipe away the grease.
grease,
Preparing
jack stands.
3. Remove the front idler assembly.
4. Remove the tension spring.
Removing
1. Remove the grease cylinder from the track frame.

(2) Bolt (M10 × 20)
3. Remove the grease from the grease cylinder

completely.
NOTE
track.
Tightening torque
98.0 to 107.8 N⋅m
(3) Grease fitting -
10.0 to 11.0 kgf⋅m
(1) Grease cylinder
5. Remove the bolt and track rollers.
Mass
(1) Grease cylinder Approximately 7.0 kg
3.22 Track roller

3.22.1 Removing and installing the track
roller
CAUTION
jacked up. (4) Bolt (M16 × P1.5 × 40) (5) Track roller
track.
U30-6S 4-51

SERVICING
Mass Service specification

(5) Track roller Approximately 8.0 kg Dimension
(e) 269 mm
Measuring
1. Check the track roller dimensions. (f) 290 mm
Tightening torque
Tread lock (male
259.9 to 304.0 N⋅m thread side)
(4) Bolt
26.5 to 31.0 kgf⋅m (ThreeBond®
1305P)
Dimension
(a) Guide diameter ϕ78 to 80 mm
(b) Outer diameter ϕ124.0 to 124.5 mm
(c) Roller width 175.0 to 175.4 mm Adjusting dimension

(d) Guide inner width 81 mm
(g) Less than 1.5 mm
Service limit
Dimension 3.22.2 Track roller components
(a) Guide diameter ϕ74 mm
(b) Outer diameter ϕ118 mm
(c) Roller width -
(d) Guide inner width 75 mm
Installing
Steel track specification
(1) Bracket 2 (6) O-ring

(2) Floating seal (7) Bracket 1
(3) Bushing (8) Plug (R1/8)
(4) Shaft (9) External circlip
(5) Track roller
3.22.3 Disassembling the track roller

1. Remove the plug to drain the oil.
(4) Bolt (M16 × P1.5 × 40) (f) Rubber track specification 2. Remove the external circlip.
(e) Steel track specification
4-52 U30-6S

SERVICING
3.22.4 Assembling the track roller

IMPORTANT
• Clean the O-rings before assembly.
• Install floating seals and O-rings correctly. Do
not kink or incline them.
• Apply small amount of oil to the sliding surface
of the floating seals.
1. Install the floating seal.
(1) Plug (R1/8) (2) External circlip
3. Remove the bracket 2 and floating seal.

NOTE
• Use a puller to remove the bracket 1.
(1) Floating seal (A) Sliding surface
2. Install the shaft assembly.
4. Remove the shaft assembly and floating seal.

5. Remove the shaft from the bracket 1.
NOTE
• Use a press to remove the bracket 1.
3. Install the O-ring to the shaft assembly.

4. Install the floating seal and bracket 2.
(3) Bracket 1 (7) Track roller

(4) Shaft (8) Shaft assembly
(5) O-ring
(6) Floating seal
(1) Floating seal (3) Bracket 2

(2) O-ring
U30-6S 4-53

SERVICING
5. Install the external circlip. • Keep hands and body away from the rotating
track.
NOTE • To avoid a direct high pressure release of the
• Clamp the bracket 2 to install the external grease,
circlip. – Do not stand in front of the grease fitting.
Preparing
jack stands.
Removing
slowly.
(4) External circlip
6. Apply gear oil and install the plug.

(2) Bolt (M10 × 20)
3. Remove the grease from the grease cylinder

completely.
NOTE
(5) Track roller (6) Plug (R1/8) track.
Recommended lubricant
Tightening torque
Engine oil
Approximately 98.0 to 107.8 N⋅m
(5) Track roller SAE 30 (3) Grease fitting -
80 ml 10.0 to 11.0 kgf⋅m
API CD
5. Set a supporting block between the track and track

Tightening torque
frame.
(6) Plug (R1/8)
9.8 N⋅m Thread lock 6. Remove the nut and carrier roller.
3.23 Carrier roller

3.23.1 Removing and installing the carrier
roller
CAUTION
jacked up.
4-54 U30-6S

SERVICING
(4) Carrier roller (A) Supporting block

(5) Nut (M12 × P1.25)
Mass
(4) Carrier roller Approximately 3.0 kg
Measuring
1. Check the outer diameter.
(a) Outer diameter ϕ76.3 mm
Service limit
(a) Outer diameter ϕ72.3 mm
Installing
Tightening torque
(5) Nut
U30-6S 4-55

5. ENGINE

MECHANISM
1. Engine device layout 5. ENGINE
MECHANISM
1. Engine device layout
(1) Muffler (3) Fuel filter (5) Radiator

(2) Water separator (4) Engine air cleaner (6) Reserve tank
U30-6S 5-1

MECHANISM
5. ENGINE
(7) Oil pan (10) Engine speed sensor (13) Compressor (16) Dipstick
(8) Engine mount (11) Supply pump (14) Fan (17) Engine oil filter
(9) Starter motor (12) Intake manifold (15) Engine stop solenoid
(8) Engine mount (19) Fan belt (21) Water temperature sensor (23) Exhaust manifold
(18) Air conditioning belt (20) Water pump (22) Alternator (24) Engine oil pressure switch
5-2 U30-6S

MECHANISM
5. ENGINE
(25) Injection nozzle (26) Glow plug
U30-6S 5-3

MECHANISM
5. ENGINE 2. Engine specifications
2. Engine specifications
Specifications
Type Canopy specification Cabin specification
Model D1803-M-DI-E2-BH-TH1 D1803-M-DI-E2-BH-TH2
Number of cylinders 3
Cylinder bore × stroke 87.0 × 102.4 mm
Total displacement 1826 cm3
Idling speed 1150 min-1(rpm) 1300 min-1(rpm)
Rated speed 2200 min-1(rpm)
Maximum speed 2470 min-1(rpm)
Compression ratio 20.0 : 1
Net
19.7 kW / 2200 min-1(rpm)
SAE J 1349
Net
20.5 kW / 2200 min-1(rpm)
ISO 8178
Rated output / speed
Net
20.5 kW / 2200 min-1(rpm)
ISO 9249
Gross
20.5 kW / 2200 min-1(rpm)
SAE J 1995
Net 102.8 N⋅m / 1600 min-1(rpm)

SAE J 1349 10.5 kgf⋅m / 1600 min-1(rpm)
Maximum torque / speed
Gross 105.6 N⋅m / 1600 min-1(rpm)
SAE J 1995 10.8 kgf⋅m / 1600 min-1(rpm)
Dimensions (L × W × H) 603.0 × 485.0 × 684.0 mm
Dry weight 163 kg
Valve clearance 0.18 to 0.22 mm
Fuel injection order 1-2-3
Combustion chamber E-CDIS
3.0 to 3.2 MPa

Compression pressure
30.6 to 32.6 kgf/cm2
Net
241.1 g/kW⋅h
Fuel consumption (at rated rotation SAE J 1349
speed) Gross
231.7 g/kW⋅h
SAE J 1995
18.6 MPa
1st stage
189.7 kgf/cm2
22.6 MPa
2nd stage
230.5 kgf/cm2
294 to 441 kPa

Engine oil pressure (at rated rotation speed)
3.00 to 4.50 kgf/cm2
Engine oil consumption (at rated rotation speed) 1.02 g/kW⋅h
Alternator 12 V, 720 W
Charging current 60 A
Regulator adjusted voltage 14.2 to 14.8 V
Battery JIS 80D26R

(Continued)
5-4 U30-6S

MECHANISM
5. ENGINE
Specifications
Battery fluid ratio 1.27 to 1.29%
Starter motor 12 V, 1.4 kW
Glow plug 0.95 to 1.35 Ω
U30-6S 5-5

MECHANISM
5. ENGINE 3. Engine dimensions
3. Engine dimensions
Dimension Dimension
(a) 624.0 mm (e) 246.3 mm
(b) 679.0 mm (f) 10.0 mm
(c) 494.0 mm (g) 225.0 mm
(d) 247.7 mm - -
5-6 U30-6S

MECHANISM
4. Engine performance curves 5. ENGINE
4. Engine performance curves

D1803-M-DI-E2-BH-TH1, TH2
(A) Net (ISO 2534, 3046) (C) Engine speed (rpm) (E) Torque
(B) Gross (ISO 2534, 3046) (D) Output (F) Fuel consumption rate
U30-6S 5-7

MECHANISM
5. ENGINE
D1803-M-DI-E2-BH-TH1, TH2
(A) Net (SAE J1349) (C) Engine speed (rpm) (E) Torque
(B) Gross (SAE J1995) (D) Output (F) Fuel consumption rate
5-8 U30-6S

SERVICING
1. Troubleshooting 5. ENGINE
SERVICING
1. Troubleshooting
1.1 Engine troubleshooting

The engine does not start
Causes Inspections Actions
The lever lock is lowered. Check the position of the lever lock. Raise the lever lock.
The fuel hose is clogged. Check the condition of the fuel hose. Clean or replace the fuel hose.
Remove the water from the water separator.

Check the fuel filter, fuel tank, and water sep-
The fuel is too viscous. Replace the fuel filter.
arator.
Replace the fuel.
Remove the water from the fuel tank or water

Check the fuel filter, fuel tank, and water sep-
Air or water is mixed into the fuel system. separator.
arator.
Purge the fuel line.
The engine oil or fuel has become too viscous

- Use specified fuel or engine oil.
due to low temperature.
The battery voltage is too low.

Check the battery voltage. Recharge or replace the battery.
The starter motor speed is low.
The fuel filter is clogged. Check the condition of the fuel filter. Replace the fuel filter.
The compression pressure is insufficient. Check the compression pressure. Follow the engine WSM to repair.
The engine power is insufficient

The fuel level is low. Check the fuel level by the fuel gauge. Refuel.
Clean the outer elements.

The engine air cleaner is clogged. Check if the engine air cleaner is clogged. Replace the inner and outer elements of the
engine air cleaner.
Piston ring is damaged.

Check the engine compression pressure. Follow the engine WSM to repair.
Valve is damaged.
The compression pressure is insufficient. Check the engine compression pressure. Follow the engine WSM to repair.
The engine is hunting


The engine air cleaner is clogged. Check the condition of the engine air cleaner. Replace the inner and outer elements of the
engine air cleaner.
Tighten the injection pipe bolts.

Fuel is leaking from the injection pipe. Check the condition of the injection pipe.
Replace the injection pipe.
Tighten each clamp.

Air is leaking from the intake air line. Check the each hose of the intake air line.
Install each hose firmly.
U30-6S 5-9

SERVICING
5. ENGINE 1. Troubleshooting
The exhaust gas color is abnormal

The fuel quality is low. - Change to fuel with proper quality.
Too much engine oil is added. Check the engine oil level with the dipstick. Drain the engine oil to adjust the oil level.

The engine air cleaner is clogged. Check the condition of the engine air cleaner. Replace the inner and outer elements of the
engine air cleaner.
Replace the piston ring.

Engine oil is leaking from the piston ring, pis- Check the condition of the piston ring, piston
Replace the piston.
ton or cylinder. and cylinder.
Repair the cylinder.
The engine is overheating

The coolant level is low. Check the coolant level in the reserve tank. Fill the reserve tank with the coolant.
Check if the radiator fins are clogged.

The radiator fins are clogged. Clean the radiator.
Check the coolant pipe.
The radiator cap is damaged. Check the radiator cap. Replace the radiator cap.
The thermostat is damaged. Check the thermostat. Replace the thermostat.
The engine oil level is low. Check the engine oil level with the dipstick. Fill with the engine oil.
Check the fan belt. Replace the fan belt.

The fan belt is damaged.
Check the tension of the fan belt. Adjust the fan belt tension.
The water pump seal is damaged. Check the water pump seal. Replace the water pump seal.
Rust is mixed into the coolant. Check the condition of the coolant. Replace the coolant.
Check the damage and oil leakage around

The cylinder head gasket is damaged. Replace the cylinder head gasket.
the cylinder head.
The fuel injection timing is incorrect. Check if the injection timing is correct. Adjust the injection timing.
The fuel quality is low. - Change to the fuel with proper quality.
5-10 U30-6S

SERVICING
2. Service specifications 5. ENGINE
2.1 Service specifications for the engine

Unit
MPa 3.1 ±0.1 2.4

Engine compression
kgf/cm2 31.6 ±1.0 24.5
Pressure
kPa 367.5 ±73.5 250
Engine oil At the rated speed
kgf/cm2 3.75 ±0.75 2.55
3. Testing
3.1 Measuring engine compression
pressure
CAUTION
fan and belt.
IMPORTANT
• Measure each cylinder individually to measure
the correct value.
Preparing
1. Warm up the engine.
2. Stop the engine.
3. Disconnect the connector of the engine stop
solenoid to stop the supply of fuel.
(2) Glow plug (B) Compression tester

(A) Adapter
Measuring
1. Crank the engine with the starter motor.
2. Measure the compression pressure with a
compression tester.
3. After measuring the engine compression pressure,
install the glow plug with the specified torque.
(1) Engine stop solenoid con-
nector
Tightening torque
4. Remove all of the glow plugs, and install a 20.0 to 24.0 N⋅m
(2) Glow plug -
2.0 to 2.4 kgf⋅m
compression tester with an adapter on one of the
glow plug holes. Service specification
NOTE 3.0 to 3.2 MPa
• Check for compression gas leakage. 30.6 to 32.6 kgf/cm2
U30-6S 5-11

SERVICING
5. ENGINE 3. Testing
Service limit IMPORTANT

2.4 MPa • Wrap the thread seal tape around the
24.5 kgf/cm2 pressure tester adapter to avoid oil leakage.
5. Install the muffler.
6. Warm up the engine.
3.2 Measuring engine oil pressure
Measuring
1. Start the engine.
CAUTION 2. Measure the oil pressure at the rated speed.
• Do not work soon after the engine has stopped. 3. After measuring the engine oil pressure, install the
– Engine, fuel, muffler, and oil are extremely engine oil pressure switch with the specified torque.
hot.
– Pressure in the engine oil line is high. IMPORTANT
• Keep hands and body away from the rotating • Wrap the thread seal tape around the engine oil
fan and belt. pressure switch to avoid oil leakage.
• Make sure that the lever lock is raised before
measuring. Tightening torque
(2) Engine oil pres- 15.0 to 19.0 N⋅m
Preparing -
sure switch 1.5 to 1.9 kgf⋅m
1. Remove the muffler.
2. Disconnect the engine oil pressure switch Service specification
connector.
294 to 441 kPa
3. Remove the engine oil pressure switch. Engine oil pressure At the rated speed
3.00 to 4.50 kgf/cm2
Service limit
250 kPa
Engine oil pressure At the rated speed
2.55 kgf/cm2
4. Repairing
4.1 Fuel hose and tank
4.1.1 Removing and installing the fuel tank
CAUTION
(1) Engine oil pressure switch (2) Engine oil pressure switch • Keep fire and flammable items away from the
connector working area.
4. Install the oil pressure tester. Preparing
the engine.
terminal.
7. Drain the fuel.
Removing
1. Disconnect the fuel level sensor connector.
(A) Oil pressure tester
5-12 U30-6S

SERVICING
4. Repairing 5. ENGINE
(1) Fuel level sensor connector (6) Clamp (7) Fuel hose
2. Remove the 2 bolts to remove the plate 1. 5. Remove the nut to remove the band assembly.
(2) Bolt (M10 × 20) ×2 (3) Plate 1 (8) Nut (M8) (9) Band assembly
3. Remove the 2 clips to remove the cover. 6. Remove the 2 clamps to disconnect the 2 fuel
hoses from the fuel tank.

(10) Clamp ×2 (12) Fuel tank
4. Remove the clamp to disconnect the fuel hose. (11) Fuel hose ×2
7. Remove the fuel tank.
U30-6S 5-13

SERVICING
5. ENGINE 4. Repairing
(12) Fuel tank
Mass
(12) Fuel tank Approximately 5.0 kg
Installing
(8) Nut (M8) (9) Band assembly
Adjusting dimension
(a) 25.00 to 30.00 mm
5-14 U30-6S

SERVICING
4.1.2 Fuel hose routing
CAUTION
• Do not make the fuel hoses contact sharp edges, high temperature parts, or rotating parts.
• Do not stretch the fuel hoses excessively.
• Do not clamp the fuel hoses with electrical wiring.
• Do not flatten the fuel hoses with clamps.
(1) Fuel drain (3) Water separator (5) Fuel cooler (7) Engine
(2) Fuel tank (4) Fuel pump (6) Fuel filter
Hose Protection tube

No.
Length Inner diameter Length Inner diameter
(a) 670 mm ϕ8.6 to 9.4 mm 540 mm ϕ16 mm
(b) 1600 mm ϕ8.0 mm 1500 mm ϕ15 mm
(c) 800 mm ϕ8.0 mm 705 mm ϕ15 mm
(d) 600 mm ϕ8.0 mm 500 mm ϕ15 mm
(e) 1500 mm ϕ8.0 mm 1400 mm ϕ15 mm
(f) - ϕ7.6 to 8.4 mm - -
(g) 220 mm ϕ8.0 mm - -
(h) - ϕ7.6 to 8.4 mm - -
(i) 550 mm ϕ4.0 mm 450 mm ϕ10 mm
(j) 1800 mm ϕ4.0 mm 1650 mm ϕ10 mm
(A) Pass the hoses through the guides.

(B) Align the guide and white tape and pass the hoses through the guides.
U30-6S 5-15

SERVICING

(C) Pass the hoses through the guide and fasten with the a cord band.
5-16 U30-6S

SERVICING
4.2 Engine
4.2.1 Removing and installing the engine
CAUTION
• Do not install the fuel hose as below:
– Contacting sharp edges, high temperature
parts, and rotating parts.
– Stretched excessively, deformed, or being
clamped with electrical wiring.
(1) Bolt (M10 × 30) ×2 (2) Cover
working area. 2. Remove the 4 bolts to remove the cover.
IMPORTANT
• Install plugs or covers to the removed fuel
hoses and radiator hoses to avoid dust
contamination.
Preparing
the engine.
4. Disconnect the battery cable from the negative (-) (3) Bolt (M8 × 25) (5) Cover
terminal. (4) Bolt (M8 × 16) ×3
5. Remove the bonnet RH 2. 3. Remove the 4 bolts to remove the center bonnet.
12. Remove the seat.
14. Remove the hydraulic pump.
16. Remove the counterweight.
Removing
4. Loosen the clamp to disconnect the inlet hose 1.
U30-6S 5-17

SERVICING
(8) Clamp (9) Inlet hose 1
5. Remove the clamp to disconnect the overflow hose. (13) Hydraulic hose
8. Remove the 2 bolts to separate the radiator

bracket.
(10) Clamp (11) Overflow hose
6. Remove the reserve tank.
(14) Bolt (M10 × 20) ×2 (15) Radiator bracket
9. Remove the 2 clamps to disconnect the 2 fuel

hoses.
(12) Reserve tank
5-18 U30-6S

SERVICING
(16) Clamp ×3 (17) Fuel hose ×3
11. Remove the 3 bolts to remove the clamp, suction

hose and discharge hose 1 (cabin specification).

hoses.
(18) Bolt (M6 × 30) ×2 (21) Bolt (M6 × 25)
(19) Discharge hose 1 (22) Clamp
(20) Suction hose
12. Remove the 2 bolts to remove the rear LH engine

stopper.
(23) Bolt (M10 × 20) ×2 (24) Rear LH engine stopper
13. Remove the 3 bolts to remove the tank stay.
U30-6S 5-19

SERVICING
(25) Bolt (M12 × 60) (27) Tank stay (29) Bolt (M12 × P1.25 × 35) ×4
(26) Bolt (M12 × 30) ×2
16. Remove the 4 bolts to remove the arch frame.
14. Attach 2 nylon slings to the arch frame and hoist for
support.
(28) Arch frame (A) Nylon sling ×2
(28) Arch frame (29) Bolt (M12 × P1.25 × 35) ×4
Mass
(28) Arch frame Approximately 44 kg
17. Loosen the clamp to disconnect the upper hose.
5-20 U30-6S

SERVICING
(30) Clamp (31) Upper hose (36) Bolt (M10 × 20) ×2 (37) Rear RH engine stopper
18. Loosen the clamp to disconnect the lower hose. 21. Remove the 2 bolts to remove the front LH engine
stopper.
(32) Clamp (33) Lower hose

(38) Bolt ((M10 × 20) ×2 (39) Front LH engine stopper
19. Remove the 2 clamps to disconnect the 2 heater
hoses. 22. Remove the 2 bolts to remove the front RH engine
stopper.
(34) Clamp ×2 (35) Heater hose ×2

(40) Bolt (M10 × 25) ×2 (41) Front RH engine stopper
20. Remove the 2 bolts to remove the rear RH engine
stopper. 23. Disconnect all of the wire harnesses from the
engine.
24. Install 2 shackles to the engine.
25. Attach a nylon sling to the engine and hoist the
support.
U30-6S 5-21

SERVICING
Installing
Tightening torque
7.9 to 11.8 N⋅m
(18) Bolt -
0.8 to 1.2 kgf⋅m

(29) Bolt
3.9 to 4.9 N⋅m

(30), (32) Clamp -
0.40 to 0.50 kgf⋅m

(43) Nut

(44) Bolt
(42) Engine (B) Shackle ×2
(A) Nylon sling
26. Remove the 3 nuts and 4 bolts to remove the 4.2.2 Removing the alternator
engine.
CAUTION
working area.
IMPORTANT
Preparing
the engine.
terminal.
7. Remove the seat.
10. Remove the air conditioning belt (cabin
specification).
11. Remove the fan belt.
Removing
(42) Engine (44) Bolt (M10 × P1.25 × 25) ×4 1. Remove the 2 bolts to remove the cover.
(43) Nut (M12 × P1.25) ×3
Mass
(42) Engine Approximately 163 kg
5-22 U30-6S

SERVICING
(1) Bolt (M10 × 30) ×2 (2) Cover (8) Terminal B (10) Alternator
(9) Connector
5. Remove the 2 bolts to remove the alternator stay.
(3) Bolt (M8 × 25) (5) Cover

(4) Bolt (M8 × 16) ×3 (11) Bolt (M8 × 22) (13) Alternator stay
(12) Bolt (M8 × 30)
6. Remove the bolt to remove the alternator.

(10) Alternator (14) Bolt (M10 × 70)
4. Disconnect the terminal B and connector from the
alternator. Mass
(10) Alternator Approximately 4.0 kg
U30-6S 5-23

SERVICING
4.2.3 Removing the starter motor
CAUTION
working area.
Preparing
the engine.
terminal.
(4) Starter motor (6) Nut (M10)
Removing (5) Bolt (M10 × 30)
1. Remove the dipstick.
Mass
(4) Starter motor Approximately 4.0 kg
4.2.4 Removing and installing the injection

nozzle
CAUTION
(1) Dipstick working area.
2. Disconnect the terminal B and connector from the
IMPORTANT
starter motor.
• Work at clean work space with clean tools and
lubricant to avoid dust contamination.
• Do not reuse the used gasket of the injection
nozzle.
Preparing
the engine.
Removing
hoses.
(2) Terminal B (4) Starter motor

(3) Connector
3. Remove the bolt and nut to remove the starter

motor.
5-24 U30-6S

SERVICING
(5) Injection pipe ×3
4. Remove the 3 bolts to remove the 3 nozzle clamps

and 3 injection nozzles.
2. Remove the 3 bolts to remove the overflow pipe.
(6) Bolt (M10 × 60) ×3 (8) Injection nozzle ×3

(7) Nozzle clamp ×3
Installing
Tightening torque
9.8 to 11.3 N⋅m
(3) Bolt -
1.0 to 1.2 kgf⋅m
25.5 to 29.4 N⋅m

(6) Bolt -
2.6 to 3.0 kgf⋅m
4.3 Radiator
(3) Bolt (M6 × 15) ×3 (4) Overflow pipe 4.3.1 Removing and installing the radiator
3. Remove the 3 injection pipes.
CAUTION
• Do not work soon after stopping the engine.
working area.
Preparing
U30-6S 5-25

SERVICING

8. Remove the counterweight.
Removing
1. Remove the clamp to disconnect the overflow hose.
(6) Hydraulic hose
5. Remove the 4 bolts to separate the hydraulic oil

cooler.
(1) Clamp (2) Overflow hose
2. Remove the reserve tank.
(7) Bolt (M8 × 20) ×4 (8) Hydraulic oil cooler
6. Disconnect the 2 clamps from the radiator bracket.
(3) Reserve tank
3. Remove the 2 bolts to separate the fuel cooler.
(9) Clamp ×2 (10) Radiator bracket
7. Remove the 2 bolts to remove the radiator bracket.
(4) Bolt (M8 × 20) ×2 (5) Fuel cooler
5-26 U30-6S

SERVICING
(10) Radiator bracket (11) Bolt (M10 × 20) ×2 (15) Clamp (17) Radiator
(16) Upper hose
8. Disconnect the clamp from the hydraulic oil cooler
support. 11. Loosen the clamp to disconnect the lower hose
from the radiator.
(12) Clamp (13) Hydraulic oil cooler support

(17) Radiator (19) Lower hose
9. Remove the 2 bolts to remove the hydraulic oil (18) Clamp
cooler support.
(13) Hydraulic oil cooler support (14) Bolt (M6 × 16) ×2

(20) Bolt (M10 × 20) ×4 (21) Cover
10. Loosen the clamp to disconnect the upper hose
from the radiator. 13. Loosen the clamp to disconnect the radiator drain
hose.
U30-6S 5-27

SERVICING
(22) Clamp (23) Radiator drain hose (17) Radiator (27) Bolt (M6 × 16) ×4
(26) Fan shroud
14. Remove the 2 plugs to remove the radiator
grommet. Mass
(17) Radiator Approximately 3.0 kg
Installing
(24) Plug ×2 (25) Radiator grommet
15. Remove the radiator and fan shroud.
(17) Radiator
(17) Radiator (26) Fan shroud
16. Remove the 4 bolts to remove the radiator from the

fan shroud. (26) Fan shroud (A) Tighten the clamp by insert-
ing a bolt from the top.
5-28 U30-6S

SERVICING
(28) Cushion (B) Make sure that pins of the (1) Nut (M10) ×4 (2) U bolt
cushions are securely insert-
ed into the bracket holes. 2. Remove the 2 bolts to remove the muffler pipe stay.
Adjusting dimension
(a) 75.00 to 81.00 mm
(b) More than 10.00 mm
Tightening torque
(15), (18), (22) 3.9 to 4.9 N⋅m
-
Clamp 0.40 to 0.50 kgf⋅m
48.1 to 55.9 N⋅m

(20) Bolt -
4.9 to 5.7 kgf⋅m
3.0 to 3.5 N⋅m

(27) Bolt -
0.31 to 0.36 kgf⋅m
(3) Bolt (M8 × 20) ×2 (4) Muffler pipe stay

4.4 Muffler
3. Remove the bolt and nut to remove the muffler pipe
4.4.1 Removing and installing the muffler band.
CAUTION
working area.
Preparing
the engine.
Removing
1. Remove the 4 nuts to remove the U bolt. (5) Bolt (M8 × 65) (7) Muffler pipe band
(6) Nut (M8)
4. Remove the pipe.
U30-6S 5-29

SERVICING
(8) Pipe (8) Pipe (A) Do not make the pipe pro-
(12) Counterweight trude from the counter-
5. Remove the 2 bolts to separate the muffler. weight.
Adjusting dimension
(a) More than 20.00 mm
Tightening torque
3.9 to 5.9 N⋅m
(5) Bolt -
0.4 to 0.6 kgf⋅m
(9) Bolt (M10 × 25) ×2 (10) Muffler
6. Remove the 2 bolts to remove the muffler.
(10) Muffler (11) Bolt (M10 × 25) ×2
Mass
(10) Muffler Approximately 7.0 kg
Installing
1. Leave the clearance between the pipe and the
counterweight.
5-30 U30-6S

6. HYDRAULIC SYSTEM

MECHANISM
1. Hydraulic device layout 6. HYDRAULIC SYSTEM
MECHANISM
1. Hydraulic device layout
(1) Boom cylinder (3) Bucket cylinder (5) Blade cylinder (7) Travel motor LH
(2) Arm cylinder (4) Swing cylinder (6) Travel motor RH
U30-6S 6-1

MECHANISM
6. HYDRAULIC SYSTEM
(8) Control valve (12) Hydraulic oil cooler (16) Swivel motor (20) Multi valve
(9) Third line valve (13) Travel control valve (17) Swivel joint
(10) Hydraulic oil tank (14) Pilot control valve LH (18) Hydraulic pump
(11) Unload valve (15) Pilot control valve RH (19) Pilot filter
6-2 U30-6S

MECHANISM
2. Hydraulic system general description 6. HYDRAULIC SYSTEM
2. Hydraulic system general description

2.1 Load sensing system general description
It is a system that always controls the pump discharge flow rate to supply only the required flow rate to the control
valve by feeding back the pump discharge pressure and the actuator load pressure to the regulator mounted on the
hydraulic pump.
(1) Outlet section (7) Travel motor RH section (13) Hydraulic oil tank (19) Travel motor LH
(2) Swivel section (8) Blade section (14) Hydraulic oil cooler (20) Travel motor RH
(3) Bucket section (9) Swing section (15) Swivel motor (21) Blade cylinder
(4) Arm section (10) AUX section (16) Bucket cylinder (22) Swing cylinder
(5) Boom section (11) Inlet section (17) Arm cylinder
(6) Travel motor LH section (12) Piston pump (P) (18) Boom cylinder
When the machine is not operating

• The hydraulic pump supplies the minimum amount of oil flow (standby flow rate) to the control valve in order to
ensure initial responsiveness.
• All of supplied hydraulic oil returns to the hydraulic oil tank.
U30-6S 6-3

MECHANISM
6. HYDRAULIC SYSTEM 2. Hydraulic system general description
When the machine is operating

• The hydraulic pump delivers an adequate amount of oil flow according to the amount of operation of the pilot
control lever and pedal, and work load.
• The hydraulic oil supplied from the hydraulic pump passes through each section of the control valve, and the
whole amount of the oil flows to the actuator.
• The maximum load pressure of each actuator and the pump discharge pressure are always fed back to the
hydraulic pump.
• The hydraulic pump discharges an adequate amount of oil according to the amount of operation of the pilot
control lever and pedal, and work load.
6-4 U30-6S

MECHANISM
2. Hydraulic system general description 6. HYDRAULIC SYSTEM
2.2 Pilot control system general description

The pilot control system is powered by oil from the gear pump, and the pilot oil shifts the spools in the control valve
according to the operation of the pilot control levers or pedal.
(1) Gear pump (Pp) (3) Unload valve (5) Pilot control valve LH (7) Travel control valve
(2) Pilot filter (4) Pilot control valve RH (6) Hydraulic oil tank (8) Control valve
When the lever lock is raised

• Since the unload valve is not excited, the oil passage inside the unload valve is cut off.
• Pressurized oil from the gear pump returns to the hydraulic oil tank through the relief valve inside the unload
valve.
When the lever lock is lowered
• The unload valve is excited to make the pilot oil flow to the pilot control valves and travel control valve.
• According to the operation of pilot control levers and pedal, the pilot control valve and travel control valve switches
hydraulic oil circuits inside the control valve.
• Pilot oil passes through the pilot control valves and travel control valve to switch the circuits inside the control
valve.
NOTE
• The following actuators are controlled by the mechanical linkage, and not by the hydraulic pilot.
– AUX
– Blade
– Swing
U30-6S 6-5

MECHANISM
6. HYDRAULIC SYSTEM 2. Hydraulic system general description
Heat up function
• Even if the lever lock is raised, the gear pump (Pp) pressurized oil is supplied to each pilot control valve.
• Since the gear pump (Pp) pressurized oil passes through each pilot control valve and returns to the hydraulic oil
tank, the actuator does not move even if the pilot control valve is moved.
• This system always supplies gear pump (Pp) pressurized oil to the pilot circuit to maintain the operation response
even in cold conditions.
6-6 U30-6S

MECHANISM
3. Hydraulic pump 6. HYDRAULIC SYSTEM
3. Hydraulic pump
3.1 Hydraulic pump specifications
(1) Piston pump (P) (2) Gear pump (Pp) (3) Regulator
Specification
Manufacturer KYB Corporation
Rotation direction Rotates right viewed from the engine
Piston pump (P) 42.0 cm3/rev

Maximum displacement
Gear pump (Pp) 7.0 cm3/rev
Piston pump (P) 92.4 L/min

Maximum flow rate
Gear pump (Pp) 15.4 L/min
24.5 MPa
Piston pump (P)
249.8 kgf/cm2
Maximum pressure
3.92 MPa
Gear pump (Pp)
40.0 kgf/cm2
Standby flow rate -
Port location table

No. Port Location No. Port Location
Control valve (P)

(4) P (8) PPS Control valve (PPS2)
Control valve (PPS2)
(5) Pp Accumulator unload valve (C) (9) Pcg -
(6) PLS Control valve (PLS) (10) CH2 Air bleeding hose
(7) PS Hydraulic oil tank (11) CH1 -
U30-6S 6-7

MECHANISM
6. HYDRAULIC SYSTEM 3. Hydraulic pump
3.2 Hydraulic pump hydraulic circuit
(1) Piston pump (P) (3) Control pin A (5) Horsepower control spool (7) Regulator
(2) Gear pump (Pp) (4) Control pin B (6) Horsepower control spring (8) Spool
6-8 U30-6S

MECHANISM
3.3 Piston pump P-Q performance
(A) Discharge flow rate: Q (L/min) (B) Discharging pressure: P

(MPa)
Pump revolution speed: 2200 rpm
Discharging pressure (MPa) Discharging flow rate (L/min)
P1 = 3.0 Q1 = 92.2 ± 3.0
P2 = 7.1 Q2 = 91.4 (Target value)
P3 = 13.6 Q3 = 53.2 (Target value)
P4 = 24.5 Q4 = 28.4±5.0
U30-6S 6-9

MECHANISM
3.4 Hydraulic pump function and structure

3.4.1 Piston pump working principles
(1) Piston (4) Swash plate (7) Discharging port (P) (B) Suction side
(2) Retainer plate (5) Cylinder block (8) Suction port
(3) Shoe (6) Valve plate (A) Discharging side
• The engine is connected to the cylinder block with the shaft.

• The cylinder block is composed of multiple pistons.
• The pistons reciprocate inside the cylinder block according to the rotation of the cylinder block and the angle of
the swash plate.
• The piston pump suctions and discharges the hydraulic oil with their reciprocating motion.
– Suction process
• The pistons are pulled out from the cylinder block.
• Hydraulic oil is suctioned into the cylinder block through the valve plate.
– Discharging process
• The pistons are pushed into the cylinder block.
• Hydraulic oil is discharged from the cylinder block through the valve plate.
• Suction and discharging flow rate depends on the angle of the swash plate.
6-10 U30-6S

MECHANISM
3.4.2 Horsepower control

Controls the discharging flow rate of the piston pump so that the total consumed horsepower (torque) of the pump
does not exceed the specified horsepower (torque) of the engine.
When pressure P is low (when load is low)
(1) Control pin A (3) Horsepower control spool (5) Horsepower control spring (7) Reaction pin
(2) Control pin B (4) Horsepower control valve (6) Swash plate (A) Discharge pressure P
• The discharging pressures P push the control pin B and the horsepower control spool.
• The control pin A becomes connected to the hydraulic oil tank via the horsepower control spool, since the
horsepower control spring keeps the horsepower control spool at the left end.
• Since there is no force applied on the control pin A, swash plate tilt angle and discharging flow become the
maximum.
When pressure P is increased (when load is increased)
(1) Control pin A (3) Horsepower control spool (5) Horsepower control spring (7) Reaction pin
(2) Control pin B (4) Horsepower control valve (6) Swash plate (A) Discharge pressure P
• The discharging pressures P increase due to the load.

• The discharging pressures P become greater than the spring force of the horsepower control spool, and the
horsepower control spool moves to the right.
• The discharging pressures P flow to the control pin A via the horsepower control spool.
• Pressure is applied on the control pin A, the inclination angle of the swash plate decreases, and the discharging
flow rate decreases.
• When the inclination angle of the swash plate decreases, the horsepower control spring returns the horsepower
control spool to the left, and shuts the discharging pressure P out of the oil passage which leads to the control pin
A, in order to keep the pressure balanced.
U30-6S 6-11

MECHANISM
3.4.3 Flow control (load sensing control)

Controls the discharging flow rate of the piston pump according to the actuator load pressure.
Regulator
(1) Spring (3) Regulator (5) PLS

(2) Spool (4) PPS
• The differential pressure between PPS (piston pump discharging pressure) and PLS (actuator load pressure)
shifts the spool in the regulator.
When the control lever is operated widely (the spool moves widely)
(3) Regulator (6) Control pin A (9) Horsepower control valve (A) Discharge pressure P
(4) PPS (7) Control pin B (10) Horsepower control spring
(5) PLS (8) Horsepower control spool (11) Swash plate
• When the control lever is operated widely, the differential pressure between the pump discharge pressure PPS
and the load pressure PLS drops temporarily, the PLS pushes the spool of the regulator, and the spool moves to
the right.
• The horsepower control spool moves to the left, and the oil line of control pin A becomes connected to the
hydraulic oil tank.
• The tilt angle of the swash plate increases.
• The discharging flow rate of the piston pump increases to supply sufficient amount of hydraulic oil to the actuators
to enable operation under high load.
6-12 U30-6S

MECHANISM
When the control lever is operated slightly (the spool moves slightly)
(3) Regulator (6) Control pin A (9) Horsepower control valve (A) Discharge pressure P
(4) PPS (7) Control pin B (10) Horsepower control spring
(5) PLS (8) Horsepower control spool (11) Swash plate
• When the control lever is operated slightly, it produces a large difference in pressure between the pump discharge
pressure PPS and the load pressure PLS, the PPS pushes the spool of the regulator, and the spool moves to the
left.
• Discharged oil flows into the oil line of the control pin A through the regulator, and pushes the control pin A.
• The control pin A presses the swash plate to decrease the swash plate angle.
• The discharging flow rate of the piston pump decreases.
3.4.4 Standby flow

Minimizes the discharging flow rate of the piston pump
to decrease the engine power consumption and the
hydraulic oil temperature while not operating.
(1) Horsepower control curve (A) Discharge flow rate

(2) Standby flow rate (B) Discharge pressure
• Discharged oil flows to the hydraulic oil tank
through the unload relief valve in the control valve.
• Part of the hydraulic oil flows into the hydraulic oil
cooler before returning to the hydraulic oil tank to
lower the oil temperature.
U30-6S 6-13

MECHANISM
3.4.5 Gain control Low engine speed
The regulator proportionally controls the discharging

flow rate of the piston pump according to the engine
speed.
(1) Regulator (4) PPS

(2) Gear pump (Pp) (5) PLS
(3) Orifice
(1) Regulator (6) Control pin A
• Differential pressure between before and after
(2) Gear pump (Pp) (7) Control pin B
passing through the orifice changes according to (3) Orifice (8) Swash plate
the engine speed.
• Spool position of the regulator is shifted by the • The spool in the regulator is pushed back, since the
differential pressure, in order to proportionally oil pressure before passing through the orifice is
control the discharging flow rate of the piston pump. low.
• The oil discharged from the piston pump flows into
High engine speed the oil line of the control pin A through the regulator
to push the control pin A.
• The control pin A presses the swash plate to
decrease the swash plate angle (the diameter of
control pin A is greater than that of control pin B, so
that the swash plate is pressed due to area
difference).
• Discharging flow rate of the piston pump
decreases.
(1) Regulator (6) Control pin A

(2) Gear pump (Pp) (7) Control pin B
(3) Orifice (8) Swash plate
• The spool in the regulator is pushed, since the oil

pressure before passing through the orifice is high.
• The hydraulic oil line of control pin A connects with
the hydraulic oil tank.
• Discharging pressure of the piston pump pushes
the control pin B to increase the swash plate angle.
• Discharging flow rate of the piston pump increases.
6-14 U30-6S

MECHANISM
4. Control valve 6. HYDRAULIC SYSTEM
4. Control valve
4.1 Control valve specifications
(1) Overload relief valve (b3B) (4) Overload relief valve (b4B) (7) Overload relief valve (b3R) (10) Overload relief valve (b4R)
(2) Overload relief valve (b2B) (5) Overload relief valve (b5L) (8) Overload relief valve (b2R) (11) Overload relief valve (b5R)
(3) Overload relief valve (b1R) (6) Main relief valve (aLS) (9) Overload relief valve (b1B)
U30-6S 6-15

MECHANISM
6. HYDRAULIC SYSTEM 4. Control valve
Specification Remark
Manufacturer KYB Corporation -
LS 24.2 to 24.8 MPa

At 28.0 L/min
(aLS) 246.8 to 252.9 kgf/cm2
Main relief valve setting pressure
Unload LS 2.1 to 2.5 MPa
At 22.0 L/min
(aUN) 21.4 to 25.5 kgf/cm2
Boom bottom (b1B)

Boom rod (b1R)
Arm bottom (b2B) 27.1 to 27.7 MPa
At 5.0 L/min
Arm rod (b2R) 276.3 to 282.5 kgf/cm2
Bucket bottom (b3B)
Bucket rod (b3R)
Overload relief valve setting pressure 31.1 to 31.7 MPa
Blade bottom (b4B) At 5.0 L/min
317.1 to 323.3 kgf/cm2
16.9 to 17.5 MPa

Blade rod (b4R) At 5.0 L/min
172.3 to 178.5 kgf/cm2
AUX LH (b5L) 20.3 to 20.9 MPa

At 5.0 L/min
AUX RH (b5R) 207.0 to 213.1 kgf/cm2
6-16 U30-6S

MECHANISM
Port location table

Travel motor LH (P1)

(12) PPS3 Control valve (Psw) (37) B5
Travel LH forwards
Travel motor LH (P2)

(13) PLS Hydraulic pump (PLS) (38) A5
Travel LH backwards
Hydraulic pump (P) Travel control valve (3)

(14) PPS2 (39) Pa5
Hydraulic pump (PPS) Travel LH backwards
Travel control valve (2)

(15) T1 Hydraulic oil tank (40) Pb4
Travel RH forwards
Multi valve (2L) Travel motor RH (P2)

(16) Pb9 (41) B4
Swivel left Travel RH forwards
Swivel motor (B) Travel motor RH (P1)

(17) B9 (42) A4
Swivel left Travel RH backwards

(18) Psw Control valve (PPS3) (43) Pa4
Travel RH backwards
Swivel motor (A)

(19) A9 (44) Link Blade lower
Swivel right
Multi valve (4L) Blade cylinder (bottom)

(20) Pa9 (45) B3
Swivel right Blade lower
Multi valve (1R) Blade cylinder (rod)

(21) Pb8 (46) A3
Bucket crowd Blade lift
Bucket cylinder (bottom)

(22) B8 (47) - Blade lift
Bucket crowd
Bucket cylinder (rod)

(23) A8 (48) Link Swing left
Bucket dump
Multi valve (3R) Swing cylinder (bottom)

(24) Pa8 (49) B2
Bucket dump Swing left
Multi valve (3L) Swing cylinder (rod)

(25) Pb7 (50) A2
Arm crowd Swing right
Arm cylinder (bottom)

(26) B7 (51) - Swing right
Arm crowd
Arm cylinder (rod)

(27) A7 (52) Link AUX LH
Arm dump
Multi valve (1L)

(28) Pa7 (53) B1 AUX LH
Arm dump
Multi valve (4R)

(29) Pb6 Boom lower (54) A1 AUX RH
Control valve (Pi)
Boom cylinder (rod)

(30) B6 (55) - AUX RH
Boom lower
(31) T4 - (56) T3 -
Swivel motor (M)

Boom cylinder (bottom)
(32) A6 (57) T2 Hydraulic oil cooler
Boom lift
Third line valve (B)
(33) DR1g Hydraulic oil tank (58) P Hydraulic pump (P)
(34) Pi Control valve (Pb6) (59) PP1 Auto-idle pressure switch
Multi valve (2R)

(35) Pa6 (60) PAI Unload valve (P)
Boom lift

(36) Pb5 (61) PPS1 -
Travel LH forwards
U30-6S 6-17

MECHANISM
4.2 Control valve hydraulic circuit
(1) Swivel motor left (9) Travel motor LH forward (17) AUX LH (25) Port PAI
(2) Swivel motor right (10) Travel motor LH backward (18) AUX RH (26) Port Psw
(3) Bucket cylinder bottom (11) Travel motor RH forward (19) Port P (27) Port T1
(4) Bucket cylinder rod (12) Travel motor RH backward (20) Port PLS (28) Port T2
(5) Arm cylinder bottom (13) Blade cylinder bottom (21) Port PPS1 (29) Port T3
(6) Arm cylinder rod (14) Blade cylinder rod (22) Port PPS2 (30) Port T4
(7) Boom cylinder rod (15) Swing cylinder bottom (23) Port PPS3
(8) Boom cylinder bottom (16) Swing cylinder rod (24) Port PP1
4.3 Control valve spool shift 4.4 Control valve function and
performance structure
4.4.1 Main relief valve
Prevents surge pressure in the hydraulic circuit.
When not relieving (working pressure < set
pressure)
(A) Pilot pressure (MPa) (C) Spool pressure receiving

(B) Spool stroke (mm) characteristics
(1) Sleeve (B) Low pressure circuit

(2) Main poppet (C) Space A
(3) Pilot poppet (D) Seating point
(A) High pressure circuit
• The space A is filled with the hydraulic oil through

the main poppet.
• The sleeve seats on the main poppet securely.
• The main relief valve does not relieve the hydraulic
oil as the pilot poppet is not moved.
6-18 U30-6S

MECHANISM
When relieving (working pressure > set pressure) 4.4.2 Overload relief valve
Releases the hydraulic oil in the case of overload.
Provides the hydraulic oil in the case of negative
pressure.
When not relieving (working pressure < setting
pressure)
(3) Pilot poppet (B) Low pressure circuit

• The pressurized oil in the high pressure circuit

opens the pilot poppet.
• The hydraulic oil flows to the low pressure circuit.
(1) Piston (A) High pressure circuit
(2) Sleeve (B) Low pressure circuit
(4) Pilot poppet (D) Seating point
• The space A is filled with the hydraulic oil through

the piston.
• The sleeve is not seated to the main poppet
securely.
• The overload relief valve does not relieve the
hydraulic oil as the pilot poppet is not moved.
When relieving (working pressure > set pressure)
(2) Main poppet (B) Low pressure circuit

(3) Pilot poppet (C) Space A
• The opening of the pilot poppet causes the

pressure decrease in the space A.
• The main poppet opens, and the hydraulic oil in the
high pressure circuit flows to the low pressure
circuit directly.
(4) Pilot poppet (B) Low pressure circuit

(A) High pressure circuit (C) Space A
• The pressurized oil in the high pressure circuit

opens the pilot poppet.
• The hydraulic oil in the space A flows to the low
pressure circuit.
U30-6S 6-19

MECHANISM
(1) Piston (B) Low pressure circuit (2) Sleeve (B) Low pressure circuit
(4) Pilot poppet (C) Space A (A) High pressure circuit
(A) High pressure circuit (D) Seating point
• When the pressure in the low pressure circuit
• The opening of the pilot poppet causes the becomes higher than that in the high pressure
pressure decrease in the space A. circuit, the sleeve opens.
• The piston moves right, and seats on the pilot • The hydraulic oil in the low pressure circuit flows to
poppet. the high pressure circuit.
(1) Piston (B) Low pressure circuit

• The pressure difference between the high pressure

circuit and the space A increases.
• The main poppet opens, and the hydraulic oil in the
high pressure circuit flows to the low pressure
circuit directly.
When make-up
The overload relief valve provides the hydraulic oil
when the pressure in the high pressure circuit becomes
negative.
6-20 U30-6S

MECHANISM
4.4.3 Boom holding valve

This is a function to decrease natural descent caused by hydraulic oil leakage.
When not operating any sections
(1) Boom holding valve (5) Port DRg (9) Port P (13) Port T3
(2) Poppet A (6) Port Pi (10) Port T2
(3) Port B (7) Port Pb (11) Port PP1
(4) Port A (8) Port Pa (12) Port PAI
• Control valve shuts off the passage on the boom rod side (B port).
• Poppet A of the boom holding valve shuts off the passage on the boom bottom side (A port).
• Poppet A of the boom holding valve is pressed down by pressure caused by the weight of boom bottom side.
• The boom holding valve closes to shut off the hydraulic oil flow from the boom to the hydraulic oil tank to prevent
internal leakage.
U30-6S 6-21

MECHANISM
When lowering the boom
(1) Boom holding valve (6) Port Pi (11) Port PP1 (16) Spring chamber
(2) Poppet A (7) Port Pb (12) Port PAI (A) Pilot pressure
(3) Port B (8) Port Pa (13) Port T3
(4) Port A (9) Port P (14) Main spool
(5) Port DRg (10) Port T2 (15) Spool
• When the boom is lowered, pilot pressure is applied on the Pb port, and the main spool of the control valve
switches.
• Discharge pressure P passes through the control valve, and the pressure is applied to the boom cylinder rod side.
• The pilot pressure is also applied to the Pi port, and the spool of the boom holding valve switches.
• The spring chamber of boom holding valve and the hydraulic oil tank become connected, and the hydraulic oil
pressing the poppet A returns to the hydraulic oil tank.
• Hydraulic oil on the boom cylinder bottom side opens the poppet A of boom holding valve from the A port and
returns to the hydraulic oil tank.
6-22 U30-6S

MECHANISM
When raising the boom
(1) Boom holding valve (5) Port DRg (9) Port P (13) Port T3
(2) Poppet A (6) Port Pi (10) Port T2 (14) Main spool
(3) Port B (7) Port Pb (11) Port PP1 (A) Pilot pressure
(4) Port A (8) Port Pa (12) Port PAI
• When the boom is raised, pilot pressure is applied on the Pa port, and the main spool of the control valve
switches.
• Discharge pressure P passes through the control valve, pushes up the poppet A, and pressurizes the cylinder
bottom side from the A port.
U30-6S 6-23

MECHANISM
4.4.4 Unload valve

Controls the pressure P according to the differential pressure between the pressure PPS and PLS.
When in neutral
(1) Main spool (2) Unload spool
• When no actuator is operating, discharge pressure PPS pushes the unload spool, since load pressure PLS is not
present.
• Discharge pressure PPS passes through the unload valve and returns to the hydraulic oil tank.
During fine operation of spool section
(1) Main spool (6) Unload valve spring chamber (11) Port P (C) From the hydraulic oil tank
(2) Unload spool (7) Inlet section (12) Port PPS (D) To the regulator (PPS)
(3) Outlet section (8) LS drain plug (13) Port T1 (E) To the regulator (PLS)
(4) Notch (9) Orifice (A) PPS pressure
(5) PLS passage (10) Hydraulic oil tank circuit (B) PLS pressure
• When the main spool of control valve is slightly moved, discharge pressure PPS flows to the actuator.
• Load pressure PLS of the actuator passes through the PLS pressure passage to pressurize the unload valve
spring chamber.
6-24 U30-6S

MECHANISM
• Since the opening of the control valve main spool is tight, load pressure PLS becomes low, and discharge
pressure PPS becomes higher than that.
• Discharge pressure PPS adjusts the opening area of the unload spool notch, and opens a passage to the
hydraulic oil tank circuit.
• Discharge pressure PPS returns to the hydraulic oil tank to maintain the differential pressure constant by being
balanced with load pressure PLS.
During operation of spool section
(1) Main spool (6) Unload valve spring chamber (11) Port P (C) From the hydraulic oil tank
(2) Unload spool (7) Inlet section (12) Port PPS (D) To the regulator (PPS)
(3) Outlet section (8) LS drain plug (13) Port T1 (E) To the regulator (PLS)
(4) Notch (9) Orifice (A) PPS pressure
(5) PLS passage (10) Hydraulic oil tank circuit (B) PLS pressure
• When the main spool of control valve is greatly moved, discharge pressure PPS flows to the actuator.
• Load pressure PLS of the actuator passes through the PLS pressure passage to pressurize the unload valve
spring chamber.
• Since the opening of the control valve main spool is wide, differential pressure between load pressure PLS and
discharge pressure PPS becomes low.
• The differential pressure between load pressure PLS and discharge pressure PPS closes the unload spool notch
and switches the unload valve.
• The passage to the hydraulic oil tank circuit of unload valve closes, and LS control of the hydraulic pump
operates.
• Load pressure PLS returns to the hydraulic oil tank through orifice to prevent the situation where pressure in the
PLS pressure passage has nowhere to go when load pressure PLS suddenly disappears (when operation is
stopped).
U30-6S 6-25

MECHANISM
4.4.5 High pressure selector function

Selects the highest load pressure of each section for the pressure PLS.
When operating independently
(1) Main spool (6) Port Pb (11) Port T3 (C) From unload valve to hydraul-
(2) Inlet section (7) Port P (12) PPS pressure passage ic oil tank line
(3) Port A (8) Port T2 (A) Pilot pressure
(4) Port B (9) Port PP1 (B) From port PPS2 to hydraulic
(5) Port Pa (10) Port PAI pump
• When the pilot valve is operated, pilot pressure is applied on the Pa port, and the main spool of the control valve
switches.
• Discharge pressure P passes through the control valve, and the pressure is applied to the actuator.
• Part of the discharge pressure P is divided in the control valve, and flows into the hydraulic pump through the PPS
pressure circuit.
6-26 U30-6S

MECHANISM
When operating multiple functions
(1) Main spool (5) Port Pa (D) High pressure selection loca- (F) Arm section
(3) Port A (6) Port Pb tion (G) From port PLS to Hydraulic
(4) Port B (13) PLS pressure passage (E) Bucket section pump
• From the loads of 2 actuators operated at the same time, the higher one is fed back to the hydraulic pump.
4.4.6 Pressure compensator valve is adjusted to the position according to this

pressure.
Controls the pressurized oil flow rate to the actuator
according to the differential pressure between the Simultaneous operation
highest load pressure and each section's load • Section where load pressure PLS is high
pressure. – Load pressure PLS of this section is selected
as the maximum load pressure, and thus
operation is performed in the same way as the
single operation.
• Section where load pressure PLS is low
– Since load pressure PLS of the section where
load pressure PLS is high is selected as the
maximum load pressure and used to control the
swash plate, almost same pressure is applied
to PC passage of each section.
– Throttle on the compensator spool creates
difference between PC passage pressure of the
section with low load pressure PLS and the
load pressure PLS, and this difference moves
the compensator spool to the balanced position.
(1) Pump pressure passage (5) Port Pa
(2) Compensator spool (6) Port Pb
(When the compensator spool is in low position,
(3) Port A (A) PLS pressure total area of the compensator spool throttle
(4) Port B becomes narrow, and difference between PC
passage pressure and load pressure PLS
Single operation becomes large)
• Pressurized oil which has passed through pump – Therefore, almost constant pressure is applied
pressure circuit, PC circuit, and compensator spool to the compensator spool even if 2 sections
flows to the upper part of compensator spool as have different load pressure PLS, which
load pressure PLS. negates the effect of load fluctuation and allows
• Since the PC passage pressure becomes nearly to obtain flow rate in accordance with the
equal to load pressure PLS, the compensator spool opening area of the spool only.
U30-6S 6-27

MECHANISM
4.4.7 Boom and arm regeneration

Increases speed by returning a part of return oil to the pressurized side using load pressure of the cylinder.
(1) Boom section (5) CT notch (9) Port Pb6 (13) Port Pb7
(2) Arm section (6) Port A6 (10) Port A7
(3) Main spool (7) Port B6 (11) Port B7
(4) Hydraulic oil tank circuit (8) Port Pa6 (12) Port Pa7
• Return oil from the actuator passes through the CT notch of main spool and flows into the hydraulic oil tank circuit.
• From the A port, a part of return oil passes through the oil circuit inside the spool and converges at the B port on
the pressurized side.
6-28 U30-6S

MECHANISM
4.4.8 Straight traveling circuit

Travel communication circuit is equipped to connect hydraulic oil circuits of left and right motors while the machine is
traveling straight (forward or backward) to ensure travel straightness.
(1) Travel communication circuit (5) Port Pb4 (9) Port Pb5 (13) Port PAI
(2) Port A4 (6) Port A5 (10) Port P (14) Port T3
(3) Port B4 (7) Port B5 (11) Port T2
(4) Port Pa4 (8) Port Pa5 (12) Port PP1
• When forward or backward travel operation is performed, the pressure lines of travel motors LH and RH become
connected together.
• The orifices equalize the load pressure of the traveling motor LH and RH and equalize the flow rate to the
traveling motor.
• The differential pressure between the travel motors LH and RH decreases to ensure straight traveling.
U30-6S 6-29

MECHANISM
4.4.9 Swivel prior circuit

Decreases change in swivel speed when switching to simultaneous operation. It also prevents decrease in swivel
speed when rotation speed of the engine is changed.
Simultaneous operation
(1) Flow rate control valve (4) Port B9 (7) Port Pa9 (C) Swivel section
(2) Spring (5) Port A9 (A) PPS pressure (D) Bucket section
(3) Pressure compensator valve (6) Port Pb9 (B) Pilot pressure
• While in simultaneous operation, load pressure PLS controls the swash plate of hydraulic pump to change the
flow rate of hydraulic pump.
• Since pump discharge pressure PPS is applied on the flow rate control valve of swivel section, this valve is not
affected by high load pressure PLS.
• Flow rate to the swivel motor does not change at the time when switching to simultaneous operation, since the
swivel section is controlled by pump discharge pressure PPS to maintain the differential pressure of the flow rate
control valve constant.
• Swivel speed does not change regardless of the engine speed, since effective control differential pressure of the
flow rate control valve is maintained constant by the spring force of flow rate control valve.
4.4.10 Auto-idle signal circuit • After 4 seconds, the engine speed automatically
decreases to idle.
This circuit detects whether the machine is being
operated from ON/OFF of the AI pressure switch. When in operation
When not operating any sections
(1) Auto-idle signal circuit (2) Auto-idle pressure switch

(1) Auto-idle signal circuit (2) Auto-idle pressure switch • Pp pressurized oil is cut off at the spool in signal
• Pp pressurized oil returns to the hydraulic oil tank circuit.
through the signal circuit. • The signal circuit pressure increases to turn on the
• The signal circuit does not apply pressure and the auto-idle pressure switch.
auto-idle pressure switch stays OFF. • The engine speed returns to the set speed.
6-30 U30-6S

MECHANISM
5. Swivel motor 6. HYDRAULIC SYSTEM
5. Swivel motor
5.1 Swivel motor specifications
(1) Relief valve (cSR) (2) Relief valve (cSL)
Manufacturer Kubota seiki -
Motor displacement 29.271 cm3/rev -
Total displacement 289.78 cm3/rev -
Maximum flow rate 20.90 L/min -
Reduction gear ratio 1 : 9.90 -
Theoretical rotational speed 72.1 rpm -
17.7 MPa
Relief valve setting pressure At 20.9 L/min
180 kgf/cm2
905 N⋅m or more

Mechanical brake torque -
92.3 kgf⋅m or more
1.5 MPa or less

Parking brake release pressure -
15 kgf/cm2 or less
U30-6S 6-31

MECHANISM
6. HYDRAULIC SYSTEM 5. Swivel motor
Port location table

Control valve (A9)

(3) A (6) DR Hydraulic oil tank
Swivel right
Control valve (B9)

(4) B (7) P Unload valve (B)
Swivel left
(5) M Control valve (T2) - - -
5.2 Swivel motor hydraulic circuit (1) Port A

(2) Port B
(4) Port DR
(5) Port P
(3) Port M
5.3 Swivel motor function and structure
5.3.1 Swivel motor working principles • The piston slides down on the swash plate to
generate the rotational force with the cylinder block.
The swivel motor converts fluid energy (pressurized oil • Flow of the pressurized oil stops when the piston is
flow) into shaft rotation. at the lowest point.
• The piston slides up on the swash plate by
rotational force from port A side.
• The piston pushes out the hydraulic oil inside the
cylinder block from port B.
• In the case of reverse rotation, pressure oil flows in
from port B and is discharged from port A.
(1) Port A (5) Piston

(2) Port B (6) Swash plate
(3) Valve plate (7) Shaft
(4) Cylinder block
• The pressurized oil flows into the cylinder block

from the port A through the valve plate.
• The pressurized oil pushes the piston.
• The piston pushes the swash plate.
6-32 U30-6S

MECHANISM
5. Swivel motor 6. HYDRAULIC SYSTEM
5.3.2 Shockless function – The spring presses the brake piston.

– The friction plate is wedged between the case
Relieves sudden pressure changes when the swivel and brake piston and is engaged with the shaft.
motor starts or stops. – The swivel motor becomes unable to rotate.
• Deactivating the parking brake (lowering the lever
lock)
– P4 pressurized oil flows into the brake piston
chamber.
– P4 pressurized oil pushes the brake piston to
compress the spring.
– The friction plate disengages the shaft and the
swivel motor is able to rotate.
5.3.4 Make-up circuit

Prevents cavitation when decelerating the swivel motor.
(1) Relief valve (4) Piston

(2) Orifice (A) Pa
(3) Chamber A (B) Pb
• When the swivel motor starts or stops its operation,

the pressurized oil that flows into port A passes
through the relief valve orifice and enters chamber
A.
• Since the pressure Pa is higher than Pb, the relief
valve operates at a pressure lower than the set
pressure (primary relief pressure).
• When the pressurized oil flowing into chamber A
pushes the piston, the pressure in chamber A rises.
• The pressures Pa and Pb becomes equal.
Therefore, the relief valve operates at a set
pressure (secondary relief pressure).
5.3.3 Swivel motor parking brake

Stops the swivel motor rotation as a negative brake.
(1) Poppet (6) Port DR

(2) Port M (A) To motor MA passage
(3) Port A (B) Motor MA passage
(4) Port B (C) Motor MB passage
(5) Port P
• When rotation of the turning body is decelerated

and stopped, inertia of the turning body rotates the
(1) Brake piston chamber (5) Case motor, and the pressure on the primary port (port A)
(2) Spring (6) Cylinder block side becomes negative.
(3) Brake piston (7) Shaft
(4) Friction plate
• The oil from port M flows into the primary line (port
A) through the poppet to prevent cavitation.
• Activating the parking brake (raising the lever lock)
U30-6S 6-33

MECHANISM
6. HYDRAULIC SYSTEM 6. Travel motor
6. Travel motor
6.1 Travel motor specifications
(1) Counterbalance valve (4) Travel automatic reduction (7) Port Ps (10) Oil inspection port
(2) Anti-cavitation valve (5) Port P1 (8) Port T (11) Oil drain port
(3) Travel speed shift valve (6) Port P2 (9) Oil fill port
Specification
Manufacturer KYB Corporation
Low speed 832.0 cm3/rev

Total displacement volume
High speed 438.0 cm3/rev
Low speed 17.1 cm3/rev

Motor displacement
High speed 9.0 cm3/rev
Reduction gear ratio 1 : 48.636
24.5 MPa
Maximum pressure
249.8 kgf/cm2
Rated flow rate 32.0 L/min
Low speed 38.5 rpm

Theoretical rotational speed
High speed 73.1 rpm
3240 N⋅m
Low speed
330.4 kgf⋅m
Theoretical output torque
1710 N⋅m
High speed
174.4 kgf⋅m
3.9 MPa
Travel speed shift pressure
39.8 kgf/cm2
1900 N⋅m
Parking brake control torque
193.8 kgf⋅m
1.3 MPa
Parking brake release pressure
13.3 kgf/cm2
18.6 to 21.0 MPa

Automatic deceleration shift pressure High → Low
189.7 to 214.1 kgf/cm2
6-34 U30-6S

MECHANISM
6. Travel motor 6. HYDRAULIC SYSTEM
Port location table

Swivel joint (D)

Travel LH forwards Swivel joint (A)
(5) P1 (7) Ps
Swivel joint (G) Travel speed shift
Travel RH backwards
Swivel joint (F)

Travel LH backwards Swivel joint (H)
(6) P2 (8) T
Swivel joint (E) Drain
Travel RH forwards
U30-6S 6-35

MECHANISM
6.2 Travel motor hydraulic circuit (1) Counterbalance valve

(2) Travel speed shift piston
(3) Travel speed shift spool
(4) Anti-cavitation valve
6.3 Travel motor function and structure
6.3.1 Travel motor working principles – The piston slides up on the swash plate by
rotational force from port B side.
Converts fluid energy (pressurized oil flow) into shaft – The piston pushes out the hydraulic oil inside
rotation. the cylinder block from port C.
Rotating in LH direction (oil flow from port B)
6.3.2 Counterbalance valve

The counterbalance valve has 3 functions: to prevent
internal oil leakage between M1 and M2 when the
travel motor is stopped, to keep rotation of the travel
(1) Cylinder block (5) Shaft

(2) Piston (6) Port B
(3) Valve plate (7) Port C
(4) Swash plate
• Input process
– The pressurized oil flows into the cylinder block
from the port B through the valve plate.
– The pressurized oil pushes the piston.
– The piston pushes the swash plate.
– The piston slides down on the swash plate to
generate rotational force with the cylinder block.
– Flow of the pressurized oil stops when the
piston is at the lowest point.
• Output process
6-36 U30-6S

MECHANISM
motor constant under any load, and to reduce shock When starting up the travel motor
when stopping the machine.
When the travel motor is stopped
(1) Plunger (7) Port P2

(2) Check valve LH (8) Port M1
(3) Check valve RH (9) Port M2
(1) Plunger (6) Port P1
(4) Control valve (10) Orifice LH
(2) Check valve LH (7) Port P2
(5) Motor (11) Plunger notch section
(3) Check valve RH (8) Port M1
(6) Port P1 (12) Orifice
(4) Control valve (9) Port M2
(5) Motor • P1 pressurized oil (primary pressurized oil) flows to
• When the travel motor is stopped, the plunger, the the port M1 through the check valve LH.
check valve LH, and the check valve RH cut off the • The orifice LH reduces the P1 pressurized oil
internal leakage between the port M1 and the port (primary pressurized oil) flow and delays the RH
M2 of the travel motor to stop the motor rotation shift of the plunger.
securely. • Return oil (secondary pressure oil) from the port M2
is cut off by the check valve RH.
• Pressure of the P1 pressurized oil (primary
pressurized oil) increases, and the P1 pressurized
oil passes through the orifice LH to push the
plunger to the RH direction.
• The return oil (secondary pressure oil) from the port
M2 flows to the port P2 through the notch inside the
plunger.
• The back pressure rises since the flow between the
port M2 and the plunger is restricted.
pressurized oil) further increases, and the P1
pressurized oil presses the plunger to RH direction
to the stroke end.
• The oil passage in the port M2 is completely
opened and the hydraulic oil returns to the hydraulic
oil tank freely.
• Back pressure in port M2 decreases.
U30-6S 6-37

MECHANISM
When stopping the rotating travel motor (1) Plunger (9) Port M2
(4) Control valve (10) Orifice LH
(5) Motor (12) Orifice
(6) Port P1 (13) Left pressure chamber
(7) Port P2 (14) Spring RH
(8) Port M1

pressurized oil) decreases. The motor rotates by
inertial force, and pressure of the return oil
(secondary pressure oil) from the port M2
increases.
• No pressurized oil flows from the port P1 and the
plunger starts returning to LH direction.
• The return oil (secondary pressure oil) from the port
M2 flows to the port P2 through the orifice inside
the plunger and prevents the port M1 pressure from
dropping down suddenly.
• The plunger presses out the hydraulic oil in
pressure chamber LH through the orifice LH.
• The plunger returns to the neutral position
gradually.
• The shock caused by stopping travel is decreased
by gradual response of the counterbalance valve.
6-38 U30-6S

MECHANISM
6.3.3 Anti-cavitation valve

Prevents cavitation when decelerating the travel motor.
When in neutral
(1) Plunger (4) Control valve (7) Port P2

(2) Spool (5) Motor (8) Port M1
(3) Anti-cavitation valve (6) Port P1 (9) Port M2
• The anti-cavitation valve functions in conjunction with the counterbalance valve.
U30-6S 6-39

MECHANISM
When starting up the travel motor

• P1 pressurized oil flows into the counterbalance valve through the check valve.
• The pressurized oil flows into the travel motor (M1) through the counterbalance valve to rotate the travel motor.
• P1 pressurized oil pushes the counterbalance valve to RH side through the orifice.
• The return oil flows to the hydraulic oil tank from the travel motor (M2) through the counter balance valve.
6-40 U30-6S

MECHANISM
When decelerating the travel motor

• The travel motor suctions the oil from the primary oil line (M1) due to the inertial force while decelerating.
• The inertial force increases the pressure in the secondary oil line (M2), causing the spool to move to the left.
• Inertial force causes negative pressure on the port M1 side, and the differential pressure caused by that switches
the spool instantly. The return oil flows from the port M2 side to the port M1 side, which prevents cavitation that
may be caused by the negative pressure on the port M1 side.
U30-6S 6-41

MECHANISM
When stopping the rotating travel motor

• Due to the workings of the orifices, the counterbalance valve shifts to the neutral position gradually.
6-42 U30-6S

MECHANISM
6.3.4 Automatic deceleration

Decelerates the travel speed automatically under high load.
Traveling in high speed (low load)
(1) Port Ps (4) Travel speed shift piston (A) Motor load pressure (D) Motor load pressure area
(2) Spool (5) P1 (B) High pressure (E) Pilot pressure area
(3) Motor load pressure chamber (6) P2 (C) Low pressure
• Pp pressurized oil pushes the travel speed shift spool to the high speed side through the port Ps.
• P1 (P2) pressurized oil pushes the travel speed shift piston to the low speed side through the counterbalance
valve.
• Port Ps pressure is higher than P1 (P2) pressure with spring force and the travel speed shift spool switches to the
high speed side.
• The travel speed shift piston presses the swash plate to increase the swash plate angle, and the machine travels
at high speed.
U30-6S 6-43

MECHANISM
Traveling under high load
(1) Port Ps (4) Travel speed shift piston (6) P2 (C) Low pressure
(2) Spool (5) P1 (A) Motor load pressure (F) Drain
• When traveling under high load (such as climbing a slope), pressure of the P1 (P2) pressurized oil increases by
external force.
• P1 (P2) pressurized oil with spring force is higher than port Ps pressure, and the travel speed shift spool switches
to the low speed side.
• Oil in the travel speed shift piston returns to the hydraulic oil tank through the drain port.
• The swash plate angle decreases, and the travel speed decelerates automatically.
6.3.5 Travel motor parking brake – The disk is wedged between the flange holder
and brake piston and is engaged with the shaft
Works as a negative brake to stop the travel motor and cylinder block.
rotation. – Friction material is attached on both sides of the
disk to generate frictional force between the
flange holder and brake piston.
– The travel motor becomes immobilized.
• Deactivating parking brake (when one or both of the
travel levers are operated)
– When a travel lever is operated, P1 (P2)
pressurized oil flows into the brake piston
chamber through the counterbalance valve.
– P1 (P2) pressurized oil pushes the brake piston
to compress the spring.
– The disk disengages from the shaft and cylinder
block, and the travel motor becomes able to
rotate.
(1) Spring (4) Disk (friction material)
(2) Brake piston chamber (5) Cylinder block
(3) Brake piston (6) Spline
• Activating parking brake (when no travel lever is

operated)
– The spring presses the brake piston.
6-44 U30-6S

MECHANISM
7. Hydraulic cylinder 6. HYDRAULIC SYSTEM
7. Hydraulic cylinder
7.1 Hydraulic cylinder specifications
NOTE
• All hole dimensions are inner dimensions with bushings installed.
Dimensions
Boom Arm Bucket Swing Blade
(a) ϕ45 mm ϕ45 mm ϕ40 mm ϕ40 mm ϕ45 mm
(b) ϕ45 mm ϕ45 mm ϕ40 mm ϕ40 mm ϕ45 mm
(c) 60 mm 60 mm 50 mm 50 mm 50 mm
(d) 60 mm 60 mm 55 mm 50 mm 50 mm
(e) ϕ45 mm ϕ45 mm ϕ40 mm ϕ40 mm ϕ45 mm
(f) ϕ80 mm ϕ75 mm ϕ65 mm ϕ80 mm ϕ80 mm
(g) ϕ92 mm ϕ87 mm ϕ76.5 mm ϕ92 mm ϕ96 mm
(h) 45 mm 45 mm 40 mm 40 mm 45 mm
(i) 45 mm 45 mm 40 mm 39 mm 48 mm
Minimum length 905±2.0 mm 905±2.0 mm 811±2.0 mm 692.5±2.0 mm 492±2.0 mm
Stroke 552±2.0 mm 590±2.0 mm 516±2.0 mm 408.5±2.0 mm 154±2.0 mm
Manufacturer KYB-YS Corporation KYB-YS Corporation KYB-YS Corporation KYB-YS Corporation KYB-YS Corporation
U30-6S 6-45

MECHANISM
6. HYDRAULIC SYSTEM 8. Swivel joint
8. Swivel joint
8.1 Swivel joint specifications
(19) Packing (21) Circlip (23) Cover

(20) Collar (22) O-ring (24) Circlip
Specification
Manufacturer Taiheiyo seiki
Rotational speed Less than 9 rpm
127 N⋅m or less

Rotational torque (no load)
13.0 kgf⋅m or less
Hydraulic oil temperature range -20 to 100 ℃
34.3 MPa
Pressure capacity
350 kgf/cm2
Travel motor 24.5 MPa

Blade cylinder 250 kgf/cm2
3.9 MPa
Maximum pressure Pilot
40 kgf/cm2
1.5 MPa
Drain
15 kgf/cm2
6-46 U30-6S

MECHANISM
8. Swivel joint 6. HYDRAULIC SYSTEM
Port location table

Upper side Lower side
Unload valve (A) Travel motor LH (Ps)

(1) A (9) A
Travel speed shift Travel speed shift LH
Control valve (B3) Travel motor RH (Ps)

(2) B (10) A
Blade lower Travel speed shift RH
Control valve (A3) Blade cylinder (bottom)

(3) C (11) B
Blade lift Blade lower
Control valve (B5) Blade cylinder (rod)

(4) D (12) C
Travel LH forwards Blade lift
Control valve (B4) Travel motor LH (P1)

(5) E (13) D
Travel RH forwards Travel LH forwards
Control valve (A5) Travel motor RH (P2)

(6) F (14) E
Travel LH backwards Travel RH forwards
Control valve (A4) Travel motor LH (P2)

(7) G (15) F
Travel RH backwards Travel LH backwards
Hydraulic oil tank Travel motor RH (P1)

(8) H (16) G
Travel motor drain Travel RH backwards
Travel motor LH (T1)

- - - (17) H
Travel motor LH drain
Travel motor RH (T2)

- - - (18) H
Travel motor RH drain
U30-6S 6-47

MECHANISM
6. HYDRAULIC SYSTEM 9. Pilot control valve
9. Pilot control valve Pilot control valve RH
9.1 Pilot control valve specifications

Pilot control valve LH
(a) Single operation angle: 21.5° (b) Simultaneous operation an-

gle: 29°
Specification
(a) Single operation angle: 21.5° (b) Simultaneous operation an-
Kawasaki Heavy industries,
gle: 29° Manufacturer
Ltd.
Specification
Port location table
Kawasaki Heavy industries,
Manufacturer No. Port Location
Ltd.
Multi valve (R1)
(1) 1
Port location table Bucket crowd
No. Port Location Multi valve (R4)

(2) 2
Boom lower
Multi valve (L1)
(1) 1
Swivel left Multi valve (R3)
(3) 3
Bucket dump
Multi valve (L4)
(2) 2
Arm dump Multi valve (R2)
(4) 4
Boom lift
Multi valve (L3)
(3) 3
Swivel right Unload valve (C)
(5) P
Pilot pressure
Multi valve (L2)
(4) 4
Arm crowd (6) T Hydraulic oil tank
Unload valve (B)

(5) P
Pilot pressure
(6) T Hydraulic oil tank
6-48 U30-6S

MECHANISM
9. Pilot control valve 6. HYDRAULIC SYSTEM
9.2 Pilot control valve performance 9.3 Pilot control valve function and
diagram structure
Reduces pressure of Pp pressurized oil to control the
direction and stroke of the spool in the control valve.
When not being operated
(1) Spool (4) Secondary setting spring

(2) Return spring (5) Output port
(3) Return spring (6) Port T
• Pp pressurized oil is cut off by the spool.

• Output port is connected to the hydraulic oil tank.
(A) Port 1, 3 (J) Single operation torque (Port

(B) Port 2, 4 1)
(C) Secondary pressure (kgf/ (K) Single operation torque (Port
cm2) 2)
(D) Secondary pressure (MPa) (L) Single operation torque (Port
(E) Operating torque (N⋅m) 3)
(F) Operating torque (kgf⋅cm) (M) Single operation torque (Port
(G) Push rod stroke (mm) 4)
(H) Operating angle (deg) (N) Secondary pressure
U30-6S 6-49

MECHANISM
6. HYDRAULIC SYSTEM 10. Travel control valve
When being operated Port location table

No. Port Location
Unload valve (B)

(1) P
Pilot pressure
(2) T Hydraulic oil tank
Control valve (Pa4)

(3) 1
Travel RH backwards
Control valve (Pb4)

(4) 2
Travel RH forwards
Control valve (Pa5)

(5) 3
Travel LH backwards
Control valve (Pb5)

(6) 4
Travel LH forwards
10.2 Travel control valve

performance diagram
(1) Spool (7) Push rod

(4) Secondary setting spring (8) Spring seat
(5) Output port (9) Port P
• The push rod pushes the spring seat.

• As the spring seat is pushed, the spool pushes the
spring.
• The spool reduces the Pp pressure to the outlet
port due to spool stroke.
• Reduced Pp pressurized oil flows to the control
valve through the output port.
(A) Secondary pressure (MPa) (D) Operating torque
(B) Operating angle (deg) (E) Secondary pressure
10. Travel control valve (C) Operating torque (N⋅m)
10.1 Travel control valve

specifications
Specification
Manufacturer Nishina Industrial
6-50 U30-6S

MECHANISM
10. Travel control valve 6. HYDRAULIC SYSTEM
10.3 Travel control valve function When being operated

and structure
Reduces Pp pressurized oil to control the direction and
stroke of spool in the control valve.
When not being operated
(1) Spool (4) Port P

(2) Port 1 (5) Port T
(3) Port 2 (6) Push rod
• The push rod pushes down the spool.

• Pp pressurized oil flows to the control valve through
(1) Spool (4) Port P the output port.
(2) Port 1 (5) Port T • The pilot pressure is controlled according to spool
(3) Port 2
stroke.
• Pp pressurized oil is cut off by the spool.
• Output port is connected to the hydraulic oil tank.
U30-6S 6-51

MECHANISM
6. HYDRAULIC SYSTEM 11. Unload valve
11. Unload valve

11.1 Unload valve specifications
(7) Pilot primary pressure relief (8) Check valve

valve
Manufacturer Nishina Industrial -
4.9 MPa
Maximum pressure -
50 kgf/cm2
Pilot primary pressure relief valve setting 3.92 to 4.21 MPa

At TEMP. 50 ℃, 14.2 L/min
pressure 40.0 to 42.9 kgf/cm2
At 2.5 MPa
Internal leakage volume at port P → port T 0.13 L/min or less
At 25 kgf/cm2
Internal leakage volume at port PAC → other At 3.92 MPa

0.09 L/min or less
ports At 40.0 kgf/cm2
Rated voltage 12 V -
Port location table

(1) PAC Accumulator (4) T Hydraulic oil tank
Swivel joint (A)

(2) A (5) P Control valve (PAI)
Travel speed shift
Swivel motor (P)

Pilot filter
Parking brake (6) C
(3) B Pilot control valve LH (P) Pilot control valve RH (P)
Travel control valve (P) - - -
Hydraulic lock cylinder - - -
6-52 U30-6S

MECHANISM
11. Unload valve 6. HYDRAULIC SYSTEM
11.2 Unload valve function and – Pp pressurized oil flows to the travel speed shift
spool through the opened spool and the travel
structure speed increases.
11.2.1 Unload valve working principles
The unload valve is composed of 2 solenoid valves.
One solenoid valve activates the pilot control valves.
The other one shifts the travel speed.
Activating the pilot control valves
(1) Spool (4) Port C

(2) Plunger (5) Port P
(3) Port B (6) Port T
• When the solenoid valve (pilot control valve) is

OFF,
– Pp pressurized oil is cut off by the spool.
– No oil flows to the pilot control valves.
– Pilot control valves are deactivated.
• When the solenoid valve (pilot control valve) is ON,
– Pp pressurized oil flows to the pilot control
valves through the opened spool, and the
machine becomes able to operate.
Shifting travel speed
(1) Spool (6) Port T

(4) Port C (7) Port A
(5) Port P (8) Solenoid
• When the solenoid valve (travel speed shift) is OFF,

– Pp pressurized oil is cut off by the spool.
– No oil flows to the travel speed shift spool, and
the machine travels in low speed.
• When the solenoid valve (travel speed shift) is ON,
U30-6S 6-53

MECHANISM
6. HYDRAULIC SYSTEM 12. Multi valve
12. Multi valve
12.1 Multi valve specifications
Specification Remarks
Manufacturer Nachi-Fujikoshi -
4.0 MPa
Maximum pressure -
41 kgf/cm2
Maximum flow rate 10 L/min -
At TEMP. 40 ℃
At 2 port
Internal leakage volume 0.25 L/min or less
At 4.0 MPa
At 41 kgf/cm2
6-54 U30-6S

MECHANISM
13. Third line valve 6. HYDRAULIC SYSTEM
Port location table

No. Port Location
(1) L1 Pilot control valve LH (1)
(5) R1 Pilot control valve RH (1)
(9) 1L Control valve (Pa7)
(10) 3L Control valve (Pb7)
(11) 2L Control valve (Pb9)
(12) 4L Control valve (Pa9)
(13) 1R Control valve (Pb8)
(14) 3R Control valve (Pa8)
(15) 2R Control valve (Pa6)
(16) 4R Control valve (Pi)
13. Third line valve Specifications Remarks
Dairen koshin seikosho

13.1 Third line valve specifications Manufacturer
LTD
-
27.4 MPa
Rated pressure -
279 kgf/cm2
34.3 MPa
Maximum pressure -
350 kgf/cm2
Lever operating tor- 3.0 N⋅m or less

-
que (no load) 0.31 kgf⋅m or less
At TEMP.
50 ℃
Internal leakage
Less than 10 ml/min At 1.0 MPa
volume
At
10 kgf/cm2
Port location table

No. Port Location
AUX RH
(1) A
Front hose
(2) B Control valve (T2)
(3) C Control valve (A1)
U30-6S 6-55

MECHANISM
6. HYDRAULIC SYSTEM 13. Third line valve
6-56 U30-6S

SERVICING
1. Troubleshooting 6. HYDRAULIC SYSTEM
SERVICING
1. Troubleshooting
1.1 Hydraulic troubleshooting for front attachment

The front attachment does not operate or operates slowly

The engine is malfunctioning. Measure the engine speed. Adjust each part of the engine.
The hydraulic oil level is low. Check for the hydraulic oil level and Replenish or replace the hydraulic
The hydraulic oil quality is low. oil quality. oil.
The suction line or suction filter is Check if the suction line or suction Clean the suction line.
clogged. filter is clogged. Replace the suction filter.
The pilot filter is clogged. Check if the pilot filter is clogged. Replace the pilot filter.
The pilot primary pressure relief Adjust or replace the pilot primary
Measure the pilot primary pressure.
valve setting pressure is too low. pressure relief valve.
The pilot primary pressure relief
Adjust or replace the pilot primary
valve spring is weakened or dam- Measure the pilot primary pressure.
pressure relief valve.
aged.
The pilot primary pressure relief Clean or replace the pilot primary
valve is clogged by contamination. pressure relief valve.
The pilot pump is damaged. Check for damage of the pilot pump. Replace the pilot pump.
The main relief valve setting pres- Measure the main relief valve pres- Adjust or replace the main relief
sure is too low. sure. valve.
The main relief valve spring is weak- Measure the main relief valve pres- Adjust or replace the main relief
ened or damaged. sure. valve.
The main relief valve is clogged by Measure the main relief valve pres- Clean or replace the main relief
contamination. sure. valve.
The hydraulic pump coupling is Check for damage of the hydraulic Replace the hydraulic pump cou-
damaged. pump coupling. pling.
The drive shaft of the hydraulic Check for damage of the hydraulic Replace the hydraulic pump drive
pump is damaged. pump drive shaft. shaft.
Measure the hydraulic pump P-Q
The internal parts of the hydraulic performance. Repair or replace the internal parts
pump are damaged or worn. Check for damage of the internal of the hydraulic pump.
parts of the hydraulic pump.
U30-6S 6-57

SERVICING
6. HYDRAULIC SYSTEM 1. Troubleshooting
The pilot control valve RH or LH does not operate or operates slowly

Check if the pilot line filter is clog-
The pilot line filter is clogged. Clean the pilot line filter.
ged.
The pilot control valve spring is Measure the pilot secondary pres-
Replace the pilot control valve.
weakened or damaged. sure.
The pilot control valve is clogged by Measure the pilot secondary pres- Clean or replace the pilot control
Power of the entire hydraulic system is weak

The pilot primary pressure relief Replace the pilot primary pressure
valve setting pressure is too low. relief valve.
The pilot primary pressure relief
Adjust or replace the pilot primary
valve spring is weakened or dam- Measure the pilot primary pressure.
pressure relief valve.
aged.
The pilot primary pressure relief Clean or replace the pilot primary
valve is clogged by contamination. pressure relief valve.
The main relief valve setting pres- Measure the main relief valve pres- Adjust or replace the main relief
sure is too low. sure. valve.
The main relief valve spring is weak- Measure the main relief valve pres- Adjust or replace the main relief
ened or damaged. sure. valve.
The main relief valve is clogged by Measure the main relief valve pres- Clean or replace the main relief
One of the cylinders does not operate or operates slowly

The pilot control valve spring is Measure the pilot secondary pres- Replace the pilot primary pressure
weakened or damaged. sure. relief valve.
The pilot control valve is clogged by Measure the pilot secondary pres- Clean or replace the pilot control
The overload relief valve setting Measure the overload relief valve
Adjust the overload relief valve.
pressure is too low. pressure.
The overload relief valve spring is Measure the overload relief valve Adjust or replace the overload relief
weakened or damaged. pressure. valve.
The overload relief valve is clogged Measure the overload relief valve Clean or replace the overload relief
by contamination. pressure. valve.
The spool of the control valve is Check for damage or sticking of the Disassemble and clean or replace
damaged or stuck. control valve. the control valve section.
6-58 U30-6S

SERVICING
1. Troubleshooting 6. HYDRAULIC SYSTEM
Large amount of cylinder leakage has occurred
Cause Inspections Actions

The overload relief valve setting Measure the overload relief valve Adjust or replace the overload relief
pressure is too low. pressure. valve.
The overload relief valve spring is Measure the overload relief valve Adjust or replace the overload relief
weakened or damaged. pressure. valve.
The spool of the control valve is Check for damage or sticking of the Disassemble and clean or replace
damaged or stuck. control valve. the control valve section.
Measure the cylinder internal leak-
The internal leakage of the cylinder
age. Repair or replace the cylinder.
is too much.
Check for damage of the seal.
1.2 Hydraulic troubleshooting for swivel

The swivel does not operate or operates slowly

The pilot control valve is clogged by Measure the pilot secondary pres- Clean or replace the pilot primary
contamination. sure. pressure relief valve.
The spool of the control valve swivel Check for damage or sticking of the Disassemble and clean or replace
section is damaged or stuck. control valve swivel section. the control valve swivel section.
The overload relief valve setting Measure the overload relief valve Adjust the overload relief valve.
The overload relief valve spring is Measure the overload relief valve Replace the overload relief valve.
weakened or damaged. pressure.
The internal leakage or drain of the Measure the swivel motor internal Repair or replace the swivel motor.
swivel motor is too much. leakage. Measure the swivel motor
drain.
The friction plate for swivel motor Check for wear or sticking of the fric- Repair or replace the friction plate.
parking brake does not disengage tion plate.
correctly.
The swivel is overrunning

(Continued)
U30-6S 6-59

SERVICING
6. HYDRAULIC SYSTEM 1. Troubleshooting

The pilot control valve is clogged by Measure the pilot secondary pres- Clean or replace the pilot primary
contamination. sure. pressure relief valve.
The spool of the control valve swivel Check for damage or sticking of the Repair or replace the control valve
section is damaged or stuck. control valve swivel section. swivel section.
The overload relief valve setting Measure the overload relief valve
Adjust the overload relief valve.
The overload relief valve spring is Measure the overload relief valve
Replace the overload relief valve.
weakened or damaged. pressure.
The make-up poppet of the swivel Check for damage or sticking of the Clean or replace the make-up pop-
motor is damaged or stuck. make-up poppet. pet.
Measure the swivel motor internal
The internal leakage or drain of the
leakage. Repair or replace the swivel motor.
swivel motor is too much.
Measure the swivel motor drain.
1.3 Hydraulic troubleshooting for traveling

Does not travel, travel slowly, or not running straight
Cause Inspections Actions

The track tension is too loose or
Check the track tension. Adjust the track tension.
tight.
Check for dirt clogging. Clean the base carrier.
The base carrier is clogged with dirt.
The travel control lever or mechani- Check the travel control lever and Adjust or replace the travel control
cal link is malfunctioning. mechanical link. lever and mechanical link.
The spool of the control valve travel Check for damage or sticking of the Disassemble and clean, or replace
section is damaged or stuck. control valve travel section. the control valve travel section.
The spool of the counterbalance Check for damage or sticking of the Disassemble and clean, or replace
valve is damaged or stuck. counterbalance valve. the counterbalance valve.
Measure the travel motor internal
The internal leakage or drain of the Disassemble or replace the travel
leakage.
travel motor is too much. motor.
Measure the travel motor drain.
Disconnect the travel outlet hose of
The internal leakage of the swivel the swivel joint and install a plug,
Replace the seal of the swivel joint.
joint is occurring. and then measure the relief pres-
sure.
6-60 U30-6S

SERVICING
2. Service specifications 6. HYDRAULIC SYSTEM
2.1 Service specifications for the hydraulic system

NOTE
– Warm up the hydraulic oil and devices to 50±5 ℃.
– Accelerate the engine to the maximum speed.
– Turn the auto-idle switch and AC switch OFF.
– Hydraulic cylinder speed does not include cushioning.

Unit
P MPa 24.5 -0.5 to +1.0

Main relief valve -
(aLS) kgf/cm2 249.8 -5.1 to +10.2
MPa 2.3 ±0.2

Unload relief valve aUN -
kgf/cm2 23.5 ±2.0
Pilot primary MPa 4.3 ±0.5

Pilot primary pressure relief valve -
(aPP) kgf/cm2 43.9 ±5.1
Boom bottom MPa 26.0 ±0.3

-
(b1B) kgf/cm2 265.1 ±3.1
Boom rod MPa 26.0 ±0.3

-
(b1R) kgf/cm2 265.1 ±3.1
Arm bottom MPa 26.0 ±0.3

-
(b2B) kgf/cm2 265.1 ±3.1
Arm rod MPa 26.0 ±0.3

-
(b2R) kgf/cm2 265.1 ±3.1
Bucket bottom MPa 26.0 ±0.3

Pressure -
(b3B) kgf/cm2 265.1 ±3.1
Overload relief valve
Bucket rod MPa 26.0 ±0.3
-
(b3R) kgf/cm2 265.1 ±3.1
Blade bottom MPa 30.0 ±0.3

-
(b4B) kgf/cm2 305.9 ±3.1
Blade rod MPa 17.0 ±0.3

-
(b4R) kgf/cm2 173.4 ±3.1
AUX LH MPa 20.0 ±0.3

-
(b5L) kgf/cm2 203.9 ±3.1
AUX RH MPa 20.0 ±0.3

-
(b5R) kgf/cm2 203.9 ±3.1
Left MPa 24.0

- -
Swivel motor overload relief pres- (cSL) kgf/cm2 244.7
sure Right MPa 24.0
- -
(cSR) kgf/cm2 244.7
Piston pump (P)

(Engine speed: maximum speed, no load, maximum L/min 86.7 - 69.4
flow rate)
Flow rate
AUX
(Engine speed: maximum speed, no load, maximum L/min 51.7 - -
flow rate)
(Continued)
U30-6S 6-61

SERVICING
6. HYDRAULIC SYSTEM 2. Service specifications

Unit
Boom
mm Less than 20.0 - 100.0
(10 min, engine stopped)
Arm
Bucket
Rubber tracks
Canopy speci- mm Less than 40.0 - 80.0
Hydraulic cylin- fication
der
Rubber tracks
Cabin specifi- mm Less than 42.0 - 84.0
Blade cation
Internal leak-
(10 min, en-
age Steel tracks
gine stopped)
fication
Steel tracks
cation
Engine stop- mm 0 26.1

-
ped ° 0 5
Swivel motor Less than
Engine running mm 156.8
156.8 -
in idle speed ° 30
Less than 30
Travel motor (20° slope) mm 0 - -
Right and left Less than

L/min - 0.5
(Rotating) 0.035
Swivel motor
L/min - 1.0
(Relief) 0.210
Low speed Less than

L/min - 0.7
(Rotating) 0.045
Drain
High speed Less than
L/min - -
(Rotating) 0.230
Travel motor
Low speed Less than
L/min - -
(Relief) 0.340

L/min - -
(Relief) 0.245
Lifting
(Ground to s 2.4 ±0.3 -
Canopy speci- highest)
fication Lowering
(Highest to s 2.5 ±0.3 -
ground)
Boom cylinder
Lifting
Speed (Ground to s 2.3 ±0.3 -
Cabin specifi- highest)
cation Lowering
ground)
Crowding s 2.8 ±0.3 -

Arm cylinder
Dumping s 2.3 ±0.3 -
(Continued)
6-62 U30-6S

SERVICING
3. Testing 6. HYDRAULIC SYSTEM

Unit

Bucket cylinder
Lifting
(Lowest to s 2.4 ±0.3 -
highest)
Blade cylinder
Lowering
lowest)
Swing left s 6.0 ±0.5 -

Swing cylinder
Swing right s 5.0 ±0.5 -
Speed rpm 8.6 ±0.9

Left -
s/3 rotations 20.9 -2.0 to +2.5
Swivel motor
rpm 8.6 ±0.9
Right -
s/3 rotations 20.9 -2.0 to +2.5
s/10 m 13.8 -1.4 to +1.9

Low speed -
km/h 2.6 ±0.3
Rubber tracks
s/10 m 8.0 ±0.8
High speed -
km/h 4.5 -0.4 to +0.5
Travel motor
s/10 m 14.4 -1.5 to +1.3
Low speed -
km/h 2.5 -0.2 to +0.3
Steel tracks
s/10 m 8.2 -0.7 to +1.0
High speed -
km/h 4.4 -0.5 to +0.4
Travel straightness
mm - - 600
(10 m)
3. Testing
3.1 Measuring the hydraulic devices
3.1.1 Measuring the boom cylinder speed
CAUTION
machine.
Measuring
1. Warm up the hydraulic oil and devices to 50±5 ℃.
2. Dump the arm to the stroke end, dump the bucket
to the stroke end, lower the boom to the ground,
and accelerate the engine to the maximum speed.
3. Turn the auto-idle switch and AC switch OFF.
4. Lift the boom to the stroke end in full-stroke
operation to measure the boom cylinder speed.
NOTE
• Do not include cushion range.
6. Measure the boom lowering speed as well.
U30-6S 6-63

SERVICING
6. HYDRAULIC SYSTEM 3. Testing
Service specification 3.1.3 Measuring the bucket cylinder speed

Lifting
(Ground to 2.1 to 2.7 s
Canopy speci- highest) CAUTION
fication • Keep any persons or objects away from the
Lowering
(Highest to 2.2 to 2.8 s machine.
Boom cylinder ground)
Measuring
speed Lifting 1. Warm up the hydraulic oil and devices to 50±5 ℃.
(Ground to 2.0 to 2.6 s
highest) 2. Dump the bucket to the stroke end and accelerate
Cabin specifi-
cation
the engine to the maximum speed.
Lowering 3. Turn the auto-idle switch and AC switch OFF.
(Highest to 2.1 to 2.7 s
ground) 4. Crowd the bucket to the stroke end in full-stroke
operation to measure the bucket cylinder speed.
NOTE
3.1.2 Measuring the arm cylinder speed • Do not hit the ground or blade with the
bucket.
CAUTION 5. Measure 3 times to calculate the average.

• Keep any persons or objects away from the 6. Measure the bucket dumping speed as well.
machine.
Measuring
2. Dump the arm to the stroke end and accelerate the
engine to the maximum speed.
4. Crowd the arm to the stroke end in full-stroke
operation to measure the arm cylinder speed.
NOTE
• Do not hit the ground or blade with the
bucket.
6. Measure the arm dumping speed as well. Service specification
Bucket cylinder Crowding 2.4 to 3.0 s

speed Dumping 1.6 to 2.2 s
3.1.4 Measuring the blade cylinder speed
CAUTION
machine.
Measuring
2. Jack up the machine with the front attachment,
lower the blade to the stroke end, and accelerate
Crowding 2.5 to 3.1 s the engine to the maximum speed.
Arm cylinder speed
Dumping 2.0 to 2.6 s
NOTE
• Do not hit the ground with the lower end of
the blade.
6-64 U30-6S

SERVICING
4. Lift the blade to the stroke end in full-stroke

operation to measure the blade cylinder speed.
6. Measure the blade lowering speed as well.
Swing cylinder Swing left 5.5 to 6.5 s

speed Swing right 4.5 to 5.5 s
Lifting
2.1 to 2.7 s 3.1.6 Measuring the swivel speed
Blade cylinder (Lowest to highest)
speed Lowering
2.4 to 3.0 s
(Highest to lowest) CAUTION
machine.
3.1.5 Measuring the swing cylinder speed Measuring
CAUTION 2. Lift the boom to the stroke end, crowd the arm to
• Keep any persons or objects away from the the stroke end, crowd the bucket to the stroke end,
machine. and accelerate the engine to the maximum speed.
Measuring 4. Swivel to left in full-stroke operation until the swivel
1. Warm up the hydraulic oil and devices to 50±5 ℃. speed becomes uniform, and measure the swivel
2. Dump the arm to the stroke end, crowd the bucket speed for 3 rotations.
to the stroke end, set the bottom surface of the 5. Measure 3 times to calculate the average.
bucket at 1 meter above the ground, and accelerate 6. Measure the right swivel speed as well.
the engine to the maximum speed.
4. Swing the boom from the left end to the right end in
full-stroke operation to measure the swing cylinder
speed.
6. Measure the reverse direction speed as well.
Left 18.9 to 23.4 s/3 rotations
Swivel speed
Right (7.7 to 9.5 rpm)
U30-6S 6-65

SERVICING
3.1.7 Measuring the travel speed 4. Dump the arm to the stroke end, crowd the bucket
to the stroke end, set the bucket bottom surface at
1 m above the ground, and stop the engine.
CAUTION
machine.
Measuring
2. Set the machine to the traveling position and
accelerate the engine to the maximum speed.
4. Perform an approach run for 5 m, and measure the
time for traveling 10 m in full-stroke operation after
the said approach run.
(a) 1 m
5. Put marks on the boom, arm, and bucket cylinder

rods.
6. Measure internal leakage for each cylinder after
waiting for 10 minutes.
NOTE
• Measure the compressed distance of the rod
of the boom cylinder.
• Measure the extended distance of the rod of
the arm cylinder.
(a) Approach run distance (5 m) (b) Measuring distance (10 m)
Low 12.4 to 15.7 s/10 m
Rubber speed 2.3 to 2.9 km/h
tracks High 7.2 to 8.8 s/10 m
Travel speed 4.1 to 5.0 km/h
speed Low 12.9 to 15.7 s/10 m
Steel speed 2.3 to 2.8 km/h
tracks High 7.5 to 9.2 s/10 m
speed 3.9 to 4.8 km/h
3.1.8 Measuring the cylinder internal Service specification

leakage Boom cylinder Less than 20.0 mm
Internal leakage Arm cylinder Less than 15.0 mm

CAUTION Bucket cylinder Less than 10.0 mm
machine. Service limit
Measuring the boom, arm, and bucket cylinders Boom cylinder 100.0 mm
Internal leakage Arm cylinder 75.0 mm
2. Put an approximately 162 kg of weight (soil) on the
bucket. Bucket cylinder 50.0 mm
3. Park the machine on the firm and level ground.
Measuring the blade cylinder
6-66 U30-6S

SERVICING
2. Operate the front attachment and blade to jack up Service limit

the machine.
Canopy speci-
3. Fully extend the blade and crowd the arm to the fication
80.0 mm
Rubber
vertical position. tracks Cabin specifi-
84.0 mm
Internal Blade cyl- cation
leakage inder Canopy speci-
86.0 mm
Steel fication
tracks Cabin specifi-
88.0 mm
cation
3.1.9 Measuring the travel motor internal

leakage
CAUTION
4. Stop the engine and put a mark on the blade machine.
cylinder rod.
5. Measure internal leakage for each cylinder after Measuring
waiting for 10 minutes. 1. Warm up the hydraulic oil and devices to 50±5 ℃.
6. Measure 3 times to calculate the average. 2. Park the machine on the firm slope with 20° of
inclination.
3. Set the machine to the traveling position and stop
the engine.
Canopy speci- Less than
Rubber fication 40.0 mm 4. Put a mark on the track frame and track.
tracks Cabin specifi- Less than 5. Measure the internal leakage between the track
Internal Blade cyl- cation 42.0 mm frame and track after 10 minutes.
leakage inder Canopy speci- Less than 6. Measure 3 times to calculate the average.
Steel fication 43.0 mm
tracks Cabin specifi- Less than
cation 44.0 mm
U30-6S 6-67

SERVICING
Service specification 9. Measure 3 times to calculate the average.

10. Measure for the opposite direction (180°) as well.
Travel motor
Internal leakage 0 mm
(20° slope)
3.1.10 Measuring the swivel motor internal

leakage
CAUTION
machine.
Measuring
2. Put an approximately 162 kg of weight (soil) into the
bucket. Service specification
3. Park the machine on a firm slope with 20° of
Swivel motor 0 mm
inclination. Swivel the machine 90° against the
(Engine is stopped) 0°
slope.
Internal leakage
4. Turn the auto-idle switch and AC switch OFF. Swivel motor Less than
(Engine is running 156.8 mm
5. Dump the arm to the stroke end, crowd the bucket
in idle speed) Less than 30°
to the stroke end, and set the boom support pin and
the bucket pin in straight line. Service limit
Swivel motor 26.1 mm
(Engine is stopped) 5°
Internal leakage Swivel motor
156.8 mm
(Engine is running
30°
in idle speed)
3.1.11 Testing the travel straightness
CAUTION
machine.
6. Put a mark on the swivel bearing and track frame. Measuring
2. Adjust the tensions of left and right tracks to be
equal.
3. Set the machine to the traveling position.
4. Mark the starting position.
5. Accelerate the engine to the maximum speed.
7. Operate the travel control lever in full stroke to
make the machine travel forwards for 10 m.
NOTE
• Make sure to start the machine straightly.
8. Measure the distance (a).
7. Running the engine in idle speed and lower the
10. Measure the distance for backward travel as well.
lever lock.
8. After waiting for 1 minute, measure the internal
leakage between the swivel bearing and the track
frame.
6-68 U30-6S

SERVICING
(a) Distance (b) 10 m
Service limit
(a) 600 mm
U30-6S 6-69

SERVICING
3.2 Measuring the hydraulic pump

3.2.1 Measuring the piston pump P-Q performance
The hydraulic pump may have a problem in case that hydraulic devices are slow and hydraulic force is insufficient.
Measure the hydraulic pump P-Q performance to check if it is normal.
CAUTION
• The hydraulic devices and oil are extremely hot. Handle with care before preparation, measurement, and
restoration.
• Before disconnecting the hydraulic hoses, release the residual pressure first.
• Keep any persons or objects away from the machine.
IMPORTANT
• Open the loading valve (restrictor valve) of the flow meter completely before starting the engine to avoid
damaging the flow meter and pressure gauge.
• Install the plugs to the removed hydraulic hoses and adapters to avoid oil leakage and dust
contamination.
Preparing
1. Park the machine on the firm and level ground, and stop the engine.
2. Release the residual pressure of the hydraulic circuit.
4. Disconnect the port P (C/V port P side) delivery hose on the hydraulic pump side and plug the disconnected
hoses.
5. Connect test hose (A) to the hydraulic pump ports P and the flow meter's [IN] port.
6. Connect test hose (B) to the control valve port P and the flow meter's [OUT] port.
7. Disconnect the port P (C/V port PPS2 side) delivery hose on the hydraulic pump side and plug to the hose and
port.
8. If the flow meter does not have an integrated pressure gauge, install pressure gauges to the ports P of the
hydraulic pump.
9. Disconnect the PPS hose on the hydraulic pump side and plug the disconnected hose.
10. Connect a test hose (C) to the PPS joint on the hydraulic pump side, and place an oil tray under the hose end to
collect the oil discharge.
11. Remove the vacuum and check for oil leakage in each piping hose in idling.
6-70 U30-6S

SERVICING
(1) Hydraulic pump (4) Port PPS (B) Pressure gauge (E) Test hose (B)
(2) Control valve (5) Port P (C/V port PPS2 side) (C) Oil tray (F) Test hose (C)
(3) Port P (C/V port P side) (A) Flow meter (D) Test hose (A)
Measuring
1. Open the loading valve (restrictor valve) of the flow meter completely and start up the engine.
3. Set the engine speed to the maximum.
5. While increasing the load pressure by closing the loading valve (restrictor valve) gradually, measure the flow rate
and engine speed at each load pressure marked on the following service specification graph, up to the setting
pressure of the main relief valve.
6. Measure the flow rate 3 times and calculate the average.
7. Calculate flow rate values at each load pressure, based on the rated engine speed.
U30-6S 6-71

SERVICING
(G) Flow rate (L/min) (H) Pressure (MPa)
Pressure Flow rate (converted to 2200 rpm)
MPa kgf/cm2 L/min
7.5 76.5 78.8
10.0 102.0 65.7
12.5 127.5 52.6
15.0 153.0 45.4
17.5 178.5 39.3
20.0 203.9 34.0
22.5 229.4 27.2
25.0 254.9 13.3
Service limit
• The service limit is 80% of the service specification.
6-72 U30-6S

SERVICING
3.2.2 Measuring the AUX flow rate
CAUTION
• The hydraulic devices and oil are extremely hot. Handle with care before preparation, measurement, and
restoration.
• Before disconnecting the hydraulic hoses, release the residual pressure first.
• Keep any persons or objects away from the machine.
IMPORTANT
• Open the loading valve (restrictor valve) of the flow meter completely before starting the engine to avoid
damaging the flow meter and pressure gauge.
• Install the plugs to removed hydraulic hoses and adapters to avoid oil leakage and dust contamination.
Preparing
1. Park the machine on the firm and level ground and stop the engine.
2. Release the residual pressure of the hydraulic circuit.
4. Connect a test hose from the AUX LH discharging port to the flow meter [IN] port.
5. Connect a test hose from the AUX RH discharging port to the flow meter [OUT] port.
(A) AUX LH discharging port (C) Test hose (E) Pressure gauge
(B) AUX RH discharging port (D) Flow meter
6. Install the pressure gauge to the return side.

7. Remove the vacuum and check for oil leakage in each piping hose in idling.
Measuring
1. Fully open the loading valve (restrictor valve) of the flow meter and start the engine.
5. Close the loading valve (restrictor valve) gradually until it reaches the setting pressure of main relief valve, and
measure the flow rate, engine speed, and back pressure in each loading pressure.
6. Measure the flow rate 3 times and calculate the average.
7. Convert all of the flow rate values to the rated engine speed.
NOTE
• If there is a need to measure the opposite side (AUX RH discharging port), exchange the hoses between
LH and RH.
U30-6S 6-73

SERVICING
(F) Flow rate (L/min) (J) AUX LH (third line open) (M) Back pressure (AUX LH (third (N) Back pressure (AUX LH (third
(G) Pressure (MPa) (K) AUX LH (third line close) line open)) line close))
(H) Back pressure (MPa) (L) AUX RH (third line close) (P) Back pressure (AUX RH (third
line close))
AUX LH (third line open)

Discharging flow rate
Pressure Back pressure
(converted to 2200 rpm)
MPa kgf/cm2 L/min MPa kgf/cm2
5.0 51.0 46.9 0.9 9.2
7.5 76.5 45.9 0.9 9.2
10.0 102.0 45.0 0.8 8.2
12.5 127.5 42.5 0.7 7.1
15.0 153.0 37.4 0.6 6.1
17.5 178.5 32.5 0.5 5.1
20.0 203.9 27.0 0.4 4.1
6-74 U30-6S

SERVICING
AUX LH (third line close)

5.0 51.0 47.7 1.7 17.3
7.5 76.5 46.5 1.6 16.3
10.0 102.0 44.9 1.4 14.3
12.5 127.5 42.9 1.3 13.3
15.0 153.0 38.4 1.1 11.2
17.5 178.5 33.7 0.9 9.2
20.0 203.9 27.8 0.7 7.1
AUX RH (third line close)

5.0 51.0 47.8 1.4 14.3
7.5 76.5 46.8 1.3 13.3
10.0 102.0 45.9 1.2 12.2
12.5 127.5 42.4 1.1 11.2
15.0 153.0 37.7 0.9 9.2
17.5 178.5 32.8 0.8 8.2
20.0 203.9 27.8 0.6 6.1
U30-6S 6-75

SERVICING
3.3 Measuring the control valve 5. To measure the pressure of main relief valve,
operate the pilot control lever gradually until the
3.3.1 Measuring the main relief valve main relief valve is relieved.
pressure 6. Measure 3 times to calculate the average.
The main relief valves may have a problem in case that Service specification
the hydraulic force is insufficient. Measure the relief 24.0 to 25.5 MPa
Main relief valve pressure
pressures of the main relief valves to check the 244.7 to 260.0 kgf/cm2
condition of the main relief valves.
2.1 to 2.5 MPa
Unload LS valve pressure
21.4 to 25.5 kgf/cm2
CAUTION
• The hydraulic devices and oil are extremely hot. Adjusting
• Before disconnecting the hydraulic hoses, CAUTION
release the residual pressure first. • Adjust main relief valves only if their pressures
• Keep any persons or objects away from the are too low.
machine. • Do not set main relief pressures exceeding their
setting pressures to avoid damage on the
IMPORTANT machine components.
contamination.
Preparing
1. Park the machine on the firm and level ground and
stop the engine.
2. Release the residual pressure of the hydraulic
circuit.
4. Install a pressure gauge to P pressure detection
port.
(3) Main relief valve (aLS)
1. Loosen the locknut of the relief valve.
(1) P pressure detection port (2) Hydraulic pump
5. Remove the vacuum and check for oil leakage in

each piping hose in idling.
Measuring
(4) Locknut (5) Adjusting screw
2. Set the engine speed to the maximum. 2. Adjust the relief pressure with the adjusting screw
3. Turn the auto-idle switch and AC switch OFF. and tighten the locknut.
4. To measure the unload LS valve pressure, check
the discharge pressure of P while no lever is being
operated.
6-76 U30-6S

SERVICING
(4) Locknut (B) Decrease relief pressure

(5) Adjusting screw
(A) Increase relief pressure
Tightening torque (A) Pressure measurement kit (C) Pipe fittings

(B) Pipe fittings
28.0 to 31.0 N⋅m
(4) Locknut -
2.9 to 3.2 kgf⋅m 6. Remove the vacuum.
3. Operate the pilot control lever while the engine Measuring

speed is maximum, and check the main relief 1. Apply pressure with the pressure measurement kit
pressure. to relieve the overload relief valve, and measure the
pressure when the overload relief valve relieves.
3.3.2 Measuring the overload relief valve
The overload relief valve may have a problem in case
that hydraulic force is insufficient. Measure the relief Bottom 25.7 to 26.3 MPa
(b1B) 262.0 to 268.2 kgf/cm2
pressure of the overload relief valve to check the Boom
condition of the overload relief valve. Rod 25.7 to 26.3 MPa
(b1R) 262.0 to 268.2 kgf/cm2
CAUTION Bottom 25.7 to 26.3 MPa

(b2B) 262.0 to 268.2 kgf/cm2
• Park the machine on the firm and level ground Arm
and stop the engine. Rod 25.7 to 26.3 MPa
• The hydraulic devices and oil are extremely hot. (b2R) 262.0 to 268.2 kgf/cm2
Handle with care before preparation, Bottom 25.7 to 26.3 MPa
measurement, and restoration. (b3B) 262.0 to 268.2 kgf/cm2
• Before disconnecting the hydraulic hoses, Bucket
Rod 25.7 to 26.3 MPa
release the residual pressure first. (b3R) 262.0 to 268.2 kgf/cm2
Bottom 29.7 to 30.3 MPa

IMPORTANT (b4B) 302.8 to 309.0 kgf/cm2
• Install plugs to removed hydraulic hoses and Blade
adapters to avoid oil leakage and dust Rod 16.7 to 17.3 MPa
(b4R) 170.3 to 176.5 kgf/cm2
contamination.
LH 19.7 to 20.3 MPa
Preparing (b5L) 200.8 to 207.0 kgf/cm2
AUX
1. Park the machine on the firm and level ground and RH 19.7 to 20.3 MPa
stop the engine. (b5R) 200.8 to 207.0 kgf/cm2
circuit. Adjusting
4. Disconnect the high pressure hose which is IMPORTANT
connected to the overload relief valve. • Adjust the overload relief pressure only if the
5. Install the pressure measurement kit. overload relief pressure is too low.
• When disconnecting the pressure measuring
kit, take appropriate care in removing it as the
line is pressurized.
• Do not set the overload relief pressure
exceeding the setting pressure to avoid damage
on the machine components.
U30-6S 6-77

SERVICING
3.4 Measuring the swivel motor

3.4.1 Measuring the swivel motor overload
relief valve pressure
Check if the relief pressure is normal. Replace as
needed.
CAUTION
(1) AUX (LH) (7) Arm (bottom)
machine.
(2) AUX (RH) (8) Arm (rod) • Before disconnecting the hydraulic hoses,
(3) Blade (bottom) (9) Bucket (bottom) release the residual pressure first.
(4) Blade (rod) (10) Bucket (rod)
(5) Boom (rod)
(6) Boom (bottom)
IMPORTANT
1. Loosen the locknut of the relief valve.
contamination.
Preparing
lower the front attachment to the ground, and stop
the engine.
circuit.
4. Install pressure gauges to the swivel motor.
(11) Locknut (12) Adjusting screw
2. Adjust the relief pressure with the adjusting screw

and tighten the locknut.
(1) Port A (2) Port B

Measuring
(11) Locknut (E) Decrease relief pressure 4. Block the swivel motor rotation by hitting the bucket
(12) Adjusting screw against a solid object.
(D) Increase relief pressure
5. Slowly swivel against the solid object and measure
3. Check the overload relief pressure with the the pressure when the overload relief valve is
pressure measurement kit. relieved.
7. Measure the opposite direction as well.
6-78 U30-6S

SERVICING
Right 24.0 MPa
Swivel motor overload relief (cSR) 244.7 kgf/cm2
pressure Left 24.0 MPa
(cSL) 244.7 kgf/cm2
Adjusting
(5) Locknut (B) Decrease relief pressure

(6) Adjustment screw
(A) Increase relief pressure
3. Check the overload relief pressure.
3.4.2 Measuring the swivel motor drain
CAUTION
(3) Swivel motor overload relief (4) Swivel motor overload relief measurement, and restoration.
valve (cSR) valve (cSL)
IMPORTANT machine.
• Adjust the overload relief pressure only if the • Before disconnecting the hydraulic hoses,
overload relief pressure is too low. release the residual pressure first.
• Do not set the overload relief pressure
exceeding the setting pressure to avoid IMPORTANT
damages on the machine components. • Install plugs to removed hydraulic hoses and
1. Loosen the locknut of the relief valve. contamination.
Preparing
the engine.
circuit.
4. Disconnect the swivel motor's drain hose from the
swivel motor side, and plug the disconnected hose.
5. Connect a test hose to the swivel motor's drain
port.
(5) Locknut (6) Adjustment screw
2. Adjust the relief pressure with the adjusting screw

and tighten the locknut.
U30-6S 6-79

SERVICING
3.5 Measuring the travel motor

3.5.1 Measuring the travel motor drain
CAUTION
machine.
track.
• When jacking up the machine, set jack stands
(1) Drain port
under the machine.
6. Remove the vacuum and check for oil leakage in • Do not work underneath when the machine is
each piping hose in idling. jacked up.
7. Perform swivel operation to fully warm up the swivel • Before disconnecting the hydraulic hoses,
motor. Avoid rapid swiveling to prevent cavitation. release the residual pressure first.
Measuring
IMPORTANT
contamination.
4. Make the machine pose for measurement by
extending the boom, arm, and bucket cylinders to Preparing
the maximum. 1. Park the machine on the firm and level ground,
5. Perform swivel operation in full stroke and collect lower the front attachment to the ground.
the drain oil into the measuring cup. 2. Jack up the machine and set jack stands under the
track frame.
6. Measure the drain amount for 1 minute.

7. Measure 3 times to calculate the average. 3. Release the residual pressure of the hydraulic
8. Measure the opposite direction as well. circuit.
Service specification 4. Vacuum the hydraulic oil tank.
5. Remove the travel motor's drain hose and install a
Right and left (rotating) Less than 0.035 L/min
plug.
Right and left (relief) Less than 0.210 L/min 6. Install the test hose to the travel motor's drain port.
Service limit
Right and left (rotating) 0.5 L/min
Right and left (relief) 1.0 L/min
6-80 U30-6S

SERVICING
7. Measure the opposite side as well.

Low speed (rotating) Less than 0.045 L/min
High speed (rotating) Less than 0.230 L/min
Low speed (relief) Less than 0.340 L/min
High speed (relief) Less than 0.245 L/min
Service limit
Low speed (rotating) 0.7 L/min
(1) Travel motor LH (B) Test hose 3.6 Measuring the pilot control valve
(2) Swivel joint
(A) Measuring cup 3.6.1 Measuring the pilot primary pressure
CAUTION
IMPORTANT
contamination.
Preparing
(2) Swivel joint (B) Test hose 1. Park the machine on the firm and level ground,
(3) Travel motor RH
(A) Measuring cup
the engine.
7. Remove the vacuum and check for oil leakage in 2. Release the residual pressure of the hydraulic
each piping hose in idling. circuit.
Measuring 3. Vacuum the hydraulic oil tank.
1. Warm up the hydraulic oil and devices to 50±5 ℃. 4. Connect the pressure gauge to the Pp pressure
2. Set the engine speed to the maximum. detection port.
4. Perform travel operation in full stroke and collect
the drain oil into the measuring cup.
(1) Pp pressure detection port (2) Pilot filter

5. Measure the drain amount for 1 minute.
Measuring
U30-6S 6-81

SERVICING
2. Set the engine speed to the maximum. 3. Turn the auto-idle switch and AC switch OFF.
3. Turn the auto-idle switch and AC switch OFF. 4. Operate the lever in full stroke and measure the
4. Measure the pilot primary pressure when unloaded. pressure.
5. Measure 3 times to calculate the average. 5. Measure 3 times to calculate the average.
Service specification Service specification
3.8 to 4.8 MPa Specification
Pilot primary pressure
38.8 to 49.0 kgf/cm2
3.9 MPa
Swivel left
39.8 kgf/cm2
3.9 MPa
3.6.2 Measuring the pilot secondary Swivel right
39.8 kgf/cm2
pressure
3.9 MPa
Arm dump
39.8 kgf/cm2
CAUTION Arm crowd
3.9 MPa
• The hydraulic devices and oil are extremely hot. 39.8 kgf/cm2
Handle with care before preparation, 3.9 MPa
Bucket dump
measurement, and restoration. 39.8 kgf/cm2
• Keep any persons or objects away from the 3.9 MPa
machine. Bucket crowd
39.8 kgf/cm2
3.9 MPa
release the residual pressure first. Boom lift
39.8 kgf/cm2
IMPORTANT 3.9 MPa

Boom lower
39.8 kgf/cm2
adapters to avoid oil leakage and dust Travel RH forwards
3.9 MPa
contamination. 39.8 kgf/cm2
3.9 MPa
Preparing Travel RH backwards
39.8 kgf/cm2
3.9 MPa
lower the front attachment to the ground, and stop Travel LH forwards
39.8 kgf/cm2
the engine.
2. Release the residual pressure of the hydraulic 3.9 MPa
Travel LH backwards
39.8 kgf/cm2
circuit.
4. Connect T-joint and test hose to the pilot port of 4. Repairing
control valve and install pressure gauge.
4.1 Hydraulic pump
hydraulic pump
CAUTION
IMPORTANT
(A) T-joint (C) Test hose • Install plugs to removed hydraulic hoses and
(B) Pressure gauge adapters to avoid oil leakage and dust
5. Remove the vacuum and check for oil leakage in contamination.
Preparing
Measuring 1. Remove the rear bonnet.
1. Warm up the hydraulic oil and devices to 50±5 ℃. 2. Remove the bonnet LH.
2. Set the engine speed to the maximum. 3. Remove the muffler.
6-82 U30-6S

SERVICING
4. Repairing 6. HYDRAULIC SYSTEM
4. Release the residual pressure. 4. Loosen the clamp to disconnect the suction hose
5. Vacuum the hydraulic oil tank. from the hydraulic pump.
Removing
1. Remove the 2 bolts and support hinge.
(5) Hydraulic pump (7) Clamp

(6) Suction hose
(1) Support hinge (2) Bolt (M10 × 30) ×2 5. Attach a nylon sling and hoist the hydraulic pump
for support.
2. Remove the 4 bolts and cover.
(5) Hydraulic pump (A) Nylon sling

(3) Cover (4) Bolt (M10 × 20) ×4
6. Remove the 2 bolts from the hydraulic pump.
3. Disconnect all of the hydraulic hoses, connectors,
and wiring clamps connected to the hydraulic NOTE
pump. • Remove the hydraulic pump by supporting it
with a crane and pulling it out.
IMPORTANT
• Put marks on the disconnected hydraulic
hoses to reconnect each hose correctly.
(5) Hydraulic pump (8) Bolt (M12 × 35) ×2
(5) Hydraulic pump
U30-6S 6-83

SERVICING
6. HYDRAULIC SYSTEM 4. Repairing
Mass Installing
(5) Hydraulic pump Approximately 31 kg Tightening torque
7. Pull out the hydraulic pump from the coupling. 48.1 to 55.9 N⋅m
(2) (4) Bolt -
4.9 to 5.7 kgf⋅m
4.9 to 5.9 N⋅m

(7) Clamp -
0.5 to 0.6 kgf⋅m
77.5 to 90.2 N⋅m

(8) Bolt -
7.9 to 9.2 kgf⋅m
4.1.2 Hydraulic pump components
(1) Snap ring (20) Pin ×3 (39) Plug (58) Nut

(2) Oil seal (21) Cylinder block (40) Orifice (2.9) (59) Gear pump
(3) Bolt ×4 (22) Collar (41) Plug (60) O-ring
(4) Plug ×12 (23) Spring (42) O-ring (61) O-ring
(5) Flange (24) Collar (43) Valve body (62) Bolt ×2
(6) Stopper (25) Snap ring (44) Bolt ×4 (63) Metal washer ×2
(7) O-ring ×2 (26) Valve plate (45) Orifice (0.8) ×2 (64) Pin
(8) Bushing ×2 (27) Pin (46) Orifice (0.6) (65) Spring seat ×2
(9) Screw ×2 (28) Thrust washer (47) O-ring ×5 (66) Spring
(10) Needle bearing (29) Needle bearing (48) Spool (67) Spring
(11) Thrust washer (30) O-ring ×2 (49) Bushing (68) O-ring
(12) Shaft (31) Gasket (50) Spring seat (69) Valve sleeve
(13) Orifice (0.5) (32) Pin (51) Spring (70) Spool
(14) Pin ×2 (33) Pin (52) Holder (71) Pin
(15) Plug ×2 (34) Pump case (53) O-ring (72) O-ring
(16) Swash plate (35) Plug ×4 (54) O-ring (73) Plug
(17) Retainer plate (36) Plug (55) Cap (74) Nut
(18) Retainer holder (37) Plug ×2 (56) Nut
(19) Piston assembly ×10 (38) O-ring ×2 (57) Set screw
6-84 U30-6S

SERVICING
4.1.3 Disassembling the piston pump

IMPORTANT
lubricants when assembling or disassembling
hydraulic devices.
• Check for scratches or damages carefully on
the sliding and mating surfaces for every part.
They might cause the oil leakage.
• Do not wipe parts with waste clothes or the like
to avoid fiber waste contamination. Use air
pressure when cleaning the parts.
1. Remove the 2 bolts and the gear pump from the

(1) Gear pump (5) O-ring
pump case. (4) O-ring
3. Remove the 4 bolts and the regulator from the

CAUTION pump case.
• Do not pinch your fingers between the port
block and the gear pump.
NOTE
• If the gear pump is difficult to remove, hit it
gently with a plastic hammer to loosen it.
(3) Pump case (7) Bolt (M6 × 16) ×4

(6) Regulator
4. Remove the 5 O-rings from the pump case.

IMPORTANT
• Take care not to scratch the surface of the
(1) Gear pump (3) Pump case
port.
(2) Bolt (M8 × 65) ×2 • Do not reuse removed O-ring.
2. Remove the 2 O-rings from the pump case.
IMPORTANT
port.
• Do not reuse removed O-ring.
(3) Pump case (8) O-ring ×5
5. Remove the 3 orifices from the regulator.
U30-6S 6-85

SERVICING
IMPORTANT
port.
(12) Flange (14) O-ring
8. Remove the 2 screws and 2 bushings from the

flange.
(6) Regulator (11) Orifice (0.8)

(9) Orifice (0.8)
(10) Orifice (0.6)
6. Remove the 4 bolts and the flange from the pump

case.
(12) Flange (16) Screw ×2

(15) Bushing ×2
9. Remove the snap ring from the flange.

NOTE
• Take care so that the snap ring does not fly
(12) Flange (13) Bolt (M10 × 35) ×4 off.
7. Remove the O-ring from the flange.
IMPORTANT
port.
(12) Flange (17) Snap ring
10. Remove the oil seal from the flange.

IMPORTANT
• Do not reuse removed oil seal.
6-86 U30-6S

SERVICING
13. Remove the O-ring and 2 pins from the pump case.
IMPORTANT
• Take care so that the snap ring does not fly
off.
(12) Flange (18) Oil seal
11. Remove the needle bearing from the flange.

IMPORTANT
• Do not reuse removed needle bearing.
(3) Pump case (22) Pin ×2

(21) O-ring
14. Remove the thrust washer from the shaft.
(12) Flange (19) Needle bearing
12. Remove the gasket from the pump case.
CAUTION (23) Thrust washer (24) Shaft

• Be careful not to cut your fingers on the
gasket. 15. Remove the swash plate.
IMPORTANT
• Do not reuse removed gasket.
(25) Swash plate
16. Remove the shaft from the pump case.
(3) Pump case (20) Gasket
U30-6S 6-87

SERVICING
(24) Shaft (3) Pump case (28) Valve plate
17. Remove the cylinder block assembly from the pump 20. Remove the 2 control pins and pin from the pump
case. case.
NOTE
• When removing the cylinder block, check
that the valve plate is not coming off
together.
(3) Pump case (31) Pin

(29) Control pin A
(30) Control pin B
21. Remove the pin from the pump case.
(3) Pump case (26) Cylinder block assembly
18. Remove the thrust washer from the pump case.
(3) Pump case (32) Pin
22. Remove the lock nut from the horsepower control

valve.
(3) Pump case (27) Thrust washer
NOTE
19. Remove the valve plate from the pump case. • Measure the width of (a) before removing
IMPORTANT the lock nut.
• Do not scratch the valve plate.
6-88 U30-6S

SERVICING
(33) Lock nut (34) Horsepower control valve (34) Horsepower control valve (37) Spring seat ×2
(35) Spring (38) O-ring
23. Remove the horsepower control valve from the (36) Spring
pump case.
25. Remove the O-ring from the horsepower control
valve.
NOTE
4.1.4 Assembling the piston pump

IMPORTANT
• Do not reuse removed O-rings and oil seals for
assembly to avoid oil leakage.
lubricant when assembling or disassembling
hydraulic devices.
(3) Pump case (34) Horsepower control valve
24. Remove the 2 springs and 2 spring seats from the the sliding and mating surfaces for every part.
pump case. They might cause oil leakage.
• To avoid seizure and rust, apply lubricant or
grease to every seal and part surface when
assembling.
• After assembling, clean the outside of hydraulic
components.
U30-6S 6-89

SERVICING
• To prevent seizure and cavitation after

assembly, fully fill the hydraulic oil from the
lubrication port.
1. Install the O-ring to the horsepower control valve.

IMPORTANT
• Apply hydraulic oil to the O-ring.
(4) Spring (6) Spring seat ×2

(5) Spring
4. Install the lock nut to the horsepower control valve

and tighten it.
NOTE
• Install the lock nut and adjust its width to (a)
which was measured before disassembly.
(1) O-ring (2) Horsepower control valve
2. Install the horsepower control valve to the pump

case.
IMPORTANT
• Apply hydraulic oil to the O-ring and sliding
surface.
(2) Horsepower control valve (3) Pump case
3. Install the 2 springs and 2 spring seats to the pump

case.
(2) Horsepower control valve (7) Lock nut
Tightening torque
61.7 to 75.4 N⋅m
(7) Lock nut -
6.3 to 7.7 kgf⋅m
5. Install the pin to the pump case.
6-90 U30-6S

SERVICING
(3) Pump case (8) Pin (3) Pump case (12) Valve plate
(8) Pin
6. Install the 2 control pins and pin to the pump case.
8. Install the thrust washer to the pump case.
IMPORTANT
• Apply hydraulic oil to the 2 control pins and
pin.
9. Install the 3 pins to the cylinder block.
(3) Pump case (11) Pin IMPORTANT

(9) Control pin A • Apply grease to the pins.
(10) Control pin B
7. Install the valve plate to the pump case.

IMPORTANT
• Lubricate the sleeve of the valve plate with
hydraulic oil.
• Align the notch with the pin position.
(14) Pin ×3 (15) Cylinder block
10. Install the retainer holder to the cylinder block.
U30-6S 6-91

SERVICING
(15) Cylinder block (16) Retainer holder (3) Pump case (19) Cylinder block assembly
11. Install the 10 piston assembles to the retainer plate 13. Install the shaft to the pump case.
and then install it to the cylinder block.
IMPORTANT
• Do not damage the piston.
• Apply grease to the piston assembles.
(3) Pump case (20) Shaft
14. Install the swash plate to the pump case.

IMPORTANT
• Do not scratch the sliding surfaces of the
(15) Cylinder block (18) Retainer plate piston shoes.
(17) Piston assembly ×10 • Make sure to install the swash plate in the
12. Install the cylinder block assembly to the pump correct direction.
case.
IMPORTANT
• Do not damage the cylinder block.
• Lubricate the sleeve of the cylinder block
with hydraulic oil.
6-92 U30-6S

SERVICING
(3) Pump case (24) Pin ×2

(23) O-ring
17. Install the gasket onto the pump case.
CAUTION
• Be careful not to cut your fingers on the
gasket.
(3) Pump case (B) Suction port side

(21) Swash plate
(A) Discharge port side
15. Install the thrust washer to the shaft.
(3) Pump case (25) Gasket
18. Install the snap ring to the flange.

IMPORTANT
• Install the snap ring so that the edged side
faces outward.

(20) Shaft
16. Install the O-ring and 2 pins to the pump case.

IMPORTANT
• Apply hydraulic oil to the O-ring.
(26) Snap ring (27) Flange
19. Using the jig 1, install the oil seal to the flange.
U30-6S 6-93

SERVICING
IMPORTANT
• Coat the lip of the oil seal with grease.
(27) Flange (31) Screw ×2

(30) Bushing ×2
Tightening torque
(27) Flange (C) Jig 1
(28) Oil seal 5.3 to 6.4 N⋅m
(31) Screw -
0.5 to 0.7 kgf⋅m
20. Using the jig 2, install the needle bearing to the
flange. 22. Install the O-ring to the flange.
IMPORTANT IMPORTANT
• Make the stamped side of the bearing face • Apply hydraulic oil to the O-ring.
upward.

(27) Flange (D) Jig 2
(29) Needle bearing 23. Install the flange to the pump case with the 4 bolts.
21. Install the 2 bushings to the flange with the 2 IMPORTANT
screws. • Do not scratch the lip of the oil seal.
IMPORTANT
• Make sure to install the bushings in the
correct directions.
6-94 U30-6S

SERVICING
(27) Flange (33) Bolt (M10 × 35) ×4 (3) Pump case (38) O-ring ×5
26. Install the regulator to the pump case with the 4

Tightening torque
bolts.
96.2 to 117.5 N⋅m
(33) Bolt -
9.8 to 12.0 kgf⋅m
24. Install the 3 orifices to the regulator.

IMPORTANT
• Each orifice has a fixed mounting position.
(3) Pump case (39) Bolt (M6 × 16) ×4

(37) Regulator
Tightening torque
11.4 to 13.9 N⋅m
(39) Bolt -
1.2 to 1.4 kgf⋅m
(34) Orifice (0.8) (37) Regulator 27. Install the 2 O-rings to the gear pump.
(35) Orifice (0.6)
(36) Orifice (0.8) IMPORTANT
• Apply hydraulic oil to the O-rings.
Tightening torque
(34) Orifice (0.8)
2.2 to 2.6 N⋅m
(35) Orifice (0.6) -
0.2 to 0.3 kgf⋅m
(36) Orifice (0.8)
25. Install the 5 O-rings to the pump case.

IMPORTANT
• Apply hydraulic oil to the O-rings.
(40) O-ring (42) Gear pump

(41) O-ring
U30-6S 6-95

SERVICING
28. Install the gear pump to the pump case with the 2
bolts.
(3) Pump case (43) Bolt (M8 × 65) ×2

(42) Gear pump
Tightening torque
26.0 to 31.7 N⋅m
(43) Bolt -
2.7 to 3.2 kgf⋅m
6-96 U30-6S

SERVICING
4.1.5 Installing adapters for the hydraulic pump
Adapter No. Port Adapter size Angle
(1) G3/8-G1/2-G3/4 40°
(2) G1/2-G1/2 -
(3) P G1/2-G1/2-RC1/8 30°
(4) G3/8-G3/8 -
(5) G3/8-G3/8 35°
(6) G1/4-G1/4 60°

PPS
(7) G1/4-G1/4 20°
(8) G1/4-G1/4 15°

CH2
(9) G1/4-Quick coupler -
(10) G3/8-G3/8 -
Pp
(11) G3/8-G3/8 40°
(12) PLS G1/4-G1/4 30°
U30-6S 6-97

SERVICING
4.1.6 Installing the pump coupling 8. Removing the travel control valve.
9. Removing the swing pedal.
Installing 10. Removing the AUX pedal.
11. Remove the third line valve.
Removing
1. Disconnect the 3 clamps and remove the 4 bolts
and partition cover.
(1) Coupling (3) Bolt (M12 × 40) ×3

(2) Bolt (M12 × 40) ×3 (4) Pump housing
IMPORTANT
• (A) : Grease the spline of the pump coupling.
• (B) : Slightly grease the seating surfaces to the (1) Partition cover (4) Clamp ×3
bolts on the pump coupling. (2) Bolt (M8 × 25)
• Do not apply thread lock. (3) Bolt (M8 × 16) ×3
• Do not grease the pump coupling body. 2. Remove the 8 screws and panel RH (cabin
specification).
Tightening torque
85.0 to 94.0 N⋅m
(2) (3) Bolt -
8.7 to 9.6 kgf⋅m
4.2 Control valve

4.2.1 Removing and installing the control
valve
CAUTION
• Before disconnecting the hydraulic hoses, (5) Panel RH (6) Screw (M6 × 12) ×8
release the residual pressure first. 3. Remove the 3 grilles (cabin specification).
IMPORTANT
contamination.
• Put a mark on the disconnected hydraulic
Preparing
1. Removing the bonnet RH 1.
2. Removing the bonnet RH 2.
4. Removing the floor panel 1.
5. Removing the battery.
6-98 U30-6S

SERVICING
(7) Grille ×3 (10) Bolt (M6 × 13.5) ×2 (16) Meter bracket (17) Bolt (M10 × 25) ×2
(8) Screw ×3
(9) Cover 8. Remove the 2 bolts and step support.
4. Remove the 2 bolts, 3 screws and cover (cabin
specification).
5. Remove the bolt and duct (cabin specification).
(18) Step support (19) Bolt (M10 × 20) ×2
9. Disconnect the 6 hydraulic hoses, 4 connectors and

4 clamps and remove the 2 hose band.
(11) Duct (12) Bolt (M6 × 13.5)
IMPORTANT
6. Remove the 6 bolts and floor panel 2. • Put marks on the disconnected hydraulic
(13) Floor panel 2 (15) Bolt (M10 × 35)

(14) Bolt (M10 × 25) ×5
7. Remove the 2 bolts and meter bracket.
U30-6S 6-99

SERVICING
(27) Control valve assembly
12. Loosen the clamp to disconnect the return hose

from the control valve assembly.
(20) Hydraulic hose ×6 (23) Clamp ×4

(21) Connector ×4
(22) Hose band ×2
10. Remove the 3 bolts and battery bracket.

(28) Return hose (29) Clamp
13. Remove the 3 clips, loosen the 3 nuts and remove

the 3 link cables.
(24) Battery bracket (26) Bolt (M10 × 20) ×2

(25) Bolt (M10 × 25)
11. Disconnect all of the hydraulic hoses, connectors

and wiring clamps from the control valve assembly. (30) Link cable ×3 (32) Nut ×3
(31) Clip ×3
IMPORTANT
14. Disconnect the hydraulic hose from the hydraulic
lock cylinder.
6-100 U30-6S

SERVICING
Mass
(27) Control valve assembly Approximately 59 kg
17. Remove the 3 clips, 3 pins and remove the 3 link

from the control valve assembly.
(33) Hydraulic hose (34) Hydraulic lock cylinder
15. Attach 2 shackles to the valve bracket of the control

valve assembly, and attach a nylon sling and hoist
the control valve for support.
(27) Control valve assembly (39) Pin ×3

(37) Link ×3
(38) Clip ×3
18. Remove the 5 bolts and valve bracket from the

control valve assembly.
(27) Control valve assembly (B) Shackle ×2

(A) Nylon sling
16. Remove the 6 bolts, and hoist the control valve

assembly to remove.
(27) Control valve assembly (40) Bolt (M10 × 16 P1.25) ×5

(35) Valve bracket

(35) Valve bracket
U30-6S 6-101

SERVICING
Installing 4.2.2 Control valve components

4.2.2.1 Control valve section components

(35) Valve bracket (40) Bolt (M10 × 16 P1.25) ×5
(1) Outlet (7) Travel LH
Tightening torque (2) Swivel (8) Blade
(3) Bucket (9) Swing
48.1 to 55.9 N⋅m
(25) (26) Bolt - (4) Arm (10) AUX
4.9 to 5.7 kgf⋅m
(5) Boom (11) Inlet
4.9 to 5.9 N⋅m (6) Travel RH
(29) Clamp -
0.5 to 0.6 kgf⋅m

(36) (40) Bolt
4.9 to 5.7 kgf⋅m (Loctite® 263) 4.2.2.2 Control valve outlet section
(1) Valve body (11) Plug

(2) Spool (12) O-ring
(3) Spring plate (13) Plug
(5) Spacer (15) Plug
(6) O-ring (16) O-ring
(7) Back up ring (17) O-ring
(8) O-ring (18) Main relief valve assembly
(10) Bolt ×2
6-102 U30-6S

SERVICING
Tightening torque 4.2.2.4 Control valve bucket section

8.8 to 11.0 N⋅m
(10) Bolt -
0.9 to 1.1 kgf⋅m
14.0 to 16.0 N⋅m

(11) Plug -
1.4 to 1.6 kgf⋅m
28.0 to 30.0 N⋅m

(13) (15) Plug -
2.9 to 3.1 kgf⋅m
4.2.2.3 Control valve swivel section
(1) Valve body (11) Flange

(2) Spool (12) Bolt ×2
(3) Spring plate ×2 (13) Spool
(4) Spring ×2 (14) O-ring
(5) Spring seat ×2 (15) O-ring
(6) O-ring ×2 (16) O-ring
(7) Cap ×2 (17) O-ring ×2
(8) Bolt ×4 (18) Spring ×2
(9) Overload relief valve ×2 (19) Poppet ×2
(10) O-ring ×2
Tightening torque
(1) Valve body (10) Cap
(2) Spool (11) Bolt ×2 7.3 to 10.0 N⋅m
(8) Bolt -
(3) Spring plate ×2 (12) O-ring 0.7 to 1.0 kgf⋅m
(5) Spring seat ×2 (14) O-ring 30.4 to 32.4 N⋅m
(12) Bolt -
(6) O-ring ×2 (15) O-ring ×2 3.1 to 3.3 kgf⋅m
(7) Cap ×2 (16) Spring ×2
(8) Bolt ×4 (17) Poppet ×2
(9) Spool assembly
4.2.2.5 Control valve arm section
Tightening torque
7.3 to 10.0 N⋅m
(8) Bolt -
0.7 to 1.0 kgf⋅m
30.4 to 32.4 N⋅m

(11) Bolt -
3.1 to 3.3 kgf⋅m

(7) Cap ×2 (17) O-ring ×2
(8) Bolt ×4 (18) Spring ×2
(10) O-ring ×2
U30-6S 6-103

SERVICING
Tightening torque 4.2.2.7 Control valve travel RH section

7.3 to 10.0 N⋅m
(8) Bolt -
0.7 to 1.0 kgf⋅m
30.4 to 32.4 N⋅m

(12) Bolt -
3.1 to 3.3 kgf⋅m
4.2.2.6 Control valve boom section

(7) Cap ×2 (15) O-ring ×2
(8) Bolt ×4
(1) Valve body (16) Plug Tightening torque

(3) Spring plate ×2 (18) Spool 7.5 N⋅m
(8) Bolt -
(4) Spring ×2 (19) Spool 0.8 kgf⋅m
(5) Spring seat ×2 (20) Bolt ×2 30.4 to 32.4 N⋅m
(6) O-ring ×2 (21) Bolt ×4 (10) Bolt -
3.1 to 3.3 kgf⋅m
(7) Cap ×2 (22) O-ring
(8) Bolt ×4 (23) O-ring
(9) Overload relief valve ×2 (24) O-ring ×2
(10) O-ring ×2 (25) O-ring 4.2.2.8 Control valve travel LH section
(11) Plug (26) O-ring
(12) O-ring (27) O-ring ×2
(13) Anti-drift valve body (28) Spring ×2
(14) Shot off valve (29) Poppet ×2
(15) O-ring
Tightening torque
7.3 to 10.0 N⋅m
(8) Bolt -
0.7 to 1.0 kgf⋅m
28.0 to 30.0 N⋅m

(14) Shot off valve -
2.9 to 3.1 kgf⋅m
69.0 to 78.0 N⋅m

(16) Plug -
7.0 to 8.0 kgf⋅m
8.8 to 10.8 N⋅m

(20) (21) Bolt -
0.9 to 1.1 kgf⋅m
(7) Cap ×2 (15) O-ring ×2
(8) Bolt ×4
Tightening torque
7.5 N⋅m
(8) Bolt -
0.8 kgf⋅m
30.4 to 32.4 N⋅m

(10) Bolt -
3.1 to 3.3 kgf⋅m
6-104 U30-6S

SERVICING
4.2.2.9 Control valve blade section Tightening torque

7.3 to 10.0 N⋅m
(7) Bolt -
0.7 to 1.0 kgf⋅m
7.5 N⋅m
(9) Screw -
0.8 kgf⋅m
30.4 to 32.4 N⋅m

(15) Bolt -
3.1 to 3.3 kgf⋅m
4.2.2.11 Control valve AUX section
(1) Valve body (11) O-ring ×2

(2) Spool (12) Flange
(3) Retainer (13) Bolt ×2
(4) Back up ring ×2 (14) Spool
(6) Cap (16) O-ring
(7) Bolt ×2 (17) O-ring
(8) Retainer (18) O-ring ×2
(9) Screw ×2 (19) Spring ×2
Tightening torque
(1) Valve body (11) O-ring ×2
7.3 to 10.0 N⋅m (2) Spool (12) Flange
(7) Bolt -
0.7 to 1.0 kgf⋅m (3) Retainer (13) Bolt ×2
(4) Back up ring ×2 (14) Spool
7.5 N⋅m (5) O-ring ×2 (15) O-ring
(9) Screw -
0.8 kgf⋅m (6) Cap (16) O-ring
30.4 to 32.4 N⋅m (7) Bolt ×2 (17) O-ring
(13) Bolt - (8) Retainer (18) O-ring ×2
3.1 to 3.3 kgf⋅m
(9) Screw ×2 (19) Spring ×2
4.2.2.10 Control valve swing section Tightening torque

7.3 to 10.0 N⋅m
(7) Bolt -
0.7 to 1.0 kgf⋅m
7.5 N⋅m
(9) Screw -
0.8 kgf⋅m
30.4 to 32.4 N⋅m

(13) Bolt -
3.1 to 3.3 kgf⋅m
(1) Valve body (12) Anti-void valve

(3) Retainer (14) Flange
(4) Back up ring ×2 (15) Bolt ×2
(5) O-ring ×2 (16) Spool
(6) Cap (17) O-ring
(7) Bolt ×2 (18) O-ring
(8) Retainer (19) O-ring
(9) Screw ×2 (20) O-ring ×2
(10) Shot off valve (21) Spring ×2
(11) O-ring (22) Poppet ×2
U30-6S 6-105

SERVICING
4.2.2.12 Control valve inlet section
(1) Valve body (6) Plug

(2) Plug (7) O-ring
(3) O-ring (8) O-ring
(4) Plug (9) O-ring
(5) O-ring (10) O-ring ×2
Tightening torque
28.0 to 30.0 N⋅m (1) Nut ×4 (2) Nut ×4
(4) Plug -
2.9 to 3.1 kgf⋅m
Assembling
4.2.3 Disassembling and assembling the IMPORTANT

• If the torque of the screw is too high, it may
control valve
cause the spool to malfunction. Therefore, be
IMPORTANT sure to use the specified torque.
• Do not reuse removed O-rings or floating seals • When installing the spools, mind the direction
for assembly to avoid oil leakage. of each of them, align them with the holes
• Work at clean work space with clean tools and correctly, and insert carefully.
lubricants when assembling or disassembling • To avoid distortion by assembling, alternately
hydraulic devices. tighten the nuts in diagonal direction, separate
• Check for scratches or damages carefully on the tightening into 2 or 3 times and tighten each
the sliding and mating surfaces for every part. nut evenly.
• Do not wipe parts with waste clothes or the like Tightening torque
to avoid fiber waste contamination. Use air 26.5 to 29.4 N⋅m
(1) (2) Nut -
pressure when cleaning the parts. 2.7 to 3.0 kgf⋅m
• Apply lubricants or greases to every seal to
avoid damage when assembling.
Disassembling
1. Remove 4 nuts on each side.
NOTE
• Fix the nuts on the other side with a ring
wrench.
2. Remove the 4 rods to disassemble each section.
NOTE
• When removing each section, take care not
to lose the load check valve and spring of
the mating surface.
• Identify the load check valve and spring of
each section to prevent mismatch.
• Apply a location mark for each section.
6-106 U30-6S

SERVICING
4.2.4 Installing adapters for the control valve
Adapter Adapter
Port Adapter size Angle Port Adapter size Angle
No. No.
(1) G3/4-ϕ27.2 mm - (43) G3/8-G3/8 -
(2) G3/4-G3/4 - (44) A9 G3/8-G3/8 30°

T1
(3) G3/4-G3/4 - (45) G3/8-G3/8 -
(4) G3/4-Flange - (46) B9 G3/8-G3/8 30°

(Continued)
U30-6S 6-107

SERVICING
Adapter Adapter
No. No.
(5) PPS3 G1/4-G1/4 15° (47) B9 G3/8-G3/8 -
(6) Psw G1/4-G1/4 30° (48) G1/4-G1/4 60°

Pb9
(7) Pa8 G1/4-G1/4 - (49) G1/4-G1/4 -
(8) Pb8 G1/4-G1/4 60° (50) G3/8-G3/8 -

A8
(9) Pa7 G1/4-G1/4 - (51) G3/8-G3/8 30°
(10) G1/4-G1/4 - (52) G3/8-G3/8 -

B8
(11) Pb7 G1/4-G1/4 60° (53) G3/8-G3/8 30°
(12) G1/4-G1/4 - (54) G3/8-G3/8 -
(13) Pa6 G1/4-G1/4 - (55) A7 G3/8-G3/8 30°
(14) DR1g G1/4-G1/4 - (56) G3/8-G3/8 -
(15) G1/4-G1/4 60° (57) G3/8-G3/8 -

Pb6 B7
(16) G1/4-G1/4 - (58) G3/8-G3/8 30°
(17) Pa5 G1/4-G1/4 - (59) G1/4-G1/4-G1/4 -
(18) G3/8-G3/8 - (60) Pi G1/4-G1/4 -

B5
(19) G1/2-G3/8 - (61) G1/4-G1/4 -
(20) Pb5 G1/4-G1/4 - (62) G3/8-G3/8 -

A6
(21) Pa4 G1/4-G1/4 - (63) G3/8-G3/8 30°
(22) Pb4 G1/4-G1/4 - (64) G3/8-G3/8 -

B6
(23) G1/4-G1/4 30° (65) G3/8-G3/8 30°
B2
(24) G1/4-G1/4 - (66) G3/8-G3/8 -
A5
(25) A1 G1/2-G3/8 - (67) G1/2-G3/8 -
(26) G1/4-G1/4 - (68) G3/8-G3/8 -

PAi A4
(27) G1/4-G1/4 45° (69) G1/2-G3/8 20°
(28) G1/4-M10 × 1.25 - (70) G3/8-G3/8 -

PP1 B4
(29) M10 × 1.25 (pressure switch) - (71) G1/2-G3/8 30°
(30) G1/2-ϕ16 mm - (72) - G3/8-G3/8 -
(31) G1/2-G1/2 - (73) A3 G3/8-G3/8 5°

T2
(32) G1/2-G1/2-G1/2 - (74) B3 G3/8-G3/8 20°
(33) G1/2-G1/2 - (75) G1/4-G3/8 -
(34) P G1/2-G3/4 30° (76) A2 G1/4-G1/4 -
(35) G3/8-G3/8 - (77) G1/4-G1/4 5°
(36) G3/8-G3/8-G3/8 - (78) B2 G1/4-G3/8 -

PPS2
(37) G3/8-G3/8 25° (79) A1 G3/8-G3/8 -
(38) G1/4-G3/8 50° (80) G1/2-G3/8 30°

B1
(39) G1/4-G1/4 - (81) G3/8-G3/8 -
PLS
(40) G1/4-G1/4 30° (82) P G3/4-G3/4 -
(41) G1/4-G1/4 45° (83) T2 G1/2-ϕ16 mm -

Pa9
(42) G1/4-G1/4 - - - - -
6-108 U30-6S

SERVICING
4.3 Swivel motor 3. Disconnect all of the hydraulic hoses from the
swivel motor.
motor
CAUTION
IMPORTANT
contamination. (4) Swivel motor (6) Bolt (M14 × P1.5 × 40) ×6
(5) Hydraulic hose
trained personnel when measuring, vacuuming, 4. Remove the 6 bolts from the swivel motor.
and charging. 5. Attach a nylon sling to the swivel motor and use a
crane to remove the swivel motor.
Preparing
2. Remove the seat (cabin specification).
3. Remove the seat support (cabin specification).
Removing
1. Disconnect the connector (cabin specification).
(A) Nylon sling
Mass
(4) Swivel motor Approximately 33 kg
Installing
Tightening torque
(6) Bolt
17.00 to 20.00 kgf⋅m (Loctite® 263)
(1) Bracket (3) Bolt (M10 × 25) ×3
(2) Connector
2. Remove the 3 bolts and the bracket (cabin

specification).
U30-6S 6-109

SERVICING
4.3.2 Swivel motor components
(1) O-ring (18) Spring seat ring ×2 (35) Piston assembly (52) Pin ×2
(2) Bolt ×2 (19) Compression spring ×2 (36) Pin ×3 (53) Plug ×2
(3) Motor housing (20) Spring guide ×2 (37) Friction plate (54) Cover
(4) Plug ×2 (21) O-ring ×2 (38) Cylinder block (55) Bolt ×5
(5) O-ring ×2 (22) Back up ring ×2 (39) Washer ×2 (56) Pinion shaft
(6) Spring ×2 (23) Back up ring ×4 (40) Spring (57) Ball bearing
(7) Poppet ×2 (24) O-ring ×2 (41) Internal circlip (58) Gear case
(8) Plug ×2 (25) O-ring ×2 (42) O-ring (59) Oil seal
(9) O-ring ×2 (26) Housing ×2 (43) Brake piston (60) Ball bearing
(10) Shockless piston (27) Set screw ×2 (44) Spring ×12 (61) External circlip
(11) Filter (28) Nut ×2 (45) O-ring (62) Holder
(12) O-ring (29) Ball bearing (46) Valve plate (63) Collar ×3
(13) Ring ×4 (30) External circlip (47) Ball bearing (64) Needle bearing ×3
(14) O-ring ×2 (31) Shaft (48) O-ring (65) Planetary gear ×3
(15) Poppet seat ring ×2 (32) Thrust plate (49) Pin ×2 (66) Thrust plate
(16) Poppet ×2 (33) Retainer plate (50) Pin (67) Bolt ×3
(17) Poppet guide ×2 (34) Retainer holder (51) O-ring ×2
6-110 U30-6S

SERVICING
4.3.3 Disassembling the swivel motor

IMPORTANT
hydraulic devices.
1. Remove the 5 bolts and cover from the motor

housing.
CAUTION
• Hold the brake piston with a hand to avoid
the brake piston popping out.
NOTE
• Blow air through the port P to remove the
brake piston.
4. Remove the 2 O-rings from the brake piston.
(1) Cover (2) Bolt ×5
2. Remove the 12 springs and 3 O-rings.
(6) Brake piston (8) O-ring

(7) O-ring
5. Remove the cylinder block assembly.

(4) O-ring ×2
3. Remove the brake piston with an air gun.
(9) Cylinder block assembly
U30-6S 6-111

SERVICING
IMPORTANT
• Work by rotating the assembly platform 90°.
6. Remove the plug and shockless piston from the
motor housing.
(16) Ball bearing (17) Shaft
10. Remove the 2 bolts and then the motor housing

from the gear case.
(10) Plug (11) Shockless piston
7. Remove the valve assembly from the motor

housing.
(18) Motor housing (19) Bolt ×2
11. Remove the 3 bolts and then the thrust plate.
(12) Valve assembly
8. Remove the poppet, spring, and plug from the

motor housing.
(20) Thrust plate (21) Bolt ×3
12. Remove the 3 planetary gears, 3 needle bearings,

3 collars and holder.
(13) Plug (15) Poppet

(14) Spring
9. Remove the shaft and ball bearing.
6-112 U30-6S

SERVICING
CAUTION
• Hold the pinion shaft with hand to avoid the
pinion shaft popping out.
NOTE
• Hit with plastic hammer and pull out by
hand to remove the pinion shaft.
15. Remove the oil seal from the gear case.
(22) Holder (25) Planetary gear ×3

(23) Collar ×3
(24) Needle bearing ×3
13. Remove the external circlip from the pinion shaft.
(29) Oil seal
4.3.4 Assembling the swivel motor

IMPORTANT
• Do not reuse removed O-rings, oil seals, or seal
rings for assembly to avoid oil leakage.
(26) External circlip (27) Pinion shaft • Do not reuse removed bearings.
IMPORTANT lubricant when assembling or disassembling
• Rotate the assembly platform 90° to work, hydraulic devices.
and do not drop the pinion shaft. • Check for scratches or damages carefully on
14. Remove the pinion shaft and ball bearing from the the sliding and mating surfaces for every part.
gear case. They might cause the oil leakage.
• Apply lubricant or grease to every seal to avoid
damage when assembling.
1. Install the oil seal to the gear case.

IMPORTANT
• Grease the lip and circumference of oil seal.
• Install oil seal in correct direction.
NOTE
• Use oil seal installation jig to install.
(27) Pinion shaft (28) Ball bearing
U30-6S 6-113

SERVICING
(1) Oil seal (A) Oil seal installation jig (3) Pinion shaft (4) External circlip
(a) ϕ61 mm
(b) ϕ89.8 mm 4. Install the holder to the gear case.
2. Install the pinion shaft to the gear case.
IMPORTANT
• Do not damage the oil seal when installing
the pinion shaft.
(5) Holder
5. Install the 3 collars, 3 needle bearings, and 3

planetary gears to the holder.
IMPORTANT
• Install the planetary gear with the protruding
(2) Gear case (3) Pinion shaft
side upwards.
3. Install the external circlip to the pinion shaft.
IMPORTANT
• Install the circlip with the rounded side
downwards.
6-114 U30-6S

SERVICING
Tightening torque
102.9 to 117.6 N⋅m
(12) Bolt 10.49 to -
11.99 kgf⋅m
8. Install the shaft and ball bearing.

IMPORTANT
• Apply grease to the outer circumference of
the ball bearing.
(6) Collar ×3 (8) Planetary gear ×3

6. Install the thrust plate to the holder with the 3 bolts.
(13) Shaft (14) Ball bearing
9. Install the poppet, spring, and plug to the motor

housing.
IMPORTANT
• Apply hydraulic oil to the poppet.
(9) Thrust plate (10) Bolt ×3
Tightening torque
(10) Bolt
1.00 to 1.15 kgf⋅m (Loctite® 271)
7. Install the motor housing to the gear case with the 2

bolts.
(15) Plug (17) Poppet

(16) Spring
Tightening torque
49.0 to 58.8 N⋅m
(15) Plug -
5.00 to 6.00 kgf⋅m
10. Install the valve assembly to the motor housing.

(11) Motor housing (12) Bolt ×2
U30-6S 6-115

SERVICING
(18) Valve assembly (21) Thrust plate
13. Install the cylinder block assembly to the motor

Tightening torque
housing.
(18) Valve assem- 58.8 to 68.6 N⋅m
- IMPORTANT
bly 6.00 to 7.00 kgf⋅m
• Apply hydraulic oil to the cylinder block and
11. Install the shockless piston and plug, to the motor piston.
housing. • Make sure that the level of the cylinder
IMPORTANT block assembly is below the edge of motor
• Apply hydraulic oil to the shockless piston. housing.
• Confirm that the shockless piston moves
smoothly.
(19) Shockless piston (20) Plug
Tightening torque
58.8 to 68.6 N⋅m
(20) Plug -
6.00 to 7.00 kgf⋅m
12. Install the thrust plate.

IMPORTANT
• Work by rotating the assembly platform 90°.
• Install the thrust plate so that the chamfered
side is under side.
(22) Cylinder block assembly
14. Install the 2 O-rings to the brake piston.

IMPORTANT
• Apply grease to the O-ring.
6-116 U30-6S

SERVICING
(23) Brake piston (25) O-ring (26) Valve plate (27) Cover
(24) O-ring
17. Install the 3 O-rings and 12 springs.
15. Install the brake piston to the motor housing.
IMPORTANT
• Align position of the anti-rotation holes.
• Install the brake piston straightly.
(28) Spring ×12 (30) O-ring ×2

(29) O-ring
18. Install the cover to the motor housing with the 5

bolts.
(23) Brake piston (C) Shaft center (31) Cover (32) Bolt ×5
(B) Brake piston anti-rotation (D) Center of hole in pin
hole Tightening torque
16. Install the valve plate to the cover. 102.9 to 117.6 N⋅m
(32) Bolt 10.49 to -
IMPORTANT 11.99 kgf⋅m
• Apply Grease to the back of the valve plate.
• Install the valve plate in correct direction.
U30-6S 6-117

SERVICING
4.3.5 Installing adapters for the swivel Preparing

1. Jack up the machine and support with support
motor
blocks or stands.

Adapter
Port Adapter size Angle 3. Release the residual pressure.
No.
(1) - G1/4-G1/4-G1/4 -
Removing
(2) B G3/8-G3/8 -
1. Remove the 3 bolts and cover.
(3) A G3/8-G3/8 -
(4) M G3/8-ϕ16 mm -
(5) Dr G1/4-ϕ13 mm -
(6) P G1/4-G1/4 -
4.4 Travel motor

4.4.1 Removing and installing the travel
motor
CAUTION
Handle with care before preparation, (1) Cover (2) Bolt (M10 × 20) ×3
measurement, or restoration. 2. Remove the 4 hydraulic hoses.
release the residual pressure first. IMPORTANT
• Place the machine on jack stands securely • Put marks on the disconnected hydraulic
when lifting the machine. hoses to reconnect each hose correctly.
jacked up.
track.
grease,
IMPORTANT
contamination.
(3) Hydraulic hose ×4
6-118 U30-6S

SERVICING
3. Attach a nylon sling and hoist the travel motor for Installing
support.
Tightening torque
48.1 to 55.9 N⋅m
(2) Bolt -
4.9 to 5.7 kgf⋅m

(5) (7) Bolt
10.5 to 12.0 kgf⋅m (Loctite® 263)
(4) Travel motor (A) Nylon sling
4. Remove the 9 bolts from the travel motor.
(4) Travel motor (5) Bolt (M12 × 30) ×9
5. Remove the travel motor and place it on the level

ground.
Mass
(4) Travel motor Approximately 41 kg
6. Remove the 9 bolts and sprocket from the travel

motor.
(4) Travel motor (7) Bolt (M12 × 30) ×9

(6) Sprocket
U30-6S 6-119

SERVICING
4.4.2 Travel motor components
(1) Plug ×3 (9) Drive gear (19) Steel ball ×132

(2) O-ring ×3 (10) Planetary gear A ×3 (20) Angular bearing
(3) Cover (11) Needle bearing ×3 (21) Floating seal ×2
(4) O-ring (12) Inner race ×3 (22) Planetary gear B ×4
(5) Wire (13) Holder (23) Needle bearing ×4
(6) Gear case (14) Snap ring (24) Inner race ×4
(7) Plug ×2 (15) Sun gear (25) Thrust washer ×4
(8) Thrust plate t = 1.6 mm (16) Thrust plate (26) Set screw ×2
Thrust plate t = 2.3 mm (17) Screw ×4 (27) Flange holder
Thrust plate t = 3.0 mm (18) Ring nut
6-120 U30-6S

SERVICING
(28) Piston ×2 (46) Spring ×8 (64) Orifice (0.5) (82) Plug

(29) Spring ×2 (47) Piston assembly ×9 (65) Orifice (0.6) ×2 (83) O-ring ×2
(30) O-ring (48) Retainer holder (66) Plug (84) Spring seat
(31) Oil seal (49) Cylinder block (67) Plug ×2 (85) Spring
(32) Ball bearing (50) Pin ×3 (68) Orifice (0.5) ×4 (86) Spool C
(33) Steel ball ×2 (51) Spring washer (69) Plug ×2 (87) Spool A
(34) Swash plate (52) Spring (70) Plug ×2 (88) Cap
(35) Retainer plate (53) Spring seat (71) O-ring ×2 (89) Pipe joint
(36) Shaft (54) Snap ring (72) O-ring ×3 (90) Plug ×2
(37) Ball bearing (55) Valve plate (73) Plug ×2 (91) O-ring ×2
(38) Friction plate (56) Pin (74) O-ring ×2 (92) Spring ×2
(39) Back-up ring (57) Base plate (75) Spring ×2 (93) Spring seat ×2
(40) O-ring (58) Bolt ×6 (76) Spring seat ×2 (94) Spool
(41) O-ring (59) Plug ×3 (77) Plug ×2 (95) Valve body
(42) Back-up ring (60) O-ring ×3 (78) O-ring ×2 (96) Bolt ×3
(43) O-ring (61) Orifice (0.5) (79) Spring ×2
(44) Brake piston (62) Plug ×2 (80) Check valve ×2
(45) Pin ×2 (63) O-ring ×2 (81) Spool
U30-6S 6-121

SERVICING
4.4.3 Disassembling the travel motor

IMPORTANT
hydraulic devices.
They might cause oil leakage.
Disassembling the gear case

(4) Plug ×2 (5) Cover
1. Mount the travel motor on the disassembly
platform. 4. Insert a bar through the hole of the 2 eye bolts.
(1) Travel motor (A) Disassembly platform (B) Bar (C) Eye bolt ×2
2. Remove the plug from the gear case. 5. Insert a rod through the gear case to keep it from
turning.
(2) Plug (3) Gear case

(3) Gear case (D) Rod
3. Remove the 2 plugs from the cover, replace them
with 2 eye bolts. 6. Rotate the cover by turning the bar until the tip of
the wire coming from the plug hole becomes visible.
Using a needle-nose pliers to pull the wire out of
the plug hole.
6-122 U30-6S

SERVICING
(5) Cover (E) Needle-nose pliers (5) Cover (C) Eye bolt ×2
(6) Wire (B) Bar
7. Using a pliers, remove the wire while rotating the 9. Remove the thrust plate.
cover with the bar.
(7) Thrust plate

(5) Cover (F) Pliers
(6) Wire
10. Remove the holder sub-assembly.
8. Remove the 2 eye bolts, attach the cover removal

tool, and knock it upwards to remove the cover.
(8) Holder sub-assembly
• Holder sub-assembly components

(5) Cover (G) Cover removal tool
• If a cover removal tool is not available

– Mount the 2 eye bolts on the cover and
insert a bar through the holes in the eye
bolts.
– Knock both sides of the bar upwards to
remove the cover.
U30-6S 6-123

SERVICING
(9) Planetary gear A ×3 (12) Holder 14. Remove the 4 screws and thrust plate.
(10) Inner race ×3
(11) Needle bearing ×3 NOTE
11. Remove the drive gear. • If the screws are too tight to remove, heat
them up with a heat gun or the like.
(13) Drive gear
12. Remove the sun gear. (15) Thrust plate (16) Screw (M6 × 16) ×4
15. Remove the 4 planetary gears B, 4 needle

bearings, 4 inner races and 4 thrust washers.
(14) Sun gear
13. Drain off any gear oil.

NOTE
• If there is not any gear oil, skip this step.
6-124 U30-6S

SERVICING
(H) Ring nut socket
18. Using a 2 removal bolts to raise the gear case up

higher than the flange holder, and remove the gear
case.
NOTE
• Tighten the removal bolts equally.
• If there is no removal bolts, hit the entire
circumference of the gear case with a
plastic hammer to remove the gear case.
(17) Planetary gear B ×4 (20) Thrust washer ×4

(19) Inner race ×4
16. Remove the 2 set screws.
(21) Set screw ×2 (22) Ring nut
17. Remove the ring nut.

IMPORTANT
• Always replace the removed ring nut with a
new one.
(3) Gear case (J) Removal bolt (M12 × 1.75 ×
NOTE (23) Flange holder 250) ×2
• Make sure that the ring nut socket does not
19. Remove the floating seal from the gear case side.
come off during removal.
U30-6S 6-125

SERVICING
(3) Gear case (24) Floating seal (3) Gear case (27) Steel ball ×132
20. Remove the floating seal from the flange holder 23. Using a press, remove the angular bearing.
side.
(23) Flange holder (25) Floating seal
21. Remove the plug from the gear case.
(28) Angular bearing
Disassembling the motor

1. Remove the 2 plugs, 2 springs, 2 spring seats and
(3) Gear case (26) Plug spool in this order.
22. Remove the 132 steel balls. IMPORTANT
NOTE • Check that there is no scratch around the
• Do not lose any of the balls. spool.
• Make sure to remove all of the balls. If there
is any ball remaining, the bearing cannot be
removed.
6-126 U30-6S

SERVICING
(29) Plug ×2 (32) Spool (29) Plug ×2 (33) Valve body

(30) Spring ×2 (30) Spring ×2 (34) Bolt (M8 × 30) ×3
(31) Spring seat ×2 (31) Spring seat ×2 (36) O-ring ×3
(32) Spool
2. Remove the 3 bolts and valve body from the base
plate. 4. Remove the plug, pipe joint, spring seat, spring,
spool C and spool A in this order.
IMPORTANT
• Check that there is no scratch around the
spools.
(33) Valve body (35) Base plate

(34) Bolt (M8 × 30) ×3
3. Remove the 3 O-rings from the valve body.

IMPORTANT
• Do not scratch the surface of the port.
(35) Base plate (40) Spring

(37) Plug (41) Spool C
(36) O-ring ×3 (38) Pipe joint (42) Spool A
(39) Spring seat
• Anti-cavitation valve components
• Travel speed shift switch components
U30-6S 6-127

SERVICING
(37) Plug (41) Spool C (43) Plug ×2 (46) Spool

(38) Pipe joint (42) Spool A (44) Spring ×2
(39) Spring seat (45) Spring seat ×2
(40) Spring
6. Remove the 6 bolts and then the base plate.
5. Remove the 2 plugs, 2 springs, 2 spring seats and
the spool in this order.
IMPORTANT
spools.
NOTE
• When removing the plug, be careful not to
let your tool slip. Clearance for a wrench or
socket is tight.
(35) Base plate (47) Bolt (M10 × 20) ×6
7. Tap the base plate with a plastic hammer to loosen

it. Once the base plate loosens a bit, insert a slotted
flat tip screwdriver in the crack, and strike the base
plate from the opposite side to remove it.
IMPORTANT
• When inserting a slotted flat tip screwdriver,
be careful not to scratch the base plate.
(35) Base plate (45) Spring seat ×2

(43) Plug ×2 (46) Spool
(44) Spring ×2
• Counterbalance valve components
(35) Base plate (K) Flat tip screwdriver
8. Remove the valve plate and 5 O-rings.
6-128 U30-6S

SERVICING
IMPORTANT
• Do not scratch the valve plate and surface
of the port.
(48) Valve plate (50) O-ring

(49) O-ring ×4
9. Remove the 8 springs.
(52) Brake piston (M) Travel speed shift switch oil

(L) Brake release oil passage passage hole
hole
11. Remove the cylinder block sub-assembly.

NOTE
• Rotate the disassembly platform 90°.
(51) Spring ×8
10. While pressing down on the brake piston with a rag,

blow air through the brake release oil passage hole
and remove the brake piston.
CAUTION
• Blow air into the passage gently. If the air
blow is too strong, the brake piston may
pop out.
(53) Cylinder block sub-assembly
• Cylinder block sub-assembly components
U30-6S 6-129

SERVICING
(54) Friction plate (58) Retainer plate (62) Spring ×2

(55) Retainer holder (59) Cylinder block
(56) Piston assembly ×9 15. Remove the 2 steel balls.
(57) Pin ×3
12. Remove the swash plate.
(63) Steel ball ×2
16. Remove the shaft and ball bearing.

(60) Swash plate
13. Remove the 2 pistons.

NOTE
• Turn the disassembly platform back.
(64) Shaft (65) Ball bearing
17. Remove the oil seal.

NOTE
• Rotate the disassembly platform 180°.
(61) Piston ×2
• If the ball bearing did not come together
when the shaft was removed, remove the
14. Remove the 2 springs. ball bearing as well.
6-130 U30-6S

SERVICING
(1) Gear case
2. After installing the angular bearing, check that the

groove (A) on the circumference of the angular
bearing is aligned to the center of the hole in the
gear case precisely.
(66) Oil seal
4.4.4 Assembling the travel motor

IMPORTANT
• Do not reuse removed O-rings or floating seals (1) Gear case (A) Circumference groove
(2) Angular bearing
for assembly to avoid oil leakage.
• Do not reuse removed bearings. 3. Install the 132 steel balls to the gear case.
hydraulic devices.
Assembling the gear case

1. Place the angular bearing in the gear case and use
a press to install it. (1) Gear case (3) Steel ball ×132
4. Install the plug.

IMPORTANT
• Wrap thread seal tape around the plug.
U30-6S 6-131

SERVICING
(1) Gear case (4) Plug (1) Gear case (6) Floating seal
(5) O-ring
Tightening torque 8. Install the floating seal in the gear case with the
6.8 to 8.8 N⋅m floating seal installation tool.
(4) Plug -
0.7 to 0.9 kgf⋅m
5. Set the floating seal installation tool on the gear

case.
(C) Floating seal installation tool

(for pusher)
9. Apply a small amount of gear oil on the sliding

(1) Gear case (B) Floating seal installation tool
surface of the floating seal (4 places).
(for gear case)
6. Apply grease to the O-ring of the floating seal and

install the O-ring.
(6) Floating seal
10. Set the flange holder on the disassembly platform.
7. Set the floating seal on the gear case.
6-132 U30-6S

SERVICING
(7) Flange holder (7) Flange holder (9) Floating seal

(8) O-ring
11. Set the floating seal installation tool on the flange
holder. 14. Install the floating seal in the flange holder with the
floating seal installation tool.
(7) Flange holder (D) Floating seal installation tool

(for flange holder) (E) Floating seal installation tool
(for pusher)
12. Apply grease to the O-ring of the floating seal and
install the O-ring. 15. Apply a small amount of gear oil on the sliding
surface of the floating seal (4 places).
13. Set the floating seal on the flange holder.

(7) Flange holder (9) Floating seal
16. Install the gear case on the flange holder.
U30-6S 6-133

SERVICING
(1) Gear case (7) Flange holder (10) Ring nut (G) Ring nut socket
17. Using a clamps to press the gear case onto the

Tightening torque
flange holder.
186.2 to 205.8 N⋅m
(10) Ring nut -
19.0 to 21.0 kgf⋅m
19. Tap the outside of the gear case with a hammer (4

places). Rotate the gear case by hand to seat the
angular bearing.
(F) Clamp
18. Using a ring nut socket, install the ring nut.

IMPORTANT
• After confirming that the ring nut is firmly
attached to the flange holder, remove the (1) Gear case
clamp.
• Always replace the removed ring nut with a 20. Install the 2 set screws to prevent rotation of the
new one. ring nut.
NOTE
• Be careful not to come off the ring nut
socket from the ring nut during tightening.
(10) Ring nut (11) Set screw ×2
6-134 U30-6S

SERVICING
Tightening torque
9.8 to 19.6 N⋅m
(11) Set screw -
1.0 to 2.0 kgf⋅m
21. Swage 2 places per set screw with a punch.
(16) Thrust plate (17) Screw (M6 × 16) ×4
Tightening torque
4.1 to 8.1 N⋅m
(17) Screw -
0.4 to 0.8 kgf⋅m
(H) Swage points
24. Install the sun gear.
22. Install the 4 thrust washers, 4 inner races, 4 needle
bearings and 4 planetary gears B.
IMPORTANT
• Be careful that it faces the right direction.
• Install with the R face down.
(18) Sun gear
25. Install the drive gear.
(19) Drive gear
26. Install the holder, 3 inner races, 3 needle bearings

and 3 planetary gears A in this order.
(12) Thrust washer ×4 (15) Planetary gear B ×4
(13) Inner race ×4
23. Install the thrust plate with the 4 screws.
U30-6S 6-135

SERVICING
29. Subtract the distance (b) from the distance (a) to

calculate the distance (c).
NOTE
• Select an appropriate thrust plate based on
the calculated distance (c).
(20) Holder (23) Planetary gear A ×3

(21) Inner race ×3
27. Measure the distance (a) between the edges of the

holder and the gear case.
Distance (c) Thrust plate thickness (t)
0.6 to 1.1 mm 1.8 mm
1.2 to 1.75 mm 2.3 mm
1.8 to 2.3 mm 2.8 mm
30. Install the selected thrust plate.
28. Measure the distance (b) between the surface of

the gear case tooth and the edge of the gear case.
(24) Thrust plate
31. Install the O-ring to the cover, and install the cover
to the gear case.
6-136 U30-6S

SERVICING
IMPORTANT
• Apply grease to the O-ring.
NOTE
• Install the cover so that its notch is aligned
with the hole in the gear case.
(1) Gear case (27) Wire

(25) Cover
34. Feed the wire into the hole in the gear case, and
rotate the cover with a bar to wind up the wire. Cut
off any wire protruding from the hole.
(1) Gear case (J) Notch

(25) Cover
(26) O-ring
32. Insert a rod through the gear case to keep it from

turning.
(25) Cover (27) Wire
35. Install the plug to the gear case.

IMPORTANT
• Wrap thread seal tape around the plug.
(1) Gear case (K) Rod
33. Bend the last 6 mm of a wire 90º and insert the tip
of the wire into the hole in the gear case.
(1) Gear case (28) Plug
Tightening torque
6.8 to 8.8 N⋅m
(28) Plug -
0.7 to 0.9 kgf⋅m
U30-6S 6-137

SERVICING
36. After installing the cover, rotate the disassembly

platform 90° and pour in gear oil. Fill gear oil until it
flows out of the inspection port and then install the
2 plugs.
IMPORTANT
• After mounting the travel motor on the
machine, double-check the gear oil level.
• Be sure to fill the specified amount of gear
oil prior to mounting the motor on the
machine.
(29) Oil fill port plug (30) Oil inspection port plug
Gear oil (7) Flange holder (L) Oil seal installation tool
(31) Oil seal
Specified amount 900 ml
2. Tap in the ball bearing.
Tightening torque IMPORTANT
(29) Oil fill port plug • Install the ball bearing so that the
37.2 to 41.2 N⋅m
- inscription comes to the upper side.
(30) Oil inspection port plug 3.8 to 4.2 kgf⋅m
• Apply grease to the circumference of the
ball bearing.
Assembling the motor
1. Place the flange holder on the disassembly platform
and tap in the oil seal with an oil seal installation
tool.
IMPORTANT
• Make the oil seal face the right direction.
• Apply grease to the oil seal's lip and its
circumference.
(7) Flange holder (32) Ball bearing
3. Install the shaft.
6-138 U30-6S

SERVICING
IMPORTANT
• Press the pistons down and make sure that
they move smoothly.
NOTE
• Apply grease to the pistons to keep them in
place.
(33) Shaft
4. Install the 2 steel balls.

NOTE
• Apply grease to the steel balls to keep them
in place.
(34) Steel ball ×2
5. Install the 2 springs. (36) Piston ×2 (N) Incorrect

(M) Correct
NOTE
7. Install the swash plate.
• Apply grease to the springs to keep them in
place. IMPORTANT
• After installing them, make sure that the
swash plate moves smoothly.
(35) Spring ×2
6. Install the 2 pistons.

(37) Swash plate
8. Install the 3 pins to the cylinder block.
U30-6S 6-139

SERVICING
IMPORTANT
• Apply grease to the pins.
(39) Cylinder block (43) Retainer plate

(42) Piston assembly ×9
11. Install the cylinder block sub-assembly to the flange

(38) Pin ×3 (39) Cylinder block holder.
9. Install the retainer holder and friction plate to the NOTE
cylinder block. • Turn the disassembly platform 90° to install
the cylinder block sub-assembly, and then
turn it back afterwards.
(39) Cylinder block (41) Friction plate

(40) Retainer holder
10. Install the 9 piston assembles to the retainer plate,

(44) Cylinder block sub-assembly
and then install the assembled parts to the cylinder
block. 12. Check that the cylinder block's sliding surface sinks
below the edge of the holder.
IMPORTANT
• Apply hydraulic oil to the pistons.
• Make sure that the pistons move smoothly.
6-140 U30-6S

SERVICING
(45) Brake piston (48) O-ring

(46) O-ring (49) Back-up ring
(47) Back-up ring
14. Install the 8 springs to the brake piston.
(P) Flange holder edge (d) Sinking amount

(Q) Cylinder block sliding sur-
face
13. Install the brake piston.

IMPORTANT (45) Brake piston (50) Spring ×8
• Apply grease to the O-rings. 15. Install the valve plate and 5 O-rings on the base
plate.
IMPORTANT
• Install the valve plate in the correct
direction.
• Align the groove on the valve plate with the
pin on the base plate.
• Apply grease to the O-rings.
U30-6S 6-141

SERVICING
(51) Valve plate (55) Base plate

(52) O-ring ×4 (R) Groove
(53) O-ring
(54) Pin
16. Install the base plate with the 6 bolts.

IMPORTANT
• Tighten the bolts in a cross pattern.
(55) Base plate (59) Spring seat ×2

(57) Plug ×2 (60) Spool
(58) Spring ×2
18. Tighten the 2 plugs.
(55) Base plate (56) Bolt (M10 × 20) ×6
Tightening torque
58.8 to 68.6 N⋅m
(56) Bolt -
6.0 to 7.0 kgf⋅m
17. Install the spool, 2 spring seats, 2 springs and 2

plugs to the base plate.
IMPORTANT
• Check that there is no scratch around the (55) Base plate (57) Plug ×2
spools.
• Check that the spool slides smoothly. Tightening torque
• Apply hydraulic oil to the spool.
235.0 to 245.0 N⋅m
(57) Plug -
24.0 to 25.0 kgf⋅m
19. Install the spool A, and install the spool C in the

spool A.
IMPORTANT
spools.
• Check that the spool slides smoothly.
• Apply hydraulic oil to the spools.
6-142 U30-6S

SERVICING
IMPORTANT
• Be careful not to forget to install the O-
rings.
• Apply grease to the O-rings.
(55) Base plate (62) Spool A

(61) Spool C
20. Install the spring seat, spring, plug and pipe joint.
(55) Base plate (68) Valve body

(67) O-ring ×3
23. Install the valve body with the 3 bolts.
(55) Base plate (64) Spring seat

(61) Spool C (65) Spring
(62) Spool A
(63) Plug
21. Tighten the plug and pipe joint.

(55) Base plate (69) Bolt (M8 × 30) ×3
(68) Valve body
Tightening torque
35.0 to 38.8 N⋅m
(69) Bolt -
3.6 to 4.0 kgf⋅m
24. Install the spool, 2 spring seats, 2 springs and 2

plugs.
IMPORTANT
spool.
• Check that the spool slides smoothly.
(55) Base plate (66) Pipe joint • Apply hydraulic oil to the spool.
(63) Plug
Tightening torque
(63) Plug 49.0 to 58.8 N⋅m
-
(66) Pipe joint 5.0 to 6.0 kgf⋅m
22. Install the 3 O-rings to the valve body.
U30-6S 6-143

SERVICING
(70) Plug ×2 (73) Spool

(71) Spring ×2
(72) Spring seat ×2
25. Tighten the 2 plugs.
(70) Plug ×2
Tightening torque
49.0 to 58.8 N⋅m
(70) Plug -
5.0 to 6.0 kgf⋅m
6-144 U30-6S

SERVICING
4.5 Hydraulic cylinder

4.5.1 Boom cylinder
4.5.1.1 Boom cylinder components
(1) Cylinder tube (7) U-ring (13) Cushion seal (19) Seal ring assembly
(2) Cylinder rod (8) O-ring (14) Spacer (20) Piston
(3) Bushing ×2 (9) Back-up ring (15) Back-up ring (21) Set screw
(4) Wiper ring (10) O-ring (16) O-ring (22) Steel ball
(5) Cylinder head (11) Holder (17) Cushion bearing (23) Grease fitting
(6) Bushing (12) Collar (18) Slide ring ×2
U30-6S 6-145

SERVICING
4.5.1.2 Disassembling the boom cylinder

IMPORTANT
hydraulic devices.
Disassembling the cylinder rod

(2) Cylinder head
1. Fasten the cylinder assembly in a vice. Support the
cylinder assembly with a stand. 5. Remove the cylinder rod and the cylinder head.
IMPORTANT
• Hold the cylinder rod assembly steadily and
draw it out horizontally. Otherwise, the
cylinder rod assembly may fall off and
cause damage to its parts.
NOTE
• Remove the plugs before pulling out the
cylinder rod and cylinder head.
• Put an oil pan below the cylinder head.
(1) Cylinder assembly
2. Remove the plugs, and drain the hydraulic oil.

3. Hit the cylinder head with a hammer and a pin
punch to open the rotation stopper.
(2) Cylinder head (3) Cylinder rod
6. Fasten the cylinder rod in a vice. Support the

cylinder rod with a stand.
(2) Cylinder head
4. Loosen the cylinder head with a hook wrench or

key wrench.
6-146 U30-6S

SERVICING
(3) Cylinder rod (6) Piston
7. Remove the set screw and steel ball. 9. Remove the piston, cushion bearing, holder, and
cylinder head in order.
NOTE
• Set screws are swaged at 2 locations.
Remove the swaged part of metal with a
hand drill to loosen the set screw.
• Rethread the screw hole with a tap (M8 ×
1.25) after removing the set screw.
• If the removed set bolt is damaged, replace
it with a new one.
(2) Cylinder head (8) Holder

(6) Piston
(7) Cushion bearing
10. Remove the 2 slide rings by hand.
(4) Set screw (A) Hand drill

(5) Steel ball
8. Loosen the piston with a socket wrench.
U30-6S 6-147

SERVICING
(9) Seal ring (B) Flat tip screwdriver (2) Cylinder head (15) U-ring
(10) O-ring
(11) Slide ring ×2 3. Use a flat tip screwdriver to remove the wiper ring.
11. Remove the seal ring by hitting a flat tip screwdriver IMPORTANT
with a hammer. • Do not reuse removed wiper ring.
IMPORTANT NOTE
• Do not reuse removed seal ring. • The wiper ring is press-fitted.
12. Remove the O-ring. • Press the rubber with a tool such as a
screwdriver, and tap it to pull it out.
IMPORTANT
Disassembling the cylinder head

1. Remove the 2 O-rings and back-up ring of the
cylinder head.
(16) Wiper ring
4. Using a press-fit jig, to remove the bushing.

IMPORTANT
• Do not reuse removed bushing.
(2) Cylinder head (14) O-ring
(12) O-ring
(13) Back-up ring
2. Use a flat tip screwdriver to remove the U-ring from

the cylinder head.
IMPORTANT
• Do not reuse removed U-ring.
6-148 U30-6S

SERVICING
(1) Cylinder head (A) Press-fit jig

(2) Bushing
2. Set the U-ring installation jig to cylinder head.
(2) Cylinder head (D) Press-fit jig 2

(17) Bushing
(C) Press-fit jig 1
4.5.1.3 Assembling the boom cylinder

IMPORTANT
• Do not reuse removed O-rings, oil seals, seal
rings, and dust seals for assembling to avoid oil
leakage. (1) Cylinder head (B) U-ring installation jig
lubricant when assembling or disassembling 3. Using a press-fit jig, install the U-ring to the
hydraulic devices. mounting grooves inside the cylinder head.
• Check for scratches or damages carefully on IMPORTANT
the sliding and mating surfaces for every part. • Apply hydraulic oil to the U-ring.
They might cause oil leakage. • Make sure that the U-ring faces to correct
• Do not wipe parts with waste clothes or the like direction.
pressure when cleaning the parts. NOTE
• Apply lubricant or grease to every seal to avoid • Before installing, put the U-ring into hot
damage when assembling. water for 5 to 10 minutes.
Assembling the cylinder head
1. Using a press-fit jig, install the bushing to the
cylinder head.
IMPORTANT
• Apply hydraulic oil to the inside of the
cylinder head.
• Make sure not to damage the bushing.
Check for damage after installing the
bushing.
U30-6S 6-149

SERVICING
IMPORTANT
• Apply hydraulic oil to the O-rings and back-
up ring.

(2) Bushing (6) Back-up ring
(3) U-ring (7) O-ring
(4) Wiper ring
Assembling the cylinder rod

1. Rethread the screw hole for the set screw with a
tap (M8 × 1.25).
2. Install the O-ring to the piston.
(1) Cylinder head (C) Press-fit jig

IMPORTANT
(2) Bushing • Apply hydraulic oil to the O-ring.
(3) U-ring
4. Using a press-fit jig, install the wiper ring to the

cylinder head.
IMPORTANT
• Apply hydraulic oil to the wiper ring.
NOTE
• Fit the jig to the annular part of the wiper
ring, and press it to install the wiper ring.
(8) O-ring (9) Piston
3. Install the seal ring onto the O-ring.

IMPORTANT
• Apply hydraulic oil to the seal ring.
NOTE
• Use the seal ring installation jig.
(1) Cylinder head (D) Press-fit jig

(4) Wiper ring
5. Install the 2 O-rings and back-up ring to the cylinder

head.
6-150 U30-6S

SERVICING
(8) O-ring (E) Seal ring installation jig 1 (8) O-ring (11) Slide ring ×2
(9) Piston (F) Seal ring installation jig 2 (9) Piston
(10) Seal ring (10) Seal ring
4. After installing the seal ring, correct the position of 6. Fasten the cylinder rod assembly in a vice. Support
the seal ring with the correction jig. the cylinder rod assembly with a stand.
7. Install the cylinder head into the cylinder rod slowly.
IMPORTANT
• Apply hydraulic oil to the U-ring, wiper ring
and bushing of the cylinder head.
• Do not damage the U-ring, wiper ring and
bushing.
(G) Correction jig
5. Install 2 slide rings to the piston.

IMPORTANT
• Apply hydraulic oil to the slide rings.
8. Install the holder and cushion bearing to the

cylinder rod.
U30-6S 6-151

SERVICING
IMPORTANT 11. Install the steel ball into the piston.

• Apply hydraulic oil to the holder.
• Make sure that the cushion bearing faces to
correct direction.
(9) Piston (15) Steel ball
12. Tighten the set screw.
(12) Cylinder rod (14) Cushion bearing

(13) Holder
9. Install the piston to the cylinder rod.
(9) Piston (16) Set screw
Tightening torque
16.2 N⋅m
(16) Set screw -
(9) Piston (12) Cylinder rod 1.7 kgf⋅m
10. Tighten the piston. 13. Swage the screw hole for the set screw with a
punch in 2 positions on the circumference.
(9) Piston
Tightening torque
1140 N⋅m
(9) Piston -
116.3 kgf⋅m
6-152 U30-6S

SERVICING
(1) Cylinder head
Tightening torque
490 N⋅m
(1) Cylinder head -
50.0 kgf⋅m
17. Set the rotation stopper.
(9) Piston (H) Punch

(15) Steel ball (J) Swage ×2
(16) Set screw
14. Fasten the bottom side of cylinder tube in a vice.

15. Install the cylinder rod to the cylinder tube.
IMPORTANT
• Apply hydraulic oil to the piston, holder,
cylinder head and cylinder rod.
(12) Cylinder rod (17) Cylinder tube
16. Tighten the cylinder head with a hook wrench or

key wrench.
U30-6S 6-153

SERVICING
4.5.2 Arm, bucket, swing, and blade cylinders

4.5.2.1 Arm, bucket, swing, and blade cylinder components
Arm cylinder
(1) Cylinder tube (5) Cylinder head (9) Back-up ring (13) Piston
(2) Cylinder rod (6) Bushing (10) O-ring (14) Set screw
(3) Bushing ×2 (7) U-ring (11) Slide ring ×2 (15) Steel ball
(4) Wiper ring (8) O-ring (12) Seal ring assembly
Bucket cylinder
(1) Cylinder tube (7) U-ring (13) Piston (19) Pipe

(2) Cylinder rod (8) O-ring (14) Set screw (20) Plug
(3) Bushing ×2 (9) Back-up ring (15) Steel ball (21) O-ring ×2
(4) Wiper ring (10) O-ring (16) Grease fitting
(5) Cylinder head (11) Slide ring ×2 (17) Pipe holder
(6) Bushing (12) Seal ring assembly (18) Bolt
6-154 U30-6S

SERVICING
Blade cylinder
(1) Cylinder tube (7) U-ring (13) Piston (19) Pipe

(2) Cylinder rod (8) O-ring (14) Set screw (20) Plug
(3) Bushing ×2 (9) Back-up ring (15) Steel ball (21) O-ring ×2
(4) Wiper ring (10) O-ring (16) Grease fitting ×2
(5) Cylinder head (11) Slide ring ×2 (17) Pipe holder
(6) Bushing (12) Seal ring assembly (18) Bolt
Swing cylinder
(1) Cylinder tube (5) Cylinder head (9) Back-up ring (13) Piston
(2) Cylinder rod (6) Bushing (10) O-ring (14) Set screw
(3) Bushing ×2 (7) U-ring (11) Slide ring ×2 (15) Steel ball
(4) Wiper ring (8) O-ring (12) Seal ring assembly
U30-6S 6-155

SERVICING
4.5.2.2 Disassembling the arm, bucket,

swing, and blade cylinder
IMPORTANT
hydraulic devices.
(2) Cylinder head
Disassembling the cylinder rod
1. Fasten the cylinder assembly in a vice. Support the 5. Remove the cylinder rod and the cylinder head.
cylinder assembly with a stand. IMPORTANT
• Hold the cylinder rod assembly steadily and
draw it out horizontally. Otherwise, the
cylinder rod assembly may fall off and
cause damage to its parts.
NOTE
• Remove the plugs before pulling out the
cylinder rod and cylinder head.
• Put an oil pan below the cylinder head.
(1) Cylinder assembly
2. Remove the plugs, and drain the hydraulic oil.

3. Hit the cylinder head with a hammer and a pin
punch to open the rotation stopper.
6. Fasten the cylinder rod in a vice. Support the

cylinder rod with a stand.
(2) Cylinder head
4. Loosen the cylinder head with a hook wrench or

key wrench.
6-156 U30-6S

SERVICING
(2) Cylinder head (4) Piston (4) Piston

(3) Cylinder rod
9. Remove the piston and cylinder head.
7. Remove the set screw and steel ball.
NOTE
• Set screws are swaged at 2 locations.
Remove the swaged part of metal with a
hand drill to loosen the set screw.
• Rethread the screw hole with a tap (M8 ×
1.25) after removing the set screw.
• If the removed set bolt is damaged, replace
it with a new one.
(2) Cylinder head (4) Piston

(3) Cylinder rod
10. Remove the 2 slide rings by hand.
(4) Piston (8) Seal ring

(7) Slide ring ×2
11. Remove the seal ring by hitting a flat tip screwdriver

with a hammer.
IMPORTANT
(5) Set screw (A) Hand drill
• Do not reuse removed seal ring.
(6) Steel ball
8. Loosen the piston with a socket wrench.
U30-6S 6-157

SERVICING
(4) Piston (9) O-ring (2) Cylinder head (12) O-ring

(7) Slide ring ×2 (B) Flat tip screwdriver (10) O-ring
(8) Seal ring (11) Back-up ring
12. Remove the O-ring. 2. Use a flat tip screwdriver to remove the wiper ring.
IMPORTANT IMPORTANT
• Do not reuse removed O-ring. • Do not reuse removed wiper ring.
NOTE
• The wiper ring is press-fitted.
• Press the rubber with a tool such as a
screwdriver, and tap it to pull it out.
(4) Piston (9) O-ring
Disassembling the cylinder head

1. Remove the 2 O-rings and back-up ring of the
cylinder head.
(2) Cylinder head (13) Wiper ring
IMPORTANT
• Do not reuse removed O-ring and back-up 3. Use a flat tip screwdriver to remove the U-ring from
ring. the cylinder head.
IMPORTANT
• Do not reuse removed U-ring.
6-158 U30-6S

SERVICING
Assembling the cylinder head

1. Using a press-fit jig, install the bushing to the
cylinder head.
IMPORTANT
• Apply hydraulic oil to the inside of the
cylinder head.
• Make sure not to damage the bushing.
Check for damage after installing the
bushing.
(2) Cylinder head (14) U-ring
4. Hit the bushing with a hammer and a flat tip

screwdriver to remove the bushing from the cylinder
head.
IMPORTANT
• Do not reuse removed bushing.
(1) Cylinder head (A) Press-fit jig

(2) Bushing
2. Set the U-ring installation jig to cylinder head.
(2) Cylinder head (B) Flat tip screwdriver

(15) Bushing
4.5.2.3 Assembling the arm, bucket, swing,

and blade cylinder
(1) Cylinder head (B) U-ring installation jig
IMPORTANT
• Do not reuse removed O-rings, oil seals, seal 3. Using a press-fit jig, install the U-ring to the
rings, and dust seals for assembling to avoid oil mounting grooves inside the cylinder head.
leakage. IMPORTANT
• Work at clean work space with clean tools and • Apply hydraulic oil to the U-ring.
lubricant when assembling or disassembling • Make sure that the U-ring faces to correct
hydraulic devices. direction.
the sliding and mating surfaces for every part. NOTE
They might cause oil leakage. • Before installing, put the U-ring into hot
• Do not wipe parts with waste clothes or the like water for 5 to 10 minutes.
U30-6S 6-159

SERVICING
IMPORTANT
• Apply hydraulic oil to the O-rings and back-
up ring.

(5) O-ring
(6) Back-up ring
Assembling the cylinder rod

1. Rethread the screw hole for the set screw with a
tap (M8 × 1.25).
2. Install the O-ring to the piston.
IMPORTANT
(1) Cylinder head (C) Press-fit jig • Apply hydraulic oil to the O-ring.
(3) U-ring
4. Using a press-fit jig, install the wiper ring to the

cylinder head.
IMPORTANT
• Apply hydraulic oil to the wiper ring.
NOTE
• Fit the jig to the annular part of the wiper
ring, and press it to install the wiper ring.
(8) Piston (9) O-ring
3. Install the seal ring onto the O-ring.

IMPORTANT
• Apply hydraulic oil to the seal ring.
NOTE
• Use the seal ring installation jig.
(1) Cylinder head (D) Press-fit jig

(4) Wiper ring
5. Install the 2 O-rings and back-up ring to the cylinder

head.
6-160 U30-6S

SERVICING
(8) Piston (E) Seal ring installation jig 1 (8) Piston (11) Slide ring ×2
(9) O-ring (F) Seal ring installation jig 2 (9) O-ring
(10) Seal ring (10) Seal ring
4. After installing the seal ring, correct the position of 6. Fasten the cylinder rod assembly in a vice. Support
the seal ring with the correction jig. the cylinder rod assembly with a stand.
7. Install the cylinder head into the cylinder rod slowly.
IMPORTANT
• Apply hydraulic oil to the U-ring, wiper ring
and bushing of the cylinder head.
• Do not damage the U-ring, wiper ring and
bushing.
(G) Correction jig
5. Install 2 slide rings to the piston.

IMPORTANT
• Apply hydraulic oil to the slide rings.
8. Install the piston to the cylinder rod.
U30-6S 6-161

SERVICING
(8) Piston (12) Cylinder rod (14) Set screw
9. Tighten the piston.

Tightening torque
Tightening torque
16.2 N⋅m
(14) Set screw -
1160 N⋅m 1.7 kgf⋅m
Arm cylinder -
118.3 kgf⋅m
12. Swage the screw hole for the set screw with a
586 N⋅m punch in 2 positions on the circumference.
Becket cylinder -
59.8 kgf⋅m
(8) Piston
862 N⋅m
Swing cylinder -
87.9 kgf⋅m
1056 N⋅m
Blade cylinder -
107.7 kgf⋅m
10. Install the steel ball into the piston.
(8) Piston (13) Steel ball
11. Tighten the set screw.
(8) Piston (H) Punch

(13) Steel ball (J) Swage ×2
(14) Set screw
13. Fasten the bottom side of cylinder tube in a vice.

14. Install the cylinder rod to the cylinder tube.
IMPORTANT
• Apply hydraulic oil to the piston cylinder
head and cylinder rod.
6-162 U30-6S

SERVICING
4.5.3 Measuring the hydraulic cylinder

4.5.3.1 Measuring hydraulic cylinder
bending
1. Put the cylinder rod on the V blocks.
2. Set a dial gauge on center of the rod.
3. Rotate the cylinder rod slowly to measure.
NOTE
• The half of measured value is bending of the
rod. Replace if exceeded the service limit.
(12) Cylinder rod (15) Cylinder tube
15. Tighten the cylinder head with a hook wrench or

key wrench.
Bending Less than 0.05 mm
Service limit
(1) Cylinder head
Bending 0.5 mm
Tightening torque
451 N⋅m
Arm cylinder 46.0 kgf⋅ - 4.5.3.2 Measuring hydraulic cylinder rod
m
and head clearance
422 N⋅m
(1) Cylinder head Becket cylinder 43.0 kgf⋅ - 1. Measure the external diameter of the cylinder rod
m and the internal diameter of the cylinder head
(inside of bushings) to calculate the clearance.
Swing cylinder 490 N⋅m
50.0 kgf⋅ -
Blade cylinder NOTE
m
• Replace if the calculated value is exceeding
16. Set the rotation stopper. the service limit.
U30-6S 6-163

SERVICING
Service specifications
Boom cylinder 0.05 to 0.30 mm
Arm cylinder 0.05 to 0.30 mm
Clearance Bucket cylinder 0.05 to 0.30 mm
Swing cylinder 0.05 to 0.30 mm
Blade cylinder 0.05 to 0.35 mm
Service limits
Boom cylinder 0.60 mm
Arm cylinder 0.60 mm
Clearance Bucket cylinder 0.60 mm

Service specifications
Swing cylinder 0.60 mm
Boom cylinder Less than 0.25 mm
Blade cylinder 0.70 mm
Arm cylinder Less than 0.25 mm
Clearance Bucket cylinder Less than 0.25 mm

4.6 Swivel joint
Swing cylinder Less than 0.25 mm
Blade cylinder Less than 0.25 mm
joint
Service limits
Boom cylinder 0.4 mm
CAUTION
Arm cylinder 0.4 mm Handle with care before preparation,
Clearance Bucket cylinder 0.4 mm measurement, and restoration.
Swing cylinder 0.4 mm
Blade cylinder 0.4 mm
IMPORTANT
4.5.3.3 Measuring hydraulic cylinder tube and adapters to avoid oil leakage and dust
contamination.
and piston wear ring clearance
1. Measure the internal diameter of the cylinder tube trained personnel when measuring, vacuuming,
and the external diameter of the cylinder wear ring and charging.
to calculate the clearance.
Preparing
NOTE 1. Jack up the machine, and secure the machine on
• Replace if the calculated value is exceeding jack stands.
the service limit. 2. Remove the cabin (cabin specification).
3. Remove the seat (cabin specification).
4. Remove the seat support (cabin specification).
9. Remove the swivel motor.
Removing
swivel joint (swivel frame side).
NOTE
6-164 U30-6S

SERVICING
(1) Hydraulic hose (3) Bolt (M12 × P1.25 × 25) ×2 (A) Nylon sling
(2) Stopper
6. Remove the 4 bolts and swivel joint.
2. Remove the 2 bolts and then the stopper.
3. Remove the 4 bolts and bottom cover from the IMPORTANT
track frame. • Loosen the bolts slowly to avoid the swivel
joint falling.
• When lowering the swivel joint, lower it
slowly.
(4) Bottom cover (5) Bolt (M10 × 20) ×4

swivel joint (bottom side).
NOTE
(7) Swivel joint (8) Bolt (M12 × P1.25 × 45) ×4
Mass
(7) Swivel joint Approximately 14 kg
(6) Hydraulic hose
5. Attach a nylon sling and hoist the swivel joint for

support.
U30-6S 6-165

SERVICING
Installing
Tightening torque
78 to 90 N⋅m Thread lock
(3) Bolt

(8) Bolt
7.90 to 9.20 kgf⋅m (Loctite® 263)
6-166 U30-6S

SERVICING
4.6.2 Installing adapters for the swivel joint
Adapter Adapter
No. No.
(1) A G1/4-Quick coupler 30° (10) A G1/4-G1/4 60°
(2) B G3/8-G3/8 - (11) A G1/4-G1/4 60°
(3) C G3/8-G3/8 - (12) B G3/8-G3/8 60°
(4) D 3/4-16UN-G1/2 - (13) C G3/8-G3/8 60°
(5) E 3/4-16UN-G1/2 - (14) D G1/2-G1/2 15°
(6) F 3/4-16UN-G1/2 - (15) E G1/2-G1/2 15°
(7) G 3/4-16UN-G1/2 - (16) F G1/2-G1/2 -
(8) H G1/4-ϕ13 mm - (17) G G1/2-G1/2 -
(9) H G1/4-G1/4 - (18) H G1/4-ϕ14 mm -
- - - - (19) H G1/4-ϕ14 mm -
U30-6S 6-167

SERVICING
4.7 Pilot control valve

4.7.1 Removing and installing the pilot
control valve
CAUTION
IMPORTANT (3) Screw (4) Upper cover

and adapters to avoid oil leakage and dust 3. Disconnect the connector from the pilot control
contamination. lever LH.
4. Disconnect all of the hydraulic hoses from the pilot
Preparing control valve LH.
Removing
1. Remove the 2 screws and lower cover.
(5) Hydraulic hose
NOTE
5. Remove the 3 bolts and pilot control valve LH.
(1) Screw ×2 (2) Lower cover
2. Remove the screw and upper cover.

(6) Bolt ×3 (7) Pilot control valve LH
6. Remove the 5 clips and panel.
6-168 U30-6S

SERVICING
(8) Clip ×5 (9) Panel (14) Bolt ×3 (15) Pilot control valve RH
7. Remove the 2 screws and bolt. Installing

NOTE
• Make sure to connect the connector correctly.
(10) Bolt (M6 × 16) (12) Cover

(11) Screw ×2
8. Disconnect all of the connectors from the cover and

remove the cover.
9. Disconnect the connector from the pilot control
lever RH.
10. Disconnect all of the hydraulic hoses from the pilot
control valve RH.
(16) Port 2 (A) Front

(17) Port T
Adjusting dimension
(a) 509 mm
(13) Hydraulic hose
NOTE
11. Remove the 3 bolts and pilot control valve RH.
U30-6S 6-169

SERVICING
4.7.2 Pilot control valve components 3. Put a mark on the casing and pressure reducing
valves.
NOTE
• Make sure to install the pressure reducing
valves in the same locations.
(1) Seal ×4 (10) Spring

(2) Plug ×4 (11) Spring
(3) O-ring ×4 (12) Spool ×4
(4) Push rod ×4 (13) Adjusting nut
(5) Spring seat ×4 (14) Bellows
(6) Spring ×4 (15) Disc nut 4. Install the universal joint tightening jig 2 to the
(7) Seat ×4 (16) Universal joint universal joint.
(8) Spring (17) Plate
(9) Spring (18) Casing
4.7.3 Disassembling the pilot control valve

IMPORTANT
hydraulic devices.
to avoid fiber waste contamination. Use air (2) Universal joint (A) Universal joint tightening jig
pressure when cleaning the parts. 2
5. Remove the universal joint with the universal joint

Removing the pressure reducing valves
tightening jig 1.
1. Fasten the pilot control valve in a vice.
2. Remove the adjusting nut and disk nut. NOTE
• Loosen the universal joint slowly to avoid
the pressure reducing valves popping out.
(1) Adjusting nut
6-170 U30-6S

SERVICING
NOTE
• Put marks on each removed spring for
reassembly.
(B) Universal joint tightening jig

1
6. Remove the plate.
(3) Plate
(5) Spring (6) Pressure reducing valve as-
7. Remove the plug with a flat tip screwdriver. sembly
NOTE Disassembling the pressure reducing valves

• Hold the plug with a hand to avoid popping 1. Remove the spring seat.
out.
• Make sure not to damage the plugs. NOTE
• Press the spring seat to compress the
spring and slide to remove.
• Do not damage the spool.
• Do not compress the spring more than
6 mm.
(4) Plug
8. Remove the pressure reducing valve assemblies

and springs.
U30-6S 6-171

SERVICING
(7) Spring seat (10) Spool (4) Plug (13) Seal

(9) Seat (12) Push rod
2. Remove the push rod from the plug.
4.7.4 Assembling the pilot control valve

IMPORTANT
hydraulic devices.
(4) Plug (12) Push rod pressure when cleaning the parts.
(11) O-ring • Apply lubricant or grease to every seal to avoid
3. Remove the O-ring and seal from the plug.
NOTE Assembling the pressure reducing valves
• Do not damage the plug. 1. Assemble the seat, spring, and spring seat to the
spool in order.
IMPORTANT
• Do not compress the spring more than
6 mm.
6-172 U30-6S

SERVICING
(1) Spool (4) Spring seat (5) Plug (7) Push rod
(2) Seat (6) O-ring
(3) Spring
2. Install the O-ring to the plug. Installing the pressure reducing valves
1. Install the springs, pressure reducing valve
assemblies, and plugs to the casing in order.
NOTE
• Install each part to the same location.
(5) Plug (6) O-ring
3. Install the seal to the plug.

NOTE
• Apply hydraulic oil to the seal.
(9) Spring
• Install the seal in correct direction.
(5) Plug (8) Seal

(6) O-ring
(7) Push rod
4. Install the push rod to the plug.

NOTE
• Apply hydraulic oil to the plug.
U30-6S 6-173

SERVICING
(11) Universal joint (A) Universal joint tightening jig

1
Tightening torque
44.2 to 50.0 N⋅m
(11) Universal joint -
4.51 to 5.10 kgf⋅m
4. Install the disk nut.

NOTE
• Tighten the disk nut until the tips of the 4
push rods of the pressure reducing valves
touch evenly.
• Do not screw in the disc nut excessively to
2. Install the plate. avoid machine malfunction.
• Apply Loctite® 262 to the top threads of the
universal joint.
(10) Plate
3. Install the universal joint with the universal joint

(12) Disk nut
tightening jig 1.
5. Tighten the adjusting nut.
6-174 U30-6S

SERVICING
4.7.5 Installing adapters for the pilot

control valve
Pilot control valve LH
(13) Adjusting nut
Tightening torque
63.7 to 73.5 N⋅m
(13) Adjusting nut -
6.50 to 7.49 kgf⋅m
6. Grease the universal joint and push rods.
(A) Forward
Adapter
Port Adapter size Angle
No.
(1) 1 G1/4-Quick coupler -
(5) G1/4-G1/4 -
(6) G1/4-G1/4-G1/4 -
P
(7) G1/4-G1/4 -
(8) G1/4-Quick coupler 15°
(9) T G1/4-Quick coupler -
U30-6S 6-175

SERVICING
Pilot control valve RH IMPORTANT

contamination.
Preparing
Removing
1. Remove the 4 bolts and then the 2 pedals.
(A) Forward
Adapter
No.
(12) G1/4-G1/4 -
3
(15) G1/4-G1/4 -
(16) G1/4-G1/4-G1/4 -
P
(18) G1/4-Quick coupler 30°
(19) T G1/4-Quick coupler - (1) Bolt (M10 × 30) ×4 (2) Pedal ×2
2. Remove the 2 split pins, pin, and 2 washers, and

4.8 Travel control valve remove the damper LH from the travel control lever
4.8.1 Removing and installing the travel LH.
control valve
CAUTION
6-176 U30-6S

SERVICING
(4) Split pin ×2 (7) Damper RH

(5) Washer ×2
(6) Pin
4. Remove the 4 bolts and then the 2 travel control

levers.
(3) Damper LH (6) Pin

(4) Split pin ×2
(5) Washer ×2
3. Remove the 2 split pins, pin, and 2 washers, and

remove the damper RH from the travel control lever
RH. (8) Travel control lever ×2 (9) Bolt (M8 × 20) ×4
5. Remove the 4 bolts and bracket.
(10) Bracket (11) Bolt (M10 × 25) ×4
6. Disconnect all of the hydraulic hoses from the travel

control valve.
NOTE
U30-6S 6-177

SERVICING
Installing
Adjusting dimension
(a) 2.0 mm or less
(b) 11 to 22 mm
(12) Hydraulic hose (13) Travel control valve
7. Remove the 2 bolts and the travel control valve.
(11) Bolt (M10 × 25) ×2 (13) Travel control valve
6-178 U30-6S

SERVICING
4.8.2 Travel control valve components
(1) Boot ×2
3. Remove the 4 set bolts.

NOTE
• There are 2 set bolts installed in each thread
hole.
(1) Boot ×2 (16) Spool ×4

(2) Collar ×4 (17) Flat metal washer ×4
(3) Set bolt ×2 (18) Shim ×4
(4) Cam ×2 (19) Shim ×4
(5) Bolt ×2 (20) Spring ×4
(6) Cover ×2 (21) Spring ×4
(7) Pin ×2 (22) Sleeve ×4
(8) Plug (23) Collar ×4
(9) O-ring (24) Bolt ×4
(10) Pin ×4 (25) O-ring ×4
(11) Plug ×6 (26) Shim ×4
(12) O-ring ×6 (27) Shim ×4
(13) Seat ×3 (28) Pusher ×4
(14) Ball ×3 (29) Ball ×4
(15) Casing (30) O-ring ×4
(2) Set bolt ×4
4.8.3 Disassembling the travel control 4. Remove the 2 pins.

valve
IMPORTANT
hydraulic devices.
Removing the pressure reducing valves

(3) Pin ×2
1. Fasten the travel control valve in a vice.
2. Remove the 2 boots. 5. Remove the 2 cams.
U30-6S 6-179

SERVICING
(4) Cam ×2 (6) Cover (7) Pusher assembly ×4
6. Remove the 2 bolts. 9. Remove the 4 O-rings.
(5) Bolt (M10 × 25) ×2 (8) O-ring ×4
7. Remove the 2 covers. 10. Put marks on the casing and 4 spool assemblies.
NOTE
• Mark them so that the spools can be
installed to the same locations afterwards.
(6) Cover ×2
8. Remove the 4 pusher assemblies from each cover.

IMPORTANT
• Return the shim to the sleeve if it comes out 11. Remove the 4 spool assemblies and 4 springs from
with the pusher assembly. the casing.
6-180 U30-6S

SERVICING
(9) Casing (11) Spool assembly ×4 (14) Seat ×3

(10) Spring ×4
15. Remove the 3 balls.
12. Remove the 4 O-rings from the casing.
(15) Ball ×3
(12) O-ring ×4
13. Remove the 6 plugs. Disassembling the pressure reducing valves

1. Remove the shim.
(13) Plug ×6
(16) Shim
14. Remove the 3 seats.
2. Fasten the spool in a vice.
NOTE
• Do not tighten the spool in a vice
excessively to avoid damage or
deformation. Protect the spool with copper
plates.
U30-6S 6-181

SERVICING
NOTE
• Do not fasten the vice excessively.
2. Install the washer, shim, spring, sleeve, and collar
in order.
(17) Bolt
3. Remove the bolt from the spool.

4. Remove each part in order.
(1) Spool (2) Flat metal washer
(16) Shim (21) Shim

(17) Bolt (22) Flat metal washer
(18) Collar (23) Spool
(19) Sleeve
(20) Spring (3) Shim
4.8.4 Assembling the travel control valve

IMPORTANT
hydraulic devices.
to avoid fiber waste contamination. Use air (4) Spring
Assembling the pressure reducing valves

1. Fasten the spool in a vice.
6-182 U30-6S

SERVICING
(5) Sleeve (5) Sleeve (8) Shim
Installing the pressure reducing valves

1. Install the 3 balls in the casing.
(6) Collar
3. Install the bolt.

(9) Casing (10) Ball ×3
2. Install the 3 seats.
(7) Bolt
Tightening torque
(11) Seat ×3
(7) Bolt
0.50 kgf⋅m (Loctite® 242) Tightening torque
4. Install the shim. (11) Seat
NOTE
• Install as many shims as those removed. 3. Install the 6 plugs.
U30-6S 6-183

SERVICING
(12) Plug ×6 (14) Spring ×4 (15) Spool assembly ×4
7. Install 2 O-rings to each cover.

Tightening torque
24.5 N⋅m
(12) Plug -
2.50 kgf⋅m
4. Install the 4 O-rings.
(16) O-ring ×4 (17) Cover ×2
8. Install the 4 pusher assemblies.
(13) O-ring ×4
5. Install the 4 springs.
(18) Pusher assembly ×4
9. Install the 2 covers with the 2 bolts.
(14) Spring ×4
6. Install the 4 spool assemblies.

NOTE
• Install each spool to the location same as
before disassembly.
6-184 U30-6S

SERVICING
(17) Cover ×2 (19) Bolt (M10 × 25) ×2 (22) Set bolt ×4
Tightening torque Tightening torque

22.6 N⋅m 9.8 N⋅m
(19) Bolt - (22) Set bolt -
2.30 kgf⋅m 1.0 kgf⋅m
10. Grease the 4 balls of the 4 pusher assemblies. 13. Install the 2 boots.
(18) Pusher assembly ×4 (23) Boot ×2
11. Grease the 2 pins to install.
(20) Pin ×2 (21) Cam ×2
12. Install the 4 set bolts.

NOTE
• Install 2 set bolts to each thread hole.
U30-6S 6-185

SERVICING
4.8.5 Installing adapter layout for the travel IMPORTANT

control valve • Install plugs to the removed hydraulic hoses
contamination.
Preparing
Removing
1. Disconnect all of the connectors and hydraulic
hoses from the unload valve.
(1) Hydraulic hose (3) Unload valve

Adapter (2) Connector
No.
2. Remove the 2 bolts and unload valve.
1
(2) G1/4-G1/4 -
(3) G1/4-G1/4 -
2
(6) G1/4-G1/4 -
(7) 4 G1/4-G1/4 -

P
(10) G1/4-G1/4 -
(11) T G1/4-Quick coupler -

(3) Unload valve (4) Bolt (M10 × 16) ×2
4.9 Unload valve Installing

4.9.1 Removing and installing the unload Tightening torque
valve 39.2 to 45.1 N⋅m
(4) Bolt -
4.00 to 4.60 kgf⋅m
CAUTION
6-186 U30-6S

SERVICING
4.9.2 Unload valve components
(1) Solenoid (3) Push rod

(2) Bolt
2. Remove 2 O-rings.
(1) Valve housing (12) O-ring

(2) O-ring (13) Spring
(3) Spool (14) Plunger
(4) Spring (15) Spring × 2
(5) O-ring (16) Spool × 2
(6) Plug (17) O-ring × 2
(7) Cover (18) Cap × 2
(8) Bolt × 2 (19) Bolt × 4
(9) Screw (20) Plug × 3
(10) Nut (21) O-ring × 3
(11) Plug
(4) O-ring
4.9.3 Disassembling and assembling the 3. Remove 2 flanged plugs.

unload valve
IMPORTANT
• Do not reuse removed O-rings for assembling
to avoid oil leakage.
hydraulic devices.
pressure when cleaning the parts. (5) Flanged plug
• Apply lubricants or greases to every seal to
avoid damage when assembling. 4. Remove the spring and spool.
Disassembling
1. Remove 4 bolts and the solenoid.
NOTE
• Make sure not to drop the push rod.
U30-6S 6-187

SERVICING
(6) Spring (7) Spool (12) Plug
5. Remove the nut and adjusting screw. 8. Remove the O-ring.
(8) Adjusting screw (9) Nut (13) O-ring
6. Remove the bolts and the cover. 9. Remove the spring.
(10) Cover (11) Bolt (14) Spring
7. Remove the plug. 10. Remove the plunger.
6-188 U30-6S

SERVICING
Adapter
No.
(1) A G1/4-G1/4 -
(2) G3/8-G1/4-G1/4 -
(3) B G1/4-G1/4 -
(4) G1/4-G1/4 -
(5) G3/8-G3/8-G1/4 30°
(6) C G1/4-G1/4 -
(7) G1/4-G1/4 -
(8) P G1/4-G1/4 -
(15) Plunger (9) G3/8-G3/8 -
Assembling (10) T G3/8-G3/8 -
(11) G3/8-G1/2 15°

IMPORTANT
• When installing the solenoid to the body, set the (12) PAC G1/2-G3/8 45°
O-ring to the solenoid before installing.
• Grease the O-rings. 4.10 Multi valve
• Apply hydraulic oil to spools and plungers.
4.10.1 Removing and installing the multi
Tightening torque valve
26.5 N⋅m
(5) Flanged plug
2.7 kgf⋅m CAUTION
3.92 N⋅m • The hydraulic devices and oil are extremely hot.
(2) (11) Bolt -
0.4 kgf⋅m Handle with care before preparation,
15.7 N⋅m measurement, and restoration.
(9) Nut
1.6 kgf⋅m • Before disconnecting the hydraulic hoses,
4.9.4 Installing adapters for the unload IMPORTANT

valve • Install plugs to the removed hydraulic hoses
contamination.
Preparing
Removing
1. Disconnect the all of the hydraulic hoses from the
multi valve.
U30-6S 6-189

SERVICING
(1) Hydraulic hose (3) Multi valve

(2) Bolt (M10 × 25) ×3
2. Remove the 3 bolts and then the multi valve.

Installing
Tightening torque
48.1 to 55.9 N⋅m
(2) Bolt -
4.90 to 5.70 kgf⋅m
6-190 U30-6S

SERVICING
4.10.2 Multi valve components
(1) Bolt ×4 (5) Plug (9) Ball (13) Spring pin

(2) Cover (6) Sleeve (10) Spring (14) O-ring
(3) O-ring ×4 (7) Spring pin (11) O-ring (15) Cover
(4) Spindle (8) Body (12) Plug (16) Bolt ×4
U30-6S 6-191

SERVICING
4.10.3 Installing adapters for the multi IMPORTANT

valve • Install plugs to the removed hydraulic hoses
contamination.
Preparing
Removing
1. Disconnect the 2 clamps.
Adapter
No.
(1) L1 G1/4-G1/4 -
(2) L2 G1/4-G1/4 -
(3) L3 G1/4-G1/4 90°
(4) L4 G1/4-G1/4 90°
(5) R1 G1/4-G1/4 - (1) Clamp ×2 (4) Joint adapter

(2) Clamp (5) Third line valve
(6) R2 G1/4-G1/4 -
(3) Hydraulic hose
(7) R3 G1/4-G1/4 90°
2. Remove the clamp.
(8) R4 G1/4-G1/4 90° 3. Disconnect all of the hydraulic hoses from the third
(9) 1L G1/4-Quick coupler 30° line valve.
4. Disconnect the joint adapter, and remove the third
(10) 2L G1/4-Quick coupler 30° line valve.
(11) 3L G1/4-G1/4 90° Installing
(12) 3L G1/4-Quick coupler -
Tightening torque
(13) 4L G1/4-Quick coupler -
2.5 to 3.4 N⋅m
(14) 1R G1/4-Quick coupler 45° (1) Clamp -
0.25 to 0.35 kgf⋅m
(15) 2R G1/4-Quick coupler -
(16) 3R G1/4-Quick coupler 45°
(17) 4R G1/4-Quick coupler 90°
4.11 Third line valve

4.11.1 Removing and installing the third
line valve
CAUTION
6-192 U30-6S

SERVICING
4.11.2 Third line valve components 4.12 Hydraulic oil tank

hydraulic oil tank
CAUTION
IMPORTANT
contamination.
and charging.
(1) Lever (7) Pin ×2 Preparing

(2) Pin (8) O-ring 1. Swivel the upper structure 90° against the blade.
(3) Washer ×2 (9) O-ring 2. Remove the bonnet RH 1.
(4) O-ring (10) External circlip
(5) O-ring (11) Body
(6) Spool 4. Remove the swivel cover RH.
4.11.3 Installing adapters for the third line 7. Vacuum the hydraulic oil tank.
8. Remove the control valve.
valve 9. Remove the unload valve.
Removing
1. Remove the drain plug and drain all of the hydraulic
oil.
2. Remove the 2 cables from the hydraulic oil tank.
Adapter
No.
(1) G1/2-G1/2 -
A
(2) G1/2-G1/2 15° (1) Cable ×2
(3) G1/2-ϕ16 mm - 3. Disconnect all of the hydraulic hoses from the
(4) G1/2-G1/2 - hydraulic oil tank.
B
(5) G1/2-G1/2-G1/2 30°
(6) G1/2-ϕ16 mm -
(7) C G1/2-G1/2 -
U30-6S 6-193

SERVICING
(2) Hydraulic hose
4. Loosen the clamp and disconnect the suction hose.
(8) Bolt (M12 × P1.25 × 40) ×5 (9) Hydraulic oil tank
Mass
(3) Clamp (4) Suction hose
(9) Hydraulic oil tank Approximately 19 kg
5. Remove the 3 bolts and then the bracket.
Installing
Tightening torque
78 to 90 N⋅m Thread lock
(8) Bolt
(5) Bolt (M12 × 30) ×2 (7) Bracket

(6) Bolt (M12 × 60)
6. Attach a nylon sling, and hoist the hydraulic oil tank

for support.
7. Remove the 5 bolts and then the hydraulic oil tank.
6-194 U30-6S

SERVICING
4.12.2 Installing adapters for the hydraulic oil tank
Adapter Adapter
No. No.
(1) - G1/4-G1/4-G1/4 - (5) - G1/4-G1/4 60°
(2) - G1/4-ϕ13 mm - (6) - G1/2-G1/2 -
(3) - G1/4-G1/4-G1/4 - (7) - G1/4-G1/4-G1/4 45°
(4) - G1/4-G1/4 - - - - -
U30-6S 6-195

SERVICING
4.13 Hydraulic hose 4.13.2 Metal fittings of hydraulic hoses

4.13.1 Length description of hydraulic
hoses
(a) Length
(a) Straight type parallel pipe (f) ORS thread

thread (Male 30° seat) (g) R thread
(b) 45° type parallel pipe thread (h) C thread
(Male 30° seat) (i) 45° type CR4 thread (Male
(c) 90° type parallel pipe thread 30° seat)
(Male 30° seat) (j) 90° type CR9 thread (Male
(d) Quick hose coupling type 30° seat)
(e) UNS thread (k) Straight type CM thread
6-196 U30-6S

SERVICING
4.13.3 Delivery hose routing
(A) Hydraulic pump (B) Control valve (C/V)
Hose
No. Point of use Guard
Length Tape color Metal fittings LH Metal fittings RH
Hydraulic pump (P) -

(1) 2255 mm White G1/2 straight G1/2 straight -
C/V (P)
Hydraulic pump (P) -

(2) 2775 mm Green G3/8 straight G3/8 straight -
C/V (PPS2)
Hydraulic pump (PPS) -

(3) 2660 mm - G1/4 straight G1/4 straight -
C/V (PPS2)
Hydraulic pump (PLS) -

C/V (PLS)
U30-6S 6-197

SERVICING
4.13.4 Front hose routing
(A) Boom cylinder (B) Control valve (C/V)
6-198 U30-6S

SERVICING
Hose
C/V (A6) - Boom

(1) 1855 mm Green G3/8 straight G3/8 straight -
cylinder (bottom)
C/V (B6) - Boom

cylinder (rod)
2090 mm
(Canopy specifi-
cation)
(2) Yellow G3/8 straight G3/8 straight -
C/V (B6) - Boom
cylinder (rod)
2070 mm
(Cabin specifica-
tion)
C/V (A7) - Boom

(3) back side (arm 2135 mm Black G3/8 straight G3/8 straight -
cylinder rod side)
C/V (B7) - Boom

back side (arm
(4) 2135 mm Blue G3/8 straight G3/8 straight -
cylinder bottom
side)
C/V (A8) - Boom

(5) back side (bucket 2195 mm Red G3/8 straight G3/8 straight -
cylinder rod side)
C/V (B8) - Boom

back side (bucket
(6) 2195 mm White G3/8 straight G3/8 straight -
cylinder bottom
side)
C/V (B1) - Boom

(7) back side (AUX 2195 mm Pink G1/2 straight G1/2 straight -
LH side)
Third line valve

(A) - Boom back
(8) 2265 mm Brown G1/2 straight G1/2 straight -
side (AUX RH
side)
Boom back side -

(9) 780 mm - G1/2 straight G1/2 straight Spring
Stop valve
Boom back side -

(10) Bucket cylinder 815 mm - G3/8 straight G3/8 straight -
(bottom)
Boom back side -

(11) Bucket cylinder 1070 mm - G3/8 straight G3/8 straight -
(rod)
Boom back side -

Arm cylinder (rod)
Boom back side -

(13) Arm cylinder (bot- 800 mm - G1/2 straight G1/2 straight -
tom)
U30-6S 6-199

SERVICING
4.13.5 Swivel and swing hoses routing
(A) Control valve (C/V) (B) Swivel motor (C) Swivel joint (S/J) (D) Swing cylinder
Hose
(1) C/V (B5) - S/J (D) 580 mm Blue G1/2 straight G1/2 90° -
(2) C/V (A5) - S/J (F) 770 mm Red G1/2 straight G1/2 90° -
(3) C/V (B4) - S/J (E) 610 mm Green G1/2 straight G1/2 90° -
(4) C/V (A4) - S/J (G) 840 mm Yellow G1/2 straight G1/2 90° -
(5) C/V (B9) - Swivel motor (B) 780 mm Gray G3/8 straight G3/8 straight -
(6) C/V (A9) - Swivel motor (A) 800 mm Light blue G3/8 straight G3/8 straight -
(7) C/V (A3) - S/J (C) 820 mm Pink G3/8 straight G3/8 45° -
(8) C/V (B3) - S/J (B) 800 mm Brown G3/8 straight G3/8 45° -
C/V (B2) - Swing cylinder

(9) 430 mm Light green G1/4 straight G1/4 90° -
(bottom)
C/V (A2) - Swing cylinder

(10) 840 mm Orange G1/4 straight G1/4 straight -
(rod)
(11) C/V (PPS3) - C/V (Psw) 270 mm - G1/4 straight G1/4 90° -
6-200 U30-6S

SERVICING
4.13.6 Travel and blade hoses routing
(A) Blade cylinder (C) Travel motor LH (E) Blade joint RH

(B) Swivel joint (S/J) (D) Travel motor RH (F) Blade joint LH
Hose
(1) S/J (D) - Travel motor LH (P1) 890 mm White G1/2 straight G1/2 straight -
(2) S/J (E) - Travel motor RH (P2) 890 mm White G1/2 straight G1/2 straight -
(3) S/J (F) - Travel motor LH (P2) 930 mm - G1/2 straight G1/2 straight -
(4) S/J (G) - Travel motor RH (P1) 930 mm - G1/2 straight G1/2 straight -
(5) S/J (A) - Travel motor LH (Ps) 1060 mm - G1/4 straight G1/4 90° -
(6) S/J (A) - Travel motor RH (Ps) 1060 mm - G1/4 straight G1/4 90° -
S/J (H) - Travel motor LH

(7) 910 mm - - - -
(Dr2)
S/J (H) - Travel motor RH

(8) 910 mm - - - -
(Dr1)
(9) S/J (C) - Blade joint RH 290 mm - G3/8 straight G3/8 straight -
(10) S/J (B) - Blade joint LH 290 mm - G3/8 straight G3/8 straight -
Blade joint RH - Blade cylinder

(rod)
Blade joint LH - Blade cylinder

(bottom)
U30-6S 6-201

SERVICING
4.13.7 Drain hose routing
(A) Hydraulic oil cooler (C) Hydraulic oil tank (E) Swivel motor
(B) Control valve (C/V) (D) Third line valve (F) Swivel joint (S/J)
Hose
(1) C/V (T2) - Swivel motor (M) 420 mm - - - -
(2) C/V (T2) - Third line valve 270 mm - - - -
Third line valve - Hydraulic oil

(3) 1200 mm - - - -
cooler
Hydraulic oil tank - Hydraulic

(4) 250 mm - - - -
oil cooler
Swivel motor (Dr) - Hydraulic

(5) 450 mm - - - -
oil tank
(6) S/J (H) - Hydraulic oil tank 590 mm - - - -
6-202 U30-6S

SERVICING
4.13.8 Pilot hose routing (delivery, drain)
(A) Hydraulic pump (C) Pilot filter (E) Swivel motor (G) Hydraulic lock cylinder
(B) Control valve (C/V) (D) Swivel joint (S/J) (F) Unload valve
Hose
Unload valve (B) - Hydraulic

(1) 610 mm - G1/4 straight G1/4 90° -
lock cylinder
Hydraulic pump (Pp) - Pilot

(2) 570 mm Yellow G3/8 straight G3/8 straight -
filter
(3) Pilot filter - Unload valve (C) 1390 mm - G3/8 straight G3/8 straight -
(4) Unload valve (P) - C/V (PAI) 340 mm - G1/4 90° G1/4 straight -
Unload valve (B) - Swivel

motor (P)
(6) Unload valve (A) - S/J (A) 2420 mm - G1/4 straight Quick coupler -
U30-6S 6-203

SERVICING
(E) Swivel motor (H) Pilot control valve LH (K) Travel control valve
(F) Unload valve (J) Pilot control valve RH
Hose
Pilot control valve LH (P) -

(7) 1470 mm - Quick coupler G1/4 90° -
Swivel motor
Pilot control valve RH (P) -

Pilot control valve LH (P)
Pilot control valve RH (P) -

Unload valve (C)
Travel control valve (P) -

Swivel motor
6-204 U30-6S

SERVICING
(B) Control valve (C/V) (H) Pilot control valve LH (K) Travel control valve
(F) Unload valve (J) Pilot control valve RH (L) Hydraulic oil tank
Hose
Pilot control valve LH (T) - White

(11) 3430 mm Quick coupler G1/4 90° -
Hydraulic oil tank White
Pilot control valve RH (T) -

Hydraulic oil tank
Travel control valve (T) -Hy-

(13) 1780 mm - Quick coupler G1/4 straight -
draulic oil tank
C/V (DR1g) - Hydraulic oil

(14) 310 mm - G1/4 straight G1/4 90° -
tank
Unload valve (T) - Hydraulic

(15) 435 mm - G1/2 90° G1/2 straight -
oil tank
U30-6S 6-205

SERVICING
4.13.9 Pilot hose routing (operation)
(A) Control valve (C/V) (B) Pilot control valve RH (C) Pilot control valve LH (D) Multi valve
6-206 U30-6S

SERVICING
Hose
C/V (Pb6) - C/V

(Pi)
C/V (Pi) - Multi

(2) 1800 mm White G1/4 straight Quick coupler -
valve (4R)
Multi valve (2R) -

(3) 1660 mm Green Quick coupler G1/4 90° -
C/V (Pa6)
Multi valve (1L) -

(4) 1660 mm Black Quick coupler G1/4 90° -
C/V (Pa7)
Multi valve (3L) - White

(5) 1540 mm Quick coupler G1/4 straight -
C/V (Pb7) Blue
Multi valve (3R) -

(6) 1700 mm Red Quick coupler G1/4 90° -
C/V (Pa8)
Multi valve (1R) -

(7) 1460 mm White Quick coupler G1/4 straight -
C/V (Pb8)
Multi valve (2L) -

(8) 1400 mm Gray Quick coupler G1/4 straight -
C/V (Pb9)
Multi valve (4L) - White

(9) 1650 mm Quick coupler G1/4 straight -
C/V (Pa9) Light blue
Pilot control valve

(10) RH (4) - Multi 1550 mm Green Quick coupler G1/4 90° -
valve (R2)
Pilot control valve

(11) RH (2) - Multi 1590 mm Yellow Quick coupler G1/4 90° -
valve (R4)
Pilot control valve

Black
(12) LH (2) - Multi 2320 mm Quick coupler G1/4 90° -
White
valve (L4)
Pilot control valve

Blue
(13) LH (4) - Multi 2140 mm Quick coupler G1/4 straight -
White
valve (L2)
Pilot control valve

(14) RH (3) - Multi 1560 mm Red Quick coupler G1/4 45° -
valve (R3)
Pilot control valve

(15) RH (1) - Multi 1590 mm White Quick coupler G1/4 45° -
valve (R1)
Pilot control valve

Gray
White
valve (L1)
Pilot control valve

Light blue
White
valve (L3)
U30-6S 6-207

SERVICING
(A) Control valve (C/V) (E) Travel control valve
Hose
Travel control
(18) valve (4) - C/V 1540 mm Blue Quick coupler G1/4 90° -
(Pb5)
Travel control
(19) valve (3) - C/V 1570 mm Red Quick coupler G1/4 90° -
(Pa5)
Travel control
(20) valve (2) - C/V 1540 mm Green Quick coupler G1/4 90° -
(Pb4)
Travel control
(21) valve (1) - C/V 1530 mm Yellow Quick coupler G1/4 90° -
(Pa4)
6-208 U30-6S

7. ELECTRICAL SYSTEM

MECHANISM
1. Electrical device 7. ELECTRICAL SYSTEM
MECHANISM
1. Electrical device
1.1 Electrical device layout
(1) Work light (boom) (2) Work light (cabin) (3) Horn (4) Wiper motor
U30-6S 7-1

MECHANISM
7. ELECTRICAL SYSTEM 1. Electrical device
(5) Cigarette socket (8) Fuel level sensor (11) AI motor

(6) Fuse and relay box (9) Lever lock switch (12) Meter panel
(7) Main ECU (10) Governor sensor (13) Starter switch
7-2 U30-6S

MECHANISM
(14) Travel speed shift solenoid (16) AI pressure switch (18) Battery (19) Hydraulic oil temperature sen-
(15) Lever lock solenoid (17) Slow blow fuse box sor
* For more information about the engine sensor positions, see 5-1.
U30-6S 7-3

MECHANISM
1.2 Switch layout
(1) Horn switch (3) Starter switch (5) Wiper switch (7) AI switch
(2) Travel speed shift switch (4) Air conditioning switch (6) Accelerator dial (8) Work light switch
7-4 U30-6S

MECHANISM
1.3 Fuse and relay layout
(1) Fuse and relay box
Labels on the fuse and relay box (canopy specification)
U30-6S 7-5

MECHANISM
Labels on the fuse and relay box (cabin specification)
7-6 U30-6S

MECHANISM
1.4 Slow blow fuse layout 1.5 Communication port layout

(1) Slow blow fuse box
Labels on the slow blow fuse box (canopy (1) Diagnostic connector
specification) Cabin specification
(2) Diagnostic connector

Labels on the slow blow fuse box (cabin
specification) NOTE
• Diagnostic connector cannot be used for this
machine.
1.6 Ground wiring layout
(1) Ground wiring 1
U30-6S 7-7

MECHANISM
(2) Ground wiring 2
(3) Ground wiring 3
7-8 U30-6S

MECHANISM
2. Functional electrical circuit 7. ELECTRICAL SYSTEM
2. Functional electrical circuit
2.1 Power supply electrical circuit diagram

U30-6S 7-9

MECHANISM
7. ELECTRICAL SYSTEM 2. Functional electrical circuit
Cabin specification
• The ground terminal of the battery is grounded to the machine body.

• When the STARTER SW is in the [STOP] position, the electrical current from the positive terminal flows to the
SBF, FUSE, RELAY, STARTER SW, ECU (MAIN), METER PANEL, METER BUZZER, STARTER, and
ALTERNATOR.
• When the engine is stopped, the battery supplies approximately 12.0 V of electricity.
• When the engine is running, the alternator supplies approximately 14.5 V of electricity.
• The alternator supplies power to the battery and all electrical devices.
7-10 U30-6S

MECHANISM
2.2 Accessory electrical circuit diagram
• When the STARTER SW is turned to [RUN], the terminals #1 and #3 become connected inside the STARTER
SW.
• The electrical current from the STARTER SW flows to each device through the fuses.
• The devices become active.
U30-6S 7-11

MECHANISM
2.3 Battery charge electrical circuit diagram
• When the STARTER SW is in [RUN] position, the electrical current from the STARTER SW #1 flows to the IG
terminal of the ALTERNATOR.
• The battery is charged by the electrical current from the B terminal of the ALTERNATOR.
• The ALTERNATOR sends signal to the METER PANEL to turn off the charge lamp.
7-12 U30-6S

MECHANISM
2.4 Engine start electrical circuit diagram
• When the STARTER SW is turned to [RUN], the terminals #1 and #3 become connected inside the STARTER
SW.
• The electrical current from the STARTER SW flows to the ECU (MAIN), RELAY [STARTER], and RELAY [GLOW]
via the FUSE [ECU (AC)].
• The electrical current from the RELAY [GLOW] flows to the glow plug, and the glow plug generates heat.
• When the STARTER SW is turned to [START], the terminals #2 and #3 become connected inside the STARTER
SW, and a signal is sent from the STARTER SW to the RELAY [STARTER].
• The RELAY [STARTER] becomes magnetized to flow the electrical current from the battery to the STARTER
MOTOR.
• The STARTER MOTOR rotates to crank the engine.
U30-6S 7-13

MECHANISM
2.5 Engine stop electrical circuit diagram
• While the engine is running, a current flows from the ECU (MAIN) to the RELAY [ENGINE STOP], and the RELAY
[ENGINE STOP] is magnetized.
• When the STARTER SW is in [STOP] position, the electrical current from the STARTER SW terminal #1 does not
flows to the ECU (MAIN) via the FUSE [ECU (AC)].
• No current flows from the ECU (MAIN) to the RELAY [ENGINE STOP], and the RELAY [ENGINE STOP] is not
magnetized.
• The current from the battery will not flow to the ENGINE STOP SOL, and the fuel is cut off and the engine stops.
7-14 U30-6S

MECHANISM
2.6 Lever lock electrical circuit diagram
• When the STARTER SW is in the [RUN] position, the electrical current from the STARTER SW #1 flows to the
LEVER LOCK SW via the FUSE [LEVER LOCK].
• When the lever lock is lowered, the electrical current from the LEVER LOCK SW flows to the LEVER LOCK SOL.
U30-6S 7-15

MECHANISM
2.7 Travel speed shift electrical circuit diagram
• When the STARTER SW is in [RUN] position, the electrical current from the STARTER SW #1 flows to the ECU
(MAIN) via the FUSE [ECU (AC)].
• When the TRAVEL SPEED SW is pressed, the electrical current from the TRAVEL SPEED SW flows to the ECU
(MAIN).
• The electrical current from the ECU (MAIN) flows to the TRAVEL SPEED SOL.
• The ECU (MAIN) sends a signal to the METER PANEL via the CAN communication line.
• The METER PANEL turns on the speed shift lamp.
7-16 U30-6S

MECHANISM
2.8 Work light electrical circuit diagram
• When the STARTER SW is in the [RUN] position, the electrical current from the STARTER SW #1 flows into the
WORK LIGHT SW via the FUSE [RELAY].
• When the WORK LIGHT SW is pressed, the electrical current from the WORK LIGHT SW flows to the RELAY
[WORK LAMP]. The RELAY [WORK LAMP] becomes magnetized.
• The electrical current from the BATTERY flows into the WORK LIGHT via the RELAY [WORK LAMP] and turns
on the WORK LIGHT.
U30-6S 7-17

MECHANISM
2.9 AI electrical circuit diagram
• When the STARTER SW is in the [RUN] position, the electrical current from the STARTER SW #1 flows to the
ECU (MAIN).
• When the AI SW is turned ON, the AI SW sends a signal to the ECU (MAIN).
• The AI PRESSURE SW detects the hydraulic pressure and sends a signal to the ECU (MAIN).
• The AI PRESSURE SW is the contact type, and thus it turns on and off when the AI signal circuit pressure
changes.
• The ECU (MAIN) receives the signal from the AI PRESSURE SW, drive the AI MOTOR according to the state of
the machine.
• When the machine is not operated, the pressure in the AI signal circuit remains low, the AI PRESSURE SW
makes contact, and a signal is sent to the ECU (MAIN) to reduce the engine speed.
• When the machine is operated, the pressure of the AI signal circuit rises, the AI PRESSURE SW breaks contact,
and the ECU (MAIN) does not receive the signal, so the engine speed does not change.
7-18 U30-6S

MECHANISM
2.10 Wiper and washer motors electrical circuit diagram
• When the STARTER SW is in the [RUN] position, the electrical current from the STARTER SW #1 flows into the
RELAY [POWER] via the FUSE [RELAY].
• The electrical current from the FUSE [WIPER / WASHER] flows to the WIPER SW and WIPER MOTOR.
• When the WIPER SW is pressed, the switch flows an electrical current to the WASHER MOTOR or WIPER
MOTOR to rotate them.
U30-6S 7-19

MECHANISM
2.11 Beacon electrical circuit diagram
• When the STARTER SW is turned to [RUN], the terminal #1 and #3 become connected inside of the STARTER
SW.
• The electrical current from the STARTER SW #1 flows to the BEACON SW via the FUSE [RELAY].
• When BEACON SW is turned on, the RELAY [BEACON] becomes magnetized, current flows from the BATTERY,
and the BEACON operates.
7-20 U30-6S

MECHANISM
3. Meter panel 7. ELECTRICAL SYSTEM
3. Meter panel
3.1 Meter panel function
(A) General display (B) Switch operation
General display
No. Name Function
(1) User setting switch (SW1) -
(2) Overload warning switch (SW2) -
(3) Arm limit switch (SW3) -
(4) Information switch (SW4) -
(5) Display switch (SW5) -
(6) Clock -
(7) Coolant temperature gauge -
(8) Hour meter / Engine speed meter -
(9) Fuel gauge -
Lit - error occurred

(10) Warning lamp
Blinking - hydraulic oil temperature is high
(11) Engine oil pressure lamp Lit - engine oil pressure is low
(12) Charging lamp Lit - charging system error occurred
(13) Travel speed shift lamp Lit - travel speed shift is activated
Switch operation
Name Function
(1) Back Returns to a previous display
(2) Down ▽ Moves the cursor down / decreases a number
(3) Up △ Moves the cursor up / increases a number
(4) Advance Moves the cursor forward
(5) Set / Select Sets a number / selects an item
U30-6S 7-21

MECHANISM
7. ELECTRICAL SYSTEM 3. Meter panel
3.2 Display mode

Mode Operation Display Remarks
Clock / Coolant temperature

- Always displayed.
gauge / Fuel gauge
Starter switch SW5 Hour meter → Engine speed -
Normal mode
[RUN]
SW2 Overload warning mode Overload warning specification only.
SW3 AUX mode Proportional AUX specification only.
Checks operated hours in recent

Operation management
3 months.
Periodic check Manages the periodic check.

Starter switch Clock setting Sets the clock.
User setting mode SW1
[RUN]
AUX flow rate setting Proportional AUX specification only.
Calender and clock setting -
Language setting -
Enables or disables crane function.

Crane function
Turn the starter switch to [RUN] Enables or disables overload warn-
Hidden user setting mode Overload warning function
while pressing SW1 ing function.
Arm limitation changing Enables or disables arm limitation.
Conducts various diagnoses for the

Diagnosis
Turn the starter switch to [RUN] machine.
Service dealer mode
while pressing SW5 Conducts various settings for the
Settings
machine.
Turn the starter switch to [RUN] Conducts various settings for anti-
Anti-theft special setting -
while pressing SW1 and SW5 theft function.
Insert the red key while the starter

Black key registration - -
switch is [STOP]
Starter switch
Fuel tank full alert SW1 or 5 - -
[STOP]
3.3 User setting mode

3.3.1 Confirming operation management
Operated hours can be checked up to 3 months ago.
2. Press SW1 to go into the user setting mode.
3. Press SW2 and SW3 to select “Log Record”, and
then press SW5.
4. Press SW2, SW3, and SW4 to select a date which
you want to confirm. Operation time is displayed on
the upper right of the screen.
(1) Operated days (black-white (3) Operated hours for the se-
inverted) lected date
(2) Non-operated days
7-22 U30-6S

MECHANISM
5. Press SW5 to display the operation hour of the

month with a bar graph.
Confirming periodic check information

(3) Operated hours for the se- (5) Days
lected date 2. Press SW1 to go into the user setting mode.
(4) Selected date 3. Press SW2 and SW3 to select “Periodic Check”.
4. Press SW5 to go into the periodic check.
5. Press SW2 and SW3 to select the periodic check
3.3.2 Operating the periodic check mode item which is displayed as an alert.
Periodic check information can be confirmed. After NOTE

confirmation, reset of a periodic check alert is required. • Remaining time is calculated by "next
Informing of periodic check alert periodic check times", "actual time on the
• The machine informs about periodic check meter", and "memorized offset time in the
according to the configured operation time (hour ECU".
meter).
• “Periodic Check Soon” is displayed, yellow lamp
blinks, and a beep sounds 10 hours before the
periodic check.
• Press SW4 to confirm the periodic check item.
(1) Remaining time
Clearing the periodic check alert

• After checking the machine, clear the periodic
check alert.
1. Press SW4 to fill a check box on the upper left of
the screen of the meter panel to select a required
check item.
NOTE
• In the case that “Setting” / “Others” /
“Periodic Check Selection” is “Auto”
(clearing periodic check alert is auto),
– Turn the starter switch repeatedly to
[RUN] and [STOP] 10 times to clear
periodic check alert automatically.
U30-6S 7-23

MECHANISM
• In the case that “Setting” / “Others” /

“Periodic Check Selection” is “Manual”
(clearing periodic check alert is manual),
– Since SW4 is disabled, a check mark
cannot be applied.
– Turn the work light switch from OFF to
ON 1 time to enable SW4.
• SW4 and SW5 are not enabled until
remaining time becomes less than 10 hours.
(1) Remaining time (exceeded

20 hours)
Alternative settings for periodic check

• There are 3 settings for periodic check in the
service dealer mode.
1. Clearing the periodic check alert (“Periodic
Check Selection”)
Select “Auto” or “Manual”.
• “Auto”: Turn the starter switch repeatedly to
2. Press SW5 to display the confirmation screen. [RUN] and [STOP] 10 times.
3. Press SW5 to complete. Press SW1 to return to the • “Manual”: Clear the periodic check alert
previous screen. manually.
2. Informing of the periodic check alert (“Periodic
Check Display”)
Select whether to inform of the periodic check alert.
• “On” (display): Informs of the periodic check by
blinking the lamp and beeping buzzer.
• “Off” (does not display): Does not inform of the
periodic check as alert.
3. Informing of the annual check alert (“Annual
Guidance”)
• “On” (display): Informs of the annual check by
blinking the lamp and beeping buzzer.
• “Off” (does not display): Does not inform of the
annual check as alert.
4. Time offset for periodic check (“Periodic Check
Set”)
In the case that checking period is exceeded This setting corrects time offset between the hour
• A black triangle is displayed on the left of the hour meter and periodic check hour.
indication. Input the hour meter time of the old ECU after
replacing the ECU.
3.3.3 Operating clock setting mode

Sets a date and time.
3. Press SW2 and SW3 to select “Clock Set”.
4. Set the clock by pressing SW2, SW3, and SW4.
7-24 U30-6S

MECHANISM
5. Press SW5 to complete the clock setting. 3.3.5 Operating the various setting mode
(calender and clock setting)
Indication settings of a calendar and a clock can be
configured.
3. Press SW2 and SW3 to select “Various Settings”,
and then select “Calendar”.
4. Press SW5 to go into the select item.
5. Press SW2 and SW3 to select a date and time
indication formats.
6. Press SW5 to complete the date indication setting.
3.3.4 Operating the AUX flow rate setting

mode
A user can select up to 5 AUX icons to be used, and
set their flow rates individually. Only used for the
proportional AUX specification.
2. Press SW1 to enter the user setting mode.
3. Press SW2 and SW3 to select “AUX Flow Ctrl
Set”.
4. Press SW2, SW3, and SW4 to select an icon to be
used, set it to a slot (icon 1 to icon 5), and set its Default setting
flow rate (if AUX LH and/or RH switch is equipped,
press left/right to configure your setting). Region Setting
5. Press SW5 to go on to the next icon. North America

Australia
6. Press SW1 to complete the AUX flow rate setting. mm/dd/yyyy 12 h
Japan
Others
NOTE
• Icons 1 and 2 are predetermined by default. Europe
dd/mm/yyyy 24 h
Asia
3.3.6 Operating the language setting mode

Select a language for the meter panel.
3. Press SW2 and SW3 to select “Language
Settings”.
4. Press SW2 and SW3 to select a language.
(1) Icon (2) Setting cursor (arrow mark)
U30-6S 7-25

MECHANISM
5. Press SW5 to complete the language setting. 2. Press SW2 and SW3 to select “Arm control mode”,
and press SW5.
3. Press SW2 and SW3 to select “On” (activate) or
“Off” (deactivate).
4. Press SW5 to complete the arm limitation function
setting.
NOTE
• Make sure to check the specification for
each machine.
3.4 Hidden user setting mode

Consists of 2 settings: “Crane mode” and “Arm control
mode”. Turn the starter switch to [RUN] while pressing
SW1 to go into hidden user setting mode.
3.4.1 Operating the crane function setting
Selects to enable or disable the crane function and the
overload warning function.
1. Turn the starter switch to [RUN] while pressing
SW1 to go into the hidden user setting mode.
2. Press SW2 and SW3 to select “Crane mode”, and
press SW5.
3. Press SW2 and SW3 to select “On” (enable) or
“Off” (disable).
4. Press SW5 to complete the crane mode setting.
NOTE
• Default setting is different for each
destination and machine. Make sure to
check the specification for each machine.
3.4.2 Operating the arm limitation function

setting
Selects to enable or disable the arm limitation function.
SW1 to go into the hidden user setting mode.
7-26 U30-6S

MECHANISM
3.5 Service dealer mode

3.5.1 Operating service dealer mode
SW5.
3. Press SW5 to confirm the language setting.
4. Press SW2 and SW3 to select “Diagnosis” or
“Setting”.
5. Turn the starter switch to [STOP] or press SW1 to
exit the service dealer mode.
U30-6S 7-27

MECHANISM
3.5.2 Service dealer mode list

The service dealer mode is used for maintenance such as checking the machine condition, setting parameters, and
adjusting the devices. Turn the starter switch to [RUN] while pressing SW3 to enter the service dealer mode.
IMPORTANT
• It is necessary to set all items after replacing the main ECU.
NOTE
• “Setting” / “AUX1 Set” and “AUX2/Thumb Set” are only used for proportional AUX specification.
• “Setting” / “AS set” is only used for RX series machine.
• “Setting” / “Crane set” is only used for crane specification.
• “Setting” / “Over Load warning” is only used for overload alarm specification.
• “Setting” / “AI Motor Drive” is only used for mechanical governor engine.
• Turn the starter switch to [STOP] to exit the service dealer mode.
Mode Detail Notes
Displays the machine information, and status of sensors

Tester mode -
and solenoids.
Diagnosis Displays the previous error code and hour meter from
Reading error history -
memory.
Clearing error history Clears error history. -
Performs auto idle setting.

• Required setting when the auto idle system is not
AI setting operating properly. -
• Required setting after repairing or replacing the AI
motor, accelerator dial, or governor sensor.
Sets the left and right ends and neutral for the AUX1
AUX1 Knob switch knob switch.
setting • Required setting after replacing the AUX knob
switch.
Sets the start-up point of the AUX with an attachment.

AUX1 Start-up point
• Required setting after replacing an attachment or
setting (with attach-
cylinder.
ment) Proportional con-
AUX1 setting • Required setting after repairing a hydraulic device.
trol AUX spec.
Sets the start-up point of the AUX without an attach-
AUX start-up point ment.
setting (without at- • Required setting after replacing an attachment or
tachment) cylinder.
• Required setting after repairing a hydraulic device.
Settings
Fine setting for the start-up point of the actuator (cylin-
AUX fine setting
der) attached to AUX.
Sets the left and right ends and neutral for the AUX2
AUX2 Knob switch knob switch.
setting • Required setting after replacing the AUX knob
switch.
Sets the start-up point of the AUX with an attachment.

AUX start-up point
• Required setting after replacing an attachment or
setting (with attach-
cylinder.
ment) Proportional AUX
AUX2/thumb settings • Required setting after repairing a hydraulic device.
spec.
Sets the start-up point of the AUX without an attach-
AUX start-up point ment.
setting (without at- • Required setting after replacing an attachment or
tachment) cylinder.
• Required setting after repairing a hydraulic device.
Fine setting for the start-up point of the actuator (cylin-

AUX fine setting
der) attached to AUX.
(Continued)
7-28 U30-6S

MECHANISM
Mode Detail Notes
Performs potentiometer settings.

• Required setting when the front avoidance function
Front angle setting is not operating properly.
• Required setting after repairing or replacing boom,
arm or offset potentiometers.
Sets the start-up point of the AS proportional valve.

• Required setting when the front avoidance function
Start-up point settings is not operating properly.
• Required setting after repairing or replacing the AS
AS settings proportional valve or control valve. RX Series
Sets the cushion feeling on the cylinder end.
• Required setting when shock on the stroke end is
Cushion settings large.
• Required setting after repairing or replacing the AS
proportional valve or control valve.
Sets the clearance between the right side of the opera-

tor's seat and the bucket.
Bucket width setting
• Required setting after mounting the wide bucket or
big attachment.
Performs potentiometer settings.

Front angle setting • Required setting after repairing or replacing the
Crane settings boom or arm potentiometers. Crane spec.
Sets the maximum engine speed during the crane
MAX rotation setting
mode.
Overload warning
Overload alarm setting Sets the pressure for an overload alarm.
spec.
Individual setting for the machine.

Model setting • Required setting after replacing the ECU or meter -
panel.
Settings
Only for mechani-
A setting to move the AI motor's lever position when re-
AI motor drive cal governor en-
placing the accelerator cable.
gine
Exchanging the
switch operations for Exchanges functions of RH and LH switches, which con- Proportional con-
AUX1 and AUX2/ trol AUX1 and 2 by default. trol AUX spec.
thumb
Clearing periodic
Select a clearing method of the periodic check alert. -
check alert
Informing of periodic Select whether to inform or not when scheduled time for
-
check alert (ON/OFF) the periodic check comes.
Informing of annual Select whether to inform or not when scheduled time for
-
check alert (ON/OFF) the annual check comes.
Other
Time offset of periodic Time offset between hour meter and periodic check
-
check hour.
Select whether to display the clock setting alert when

Clock setting alert -
the clock is offset.
Arm limitation fine ad- Fine adjustment of the stop position which is set for the Arm limitation
justment arm limitation function. spec.
Multipurpose function Sets the operations of the multipurpose switch. -
Displays the previous error code and hour meter from

Reading all error his- memory.
-
tory • The whole error history remains even after clearing
the error history manually.
Opening screen set-

Select the opening display screen. -
ting
U30-6S 7-29

MECHANISM
3.5.3 Operating the tester mode

Displays the machine information, and status of sensors and solenoids.
Operating tester mode
1. Turn the starter switch to [RUN] while pressing SW5.
3. Press SW2 and SW3 to select “Diagnosis”, and press SW5.
4. Press SW2 and SW3 to select “Tester”, and press SW5 to go into tester mode.
5. Press SW2 and SW3 to select an item you want to check.
6. Turn the starter switch to [STOP] to exit the service dealer mode, or press SW1 to exit the tester mode.
Tester mode item list
No. Display Content displayed Description Remarks
Engine speed • Present value (engine speed) -
Battery voltage • Battery voltage ±0.5 V -
Oil switch • Engine stopped: ON -

1
Charging switch • Engine running: OFF -
• Starter switch [START]: ON

Starter switch -
• Starter switch [RUN] or [STOP]: OFF
CRS engine voltage

Coolant temperature • Present value (V): 4.38 to 0.91
(V) is a dummy data
2 • Present value (V)

Fuel -
• Present value (Ω)
Fuel supply switch • Switch pressed: ON For EU spec. only
Travel speed shift switch • Switch pressed: ON -
Travel speed shift sole- • With output signal from main ECU: ON
-
noid • No output signal from main ECU: OFF
• Lever down: ON
Lever lock switch -
• Lever up: OFF
3
• With output signal from main ECU: ON
Lever lock solenoid -
• No output signal from main ECU: OFF
• More than 104 ℃ (219 ℉): hydraulic oil

Hydraulic oil temperature overheating warning
-
sensor • Less than -1 ℃ (30 ℉): hydraulic oil warm-
ing up warning (yellow lamp blinking)
• Present value: 0.25 to 4.75 V

Accelerator potentiometer -
• Setting value: MIN/MAX
• Present value: 0.25 to 4.75 V Values for the CRS

4 Governor potentiometer
• Setting value: MIN/MAX engine and electronic
• AI motor in operation: 0.0 to 15.0 A governor engine are
Motor amperage dummy data
• AI motor hold: 0.0 to 2.0 A
• Not operating: ON
AI pressure switch -
• Operating: OFF
• Switch pressed: ON
AI control switch -
5 • Switch released: OFF
Compressor • Operating: ON -
Coolant temperature • Present value (℃) -

(Continued)
7-30 U30-6S

MECHANISM
Values for the CRS

engine and electronic
5 Idle up • Idle up setting value (V)
governor engine are
dummy data

AUX1 • Setting value: left or right
• Setting value: neutral
Hand proportional
6 • Operating: 0.5 to 2.0 A
AUX current AUXspec.
• Stopped: 0 to 0.2 A
AUX hold switch
• Switch released: OFF

Hand proportional
AUX current AUX2 spec.
AUX hold switch
AUX1 right setting
AUX1 left setting Hand proportional

8 • AUX start point set value
AUX2 right setting AUXspec.
AUX2 left setting
Arm potentiometer • Present value: 0.25 to 4.75 V
Arm limit set value • Arm stop setting value

9 Arm limit spec.
Multipurpose solenoid
• Antenna working normally: ○

Anti-theft antenna
• Antenna error: ×
Key exists / does not exist Key exists: ○ Anti-theft mode on: ○
Enabled / Disabled Key does not exist: × Anti-theft mode off: ×
Red key is matched: Black key is matched:

Red key ○ ○
Black key Red key is mismatch- Red or black key is
ed: × mismatched: × If unknown or can-
10
celed: -
Yellow key is match- Green key is match-
Yellow key ed: ○ ed: ○
Green key Yellow key is mis- Green key is mis-
matched: × matched: ×

(Tag) yellow ed: ○ ed: ○
(Tag) green Yellow key is mis- Green key is mis-
Angle switch RH • Switch pressed: ON

Angle switch LH • Switch released: OFF
11 Angle blade spec.
Angle solenoid RH • With output signal from main ECU: ON
Angle solenoid LH • No output signal from main ECU: OFF
(Continued)
U30-6S 7-31

MECHANISM
Tilt switch RH • Switch pressed: ON

Tilt switch LH • Switch released: OFF
12 Tilt angle blade spec.
Tilt solenoid RH • With output signal from main ECU: ON
Tilt solenoid LH • No output signal from main ECU: OFF
Actual load • Present value (kg)
Rated load • Present value (kg)
13 Radius • Present value (mm)
Height • Present value (mm)
Travel pressure • Present value (MPa)
• Present value: 0.25 to 4.75 V Crane spec.

Arm potentiometer • Setting value: arm crowd (low) to arm
dump (high)

14
Boom potentiometer • Setting value: boom down (low) to boom
up (high)
Bottom pressure / rod

pressure
• Present value (V)

Boom bottom pressure
• Present value (MPa) For EU spec. only
15 Warning pressure • Present value (MPa)

Boom rod pressure Dummy data
• Present value (MPa)
Multipurpose1 switch 1 (AI

console) • Switch pressed: ON
Multipurpose1 switch 2 • Switch released: OFF Multipurpose switch
16
(AUX knob LH) spec.
Multipurpose switch sole- • With output signal from main ECU: ON

Compressor switch • Operating: ON -
• Stopped / fine control: ON

Boom up pressure switch -
• Full stroke operation: OFF
• Switch pressed: ON For eco mode spec.

17 Eco switch
• Switch released: OFF only
Pump solenoid • Operating: ON -
For eco mode spec.

Eco solenoid • Operating: ON
only
• Present value (V) -

Travel pressure sensor
• Present value (MPa) -
18 DPF switch -
Work light switch -
Engine stop switch CRS spec.
(Continued)
7-32 U30-6S

MECHANISM
Boom potentiometer
19 Offset potentiometer
Boom arm setting • Setting value: boom raise, arm crowd
Offset setting • Setting value: offset RH (high)
Boom solenoid
• Operating: 0.4 to 1.2 A
Arm dumping/crowding
• Stopped: 0.0 to 0.6 A
Offset solenoid RX series
20
Arm dumping / arm crowd-
• Start point setting: arm dump, arm crowd
ing setting
Boom offset setting • Start point setting: boom raise, offset right
Emergency switch
• During boom raise operation: ON

21 Boom up pressure switch
• Not operating: OFF
• Normal: ON
Boom height limit
• At the height limit: OFF
Meter • Normal: ○ (with meter panel) -
ECU (Main) • Normal: ○ (with ECU (main)) -
22 ECU (AS) • Normal: × (with ECU (AS)) RX series
CRS spec.
ECU (Eng) • Normal: × (with ECU (engine)) Electrical governor
sensor spec.
Meter - -
Ver. • Program version -

23
Rev. • Program creation date (Y/M/D) -
Serial No. • Serial No. -
ECU (Main) - -

24
ECU (AS) -
Ver. • Program version

25 RX series
Rev. • Program creation date (Y/M/D)
Serial No. • Serial No.
3.5.4 Reading error history 4. Press SW2 and SW3 to select “Retrieve Fail
Record”, and press SW5.
Displays the previous error code and hour meter from
5. Press SW2 and SW3 to select other error histories.
the memory.
SW5.
2. Press SW2 and SW3 to select a language, and
press SW5.
3. Press SW2 and SW3 to select “Diagnosis”, and
press SW5.
U30-6S 7-33

MECHANISM
6. Turn the starter switch to [STOP] to exit the service • “All Fail Record” (reading all error history)
dealer mode, or press SW1 to exit the tester mode. cannot be cleared.
(1) Error item (4) Latest occurrence date and

(2) Number of occurrences (up hour meter
to 255)
(3) First occurrence date and 3.5.6 Operating the AI setting
hour meter
Setting for auto idling.
NOTE SW5.
• Select “Delete Fail Record” to clear the fail 2. Press SW2 and SW3 to select a language, and
record in the service dealer mode. press SW5.
3. Press SW2 and SW3 to select “Setting”, and
No error history
press SW5.
4. Press SW2 and SW3 to select “AI Set”, and press
SW5.
5. Operate the machine by following the instruction
displayed on the meter panel.
6. Press SW1 to exit the “AI Set” mode.
NOTE
• “AI Set” can be set either with or without
running the engine.
3.5.5 Clearing error history

Clears error history from memory.
SW5.
press SW5.
3. Press SW2 and SW3 to select “Diagnosis”, and
press SW5.
Setting flow
4. Press SW2 and SW3 to select “Delete Fail
1. “Idling RPM 0000 n/min” / Input a number
Record”, and press SW5.
manually and press SW5.
5. Turn the starter switch to [STOP] to exit the service 2. “Accel to MAX” / Operate the accelerator dial to the
dealer mode. maximum manually and press SW5.
NOTE 3. “Accel to Idling” / Operate the accelerator dial to
• “Retrieve Fail Record” (reading error the minimum manually and press SW5.
history) will be cleared by this operation. 4. “Setup Completed”.
7-34 U30-6S

MECHANISM
3.5.7 AUX1 setting If not an RX series
Various settings for proportional AUX1 specification.

NOTE
• This setting is necessary for AUX1 specification
only.
In case of not proportional AUX specification
3.5.10 Crane settings

Various setting only for crane specification.
NOTE
• This setting is necessary for crane specification
only.
3.5.8 AUX2 setting If not the crane specification
Various settings for proportional AUX2 specification.

NOTE
• This setting is necessary for AUX2 specification
only.
In case of not proportional AUX specification
3.5.11 Overload alarm setting

Settings only for overload alarm specification.
NOTE
• This setting is necessary for overload alarm
specification only.
3.5.9 AS settings
Various setting only for RX series machines.
NOTE
• This setting is necessary for RX series machine
only.
U30-6S 7-35

MECHANISM
If not the overload alarm specification
3.5.12 Operating model setting

Individual settings for each machine.
NOTE
• It is necessary to set this mode after replacing or repairing the ECU or meter panel.
• It is necessary to set the “AI Set” and “Knob Set” settings again after configuring the model setting.
1. Turn the starter switch to [RUN] while pressing SW5.

2. Press SW2 and SW3 to select a language, and press SW5.
3. Press SW2 and SW3 to select “Setting”, and press SW5.
4. Press SW2 and SW3 to select “Model Set”, and press SW5.
5. Configure all machine-specific parameters (items) according to the model, destination, and specification of your
machine.
6. Press SW5 to set “Engine type System” and complete the setting.
7. Press SW1 to exit model setting mode.
7-36 U30-6S

MECHANISM
Default setting
IMPORTANT
• @ - Input a parameter according to the specification of the machine.
U30-6S 7-37

MECHANISM
Screen No. Content displayed U30-6S Remarks
(1) Model “U30” -
(2) Region / Area “Asia” @
(3) AI “YES” -
(4) Overload warning “NO” -
(5) AUX1 “Foot (No)” -
(6) AUX2 / Thumb “Foot (No)” -
(7) Arm control “NO” -
(8) Angle (blade) “NO” @
(9) Tilt (blade) “NO” -
(10) Multipurpose operating “NO” -
Arm type
(11) 1: Standard 1 -
2: Long
Canopy spec.: “Canopy”

(12) Compartment -
Cabin spec.: “Cab”
Engine power limit

0: Standard
(13) 1: Eco mode (EP solenoid) 0 -
2: Air conditioning
3: Eco mode (gain solenoid)
Engine type
1: Common rail engine or electrical
(14) 2 -
governor engine
2: Mechanical engine
(15) Setup complete - -
3.5.13 Other setting

3.5.13.1 Operating AI motor drive
Move the lever of the AI motor for manual
maintenance.
SW5.
press SW5.
press SW5.
4. Press SW2 and SW3 to select “Others”, and press
SW5.
5. Press SW2 and SW3 to select “AI Motor Drive”, SW2 “SW2 CCW”: Counterclockwise
and press SW5. SW3 “SW3 CW”: Clockwise
6. Press SW2 or SW3 to move the lever of the AI
motor.
7. Press SW1 to exit the AI motor drive mode. 3.5.13.2 Exchanging the switch operations
for AUX1 and AUX2/thumb
Functions of RH and LH switches, which control AUX1
and 2 by default, can be exchanged. This function is
7-38 U30-6S

MECHANISM
only available for machines equipped with both AUX1 2. Press SW2 and SW3 to select a language, and
and AUX2. press SW5.
1. Turn the starter switch to [RUN] while pressing 3. Press SW2 and SW3 to select “Setting”, and
SW5. press SW5.
2. Press SW2 and SW3 to select a language, and 4. Press SW2 and SW3 to select “Others”, and press
press SW5. SW5.
3. Press SW2 and SW3 to select “Setting”, and 5. Press SW2 and SW3 to select “Periodic Check
press SW5. Selection”, and press SW5.
4. Press SW2 and SW3 to select “Others”, and press 6. Press SW2 or SW3 to select “Auto” or “Manual”,
SW5. and press SW5.
5. Press SW2 and SW3 to select “Exchange (AUX1) 7. Press SW1 to exit the periodic check information
(2/Thumb)”, and press SW5. clearing method mode.
6. Press SW2 or SW3 to select “Normal” or “Reverse”,
and press SW5.
7. Press SW1 to exit the switch operation exchange
mode.
Default setting
Mode Destination Clearing method
Japan • Turn the starter

America switch repeatedly
AUX1 AUX2 Canada from [STOP] to
Auto Australia [RUN] 10 times.
Controlled by RH Controlled by LH China • Put a check on the
Normal
switch switch East Europe periodic check mode
Controlled by LH Controlled by RH Asia check box manually.
Reverse
switch switch • Put a check on the
periodic check mode
Default setting check box manually.
It is necessary to
Manual EU
Display Destination push the work light
switch before putting
Japan a check on the check
Australia box.
EU
Normal
China
Asia
East Europe 3.5.13.4 Informing of periodic check alert
America
Reverse
Canada
Whether to inform of the periodic check can be
configured.
SW5.
3.5.13.3 Operating periodic check 2. Press SW2 and SW3 to select a language, and
information clearing method press SW5.
Settings for periodic check information clearing method. 3. Press SW2 and SW3 to select “Setting”, and
1. Turn the starter switch to [RUN] while pressing press SW5.
SW5. 4. Press SW2 and SW3 to select “Others”, and press
SW5.
U30-6S 7-39

MECHANISM
5. Press SW2 and SW3 to select “Periodic Check

Display”, and press SW5.
6. Press SW2 or SW3 to select “On” or “Off”, and
press SW5.
7. Press SW1 to exit the periodic check alert mode.
8.
Default setting
Display Destination Setting
Japan
America
Canada
Australia
Default setting Off • Does not inform.
EU
China
Display Destination Setting
Asia
Japan East Europe
America
• Informs of annual
Canada • Informs of peri-
On - check alert at the set
Australia odic check
On time.
EU alert at the set
China time.
Asia Turning “On” the annual check alert
East Europe 1. Press SW2, SW3, and SW4 to set the year and
• Does not in- month to be checked.
Off -
form. 2. Press SW5 to confirm the year and month setting,
and press SW1 to exit the annual check mode.
3.5.13.5 Informing of annual check alert

Whether to inform of the annual check can be
configured.
SW5.
press SW5.
press SW5.
SW5.
5. Press SW2 and SW3 to select “Annual Guidance”,
and press SW5. (1) Date (year / month)
6. Press SW2 or SW3 to select “On” or “Off”, and
press SW5. Informing of annual check alert
7. Press SW1 to exit the annual check alert mode. NOTE
• The alert is displayed for 10 seconds when the
starter switch to [RUN].
7-40 U30-6S

MECHANISM
6. Press SW2 to decrease the time, and press SW3 to

increase the time.
7. Press SW5 to input the hours of operation before
replacing the ECU.
8. Press SW1 to exit the “Periodic Check Set” mode.
IMPORTANT
• After replacing the main ECU, input the
hours of operation up to the replacement of
the main ECU, which is displayed on the
meter.
Clearing annual check alert

1. Enter the periodic check mode, and press SW2 and
SW3 to select the annual check screen.
2. Press SW4 to put a check on the check box on the
upper left of the annual check screen on the meter
panel.
3. Press SW5 to display the confirmation screen.
4. Press SW5 to complete. Press SW1 to return to the
previous screen.
3.5.13.7 Displaying a clock setting alert

Whether to display a clock setting alert with a lamp or
not when the clock is off can be configured.
SW5.
press SW5.
press SW5.
(1) Date (year / month) (2) Remaining month (1 month 4. Press SW2 and SW3 to select “Others”, and press
has passed) SW5.
5. Press SW2 and SW3 to select “Clock Set Warning
(Y/N)”, and press SW5.
3.5.13.6 Adjusting the time offset of 6. Press SW2 or SW3 to select “YES” or “NO”, and
periodic check press SW5.
Adjusts the time offset between the hour meter and
periodic check hour. This setting is required after
replacing the ECU.
SW5.
press SW5.
press SW5.
SW5.
5. Press SW2 and SW3 to select “Periodic Check
Set”, and press SW5.
U30-6S 7-41

MECHANISM
7. Press SW1 to exit the setting mode.
Default setting 3.5.13.9 Setting multipurpose function

Display Destination Setting Setting for multipurpose function.
Japan NOTE
America • It is necessary to set “YES” in service dealer
Canada mode / “Setting” / “Model Set” / “Multipurpose
Australia • Informs of a clock set
Yes Operating”.
EU alert if the clock is off.
China
Asia
East Europe
• Does not inform of a

No -
clock set alert.
3.5.13.8 Arm limitation fine adjustment

Fine adjustment of the stop position for the arm
limitation. Only for arm limit specification.
SW5.
press SW5.
3. Press SW2 and SW3 to select “Setting”, and 1. Turn the starter switch to [RUN] while pressing
press SW5. SW5.
4. Press SW2 and SW3 to select “Others”, and press 2. Press SW2 and SW3 to select a language, and
SW5. press SW5.
5. Press SW2 and SW3 to select “Arm control Adj”, 3. Press SW2 and SW3 to select “Setting”, and
and press SW5. press SW5.
6. Press SW2 to decrease the time, and press SW3 to 4. Press SW2 and SW3 to select “Others”, and press
increase the time. SW5.
7. Press SW5 to confirm the arm limitation setting. 5. Press SW2 and SW3 to select “Multipurpose
8. Press SW1 to exit the “Arm control Adj” mode. mode”, and press SW5.
6. Press SW2, SW3 and SW4 to input a designated
IMPORTANT number.
• This setting is only for arm limitation
specification. NOTE
• Input a number from 00 to 10 to associate a
selected mode number with an attachment
you want to use.
7. Press SW5 to set the mode number.
7-42 U30-6S

MECHANISM
8. Press SW1 to exit the “Multipurpose mode”.

NOTE
• Some of the multipurpose modes require
solenoid valves, wire harnesses, hydraulic
hoses or other devices to be installed.
No history
Default setting
Multipurpose function: disabled
00
AUX2 hold function: disabled
3.5.13.10 Reading all error histories

Displays all error codes and hour meters in the
memory.
SW5. 3.5.13.11 Selecting an opening screen
2. Press SW2 and SW3 to select a language, and Select an illustration or a logo on the opening screen.
press SW5. 1. Turn the starter switch to [RUN] while pressing
3. Press SW2 and SW3 to select “Setting”, and SW5.
press SW5. 2. Press SW2 and SW3 to select a language, and
4. Press SW2 and SW3 to select “Others”, and press press SW5.
SW5. 3. Press SW2 and SW3 to select “Diagnosis”, and
5. Press SW2 and SW3 to select “All Fail Record”, press SW5.
and press SW5. 4. Press SW2 and SW3 to select “Opening select”,
6. Press SW2 and SW3 to select other error histories. and press SW5.
7. Turn the starter switch to [STOP] to exit the service 5. Press SW2 and SW3 to select an opening screen.
dealer mode, or press SW1 to exit the tester mode. 6. Press SW5 to confirm the opening screen setting.
NOTE
• This history is not erased even if the “Delete
Fail Record” is done.
U30-6S 7-43

MECHANISM
7. Press SW1 to exit.
Default setting
Destination Setting
(1) Japan Illustration
America
Canada
Australia
(2) EU Kubota logo
China
Asia
East Europe
7-44 U30-6S

SERVICING
1. Troubleshooting 7. ELECTRICAL SYSTEM
SERVICING
1. Troubleshooting
1.1 Electrical troubleshooting

The starter motor does not work
The ground terminals are disconnected or Check if the related ground terminals are con-
Tighten the loosened ground terminals.
connected loosely. nected to the machine.
The battery has discharged or is damaged. Check the battery voltage. Recharge or replace the battery.
Check if the fuses and slow blow fuses for the

Specify the cause of the fuse blowing and re-
The fuse or slow blow fuse has blown. lever lock, starter switch, starter signal, or
place the fuse.
ECU main AC have blown.
Check for the conduction of the starter motor

The starter motor relay is malfunctioning. Replace the starter motor relay.
relay.
Check for the conduction of the wire harness-

Repair or replace the damaged wire harness-
The wire harnesses are damaged. es related to the starter motor, starter switch,
es.
and lever lock switch.
Check for the conduction between the starter

The starter switch is damaged. Replace the starter switch.
switch terminals.
The lever lock switch is damaged or adjusted Check for the conduction between the lever
Adjust or replace the lever lock switch.
improperly. lock switch terminals.
Measure the voltage of the starter motor.

The starter motor is malfunctioning. Replace the starter motor.
Check the condition of the starter motor.
The engine does not start
Check for the conduction of the relating wire

Wire harnesses are damaged. harnesses of the starter motor, starter switch, Repair or replace the wire harness.
and lever lock switch.
U30-6S 7-45

SERVICING
7. ELECTRICAL SYSTEM 1. Troubleshooting
1.2 Error warning list (Red lamp)

NOTE
• If ( ) mark is indicated on the bottom right of the screen, press SW4 to open the detail screen.
No. Display Error Cause(s)
Engine oil pressure switch is ON while the engine is running

(700 rpm or more).
• Low engine oil
001 Engine oil pressure error
• Engine problem
• Short-circuited wire harness
• Engine oil pressure switch malfunction
Engine water temperature is higher than 123 ℃ while the engine is

running (700 rpm or more).
002 Overheating (coolant) • Overheated
• Low coolant
(Engine speed goes to idle)
The charge switch is ON (no output from the L terminal of the alter-
nator) while the engine is running (700 rpm or more).
003 Battery charging error
• Alternator malfunction
• Broken wire harness
Fuel level sensor resistance is higher than 131 Ω.

004 Fuel sensor error • Broken wire harness
• Fuel level sensor malfunction
Engine water temperature is lower than -50 ℃ or higher than 150 ℃.

Water temperature sen-
005 • Broken or short-circuited wire harness
sor error
• Engine water temperature sensor malfunction
Communication between main ECU is interrupted.

007 CAN system (main) • Broken wire harness
• Main ECU malfunction
010 Setting data error Perform model setting again.
Travel speed shift system has detected short circuit during travel
Travel speed shift system speed shift is activated.
035
error • Short-circuited wire harness
• Travel speed shift solenoid malfunction
Over voltage system er- Power supply voltage is over 18 V.

041
ror • Alternator malfunction
(Continued)
7-46 U30-6S

SERVICING
No. Display Error Cause(s)
Breakage or short circuit has occurred in the accelerator sensor cir-

cuit.
Accelerator sensor
• Broken or short-circuited wire harness
• Accelerator sensor malfunction
Breakage or short circuit has occurred in the governor potentiometer

046 circuit.
Governor sensor
• Broken or short-circuited wire harness
• Governor sensor malfunction
AI system has detected an error in the AI motor circuit.

AI motor • Broken or short-circuited wire harness
• Stuck AI motor
Short circuit has occurred in the lever lock solenoid circuit.

058 Lever lock solenoid • Short-circuited wire harness
• Lever lock solenoid malfunction
Voltage of the external 5 V detection port is high.

060 External 5 V
• Short circuit has occurred in the external 5 V line.
High hydraulic oil temper-

086 The hydraulic oil temperature is higher than 104 ℃.
ature warning
U30-6S 7-47

SERVICING
7. ELECTRICAL SYSTEM 1. Troubleshooting
1.3 Alert list (Yellow lamp)

NOTE
• If indicate ( ) mark on bottom right, press SW4 to open other screen which is detail of an alert.
Number Display Alert Number Display Alert
6 Low fuel 67 Past the periodic check term
Water temperature rising

• The coolant temperature is
11 68 Monthly periodic inspection
higher than 118 ℃ less than
122 ℃.
Warming up
36 • Engine speed is limited due 69 Time on the clock is off
to low oil temperature.
High oil temperature

• The hydraulic oil tempera-
ture is between 99 and
66 10 hours before periodic check 85
103 ℃ while the engine is
running (higher than
700 rpm).
7-48 U30-6S

SERVICING
1.4 Message list

NOTE
• If indicate ( ) mark on bottom right, press SW4 to open other screen which is detail of a message.
Number Display Message Number Display Message
Pressed SW2 when the crane Started the engine while the lever
292*1 465
function is disabled in the setting. lock is lowered.
No setting has been done after

296 466 Need to lower the lever lock.
replacing the ECU.
Confirming replaced or not the Turned the key switch to [STOP],

297 468
meter panel. and still inserting the key.
Press SW2 when the AUX func-

Require needed setting after re- tion is disabled in the setting.
299 495
placing meter panel or ECU. Pressed SW3 (AUX) when AUX1
or AUX2 settings are disabled.
Pressed SW3 when the arm limi-

Pressed non-registered multipur-
342 tation function is disabled in the 514
pose function
setting.
*1 English only
U30-6S 7-49

SERVICING
7. ELECTRICAL SYSTEM 2. Handling error warning
2. Handling error warning

2.1 Handling engine oil pressure
error
Engine oil pressure switch is ON while the engine is
running (700 rpm or more).
Checking the meter panel
1. Check the meter panel for the following error
message.
(1) Engine oil dipstick (A) Correct oil level range

(2) Oil filling port
2. Check the engine oil pressure switch.

• Check the connector(s) for loose connection or
poor contact.
• Disconnect and reconnect the connector(s) and
check if the error is resolved.
• Check the cover of the wiring for damage and
that they are not touching the body.
2. Check the status of the engine oil pressure switch

in tester mode.
(3) Engine oil pressure switch
3. Measure the resistance of the engine oil pressure

switch.
• Disconnect the engine oil pressure switch
Engine stop- Engine run- connector.
Tester mode
ped ning
Normal • Measure the resistance between the engine oil
“Oil SW” pressure switch terminal and the body GND.
Checking the devices

1. Check the engine oil level.
7-50 U30-6S

SERVICING
2. Handling error warning 7. ELECTRICAL SYSTEM
Engine stopped Engine running • Turn the starter switch to [STOP] and
Normal disconnect the engine oil pressure switch
Conducting Not conducting
connector and meter panel connector.
4. Check the meter panel connector.
12 V GND
poor contact. (3) Engine oil pres-
1 -
sure switch
check if the error is resolved. (4) Meter panel
9 -
• Check the cover of the wiring for damage and connector
Normal Conducting
Measuring the engine oil pressure

1. Measure the engine oil pressure at the maximum
engine speed.
NOTE
• The oil pressure switch turns on when the
pressure is less than 49 kPa (0.50 kgf/cm2) .
• For more information about the measuring
the engine oil pressure, see 5-12.
(4) Meter panel connector
Checking the wire harness
Engine maximum 294 to 441 kPa
Engine oil pressure
speed 3.0 to 4.5 kgf/cm2
Steps to take after completing repairs

1. Delete the fail record.
(3) Engine oil pressure switch (4) Meter panel connector
1. Measure the voltage of the wire harness.

• Disconnect the engine oil pressure switch
connector, and turn the starter switch to [RUN].
(+) (-)
(3) Engine oil pres-

1 Body GND
sure switch
Starter switch Starter switch

Normal [STOP] [RUN]
0V 12 V
(B) “No Fail Record”
2. Check the conduction of the wire harness.
U30-6S 7-51

SERVICING
• While in the service dealer mode, select • If the engine coolant temperature is
“Delete Fail Record” and delete the record. displayed as 150 ℃, the coolant temperature
• After deleting the record, start the engine again circuit is causing a short circuit.
and check that the warning is not shown on the
meter panel. Checking the devices
1. Check the engine coolant level.
2.2 Handling overheating

Engine water temperature is higher than 123 ℃ while
the engine is running (700 rpm or more).
Checking on the meter panel
message.
(1) Reserve tank (B) Low

(A) Full
2. Check the condition of the radiator fin and radiator

cap.
2. Check the engine coolant temperature in tester

mode.
• Turn the starter switch to [RUN] and check the
item of “Water Temp.”.
(2) Radiator fin (3) Radiator cap

Tester mode Water temperature

Normal
“Water Temp.” Lower than 123 ℃
NOTE
• If the engine coolant temperature is between
118 and 122 ℃, the meter displays “Water
temp. Rising”, and if the engine coolant
temperature is over 123 ℃, the meter
displays “Overheat Engine to Idle for
(C) “No Fail Record”
cooling”.
7-52 U30-6S

SERVICING
• While in the service dealer mode, select

“Delete Fail Record” and delete the record.
• After deleting the record, start the engine again
meter panel.
2.3 Handling battery charging error

The charge switch is ON (no output from terminal L of
the alternator) while the engine is running (700 rpm or
more).
message.
Push with 58.8 to
(a) Alternator belt
9 to 11 mm 68.6 N
tension
(6 to 7 kgf)
2. Check the alternator connector (terminal L).

poor contact.
2. Check the charging switch in tester mode.

• Start the engine and check the item of
“Charging”.
(1) Alternator connector (termi-

nal L)
3. Measure the voltage of the alternator.

• Measure the voltage between the terminal B of
the alternator and the body GND.
Engine stop- Engine run-

Tester mode
ped ning
Normal
“Charging”

1. Check the engine.
• Check the tension of the alternator belt, and
check for its damage and slippage.
U30-6S 7-53

SERVICING
(2) Terminal B
Engine stop Engine running

Normal
12 V Approximately 14 V

poor contact. (1) Alternator connector (termi- (3) Meter panel connector
• Disconnect and reconnect the connector(s) and nal L)
• Turn the starter switch to [STOP] and
disconnect the alternator connector, meter
panel connector, and joint connector.
12 V GND
(1) Alternator con-

2 -
nector (terminal L)
(3) Meter panel

10 -
connector
Normal Conducting

(A) “No Fail Record”

7-54 U30-6S

SERVICING

meter panel.
2.4 Handling fuel level sensor error

Fuel level sensor resistance is higher than 131 Ω.
message.
2. Check the fuel level sensor connector.

poor contact.
that it is not touching the body.
2. Check the fuel level sensor in tester mode.
item of “Fuel”.
(2) Fuel level sensor connector
3. Measure the resistance of the fuel level sensor.

• Remove the fuel level sensor.
(Fuel level sensor
Tester mode
resistance)
Normal
3±1 Ω (Full) to
“Fuel”
110±2.5 Ω (Empty)

poor contact.
U30-6S 7-55

SERVICING
Float posi-
(A) (B) (C)
tion
107.5 to
Resistance 2 to 4 Ω 32.5 Ω
112.5 Ω
(D) “No Fail Record”

and check to make sure that the warning is not
shown on the meter panel.
(1) Meter panel connector (2) Fuel level sensor connector

2.5 Handling water temperature
• Disconnect the fuel level sensor connector, and
sensor error
turn the starter switch to [RUN]. The engine water temperature is displayed as lower
than -50 ℃ or higher than 150 ℃ due to broken wire or
(+) (-) short circuit.
(2) Fuel level sen- Checking on the meter panel
1 2
sor connector 1. Check the meter panel for the following error
message.
Normal [STOP] [RUN]
0V 12 V

disconnect the fuel level sensor connector,
meter panel connector.
12 V GND
(1) Meter panel

1 -
connector
(2) Fuel level sen-

1 2
sor connector
2. Check the water temperature sensor in tester
Body GND - ○ mode.
Normal Conducting item of “Water Temp.”.

7-56 U30-6S

SERVICING
(1) Water temperature sensor

Tester mode Water temperature connector
Normal
“Water Temp.” -49 to 149 ℃
Water
tempera- -20 ℃ 20 ℃ 80 ℃ 110 ℃
NOTE ture
• When the water temperature rises above Resist-
123 ℃, “Overheat Engine to Idle for 15.04 kΩ 2.45 kΩ 0.318 kΩ 0.14 kΩ
ance
cooling”is detected.
Checking the devices • Check the connector(s) for loose connection or
1. Check the water temperature sensor connector. poor contact.
• Check the connector(s) for loose connection or • Disconnect and reconnect the connector(s) and
poor contact. check if the error is resolved.
• Disconnect and reconnect the connector(s) and • Check the cover of the wiring for damage and
check if the error is resolved. that it is not touching the body.
(1) Water temperature sensor

connector
2. Measure resistance of the water temperature

sensor.
• Disconnect the water temperature sensor
connector.
U30-6S 7-57

SERVICING
(1) Water temperature sensor (2) Meter panel connector

connector
1. Measure voltage of the wire harness. • After deleting the record, start the engine again
• Disconnect the water temperature sensor and check to make sure that the warning is not
connector, and turn the starter switch to [RUN]. shown on the meter panel.
(+) (-)
(1) Water tempera- 2.6 Handling CAN communication

ture sensor connec-
tor
1 2 error (Main)
There is no communication between the meter panel
and main ECU.
[STOP] [RUN] Checking on the meter panel
Normal
0V 5V
message.
2. Check the conduction of the wire harness. 2. Press the info switch, and check the error message.
disconnect the water temperature sensor
connector and meter panel connector.
5V GND
(1) Water tempera-

ture sensor connec- 1 2
tor
(2) Meter panel

2 3
connector
Normal Conducting

1. Delete the fail record. Information “CAN Sys (Main)”
3. Check the communications with each ECU in tester

mode.
7-58 U30-6S

SERVICING
(2) Main ECU connector

Tester mode Condition
3. Check the CAN junction connector.
“Meter” ○ • Check the connector(s) for loose connection or
“ECU(Main)” ○ poor contact.
Normal • Disconnect and reconnect the connector(s) and
“ECU (AS)” ×
“ECU(Eng)” × • Check the cover of the wiring for damage and
poor contact.
(3) CAN junction connector
2. Check the main ECU connector.

poor contact.
U30-6S 7-59

SERVICING

2.7 Handling travel speed shift

system error
Travel speed shift system has detected short circuit
during travel speed shift is activated.
message.
2. Press the info switch, and check the error message.
(1) Meter panel connector (3) CAN junction connector
(2) Main ECU connector (4) Diagnostic connector

• Turn the starter switch to [STOP] to disconnect
the main ECU connector and the meter panel
connector.
NOTE
• The numbers in parentheses ( ) are for CAN
junction connector.
CAN-HIGH CAN-LOW
(1) Meter panel 6 5

connector (1) (4)
(2) Main ECU con- 60 79

nector (2) (3) Information “2 Speed SOL”
3. Check the travel shift speed switch and travel

Normal Conducting speed solenoid in tester mode.
• Start the engine and lower the lever lock.
Steps to take after completing repairs • Operate the travel speed shift switch and check
1. Delete the fail record. the items of “2 Speed SOL”.
7-60 U30-6S

SERVICING
Travel speed Travel speed Normal 10.8 to 13.2 Ω

Tester mode shift switch shift switch
ON OFF 3. Check the main ECU connector.
Normal • Check the connector(s) for loose connection or
“2 Speed SW”
poor contact.
“2 Speed • Disconnect and reconnect the connector(s) and
SOL” check if the error is resolved.
Checking the devices that they are not touching the body.
1. Check the travel speed solenoid connector.
poor contact.
(1) Travel speed solenoid con-

nector
2. Measure the resistance of the travel speed

solenoid.
U30-6S 7-61

SERVICING

(1) Travel speed solenoid con- (2) Main ECU connector 2.8 Handling battery overcharging
nector
Power supply voltage is over 18 V.
1. Measure the voltage of the wire harness. Checking on the meter panel
• Disconnect the travel speed solenoid connector. 1. Check the meter panel for the following error
• Turn the starter switch to [RUN] and lower the message.
lever lock. 2. Press the info switch, and check the error message.
(+) (-)
(1) Travel speed

1 2
solenoid connector
Travel shift speed Travel shift speed

Normal switch OFF switch ON
0V 12 V

disconnect the travel speed solenoid connector
and main ECU connector.
12 V GND
(1) Travel speed Information “Overvoltage”

1 2
solenoid connector
3. Check the battery voltage in tester mode.
(2) Main ECU con- • Start the engine and check the item of “Battery
81 -
nector
V”.
Normal Conducting

7-62 U30-6S

SERVICING
(1) Terminal B
Engine run-
Tester mode Engine stop
ning
Normal Engine stopped Engine running
Approximately Normal
“Battery V” 12 V 12 V Approximately 14 V
14 V
Checking the devices Steps to take after completing repairs

1. Check the battery. 1. Delete the fail record.
• Check that 24 V was not selected to use for
jump start.
• Check that a 24 V battery is not installed to the
machine.

2.9 Handling AI system error

(A) 12 V (B) 24 V 2.9.1 Handling AI system error (accelerator
2. Measure the voltage of the alternator. sensor)
• Measure the voltage between terminal B of the
Short-circuit or broken harness in the AI console line.
alternator and body GND.
1. Check the meter panel.
U30-6S 7-63

SERVICING
Tester mode Engine speed Voltage
Approximately
Idling speed
1.5 V
Normal “Accel POT”
Maximum Approximately
speed 3.1 V

1. Check the AI console.
• Check the connectors for loose connection or
poor contact.
• Disconnect and reconnect the connectors, and
check them in the tester mode.
2. Press the Info switch, and check the error check that they are not touching the body.
message.
IMPORTANT
Information “Accel Sensor” • AI setting is required after replacing the
parts.
3. Check the accelerator sensor in tester mode.
NOTE
• There is a possibility of broken wire harness
in case that the voltage is less than 0.25 V.
• There is a possibility of short-circuit wire
harness in case that the voltage is higher
than 4.75 V or not stable.
(1) AI console connector
2. Measure the resistance of the AI console.

• Disconnect the AI console connector.
• Measure the resistance of the AI console.
(1) AI console connector (B) Maximum position

(A) Idling position
(A) Idling position (B) Maximum position
7-64 U30-6S

SERVICING
Resistance (+) (-)
Idling speed Maximum speed (1) AI console con-

8 4
nector
Between 4 and 8 1 kΩ±10% 1 kΩ±10%
Between 7 and 8 650 Ω 350 Ω

Between 4 and 7 350 Ω 650 Ω Normal [STOP] [RUN]
0V 5V
• Check the connector(s) for loose connection or 2. Check conduction of the wire harness.
poor contact. • Turn the starter switch to [STOP] and
• Disconnect and reconnect the connector(s) and disconnect the AI console connector.
• Check the cover of the wiring for damage and 5V Signal GND
that it is not touching the body. (1) AI console
8 7 4
connector
(2) Main ECU

11 7 10
connector
Normal Conducting


2.9.2 Handling AI system error (governor

sensor)
Short-circuit or broken harness in the governor sensor
line.
(1) AI console connector (2) Main ECU connector

• Disconnect the AI console connector.
U30-6S 7-65

SERVICING
Tester mode Engine speed Voltage
Idling speed 1.48 to 1.88 V

“Governor
Normal Maximum
POT” 3.11 to 3.67 V
speed

1. Check the governor sensor connector.
poor contact.
check in the tester mode.
2. Press the Info switch, and check the error
message.
Information “Governor Sensor”
3. Check the governor sensor in tester mode.

NOTE
• There is a possibility of broken wire harness
in case that the voltage is less than 0.25 V.
• There is a possibility of short-circuit wire
harness in case that the voltage is higher
than 4.75 V or not stable.
(1) Governor sensor connector
2. Measure the resistance of the governor sensor.

• Disconnect the governor sensor connector.
• Measure between the governor sensor terminal
and body GND.
IMPORTANT
• AI setting is required after replacing the
parts.
Normal Resistance 1.6 to 2.4 kΩ

(A) Idling position (B) Maximum position
poor contact.
7-66 U30-6S

SERVICING
• Check the cover of the wiring for damage and 5V Signal GND
(1) Governor
sensor 3 2 1
connector
(2) Main ECU

11 27 10
connector
Normal Conducting


2.9.3 Handling AI system error (AI motor)

Short-circuit or broken harness in the AI motor line.
(1) Governor sensor connector (2) Main ECU connector

• Disconnect the governor sensor connector.
(+) (-)
(1) Governor sensor

3 1
connector
Starter switch at Starter switch at

Normal [STOP] [RUN]
0V 5V
2. Check conduction for the wire harness.

disconnect the governor sensor connector. 2. Press the Info switch, and check the error
message.
Information “AI Motor”
3. Check the AI motor in tester mode.
U30-6S 7-67

SERVICING
• Remove the AI motor.

• Connect the battery to the AI motor and check
the AI motor operation.
IMPORTANT
• Do not short-circuit the AI motor when
connecting the battery to the starter motor.
• AI setting is required after replacing the
parts.

poor contact.
(A) Idling position (B) Maximum position check if the error is resolved.
Tester mode AI motor Current that it is not touching the body.
“Motor Cur‐ In operation 0.0 to 15.0 A
Normal
rent” Stop 0.0 to 2.0 A

1. Check the AI motor.
poor contact.
(1) AI motor
2. Check the AI motor operation.
7-68 U30-6S

SERVICING

(1) AI motor (2) Main ECU connector
1. Measure the voltage of the wire harness. 2.10 Handling lever lock system
• Disconnect the AI motor connector. error
• Turn the starter switch to [RUN] and operate
Short circuit has occurred in the lever lock solenoid
the accelerator dial.
circuit.
(+) (-) Checking on the meter panel
1 Body GND
(1) AI motor message.
2 Body GND 2. Press the info switch, and check the error message.

[RUN] [RUN]
Starter switch
(Not operating (Operating the
Normal [STOP]
the accelera- accelerator di-
tor dial) al)
0V 0V 12 V
2. Check conduction for the wire harness.

disconnect the AI motor connector and main
ECU connector.
12 V 12 V GND
(1) AI motor 1 2 -
Information “Lever Lock SOL”
(2) Main ECU
5 4 1
connector
3. Check the lever lock switch and lever lock solenoid
Body GND - - 〇 in tester mode.
• Start the engine and lower the lever lock.
Normal Conducting • Operate the lever lock switch and check the
items of “Lever Lock SOL”.
U30-6S 7-69

SERVICING
Lever lock Lever lock Normal 10.8 to 13.2 Ω

Tester mode
switch ON switch OFF
“Lever Lock
Normal
SW”
poor contact.
“Lever Lock • Disconnect and reconnect the connector(s) and
SOL”
Checking the devices that it is not touching the body.
1. Check the lever lock solenoid connector.
poor contact.
(1) Lever lock solenoid connec-

tor
2. Measure the resistance of the lever lock solenoid.
7-70 U30-6S

SERVICING
Checking the wire harness Normal Conducting


2.11 Handling 5 V error

(1) Lever lock solenoid connec- (3) Lever lock switch connector
tor (4) Fuse (lever lock)
Voltage of the external 5 V detection port is high (short
(2) Main ECU connector circuit in the 5 V line).
1. Measure the voltage of the wire harness. 1. Check the meter panel for the following error
• Disconnect the lever lock solenoid connector. message.
• Turn the starter switch to [RUN] and lower the 2. Press the info switch, and check the error message.
lever lock.
(+) (-)
(1) Lever lock sole-

1 2
noid connector
Lever lock switch Lever lock switch

OFF ON
Normal (Up) (Down)
0V 12 V

• Turn the starter switch to [STOP], and
disconnect the lever lock solenoid connector
and main ECU connector.
Information “External 5V”
Lever lock sole-
12 V
noid signal
(1) Lever lock sole- 1. Check the AI console connector.
1 2
noid connector
(2) Main ECU con-
67 62 poor contact.
nector • Disconnect and reconnect the connector(s) and
U30-6S 7-71

SERVICING


(1) AI console connector
2. Check the governor sensor connector.

poor contact.
(2) Governor sensor connector

poor contact.
(1) AI console connector (3) Main ECU connector
check if the error is resolved. (2) Governor sensor connector
that it is not touching the body. 1. Measure the voltage of the wire harness.
• Disconnect the AI console connector and
governor sensor connector.
(+) (-)
(1) AI console con-

8 4
nector
(2) Governor sensor

3 1
connector
7-72 U30-6S

SERVICING

Normal [STOP] [RUN]
0V 5V

• Turn the starter switch to [STOP], and
disconnect the AI console connector, governor
sensor connector, and main ECU connector.
5V GND
(1) AI console con-

8 4
nector
(2) Governor sensor

3 1
connector 2. Check the hydraulic oil temperature in the tester
(3) Main ECU con- mode.
11 10
nector • Turn the starter switch to [RUN] and check the
item of “Hydoil”.
Normal Conducting

Hydraulic tempera-
Tester mode
Normal ture
“Hydoil” Lower than 103 ℃

• While in the service dealer mode, select 1. Check the hydraulic oil level and replenish if
“Delete Fail Record” and delete the record. necessary.
NOTE
• The hydraulic oil level needs to be at the
center of the gauge.
2.12 Handling high hydraulic oil

temperature warning
The hydraulic oil temperature is higher than 104 ℃.
message.
U30-6S 7-73

SERVICING
Hydraulic
oil
-20 ℃ 20 ℃ 80 ℃ 110 ℃
tempera-
ture
Resist-
15.04 kΩ 2.45 kΩ 0.318 kΩ 0.14 kΩ
ance
(1) Hydraulic oil level gauge (B) Lower limit

(A) Upper limit
2. Check if the fins of the hydraulic oil cooler are

clogged or damaged.

(2) Hydraulic oil cooler
3. Check that no hydraulic oil leaks from the machine.

• Make sure that there is no leakage of hydraulic
oil from each part of the hydraulic circuit.
4. Measure the resistance of the hydraulic oil
temperature sensor.
• Disconnect the hydraulic oil temperature sensor
connector.
(3) Hydraulic oil temperature

sensor
7-74 U30-6S

8. AIR CONDITIONING AND HEATER
SYSTEM

MECHANISM
1. Air conditioning device layout 8. AIR CONDITIONING AND HEATER SYSTEM
MECHANISM
1. Air conditioning device layout
(1) Air conditioning control panel (4) Outlet air duct (7) Compressor
(2) Air conditioning unit (5) Air conditioning filter (8) Receiver
(3) Outlet air duct (6) Inlet air duct (9) Condenser
U30-6S 8-1

MECHANISM
8. AIR CONDITIONING AND HEATER SYSTEM
(10) Heater valve cable (11) Heater valve (12) Blower resister (13) Pressure switch
8-2 U30-6S

MECHANISM
2. Air conditioning and heater system general description 8. AIR CONDITIONING AND HEATER SYSTEM
2. Air conditioning and heater system general description

The air conditioning unit supplies cool air with the cooling cycle and also supplies warm air with the heating cycle.
(1) Capillary tube (7) Condenser (A) High temperature and pres- (D) Low temperature and pres-
(2) Expansion valve (8) Receiver sure gas refrigerant sure refrigerant gas
(3) Evaporator (9) Dryer (B) Refrigerant liquid (E) Ambient inlet air
(4) Blower (10) Pressure switch (C) Low temperature and pres- (F) Cool air
(5) Compressor (11) Heater core sure refrigerant liquid (G) Warm air
(6) Condenser fan (12) Heater valve (H) Coolant
Cooling cycle
• The compressor compresses the refrigerant gas and discharges it into the condenser.
• The condenser cools down and liquefies the discharged refrigerant gas, and the refrigerant liquid flows into the
receiver.
• The receiver filters water, contamination, and air from the refrigerant liquid and the refrigerant liquid flows into the
expansion valve.
• The expansion valve sprays the optimal volume of the refrigerant liquid into the evaporator.
• The sprayed refrigerant liquid turns into gas in the evaporator and takes evaporation heat from the cabin air and
ambient inlet air.
• The refrigerant gas returns to the compressor.
Heating cycle
• The heated coolant flows into the heater core through the heater valve, and heats up the cabin air and ambient
inlet air by the heat convection.
• The heater valve controls the flow rate of the heated coolant. The air temperature increases as the flow rate
increases.
• The coolant returns to the engine.
Air conditioning system
• The air conditioning unit supplies the optimal amount of cool air with the combination of the cooling cycle and
heater cycle.
Heater system
• The air conditioning unit supplies the optimal amount of warm air with the heater cycle.
U30-6S 8-3

MECHANISM
8. AIR CONDITIONING AND HEATER SYSTEM 3. Compressor
3. Compressor
3.1 Compressor specifications
(1) Compressor (2) Magnetic clutch pulley (3) Temperature switch (4) Safety valve
Specification
Model SV07E
Discharging volume 0.07 L
Maximum speed 6000 rpm

Compressor
ND-oil8
Lubricant
110 ml
Mass 1.78 kg
Model K20
More than 22 N⋅m

Transmission torque
More than 2.2 kgf⋅m
Magnetic clutch pulley
Maximum speed 6000 rpm
Pulley diameter ϕ108 mm
Mass 1.1 kg
3.43 to 4.12 MPa

Releasing pressure
34.98 to 42.01 kgf/cm2
Safety valve
2.75 MPa
Shutting pressure
28.0 kgf/cm2
On 115 to 125 ℃
Temperature switch
Off 153 to 163 ℃
8-4 U30-6S

MECHANISM
3. Compressor 8. AIR CONDITIONING AND HEATER SYSTEM
3.2 Compressor function and 3.2.2 Magnetic clutch pulley

structure Engages the pulley and compressor shaft with a
electromagnet clutch.
3.2.1 Compressor working principles
Compresses and discharges the refrigerant.
(1) Hub plate (4) Pulley

(2) Ball bearing (5) Stator
(3) External circlip (6) External circlip
• The magnetic clutch engages the pulley and

compressor shaft when the pressure switch is
turned on.
• The magnetic clutch disengages the pulley and the
compressor shaft when the pressure switch is
turned off.
(1) Housing (6) Discharging valve

(2) Suction port (A) Suction process 3.2.3 Safety valve
(3) Rotor (B) Compression process
(4) Vane (C) Discharging process Relieves the refrigerant to the atmosphere to protect
(5) Discharging port the compressor in the case that the discharged
• The gas refrigerant flows into the vane chamber. refrigerant pressure is extremely high.
• The rotor rotates, the vane chamber volume
decreases, and the gas refrigerant is compressed.
• The compressed gas refrigerant opens the
discharging valve and is discharged from the
discharging port.
(1) Safety valve (B) Discharged refrigerant pres-

(A) Relieved refrigerant volume sure
• The discharged refrigerant presses the poppet in

the safety valve.
• The discharged refrigerant opens the poppet and
flows out to the atmosphere in the case that the
discharged refrigerant pressure is higher than the
set pressure of the safety valve.
U30-6S 8-5

MECHANISM
8. AIR CONDITIONING AND HEATER SYSTEM 3. Compressor
3.2.4 Temperature switch

Cuts off the current flow to the magnetic clutch to
protect the compressor in the case that the discharged
refrigerant temperature is extremely high.
(1) Temperature switch (4) Bimetallic strip

(2) Compressor (5) Rod
(3) Switch (A) From the relay
• The discharged refrigerant heats the bimetallic strip

in the temperature switch and the bimetallic strip
deforms by the heat.
• The deformation of the bimetallic strip increases
and presses the rod in the case that the refrigerant
temperature increases extremely.
• The rod presses the switch and breaks the
conduction.
8-6 U30-6S

MECHANISM
4. Air conditioning unit 8. AIR CONDITIONING AND HEATER SYSTEM
4. Air conditioning unit

4.1 Air conditioning unit specifications
(1) Blower motor (3) Heater core (5) Expansion valve (A) Coolant inlet
(2) Blower fan (4) Evaporator (6) Thermostat (B) Coolant outlet
Air conditioning performance 2.52 to 3.08 kW At 1800 rpm (compressor)
Air conditioning air flow rate 280 m3/h -
At 6 L/min (coolant)
With the coolant 65 ℃
Air conditioning unit Heater performance 3.24 to 3.96 kW
hotter than the ambient
temperature
Heater air flow rate 250 m3/h -
Mass 6.9 kg -
Thermostat On 3.35 ℃ -
Thermos-amplifier
Off 2℃ -
Blower
Rotating direction (viewing from the fan side) Clockwise -
(Continued)
U30-6S 8-7

MECHANISM
8. AIR CONDITIONING AND HEATER SYSTEM 4. Air conditioning unit
Rotating speed (without load) 3900 to 4700 rpm -
Current (without load) 1 to 3 A -
Rotating speed (with load) 2520 to 3080 rpm -

Blower
Current (with load) 16.5 to 20.1 A -
461 N⋅m
Rated load torque -
47.0 kgf⋅m
Fan switch [1] 0.85 Ω -

Resistance
Blower resister Fan switch [2] 0.65 Ω -
Thermal fuse capacity 174 to 194 ℃ -
8-8 U30-6S

MECHANISM
4.2 Air conditioning unit function 4.2.3 Blower

and structure Blows the air to the evaporator and heater core.
4.2.1 Evaporator
Cools down the air which flows through the evaporator
by the evaporation heat.
(1) Fan (A) Air flow

(2) Blower motor
• The blower motor rotates the fan.

• The fan blows the air from inside to outside.
(1) Fin (A) Refrigerant liquid inlet • The air flows to the evaporator and heater core.
(2) Tube (B) Refrigerant liquid outlet
• The expansion valve sprays refrigerant liquid into

the evaporator. 4.2.4 Blower resistor
• The refrigerant liquid is evaporated due to the Controls the rotating speed of the blower.
sudden pressure decrease.
• The evaporator cools down the cabin air and
ambient inlet air by taking the evaporation heat.
4.2.2 Heater core

Heats up the air which flows through the heater core
with heat convection.
(A) [HI] (C) [LO]

(B) [MID]
• The fan switch shifts the current flow in the blower

resistor.
• The fan switch [1] operation conducts the [HI]
terminal to the [LO] terminal and the blower motor
rotates at low speed due to high resistance.
• The fan switch [2] operation conducts the [HI]
(1) Heater core (B) Coolant outlet terminal to the [MID] terminal and the blower motor
(A) Coolant inlet
rotates at medium speed due to low resistance.
• Heated coolant flows into the heater core. • The fan switch [3] operation cuts off the current
• The heater core heats up the air which flows flow to the resistor and the blower motor rotates at
through the heater core with heat convection. high speed due to no resistance.
U30-6S 8-9

MECHANISM
8. AIR CONDITIONING AND HEATER SYSTEM 4. Air conditioning unit
4.2.5 Expansion valve 4.2.6 Thermostat

Sprays the optimal volume of the refrigerant into the Cuts off the current flow to the compressor's magnetic
evaporator according to the temperature and pressure clutch to prevent frosting of the evaporator in case that
of the gas refrigerant. the evaporator is overcooled.
(1) Evaporator (8) Charged refrigerant

(2) Expansion valve (A) From the receiver (high pres-
(3) Diaphragm sure)
(4) Thermo-sensitive rod (B) To the compressor (low pres-
(5) Spring sure)
(6) Needle valve (C) To the evaporator
(7) Evaporated refrigerant (D) From the evaporator
• The refrigerant flows into the expansion valve and

is sprayed into the evaporator through the needle
valve. (1) Thermostat (3) Thermistor
• The evaporated refrigerant returns into the (2) Thermo-amplifier
expansion valve and presses the diaphragm. • The thermistor converts the evaporator temperature
• The refrigerant presses the diaphragm against the to the electric resistance.
evaporated refrigerant. • The temperature decreases, the resistance
• The expansion valve controls the spraying volume increases, and the thermo-amplifier cuts off the
according to the balance of the evaporated current flow to the compressor's magnetic clutch to
refrigerant pressure, refrigerant, and needle valve prevent frosting of the evaporator.
spring.
– The needle valve decreases the spraying
volume as the pressure of the evaporated
refrigerant increases.
– The spraying volume increases as the pressure
of the charged refrigerant increases due to the
increase of temperature.
8-10 U30-6S

MECHANISM
4.2.7 Heater valve 5.2 Condenser function and

Adjusts the coolant flow rate according to the motion of structure
the servomotor. Cools down and liquefies the discharged refrigerant
gas by heat convection.
(1) Heater valve (4) Coolant outlet

(2) Arm (A) Open
(3) Coolant inlet (B) Closed
• The servomotor connected to the heater valve

controls the arm of the heater valve according to
the air conditioning switch operation.
• The heater valve opens and the coolant flows into
the heater core.
5. Condenser
5.1 Condenser specifications
(1) Tube (A) Gas

(2) Fin (B) Vapor
(3) Refrigerant gas inlet (C) Liquid
(4) Refrigerant liquid outlet
• The discharged refrigerant gas flows into the

condenser from the compressor.
• The condenser cools down and liquefies the
refrigerant gas by heat convection.
(A) Refrigerant inlet (B) Refrigerant outlet
Specification
Manufacturer Denso
Mass 1.1 kg
U30-6S 8-11

MECHANISM
8. AIR CONDITIONING AND HEATER SYSTEM 6. Receiver
6. Receiver 6.2 Receiver function and structure

6.1 Receiver specifications Removes water and contamination from the refrigerant
liquid and accumulates the refrigerant liquid.
(1) Receiver (B) Refrigerant outlet

(A) Refrigerant inlet (1) Dryer (4) Tank
(2) Tube (A) Refrigerant liquid inlet
(3) Strainer (B) Refrigerant liquid outlet
Specification
• The refrigerant liquid flows into the receiver.
Capacity 0.55 L
• The refrigerant liquid flows through the dryer and
Hygroscopic capacity 32 g the dryer absorbs water in the refrigerant liquid.
5.30 MPa • The refrigerant liquid flows through the strainer, and
Pressure capacity
54.0 kgf/cm2 the strainer filters contamination in the refrigerant
liquid.
• The refrigerant liquid flows into the tank. The tank
accumulates the refrigerant liquid to supply
sufficient amount of refrigerant liquid constantly to
the expansion valve even if the compressor stops
temporarily.
8-12 U30-6S

MECHANISM
7. Pressure switch 8. AIR CONDITIONING AND HEATER SYSTEM
7. Pressure switch When the refrigerant liquid pressure is normal
7.1 Pressure switch specifications
(1) Diaphragm (5) Electrode

(2) Spring plate (6) Spring
(3) Pin (A) Refrigerant liquid
(1) Pressure switch (4) Plate
0.176 to 0.216 MPa • The refrigerant liquid presses the plate against the
Low cut off pressure
1.79 to 2.20 kgf/cm2 spring.
2.94 to 3.34 MPa
• The contacted electrodes conducts the current flow
High cut off pressure to the compressor's magnetic clutch.
30.0 to 34.0 kgf/cm2
When the refrigerant liquid pressure is extremely
high
7.2 Pressure switch function and
structure
Cuts off the current flow to the compressor's magnetic
clutch to protect the air conditioning devices in the case
that the refrigerant liquid pressure is extremely low or
high.
When the refrigerant liquid pressure is extremely
low
(1) Diaphragm (5) Electrode

(4) Plate
• The refrigerant liquid presses the pin.

• The pin separates the electrodes.
• The separated electrodes cut off the current flow to
the compressor's magnetic clutch to protect the air
conditioning devices by preventing increment of the
(1) Diaphragm (5) Electrode refrigerant liquid pressure.
(4) Plate
• The spring presses the plate.

• The separated electrodes cut off the current flow to
the compressor's magnetic clutch to protect the
compressor.
U30-6S 8-13

MECHANISM
8. AIR CONDITIONING AND HEATER SYSTEM 7. Pressure switch
8-14 U30-6S

SERVICING
1. Troubleshooting 8. AIR CONDITIONING AND HEATER SYSTEM
SERVICING
1. Troubleshooting
1.1 Air conditioning troubleshooting

Air conditioning is not working effectively
The condenser is clogged. Check the condition of the condenser. Clean the condenser.
Check the connection of the related connec-

The connector is disconnected. Reconnect the connector.
tors.
Check the conduction of the related fuses and Specify the cause of the fuse blowing and re-
The fuse or slow blow fuse has blown.
slow blow fuses. place the fuse.
The relay is malfunctioning. Check the conduction of the related relays. Replace the relay.
Operate the air conditioning switch and check

The air conditioning switch is malfunctioning. Replace the air conditioning switch.
the responses of the air conditioning devices.
The air conditioning belt is slipping. Check the tension of the air conditioning belt. Adjust the tension of the air conditioning belt.
Check the condition of the refrigerant with the

sight glass on the receiver. Specify the cause of the undercharging and
The refrigerant is undercharged.
Check the pressure of the refrigerant with a charge the refrigerant.
manifold gauge.
Check the condition of the refrigerant with the Specify the cause of air mixing and charge
Air is mixed in the refrigerant circuit.
sight glass on the receiver. the refrigerant.
Check the flow of the refrigerant with the sight

glass on the receiver.
The compressor is malfunctioning. Replace the compressor.
Check the pressure of the refrigerant with a
manifold gauge.

sight glass on the receiver.
The refrigerant is overcharged. Charge the refrigerant after vacuuming.
manifold gauge.
The pressure switch is malfunctioning Check the conduction of the pressure switch. Replace the pressure switch.

The expansion valve is malfunctioning. Replace the expansion valve.
manifold gauge.
Adjust the magnetic clutch air gap with the

The magnetic clutch air gap is too large. Check the air gap of the magnetic clutch.
shim.

The magnetic clutch is malfunctioning. Replace the magnetic clutch.
manifold gauge.
The evaporator is clogged or frosted. Check the condition of the evaporator. Clean the evaporator.
The thermostat is malfunctioning. Check the conduction of the thermostat. Replace the thermostat.

The receiver is clogged. Replace the receiver.
manifold gauge.
(Continued)
U30-6S 8-15

SERVICING
8. AIR CONDITIONING AND HEATER SYSTEM 1. Troubleshooting
Check the conduction of the related wire har-

The wire harness is damaged. Repair or replace the wire harness.
nesses.
The heater valve cable is not installed proper- Check the movement of the lever of the air
Adjust the heater valve cable installation.
ly. conditioning switch.
Not heating effectively
The heater hose is bent, damaged or Check the bend, damage, and pinch of the
Replace the heater hose.
pinched. heater hoses.

tors.
The heater valve is clogged. Check the condition of the heater valve. Replace the heater valve.

The heater valve cable is not installed proper- Check the movement of the lever of the air
Adjust the heater valve cable installation.
ly. conditioning switch.

nesses.
Air flow is too cold
The thermostat is malfunctioning. Check the conduction of the thermostat. Replace the thermostat.

The heater valve is clogged. Check the condition of the heater valve. Replace the heater valve.
Check the movement of the heater valve ca-

The heater valve cable is damaged. Replace the heater valve cable.
ble.
The heater valve cable is disconnected or Check the installation of the heater valve ca-
Reinstall the heater valve cable.
connected insecurely. ble.
The heater hose is bent, damaged or Check the bend, damage, and pinch of the
Replace the heater hose.
pinched. heater hoses.
Air flow is too hot
Check the motion of the servomotor on the

The heater valve is stuck. Replace the heater valve.
heater valve.

Check the movement of the heater valve ca-

The heater valve cable is damaged. Replace the heater valve cable.
ble.
8-16 U30-6S

SERVICING
1. Troubleshooting 8. AIR CONDITIONING AND HEATER SYSTEM
Insufficient air flow
Clean the air filter.

The air filter is clogged. Check the condition of the air filters.
Replace the air filter.
Clean the air vent.

The air vent is clogged. Check the condition of the air vents.
Replace the air vent.

The connector is connected insecurely. Reconnect the connector.
tors.
The fan switch is damaged. Check the conduction of the fan switch. Replace the fan switch.
The fan is deformed. Check the deformation of the fan. Replace the blower.
The blower motor is malfunctioning. Check the motion of the blower motor. Replace the blower.
The blower resister is damaged. Check the resistance of the blower resister. Replace the blower resister.
The air duct is detached. Check the connections of the air ducts. Reinstall the air duct.

nesses.
Clean the air duct.

The air duct is clogged. Check the condition of the air ducts.
Replace the air duct.
Insufficient air flow
Clean the air filter.

The air filter is clogged. Check the condition of the air filters.
Replace the air filter.
Clean the air vent.


The connector is connected insecurely. Reconnect the connector.
tors.

nesses.
Clean the air duct.

U30-6S 8-17

SERVICING
8. AIR CONDITIONING AND HEATER SYSTEM 1. Troubleshooting
No air flow
The relay is malfunctioning. Check the conduction of the related relays. Replace the relay.

tors.

nesses.
Clean the air duct.

Clean the air vent.

Noise
The air conditioning belt is slipping. Check the tension of the air conditioning belt. Adjust the tension of the air conditioning belt.
The compressor is malfunctioning. Check the noise of the compressor. Replace the compressor.
The blower motor is malfunctioning. Check the noise of the blower motor. Replace the blower.

sight glass on the receiver.
The refrigerant is overcharged. Charge the refrigerant after vacuuming.
manifold gauge.

sight glass on the receiver. Specify the cause of the undercharging and
The refrigerant is undercharged.
Check the pressure of the refrigerant with a charge the refrigerant.
manifold gauge.
Check the noise the fan.

The fan is deformed. Replace the blower.
Check the deformation of the fan.
Clean the air duct.

Clean the air vent.

8-18 U30-6S

SERVICING
2. Service specifications 8. AIR CONDITIONING AND HEATER SYSTEM
2.1 Service specifications for the air conditioning system

Unit
Amount Refrigerant g 930 ±50 -
Air gap Magnetic clutch mm 0.5 -0.20 to +0.15 -
MPa 1.47 ±0.20

High pressure -
kgf/cm2 15.0 ±2.0
Pressure Refrigerant
MPa 0.18 ±0.02
Low pressure -
kgf/cm2 1.84 ±0.2
Dimension Air conditioning belt mm 13.5 ±1.5 -
3. Testing
3.1 Measuring the refrigerant
pressure
Measure the refrigerant pressure with a manifold gauge
to check the condition of the cooling circuit.
CAUTION
working area. (A) Manifold gauge (D) High pressure gauge
(B) High pressure valve (E) Low pressure gauge
IMPORTANT (C) Low pressure valve
• The R134a refrigerant must be handled by 2. Connect the refrigerant charging hose (red) to the
trained personnel when measuring, vacuuming, high pressure charging port and the refrigerant
and charging. charging hose (blue) to the low pressure charging
• Work at the clean and dry work space with port.
manual for details when handling the manifold
gauge.

manifold gauge.
U30-6S 8-19

SERVICING
8. AIR CONDITIONING AND HEATER SYSTEM 3. Testing
(A) Manifold gauge (H) Refrigerant charging hose (L) Fan switch position [1] (N) Fan switch position [3]
(B) High pressure valve (red) (M) Fan switch position [2]
(C) Low pressure valve (J) Refrigerant charging hose
(F) High pressure charging port (blue) 10. Warm up the engine in the idling speed to warm up
([H] mark) the refrigerant.
(G) Low pressure charging port 11. Accelerate the engine speed to 1500 rpm.
([L] mark)
12. Measure the high and low pressures of the
3. Open the low pressure valve of the manifold gauge refrigerant.
slightly and press the air bleeding valve to release
the air in the refrigerant charging hose (blue) and NOTE
manifold gauge. • Close the cabin door and windows if the
ambient temperature exceeds 40 ℃.
• Turn the fan switch to the minimum air flow
(fan switch position [1]) if the ambient
temperature exceeds 40 ℃.
1.27 to 1.67 MPa
High pressure
13.0 to 17.0 kgf/cm2
0.16 to 0.20 MPa

Low pressure
1.6 to 2.0 kgf/cm2
13. Stop the engine and disconnect the refrigerant

charging hoses.
NOTE
(A) Manifold gauge (K) Air bleeding valve
(B) High pressure valve • Disconnect the refrigerant charging hoses
(C) Low pressure valve from the charging ports quickly to avoid
refrigerant leaking to atmosphere.
4. Close the low pressure valve of the manifold gauge
after bleeding air completely.
5. Open the high pressure valve of the manifold gauge
slightly and press the air bleeding valve to release
3.2 Checking the fan switch
the air in the refrigerant charging hose (red) and Check the conduction of the fan switch in each
manifold gauge. operation to check the condition of the fan switch.
6. Close the high pressure valve of the manifold Preparing
gauge after bleeding air completely. 1. Stop the engine.
7. Start the engine and open the cabin door and 2. Open the bonnet RH 1.
windows. 3. Disconnect the negative (-) terminal of the battery.
8. Turn on the air conditioning switch and adjust the 4. Disconnect all connectors from the air conditioning
temperature switch to the coolest level. panel, and remove the air conditioning panel.
9. Turn the fan switch to the maximum air flow (fan
Checking
switch position [3]).
1. Check the conduction of the fan switch position [1]
operation.
8-20 U30-6S

SERVICING
3. Testing 8. AIR CONDITIONING AND HEATER SYSTEM
(A) Fan switch position [1] (C) Fan switch position [3] • The terminals 2 and 7 conduct.
(B) Fan switch position [2]
• The terminals 2 and 3 conduct.
3. Check the conduction of the fan switch [3]
operation.
(1) Fan switch connector

3.3 Measuring the magnetic clutch

pulley air gap
There is a possibility of the magnetic clutch trouble in
case that air conditioning is not working effectively.
Measure the magnetic clutch pulley air gap and adjust
as needed.
Preparing
• The terminals 2 and 7 conduct. 1. Stop the engine.
2. Check the conduction of the fan switch position [2] 2. Open the rear bonnet.
operation. 3. Remove the 2 clamps to disconnect the wire
harness.
4. Remove the 2 bolts to remove the fan cover.
U30-6S 8-21

SERVICING
8. AIR CONDITIONING AND HEATER SYSTEM 3. Testing
(1) Clamp ×2 (3) Fan cover (4) Hub plate (7) Bolt (M6 × 16)
(2) Bolt (M8 × 16) ×2 (5) Pulley
(6) Shim
Measuring 2. Adjust the air gap by installing proper thickness
1. Check the air gap between the pulley and hub plate shims.
with a feeler gauge. 3. Install the pulley and bolt.
Tightening torque
15 to 21 N⋅m
(7) Bolt -
1.5 to 2.1 kgf⋅m
4. Check the air gap.
3.4 Checking the blower resister

Check the resistance of the blower resister in each
operation.
Preparing
Checking
1. Disconnect the blower resister connector from the
blower resister.
(4) Hub plate (a) Air gap

(5) Pulley
Service specification (1) Blower resister connector (2) Blower resister

(a) 0.30 to 0.65 mm 2. Check the resistance of the blower resister.
Adjusting
1. Remove the bolt and pulley.
8-22 U30-6S

SERVICING
4. Repairing 8. AIR CONDITIONING AND HEATER SYSTEM
Preparing
3. Remove the air conditioning belt.
4. Tilt the seat.
Removing
1. Remove the 3 bolts to remove the clamp, suction
hose and discharge hose 1.
(1) Blower resister connector (E) Fan switch [2] operation

(A) [HI] (conducting [HI] and [MID])
(B) [MID]
(C) [LO]
(D) Fan switch [1] operation
(conducting [HI] and [LO])
(D) 1.50 Ω
(E) 0.65 Ω
(1) Bolt (M6 × 30) ×2 (4) Bolt (M6 × 25)

(2) Discharge hose 1 (5) Clamp
4. Repairing (3) Suction hose
4.1 Compressor 2. Remove the 5 bolts to remove the center cover.

compressor
CAUTION
working area.
corrosion.
IMPORTANT 3. Disconnect the magnetic clutch connector.
• The R134a refrigerant must be handled by 4. Remove the bolt and 2 nuts to remove the
trained personnel when measuring, vacuuming, compressor bracket and compressor.
and charging.
contamination.
on.
damage when installing.
U30-6S 8-23

SERVICING
8. AIR CONDITIONING AND HEATER SYSTEM 4. Repairing
NOTE
• Make sure to adjust the volume of the
compressor oil to prevent filling excessive
volume of the compressor oil into the
cooling circuit.
3. Install the compressor.
NOTE
• Tighten the bolts near the magnetic clutch
pulley first.
• Insert the bushing as the bushing flange
seats between the compressor and bracket.
(8) Bolt (M8 × 25) (11) Compressor (9) Compressor bracket (16) Bushing
(9) Compressor bracket (11) Compressor (17) Bushing flange
(10) Nut (M6) ×2 (14) Bolt (M8 × 25) ×2 (18) Magnetic clutch pulley
(15) Bolt (M8 × 35)
Installing 4. Install the air conditioning belt and adjust its
1. Drain the compressor oil and measure the volume tension.
of the compressor oil in the removed and new
compressors.
(11) Compressor (23) Crankshaft pulley

(19) Bolt (M12 × 25) (24) Locknut (M8)
(12) New compressor (A) Excessive oil (20) Tension pulley stay (25) Adjusting bolt (M8 × 100)
(13) Removed compressor (21) Tension pulley
(22) Air conditioning belt
NOTE Adjusting dimension

• New compressor contains 110 to 120 ml of
Push with 58.8 to
compressor oil.
68.6 N
(a) 12 to 15 mm
2. Fill the same volume of the compressor oil into the Push with 6.0 to
new compressor as the volume of the removed 7.0 kgf
compressor's oil. 5. Install the suction hose and discharge hose 1.
8-24 U30-6S

SERVICING
Tightening torque
7.9 to 11.8 N⋅m
(1) Bolt -
0.8 to 1.2 kgf⋅m
16.7 to 19.6 N⋅m

(14) (15) Bolt -
1.7 to 2.0 kgf⋅m
17.7 to 20.6 N⋅m

(24) Locknut -
1.8 to 2.1 kgf⋅m
6. Charge the refrigerant.
4.2 Air conditioning unit

4.2.1 Removing and installing the air
conditioning unit (1) Bolt (M10 × 30) ×2 (2) Cover

CAUTION
working area.
corrosion.
IMPORTANT
and charging.
• Work at the clean and dry work space with (3) Bolt (M8 × 25) (5) Partition cover
(4) Bolt (M8 × 16) ×3
• Install plugs to the disconnected hoses, pipes, 3. Remove the 4 bolts to remove the center bonnet.
contamination.
on.
damage when installing.
Preparing
4. Remove the bonnet LH. (6) Bolt (M10 × 20) × 4 (7) Center bonnet
5. Vacuum the refrigerant from the cooling circuit. 4. Remove the 4 bolts to remove the plate and
6. Drain the coolant. grommet.
7. Remove the cabin.
8. Remove the seat.
Removing
U30-6S 8-25

SERVICING
(8) Bolt (M8 × 100) × 2 (11) Grommet (18) Bolt (M10 × 16) ×4 (19) Air conditioning unit
(9) Bolt (M8 × 20) × 2
(10) Plate Installing
5. Remove the 2 nuts to disconnect the suction hose
IMPORTANT
and liquid hose 2.
• Charge the refrigerant after installing.
• Fill the coolant into the engine after installing.
Tightening torque
29.4 to 34.3 N⋅m
(12) Nut -
3.0 to 3.5 kgf⋅m
11.6 to 14.7 N⋅m

(13) Nut -
1.2 to 1.5 kgf⋅m
4.3 Blower resistor

4.3.1 Removing the blower resister
Preparing
(12) Nut (M24) (15) Liquid hose 2
(13) Nut (M16) Removing
(14) Suction hose
1. Disconnect the blower resister connector from the
6. Remove the 2 clamps to disconnect the 2 heater blower resister.
hoses.
(1) Blower resister connector (2) Blower resister

2. Remove the 2 screws to remove the blower
7. Remove the 4 bolts to remove the air conditioning resister.
unit.
8-26 U30-6S

SERVICING
(2) Blower resister (3) Screw ×2 (1) Bolt (M10 × 30) ×2 (2) Cover

4.4 Heater valve
4.4.1 Removing and installing the heater
valve
CAUTION
working area.
corrosion. (3) Bolt (M8 × 25) (5) Partition cover
(4) Bolt (M8 × 16) ×3
IMPORTANT
and charging.
contamination.
Preparing
7. Remove the cabin. 4. Remove the 2 clamps to disconnect the 2 heater
8. Remove the seat. hoses.
Removing
U30-6S 8-27

SERVICING
Installing
5. Remove the screw to disconnect the heater valve (11) Heater valve cable (D) To switch the heater valve
cable from the heater valve. (12) Heater valve lever to the close position,
(14) Air conditioning switch as- clamp the outer part of the
sembly cable while pulling the cable
(A) Cooling and the lever of the air con-
(B) Valve closed ditioner switch assembly is in
(C) Pull out the outer part of the the cooler position.
cable 5 mm from the clamp
and set it.
4.5 Condenser
condenser
CAUTION
(10) Screw (12) Heater valve
(11) Heater valve cable protect your skin and eyes. Liquid refrigerant
6. Remove the 2 screws to remove the heater valve. • Keep fire and flammable items away from the
working area.
corrosion.
IMPORTANT
and charging.
contamination.
(12) Heater valve (13) Screw ×2
on.
Preparing
3. Remove the receiver.
8-28 U30-6S

SERVICING
Removing Tightening torque

1. Remove the nut to remove the discharge hose 2.
19.6 to 24.5 N⋅m
(1) Nut -
2.0 to 2.5 kgf⋅m
4.6 Receiver
4.6.1 Removing and installing the receiver
CAUTION
working area.
(1) Nut (M22) (2) Discharge hose 2 Residual water in the cooling circuit may cause
2. Disconnect the condenser fan switch connector. corrosion.
IMPORTANT
and charging.
contamination.
(3) Condenser fan switch con- on.
nector • Apply compressor oil to every O-ring to avoid
3. Remove the 3 bolts to remove the condenser damage when installing.
assembly. • Remove plugs on a new receiver just before
installation. If removed beforehand, dryer in the
receiver absorbs moisture in the atmosphere.
Preparing
Removing
1. Remove the 4 bolts to remove the condenser cover.
(4) Bolt (M10 × 25) ×3 (5) Condenser assembly
Installing
IMPORTANT
U30-6S 8-29

SERVICING
(1) Bolt (M8 ×20) ×4 (2) Condenser cover (8) Bolt (M8 × 16) ×2 (9) Receiver
2. Disconnect the pressure switch connector. Installing

IMPORTANT
Tightening torque
4.0 to 6.8 N⋅m
(4) Bolt -
0.4 to 0.7 kgf⋅m
(3) Pressure switch connector
3. Remove the 3 bolts to remove the liquid hose 1,

liquid pipe and clamp.
(4) Bolt (M6 × 25) ×2 (7) Liquid hose 1

(5) Bolt (M6 × 12)
(6) Liquid pipe
4. Remove the 2 bolts to remove the receiver.
8-30 U30-6S

SERVICING
4.7 Air conditioning and heater hoses

4.7.1 Air conditioning and heater hose routing
Air conditioning hoses
U30-6S 8-31

SERVICING
(1) Liquid pipe (8) Air conditioning unit (B) Pass above the arch guide (F) Make the end of the clamp
(2) Liquid hose 2 (9) Compressor bar. face the radiator side.
(3) Liquid hose 1 (10) Receiver (C) Pass under the arch guide (G) Clamp with a cord band.
(4) Discharge hose 1 (11) Condenser bar. (H) Clamp at the hose tape posi-
(5) Discharge hose 3 (A) Pass between the arch guide (D) Make the hexagonal end con- tion (the tape is on the radiator
(6) Discharge hose 2 bars. tact the rubber clamp. side).
(7) Suction hose (E) Align with the white tape. (a) 15°
(b) 60°
8-32 U30-6S

SERVICING
(1) Liquid pipe (4) Discharge hose 1 (7) Suction hose (L) M24 × 1.5
(2) Liquid hose 2 (5) Discharge hose 3 (J) M16 × 1.5
(3) Liquid hose 1 (6) Discharge hose 2 (K) M22 × 1.5
U30-6S 8-33

SERVICING
No. Point of use Hose Length Protection tube Length
(c) 262 to 278 mm

(2) Receiver - Air conditioning unit (e) 835 mm
(d) 1980 to 2020 mm
(3) Condenser - Receiver (f) 180 to 200 mm - -
(4) (g) 352 to 368 mm - -
(5) Compressor - Condenser (h) 2574 to 2626 mm (i) 820 mm
(6) (j) 750 to 770 mm (k) 404 mm
(7) Air conditioning unit - Compressor (m) 1085 to 1115 mm - -
Heater hoses
IMPORTANT
• Do not kink the heater hoses.
• Do not make the heater hoses contact the exhaust manifold.
• Firmly insert the heater hoses.
(8) Air conditioning unit (13) Heater hose (outlet) (15) Engine
(12) Heater hose (inlet) (14) Heater valve
No. Point of use Inner diameter
(12) Engine - Heater core ϕ13 mm
(13) Heater core - Engine ϕ13 mm
8-34 U30-6S

9. APPENDICES

APPENDICES
1. Servicing information 9. APPENDICES
APPENDICES
1. Servicing information
1.1 Service specifications for the machine body

– Engine speed: Maximum

Unit
1 mm of wear on the
Pin - - -
pin outer diameter
Wear 1 mm of wear on the
Bushing - - - bushing inner diam-
eter
Swivel bearing (vertical play) mm Less than 1.04 - Less than 2.08
Play
Front attachment mm Less than 70 - Less than 140
Swing bracket (vertical clearance) mm 0.45 ±0.35 -

Clearance
Front attachment (each pin) mm 0.6 - -
N 11 ±5.0
Forward -
kgf 1.1 ±0.51
Pilot control N 10 ±5.0

Backward -
lever kgf 1.0 ±0.51
N 7 ±5.0
RH and LH -
kgf 0.7 ±0.51
N 19 ±5.0
Forward -
Travel con- kgf 1.9 ±0.51
trol lever N 19 ±5.0
Control lever Backward -
kgf 1.9 ±0.51
N 25 ±5.0
Forward -
Blade control kgf 2.5 ±0.51
lever N 24 ±5.0
Force Backward -
kgf 2.4 ±0.51
N 69 ±14.5
Raising -
kgf 7.0 ±1.48
Lever lock
N 69 ±9.5
Lowering -
kgf 7.0 ±0.97
N 56 ±10.0
RH -
Swing con- kgf 5.7 ±1.02
trol pedal N 63 ±10.0
LH -
kgf 6.4 ±1.02
Control pedal
N 73 ±10.0
Forward -
AUX control kgf 7.4 ±1.02
pedal N 76 ±10.0
Backward -
kgf 7.8 ±1.02
(Continued)
U30-6S 9-1

APPENDICES
9. APPENDICES 1. Servicing information

Unit
Width mm 300 - -
Link length mm 406.4 - 416.4
Height mm 68 - 63
Grouser height mm 16.5 - 8.0
Bushing length mm 55 -0.2 -
Bushing inner +0.40

mm ϕ17 ϕ19.6
diameter +0.55
Bushing outer
mm ϕ28 -0.04 ϕ25.4
diameter
Steel track Master pin
mm 96.5 - -
length
Master pin out-

mm ϕ17 -0.03 -
er diameter
Track
Pin length mm 97 ±0.5 -
Pin outer di- +0.17

mm ϕ17 ϕ13
ameter +0.23
Number of
- 42 - -
links
Tension di-
mm 77.5 ±2.5 -
mension
Lug height mm 22 - -
Link height mm 23.5 - -

Dimension
Width mm 295 - -
Rubber track
Height mm 75 - -
Tension di-
mm 12.5 ±2.5 -
mension
Carrier roller Outer diameter mm ϕ76.3 - ϕ72.3
Front idler Guide width mm 30 - 24
Idler width mm 72 - -
-2.0
Outer diameter mm ϕ361 ϕ355
+1.0
Sprocket Inner diameter mm ϕ184 - -
Sprocket width mm 18 - 12
Gear height mm 88.25 ±0.75 85.25
Spring dimen-
Steel track mm 251 ±1.0 -
sion
Tension spring
Spring dimen-
Rubber track mm 242 ±1.0 -
sion
Guide diameter mm ϕ80 -2.0 ϕ74
Guide width mm 81 - 87
Track roller
Roller width mm 175 +0.4 -
9-2 U30-6S

APPENDICES
1.2 Service specifications for the engine

Unit
MPa 3.1 ±0.1 2.4

Engine compression
kgf/cm2 31.6 ±1.0 24.5
Pressure
kPa 367.5 ±73.5 250
Engine oil At the rated speed
kgf/cm2 3.75 ±0.75 2.55
1.3 Service specifications for the hydraulic system

NOTE
– Warm up the hydraulic oil and devices to 50±5 ℃.
– Accelerate the engine to the maximum speed.
– Turn the auto-idle switch and AC switch OFF.
– Hydraulic cylinder speed does not include cushioning.

Unit
P MPa 24.5 -0.5 to +1.0

Main relief valve -
(aLS) kgf/cm2 249.8 -5.1 to +10.2
MPa 2.3 ±0.2

Unload relief valve aUN -
kgf/cm2 23.5 ±2.0
Pilot primary MPa 4.3 ±0.5

Pilot primary pressure relief valve -
(aPP) kgf/cm2 43.9 ±5.1
Boom bottom MPa 26.0 ±0.3

-
(b1B) kgf/cm2 265.1 ±3.1
Boom rod MPa 26.0 ±0.3

-
(b1R) kgf/cm2 265.1 ±3.1
Arm bottom MPa 26.0 ±0.3

-
(b2B) kgf/cm2 265.1 ±3.1
Arm rod MPa 26.0 ±0.3

-
(b2R) kgf/cm2 265.1 ±3.1
Pressure
Bucket bottom MPa 26.0 ±0.3
-
(b3B) kgf/cm2 265.1 ±3.1
Overload relief valve
Bucket rod MPa 26.0 ±0.3
-
(b3R) kgf/cm2 265.1 ±3.1
Blade bottom MPa 30.0 ±0.3

-
(b4B) kgf/cm2 305.9 ±3.1
Blade rod MPa 17.0 ±0.3

-
(b4R) kgf/cm2 173.4 ±3.1
AUX LH MPa 20.0 ±0.3

-
(b5L) kgf/cm2 203.9 ±3.1
AUX RH MPa 20.0 ±0.3

-
(b5R) kgf/cm2 203.9 ±3.1
Swivel motor overload relief pres- Left MPa 24.0

- -
sure (cSL) kgf/cm2 244.7
(Continued)
U30-6S 9-3

APPENDICES

Unit
Swivel motor overload relief pres- Right MPa 24.0

Pressure - -
sure (cSR) kgf/cm2 244.7
Piston pump (P)

(Engine speed: maximum speed, no load, maximum L/min 86.7 - 69.4
flow rate)
Flow rate
AUX
(Engine speed: maximum speed, no load, maximum L/min 51.7 - -
flow rate)
Boom
Arm
Bucket
Rubber tracks
Hydraulic cylin- fication
der
Rubber tracks
Blade cation
Internal leak-
(10 min, en-
age Steel tracks
gine stopped)
fication
Steel tracks
cation
Engine stop- mm 0 26.1

-
ped ° 0 5
Swivel motor Less than
Engine running mm 156.8
156.8 -
in idle speed ° 30
Less than 30
Travel motor (20° slope) mm 0 - -

L/min - 0.5
(Rotating) 0.035
Swivel motor
L/min - 1.0
(Relief) 0.210
Low speed Less than

L/min - 0.7
(Rotating) 0.045
Drain
L/min - -
(Rotating) 0.230
Travel motor
Low speed Less than
L/min - -
(Relief) 0.340

L/min - -
(Relief) 0.245
Lifting
(Ground to s 2.4 ±0.3 -
Canopy speci- highest)
Speed Boom cylinder fication Lowering
ground)
(Continued)
9-4 U30-6S

APPENDICES

Unit
Lifting
(Ground to s 2.3 ±0.3 -
Cabin specifi- highest)
Boom cylinder
cation Lowering
ground)

Arm cylinder

Bucket cylinder
Lifting
(Lowest to s 2.4 ±0.3 -
highest)
Blade cylinder
Lowering
Speed lowest)
Swing left s 6.0 ±0.5 -

Swing cylinder
Swing right s 5.0 ±0.5 -
rpm 8.6 ±0.9

Left -
s/3 rotations 20.9 -2.0 to +2.5
Swivel motor
rpm 8.6 ±0.9
Right -
s/3 rotations 20.9 -2.0 to +2.5
s/10 m 13.8 -1.4 to +1.9

Low speed -
km/h 2.6 ±0.3
Rubber tracks
s/10 m 8.0 ±0.8
High speed -
km/h 4.5 -0.4 to +0.5
Travel motor
s/10 m 14.4 -1.5 to +1.3
Low speed -
km/h 2.5 -0.2 to +0.3
Steel tracks
s/10 m 8.2 -0.7 to +1.0
High speed -
km/h 4.4 -0.5 to +0.4
Travel straightness
mm - - 600
(10 m)
U30-6S 9-5

APPENDICES
1.3.1 Piston pump P-Q performance

– Hydraulic oil and devices temperature: 50 ℃ (including motor, pump, and cylinders)
– Engine speed: maximum
– AI switch and AC switch: OFF
(A) Flow rate (L/min) (B) Pressure (MPa)
Pressure Flow rate (converted to 2200 rpm)
MPa kgf/cm2 L/min
7.5 76.5 78.8
10.0 102.0 65.7
12.5 127.5 52.6
15.0 153.0 45.4
17.5 178.5 39.3
20.0 203.9 34.0
22.5 229.4 27.2
25.0 254.9 13.3
Service limit
• The service limit is 80% of the service specification.
9-6 U30-6S

APPENDICES
1.3.2 AUX P-Q performance

– Hydraulic oil and devices temperature: 50 ℃ (including motor, pump, and cylinders)
– Engine speed: maximum
– AI switch and AC switch: OFF
(A) Flow rate (L/min) (D) AUX LH (third line open) (G) Back pressure (AUX LH (third (H) Back pressure (AUX LH (third
(B) Pressure (MPa) (E) AUX LH (third line close) line open)) line close))
(C) Back pressure (MPa) (F) AUX RH (third line close) (J) Back pressure (AUX RH (third
line close))
AUX LH (third line open)

5.0 51.0 46.9 0.9 9.2
7.5 76.5 45.9 0.9 9.2
10.0 102.0 45.0 0.8 8.2
12.5 127.5 42.5 0.7 7.1
15.0 153.0 37.4 0.6 6.1
17.5 178.5 32.5 0.5 5.1
20.0 203.9 27.0 0.4 4.1
U30-6S 9-7

APPENDICES
AUX LH (third line close)

5.0 51.0 47.7 1.7 17.3
7.5 76.5 46.5 1.6 16.3
10.0 102.0 44.9 1.4 14.3
12.5 127.5 42.9 1.3 13.3
15.0 153.0 38.4 1.1 11.2
17.5 178.5 33.7 0.9 9.2
20.0 203.9 27.8 0.7 7.1
AUX RH (third line close)

5.0 51.0 47.8 1.4 14.3
7.5 76.5 46.8 1.3 13.3
10.0 102.0 45.9 1.2 12.2
12.5 127.5 42.4 1.1 11.2
15.0 153.0 37.7 0.9 9.2
17.5 178.5 32.8 0.8 8.2
20.0 203.9 27.8 0.6 6.1
9-8 U30-6S

APPENDICES
1.4 Service dealer mode
1.4.1 Tester mode

Tester mode item list
Engine speed • Present value (engine speed) -
Battery voltage • Battery voltage ±0.5 V -
Oil switch • Engine stopped: ON -

1
Charging switch • Engine running: OFF -
• Starter switch [START]: ON

Starter switch -
• Starter switch [RUN] or [STOP]: OFF
CRS engine voltage

Coolant temperature • Present value (V): 4.38 to 0.91
(V) is a dummy data
2 • Present value (V)

Fuel -
• Present value (Ω)
Fuel supply switch • Switch pressed: ON For EU spec. only
Travel speed shift switch • Switch pressed: ON -
Travel speed shift sole- • With output signal from main ECU: ON
-
• Lever down: ON
Lever lock switch -
• Lever up: OFF
3
Lever lock solenoid -
• More than 104 ℃ (219 ℉): hydraulic oil

Hydraulic oil temperature overheating warning
-
sensor • Less than -1 ℃ (30 ℉): hydraulic oil warm-
ing up warning (yellow lamp blinking)

Accelerator potentiometer -
• Setting value: MIN/MAX
• Present value: 0.25 to 4.75 V Values for the CRS

4 Governor potentiometer
• Setting value: MIN/MAX engine and electronic
• AI motor in operation: 0.0 to 15.0 A governor engine are
Motor amperage dummy data
• AI motor hold: 0.0 to 2.0 A
• Not operating: ON
AI pressure switch -
• Operating: OFF
AI control switch -
Compressor • Operating: ON -
5
Coolant temperature • Present value (℃) -
Values for the CRS

engine and electronic
Idle up • Idle up setting value (V)
governor engine are
dummy data

• Setting value: neutral Hand proportional
6
AUX spec.
AUX current
(Continued)
U30-6S 9-9

APPENDICES
• Switch pressed: ON Hand proportional

6 AUX hold switch
• Switch released: OFF AUX spec.

Hand proportional
AUX current AUX2 spec.
AUX hold switch
AUX1 right setting
AUX1 left setting Hand proportional

8 • AUX start point set value
AUX2 right setting AUX spec.
AUX2 left setting
Arm limit set value • Arm stop setting value

9 Arm limit spec.
Multipurpose solenoid
• Antenna working normally: ○

Anti-theft antenna
• Antenna error: ×
Key exists / does not exist Key exists: ○ Anti-theft mode on: ○
Enabled / Disabled Key does not exist: × Anti-theft mode off: ×
Red key is matched: Black key is matched:

Red key ○ ○
Black key Red key is mismatch- Red or black key is
ed: × mismatched: × If unknown or can-
10
celed: -
Yellow key ed: ○ ed: ○
Green key Yellow key is mis- Green key is mis-

(Tag) yellow ed: ○ ed: ○
(Tag) green Yellow key is mis- Green key is mis-
Angle switch RH • Switch pressed: ON

Angle switch LH • Switch released: OFF
11 Angle blade spec.
Angle solenoid RH • With output signal from main ECU: ON
Angle solenoid LH • No output signal from main ECU: OFF
Tilt switch RH • Switch pressed: ON

Tilt switch LH • Switch released: OFF
12 Tilt angle blade spec.
Tilt solenoid RH • With output signal from main ECU: ON
Tilt solenoid LH • No output signal from main ECU: OFF
(Continued)
9-10 U30-6S

APPENDICES
Actual load • Present value (kg)
Rated load • Present value (kg)
13 Radius • Present value (mm)
Height • Present value (mm)
Travel pressure • Present value (MPa)
• Present value: 0.25 to 4.75 V Crane spec.

Arm potentiometer • Setting value: arm crowd (low) to arm
dump (high)

14
Boom potentiometer • Setting value: boom down (low) to boom
up (high)
Bottom pressure / rod

pressure

Boom bottom pressure
• Present value (MPa) For EU spec. only
15 Warning pressure • Present value (MPa)

Boom rod pressure Dummy data
• Present value (MPa)
Multipurpose1 switch 1 (AI

console) • Switch pressed: ON
Multipurpose1 switch 2 • Switch released: OFF Multipurpose switch
16
(AUX knob LH) spec.
Multipurpose switch sole- • With output signal from main ECU: ON

Compressor switch • Operating: ON -
• Stopped / fine control: ON

Boom up pressure switch -
• Full stroke operation: OFF
• Switch pressed: ON For eco mode spec.

17 Eco switch
• Switch released: OFF only
Pump solenoid • Operating: ON -
For eco mode spec.

Eco solenoid • Operating: ON
only
• Present value (V) -

Travel pressure sensor
• Present value (MPa) -
18 DPF switch -
Work light switch -
Engine stop switch CRS spec.
Boom potentiometer
19 Offset potentiometer RX series

Boom arm setting • Setting value: boom raise, arm crowd
Offset setting • Setting value: offset RH (high)

(Continued)
U30-6S 9-11

APPENDICES
Boom solenoid
Arm dumping/crowding
• Stopped: 0.0 to 0.6 A
Offset solenoid
20
Arm dumping / arm crowd-
• Start point setting: arm dump, arm crowd
ing setting
Boom offset setting • Start point setting: boom raise, offset right RX series
Emergency switch
• During boom raise operation: ON

21 Boom up pressure switch
• Not operating: OFF
• Normal: ON
Boom height limit
• At the height limit: OFF
Meter • Normal: ○ (with meter panel) -
ECU (Main) • Normal: ○ (with ECU (main)) -
22 ECU (AS) • Normal: × (with ECU (AS)) RX series
CRS spec.
ECU (Eng) • Normal: × (with ECU (engine)) Electrical governor
sensor spec.
Meter - -

23
ECU (Main) - -

24
ECU (AS) -
Ver. • Program version

25 RX series
Rev. • Program creation date (Y/M/D)
Serial No. • Serial No.
1.4.2 Default settings

IMPORTANT
• @ - Input a parameter according to the specification of the machine.
9-12 U30-6S

APPENDICES
Screen No. Content displayed U30-6S Remarks
(1) Model “U30” -
(2) Region / Area “Asia” @
(3) AI “YES” -
(4) Overload warning “NO” -
(5) AUX1 “Foot (No)” -
(6) AUX2 / Thumb “Foot (No)” -
(7) Arm control “NO” -
(8) Angle (blade) “NO” @
(9) Tilt (blade) “NO” -
(10) Multipurpose operating “NO” -
Arm type
(11) 1: Standard 1 -
2: Long
Canopy spec.: “Canopy”

(12) Compartment -
Cabin spec.: “Cab”
Engine power limit

0: Standard
(13) 1: Eco mode (EP solenoid) 0 -
2: Air conditioning
3: Eco mode (gain solenoid)
Engine type
1: Common rail engine or electrical
(14) 2 -
governor engine
2: Mechanical engine
(15) Setup complete - -
U30-6S 9-13

APPENDICES
9-14 U30-6S

APPENDICES
2. Hydraulic circuit diagram 9. APPENDICES
2. Hydraulic circuit diagram
U30-6S 9-15

APPENDICES
9. APPENDICES 3. Wire harness
3. Wire harness
9-16 U30-6S

APPENDICES
9. APPENDICES
U30-6S 9-17

APPENDICES
9. APPENDICES
9-18 U30-6S

APPENDICES
9. APPENDICES
U30-6S 9-19

APPENDICES
9. APPENDICES
9-20 U30-6S

APPENDICES
9. APPENDICES
U30-6S 9-21

APPENDICES
9. APPENDICES 4. Normal mode and user setting mode flow chart
4. Normal mode and user setting mode flow chart
9-22 U30-6S

APPENDICES
5. Service dealer mode flow chart 9. APPENDICES
5. Service dealer mode flow chart
U30-6S 9-23

APPENDICES
9. APPENDICES
9-24 U30-6S

APPENDICES
9. APPENDICES
U30-6S 9-25

W/H30
NNBI: 30.0 f B/R BASE: 3.0 B
GND1 BONDER A
BASE: 3.0 B
W/H33
Composition Specification Code Notes
BASE: 20.0 B/Y BASE: 20.0 B/Y GND2 BONDER B
+ GND1 BASE All use
BATTERY GND2
-
BASE: 20.0 B/Y
GND3
JOINT CONNECTOR1 CNP Canopy specification
1
1
ENGINE
BONDER C BASE: 3.0
ACD: 3.0
B
B
2
2 AI Auto idle
J/C1 (TO W/H30) J/C1 (TO W/H00) BASE: 20.0 B/Y 3
3
NNBI: 8.0 R
2 2
NNBI: 8.0 R W/H34 1 BASE: 3.0 B
4
4
NEG Not electronic governor
BASE: 3.0 B
5
BONDER B
CAB: 3.0 B
6
5
AT Anti-theft
6
SBF (MAIN POWER)

BASE: 5.0 R
STARTER SW BONDER A N_AT Not anti-theft
50 1 1
START
NNBI Not battery isolator (JP)
STOP
RUN
R
R
BASE: 3.0 R
SBF (ALTERNATOR)
ATNBI Anti-theft and not battery isolator
BASE: 3.0
BASE: 5.0
5.0
BASE: 5.0
BASE: 5.0
BASE: 3.0
NEG: 8.0 R NNBI: 8.0 R BASE: 3.0 R/W R/W
1 1 80 3 3
1
BASE: 3.0 B/W B/W
HS:
2
NESE Not engine stop SW (ECU)
R/W
BASE: 3.0 R
FUSE BOX
R
3
B/W
A2 Arm limit specification
BASE: 3.0
RELAY (POWER)
BASE: 3.0
Null
BASE: 5.0 R 30 87
4
107
BASE: 3.0 W
NEG: 8.0 R
ALTERNATOR BCN Beacon
105 +B
3 5
B-1
BASE: 0.5 L
103
1
86 85
2 104
BASE: 0.3 B
NEG: 1.25 Y
A-1
IG
LCD Meter panel (LCD)
NEG: 1.25 W/R L
A-2
HS Horn SW (Right grip)
MIC
BONDER B NATHS Not anti-theft and Horn SW (Right grip)

NB Normal blade
SFD Fuel level sensor (direct)
RELAY (STARTER)
Null
4
STARTER MOTOR
BASE: 3.0 B/W 30 87 BASE: 3.0 B/W 50
75 77
3 5 A-1
BASE: 0.5 R/B 86 85 30 +B
73 74
1 2 B-1
NNBI: 30.0 f B/R

M
RELAY (GLOW)
Null
4
GLOW PLUG
BASE: 3.0 R 30 87 BASE: 3.0 R/B
85 87
3 5 1
BASE: 0.5 R/B 86 85 BASE: 0.5 B/R
83 84
FUSE (ALTERNATOR) 1 2
NEG: 1.25 Y
10 3
FUSE (LEVER LOCK) RELAY (ENGINE STOP) ENGINE STOP SOL

BASE: 3.0 R/W BASE: 0.5 f L/W
4 5 1 Null NEG: 2.0 f R/W MAGNET
4 1
NEG: 3.0 R 30 87 NEG: 3.0 R/W NEG: 2.0 f R/W HOLD
3 5
3 5 2
NEG: 0.5 B
1 86 85 2 BONDER E
1 2
FUSE (ECU (AC)) BONDER B
BASE: 0.5 R/B
5 5
RELAY (ECU (POWER))

Null
FUSE (ECU (POWER)) 4
BASE: 5.0 R BASE: 3.0 Y/R BASE: 3.0 Y/R 30 87 BASE: 3.0 Y/G
39 20 40 65
3 5
67
BASE: 2.0 f Y/R 86 85 BASE: 0.3 Y/G
63 64
1 2
LEVER LOCK SOL
FUSE (METER (+B)) BASE: 0.5 f G/W (+) (-) BASE: 0.5 G
LCD: 0.5 R 1 2
5 38
LEVER LOCK SW BASE: 0.5 G/W
BASE: 0.5 f L/W B B BASE: 0.5 f G/W
2 1
ECU (MAIN)
FUSE (STARTER SIGNAL) BASE: 0.5 L
TxD CAN-H
BASE: 0.5 Y
BASE: 3.0 B/W BASE: 0.5 Y/B 61 60
27 5 28 BASE: 0.5 B/Or BASE: 0.5 G
80 RxD CAN-L 79
FUSE BOX RELAY (ECU MAIN POWER) BASE: 2.0 f Y/G
3
TxD (ANTI-THEFT)
NEG: 1.25 R
AI MOTOR (+) 4 AI MOTOR
RxD (ANTI-THEFT) NEG: 1.25 G NEG: 1.25 G CCW(G) CW(R) NEG: 1.25 R
ACD: 0.5 Y
AI MOTOR (-) 5 1 M 2
PTC
AI PRESSURE SW 45 COMPRESSOR CLUTCH
BASE: 2.0 f B 0.1µF
AI: 0.5 R/B NC NC AI: 0.5 G/W AI: 0.5 G/W AI MOTOR (GND) 1
1 2 50 AI PRESSURE SW
BASE: 0.3 R/W
WORK LIGHT SW BONDER A
44
BASE: 0.5 Y/B
46 STARTER SW
NESE: 0.5 W/B
AI CONSOLE 63 ENGINE STOP SW
+5V AI: 0.5 R/B
8
1kohm,0.4W AI POT AI: 0.3 R
7
GND AI: 0.85 B/Y
4
+12V AI: 0.5 R/B
750ohm,0.5W 2 AI: 0.3 B/R
AUX LED AI: 0.3 W
74 MULTIPURPOSE SW
5
750ohm,0.5W AI LED AI: 0.3 L/W AI: 0.3 Or
1 75 AI SW
150ohm,2W AUX SW AI: 0.3 B/R
NB: 0.5 Y/B
150ohm,2W AI SW
3
AI: 0.3 Or 57 TRAVEL SPEED SW
6
TRAVEL SPEED SOL
BASE: 0.5 Y BASE: 0.5 Y (+) (-) BASE: 0.5 B
TRAVEL SPEED SW TRAVEL SPEED SOL 81 1 2
Vcc(W) NB: 0.5 W/B
1
NB: 0.5 Y/B ARM LIMIT SOL BONDER C
PUSH SW(B)
2
BASE: 0.5 G/W

67 LEVER LOCK SW
BASE: 0.5 G
LEVER LOCK SOL 62
HYDRAULIC OIL TEMP. SENSOR

BASE: 0.75 f L BASE: 0.75 f B/Y BASE: 0.5 Y/B
METER BUZZER
1 2 METER BUZZER 40 NNBI: 0.5 Y/R AV0.5R(+)
1
BASE: 0.5 Y/B AV0.5B(-)
2
AI: 0.5 R/B BASE: 0.5 B/R

11 5V OUT RELAY (GLOW) 33
AI: 0.85 B/Y
10 GND (SENSOR)
BASE: 0.5 L/B

53
TRAVEL PRESSURE SENSOR
AT: 0.3 R
BASE: 0.75 f L ANTI-THEFT LED 37
36 HYDRAULIC OIL TEMP. SENSOR
AI: 0.3 W
MULTIPURPOSE LED 38
AI: 0.3 L/W

AI SW LED 39 FUEL LEVEL SENSOR
SFD: 0.5 L FUEL SENDER EARTH SFD: 0.5 B
RELAY (ECU MAIN POWER) 12
BASE: 0.3 Y/G
1 2
DUMMY
AI: 0.3 R
7 ACCELERATOR 3
NEG: 0.5 Br
BONDER C
27 GOVERNOR SENSOR
A2: 0.5 W METER PANEL
8 ARM POTENTIOMETER LCD: 0.5 R +B
7
LCD: 0.5 G CAN(L)
5
LCD: 0.5 Y CAN(H)
6
LCD: 0.5 R/B AC SW
8
SFD: 0.5 L FUEL SENSOR
1
LCD: 0.75 f Y WATER TEMP SENSOR
2
LCD: 0.75 f W ANALOG GND
NEG: 0.75 f G
52 ENGINE ROTATION SPEED SENSOR 3
CN VSS
LCD: 0.5 B/W 4
31 METER WAKEUP SIGNAL LCD: 0.75 f L OLS SW
NEG: 0.75 f W/B 9
J/C3 (TO W/H12) 41 12V OUT NEG: 0.75 f W/R CHARGE SW
10
NEG: 0.5 B/Y BASE: 0.5 R/B LCD: 0.5 B/W
1
76 AC SW WAKEUP OUT
11
REMOTE WAKE UP
NNBI: 0.5 Y/R
59 +B 12
J/C3 (TO W/H12) BASE: 2.0 f B 13
NEG: 0.5 R/B 2 GND (POWER) LCD: 0.5 B GND
3
BONDER A 14
J/C3 (TO W/H12)
A2: 0.5 W
BONDER C
2
ENGINE OIL PRESSURE SW

CAP (J/C3 (TO W/H12)) ATNBI: 0.5 Y/R LCD: 0.75 f L
1
NNBI: 0.5 Y/R
1 WATER TEMP. SENSOR
2 LCD: 0.75 f Y LCD: 0.75 f W
1 2
3
FUSE (K-OBD)
BASE: 5.0 R BASE: 0.5 R
20 5 19
GOVERNER SENSOR
FUSE (ENGINE STOP) NEG: 0.5 R/B PW CCW GND NEG: 0.85 B/Y
NEG: 3.0 R 3 1
30 21 OUTPUT NEG: 0.5 Br DIAGNOSTIC CONNECTOR
2 BASE: 0.5 Y MAIN-CAN1-H
1 1
1
BASE: 0.5 G MAIN-CAN1-L
FUSE BOX 7 7
7
SERVICE-CAN0-H
2
SERVICE-CAN0-L
8
CAN2-H-null
3
CAN2-L-null
9
1
CAN3-H-null
FUSE (ECU (+B)) 4
NNBI: 0.5 Y/R BONDER(1) CAN3-L-null
5 52
10
BASE: 0.5 L
5 5
5
FUSE (HORN) BASE: 0.5 B/Or
11 11
BASE: 5.0 R BASE: 0.5 L/W 11
49 10 50 BASE: 0.5 R
6 6 +B
6
BASE: 0.5 B
ENGINE ROTATION SPEED SENSOR 12 12
12
GND
FUSE (ROOM LIGHT) NEG: 0.75 f W/B VCC SIGNAL NEG: 0.75 f G
CAB: 0.5 Or 3 2 BONDER B
5 48 NEG: 0.75 f B GND
1 BASE: 0.75 f B/Y
FUSE BOX
BONDER A BASE: 0.5 R/B
BASE: 0.5 B/Y
NEG: 0.5 R/B NEG: 0.85 B/Y
JOINT CONNECTOR2
BASE: 0.5 Y
5 5
BASE: 0.5 G
8 8
6 6
7 7
LCD: 0.5 Y
1 1
LCD: 0.5 G
4 4
BASE: 0.5 G
3 3
BASE: 0.5 Y
2 2
FUSE (HORN SWITCH)

HS: 5.0 R HS: 0.5 Lg
43 5 44
RELAY (HORN)
Null
4
HORN
BASE: 0.5 L/W BASE: 1.25 L BASE: 1.25 L
FUSE (BEACON) 80
3
30 87
5
82
A-1
T1
BCN: 1.25 W NATHS: 0.5 L/R 86 85 BASE: 0.5 B BASE: 1.25 B T2

15 46
1 2
79
B-1
L
FUSE BOX BONDER B

WORK LIGHT SW HORN SW DIODE (HORN)
BASE: 0.5
R/W
HS: 0.5 Lg NO NO NATHS: 0.5 L/R BASE: 0.5 L C A BASE: 0.5 B

OFF ON 1 2 1 2
FUSE (RELAY)
BASE: 0.3
BASE: 0.5 L BASE: 0.5 L Vcc

5 7
7
OFF
9
L
BASE: 0.5 R/W

ON
RELAY (WORK LAMP)
FUSE (FUEL PUMP) 6
BCN: 0.5
BASE: 3.0 R/W BASE: 0.5 Y/R 8

Null Null
4
FUSE (FRONT WORK LIGHT) J/C2 (TO W/H12) J/C2 (TO W/H00) FRONT WORK LIGHT J/C2 (TO W/H00) J/C2 (TO W/H12)
8 5 9
Null BASE: 3.0 R 30 87 BASE: 2.0 f Y BASE: 1.25 Y BASE: 1.25 f Y CA R(+) CB B(-) BASE: 1.25 f B BASE: 1.25 B
3
60
3 5
62 15 25 1 1
A-1 B-1
2 2
Null BASE: 0.5 R/W 86 85 BASE: 0.5 B
2
58
1 2
59 BONDER B
FUSE BOX BASE: 0.5 L LED(+) LED(GND) BASE: 0.5 B W/H12
4 10
3.9kohm
1
Null Null
5
FUSE (CAB WORK LIGHT)
BASE: 2.0 f Y BASE: 2.0 f Y BASE: 1.25 R CA R(+) CB B(-) BASE: 1.25 B
24 20 23
A-1 B-1
BONDER A BONDER B
J/C4_(TO_W/H23) J/C4_(TO_W/H00)
FUSE BOX CNP: 1.25 Y BASE: 1.25 R J/C5_(TO_W/H00) J/C5_(TO_W/H23)
RELAY (BEACON) 1 1 BASE: 1.25 B CNP: 1.25 B
Null BASE: 1.25 R CA R(+) CB B(-) BASE: 1.25 B 1 1
4 A-1 B-1
BCN: 1.25 W BCN: 1.25 Br
55
3
30 87
5
57 W/H23
BCN: 0.3 R/B 86 85 BCN: 0.5 R/Y
53 54
1 2
J/C6 (TO W/H19)

BEACON SW BASE: 2.0 f Y
4 4
OFF ON BCN: 1.25 Br
8 8
CAB: 0.5 Or
BCN: 0.5 R/Y 3 3
Vcc
7 CAB: 1.25 G
7 7
OFF
9 CAB: 3.0 B
BCN: 0.5 B 5 5
ON
6 CAB: 0.85 B
1 1
Null
8
Null
GND3
3 BONDER C
Null
2
BCN: 0.5 L LED(+) LED(GND) BCN: 0.5 B
4 10
680ohm
1
Null Null
5
CAP (J/C6 (TO W/H19))
1
CIGARETTE SOCKET
BASE: 1.25 G (+)
(+)
1
BASE: 2.0 B (-)
GND
2
BONDER C ELECTROMAGNETIC FUEL FEED PUMP

BASE: 0.5 Y/R +
1
BASE: 0.5 B -
2
BONDER A
FUSE (ELECTRICAL OUTLET)
BASE: 3.0 W BASE: 1.25 G
31 15
FUSE BOX
W/H00 W/H(MAIN)
W/H12 W/H(FRONT)
W/H30 CORD,BATTERY(+)
W/H33 CORD,BATTERY(-)
W/H34 CORD,BODY EARTH
ELECTRICAL CIRCUIT DIAGRAM (U30-6S CANOPY SPEC.)

2RNNQ00002A01enUS

W/H30
NNBI: 30.0 f B/R BASE: 3.0 B
GND1 BONDER A
BASE: 3.0 B
Composition Specification Code Notes
W/H33
BONDER B
BASE: 20.0 B/Y BASE: 20.0 B/Y GND2 BASE All use
+ GND1
BATTERY BASE: 20.0 B/Y GND2 JOINT CONNECTOR1 CAB Cabin specification
- GND3 1
BONDER C BASE: 3.0 B

2
1
ACD A/C specification (domestic)
ENGINE ACD: 3.0 B
2
J/C1 (TO W/H30)
NNBI: 8.0 R
J/C1 (TO W/H00)
NNBI: 8.0 R
BASE: 20.0
W/H34
B/Y
1 BASE: 3.0 B
3
3 AI Auto idle
2 2 4
SBF (MAIN POWER (2)) 4
50 2 2
ACD: 5.0 R/Y
BASE: 3.0 B
5
5 NEG Not electronic governor
CAB: 3.0 B
BONDER B 6
AT
6
Anti-theft
SBF (MAIN POWER (1)) STARTER SW
BASE: 5.0 R BONDER A
50 1 1
N_AT Not anti-theft
START
STOP
RUN
R
R
SBF (ALTERNATOR)
BASE: 3.0 R
NNBI Not battery isolator (JP)
BASE: 3.0
BASE: 5.0
5.0
BASE: 5.0
BASE: 5.0
BASE: 3.0
NEG: 8.0 R NNBI: 8.0 R BASE: 3.0 R/W R/W
1 1 80 3 3
1
BASE: 3.0 B/W B/W AYNBI Not battery isolator (JP)
HS:
2
R/W
BASE: 3.0 R
FUSE BOX
R
3
NESE Anti-theft and not battery isolator
W
B/W
BASE: 3.0
RELAY (POWER)
CAB: 3.0
A2 Arm limit specification
BASE: 3.0
Null
4 ALTERNATOR
BASE: 5.0 R 30 87 BASE: 3.0 W
105 107 NEG: 8.0 R
BCN Beacon
+B
3 5
BASE: 0.5 L BASE: 0.3 B B-1
103 86 85 NEG: 1.25 Y IG
1 2 104
A-1
NEG: 1.25 W/R
A-2
L
LCD Meter panel (LCD)
MIC HS Horn SW (Right grip)
BONDER B
NATHS Not anti-theft and Horn SW (Right grip)
NB Normal blade
SFD Fuel level sensor (direct)
RELAY (STARTER)
Null
4
STARTER MOTOR
BASE: 3.0 B/W 30 87 BASE: 3.0 B/W 50
75 77
3 5 A-1
BASE: 0.5 R/B 86 85 30 +B
73 74
1 2 B-1
NNBI: 30.0 f B/R

M
RELAY (GLOW)
Null
4
GLOW PLUG
BASE: 3.0 R 30 87 BASE: 3.0 R/B
85 87
3 5 1
BASE: 0.5 R/B 86 85 BASE: 0.5 B/R
83 84
FUSE (ALTERNATOR) 1 2
NEG: 1.25 Y
10 3
FUSE (LEVER LOCK) RELAY (ENGINE STOP) ENGINE STOP SOL

BASE: 3.0 R/W BASE: 0.5 f L/W
4 5 1 Null NEG: 2.0 f R/W MAGNET
4 1
NEG: 3.0 R 30 87 NEG: 3.0 R/W NEG: 2.0 f R/W HOLD
3 5
3 5 2
NEG: 0.5 B
1 86 85 2 BONDER E
1 2
FUSE (ECU (AC)) BONDER B
BASE: 0.5 R/B
5 5
RELAY (ECU (POWER))

Null
FUSE (ECU (POWER)) 4
BASE: 5.0 R BASE: 3.0 Y/R BASE: 3.0 Y/R 30 87 BASE: 3.0 Y/G
39 20 40 65
3 5
67
BASE: 2.0 f Y/R 86 85 BASE: 0.3 Y/G
63 64
1 2
LEVER LOCK SOL
FUSE (METER (+B)) BASE: 0.5 f G/W (+) (-) BASE: 0.5 G
LCD: 0.5 R 1 2
5 38
LEVER LOCK SW BASE: 0.5 G/W
BASE: 0.5 f L/W B B BASE: 0.5 f G/W
2 1
ECU (MAIN)
FUSE (STARTER SIGNAL) BASE: 0.5 L
TxD CAN-H
BASE: 0.5 Y
BASE: 3.0 B/W BASE: 0.5 Y/B 61 60
27 5 28 BASE: 0.5 B/Or BASE: 0.5 G
80 RxD CAN-L 79
FUSE BOX RELAY (ECU MAIN POWER) BASE: 2.0 f Y/G
3
TxD (ANTI-THEFT)
NEG: 1.25 R
AI MOTOR (+) 4 AI MOTOR
RxD (ANTI-THEFT) NEG: 1.25 G NEG: 1.25 G CCW(G) CW(R) NEG: 1.25 R
ACD: 0.5 Y
AI MOTOR (-) 5 1 M 2
PTC
AI PRESSURE SW 45 COMPRESSOR CLUTCH
BASE: 2.0 f B 0.1µF
AI: 0.5 R/B NC NC AI: 0.5 G/W AI: 0.5 G/W AI MOTOR (GND) 1
1 2 50 AI PRESSURE SW
BASE: 0.3 R/W
WORK LIGHT SW BONDER A
44
BASE: 0.5 Y/B
46 STARTER SW
NESE: 0.5 W/B
AI CONSOLE 63 ENGINE STOP SW
+5V AI: 0.5 R/B
8
1kohm,0.4W AI POT AI: 0.3 R
7
GND AI: 0.85 B/Y
4
+12V AI: 0.5 R/B
750ohm,0.5W 2 AI: 0.3 B/R
AUX LED AI: 0.3 W
74 MULTIPURPOSE SW
5
750ohm,0.5W AI LED AI: 0.3 L/W AI: 0.3 Or
1 75 AI SW
150ohm,2W AUX SW AI: 0.3 B/R
NB: 0.5 Y/B
150ohm,2W AI SW
3
AI: 0.3 Or 57 TRAVEL SPEED SW
6
TRAVEL SPEED SOL
BASE: 0.5 Y BASE: 0.5 Y (+) (-) BASE: 0.5 B
TRAVEL SPEED SW TRAVEL SPEED SOL 81 1 2
Vcc(W) NB: 0.5 W/B
1 BONDER C
PUSH SW(B) NB: 0.5 Y/B ARM LIMIT SOL
2
BASE: 0.5 G/W

67 LEVER LOCK SW
BASE: 0.5 G
LEVER LOCK SOL 62
HYDRAULIC OIL TEMP. SENSOR

BASE: 0.75 f L BASE: 0.75 f B/Y BASE: 0.5 Y/B
METER BUZZER
1 2 METER BUZZER 40 NNBI: 0.5 Y/R AV0.5R(+)
1
BASE: 0.5 Y/B AV0.5B(-)
2
AI: 0.5 R/B BASE: 0.5 B/R

11 5V OUT RELAY (GLOW) 33
AI: 0.85 B/Y
10 GND (SENSOR)
BASE: 0.5 L/B

53
TRAVEL PRESSURE SENSOR
AT: 0.3 R
BASE: 0.75 f L ANTI-THEFT LED 37
36 HYDRAULIC OIL TEMP. SENSOR
AI: 0.3 W
MULTIPURPOSE LED 38
AI: 0.3 L/W

AI SW LED 39 FUEL LEVEL SENSOR
SFD: 0.5 L FUEL SENDER EARTH SFD: 0.5 B
RELAY (ECU MAIN POWER) 12
BASE: 0.3 Y/G
1 2
DUMMY
AI: 0.3 R
7 ACCELERATOR 3
NEG: 0.5 Br
BONDER C
27 GOVERNOR SENSOR
A2: 0.5 W METER PANEL
8 ARM POTENTIOMETER LCD: 0.5 R +B
7
LCD: 0.5 G CAN(L)
5
LCD: 0.5 Y CAN(H)
6
LCD: 0.5 R/B AC SW
8
SFD: 0.5 L FUEL SENSOR
1
LCD: 0.75 f Y WATER TEMP SENSOR
2
LCD: 0.75 f W ANALOG GND
NEG: 0.75 f G
52 ENGINE ROTATION SPEED SENSOR 3
CN VSS
LCD: 0.5 B/W 4
31 METER WAKEUP SIGNAL LCD: 0.75 f L OLS SW
NEG: 0.75 f W/B 9
J/C3 (TO W/H12) 41 12V OUT NEG: 0.75 f W/R CHARGE SW
10
NEG: 0.5 B/Y BASE: 0.5 R/B LCD: 0.5 B/W
1
76 AC SW WAKEUP OUT
11
REMOTE WAKE UP
NNBI: 0.5 Y/R
59 +B 12
J/C3 (TO W/H12) BASE: 2.0 f B 13
NEG: 0.5 R/B 2 GND (POWER) LCD: 0.5 B GND
3
BONDER A 14
J/C3 (TO W/H12)
A2: 0.5 W
BONDER C
2
ENGINE OIL PRESSURE SW

CAP (J/C3 (TO W/H12)) ATNBI: 0.5 Y/R LCD: 0.75 f L
1
NNBI: 0.5 Y/R
1 WATER TEMP. SENSOR
2 LCD: 0.75 f Y LCD: 0.75 f W
1 2
3
FUSE (K-OBD)
BASE: 5.0 R BASE: 0.5 R
20 5 19
GOVERNER SENSOR
FUSE (ENGINE STOP) NEG: 0.5 R/B PW CCW GND NEG: 0.85 B/Y
NEG: 3.0 R 3 1
30 21 OUTPUT NEG: 0.5 Br DIAGNOSTIC CONNECTOR
2 BASE: 0.5 Y MAIN-CAN1-H
1 1
1
BASE: 0.5 G MAIN-CAN1-L
FUSE BOX 7 7
7
SERVICE-CAN0-H
2
SERVICE-CAN0-L
8
CAN2-H-null
3
CAN2-L-null
9
1
CAN3-H-null
FUSE (ECU (+B)) 4
NNBI: 0.5 Y/R BONDER(1) CAN3-L-null
5 52
10
BASE: 0.5 L
5 5
5
FUSE (HORN) BASE: 0.5 B/Or
11 11
BASE: 5.0 R BASE: 0.5 L/W 11
49 10 50 BASE: 0.5 R
6 6 +B
6
BASE: 0.5 B
ENGINE ROTATION SPEED SENSOR 12 12
12
GND
FUSE (ROOM LIGHT) NEG: 0.75 f W/B VCC SIGNAL NEG: 0.75 f G
CAB: 0.5 Or 3 2 BONDER B
5 48 NEG: 0.75 f B GND
1
BASE: 0.75 f B/Y
FUSE BOX
BONDER A BASE: 0.5 R/B
BASE: 0.5 B/Y
NEG: 0.5 R/B NEG: 0.85 B/Y
JOINT CONNECTOR2
BASE: 0.5 Y
5 5
BASE: 0.5 G
8 8
6 6
7 7
LCD: 0.5 Y
1 1
LCD: 0.5 G
4 4
BASE: 0.5 G
3 3
BASE: 0.5 Y
2 2
FUSE (HORN SWITCH)

HS: 5.0 R HS: 0.5 Lg
43 5 44
RELAY (HORN)
Null
4
HORN
BASE: 0.5 L/W BASE: 1.25 L BASE: 1.25 L
FUSE (BEACON) 80
3
30 87
5
82
A-1
T1
BCN: 1.25 W NATHS: 0.5 L/R 86 85 BASE: 0.5 B BASE: 1.25 B T2

15 46
1 2
79
B-1
L
FUSE BOX BONDER B

WORK LIGHT SW HORN SW DIODE (HORN)
BASE: 0.5
R/W
HS: 0.5 Lg NO NO NATHS: 0.5 L/R BASE: 0.5 L C A BASE: 0.5 B

OFF ON 1 2 1 2
FUSE (RELAY)
BASE: 0.3
BASE: 0.5 L BASE: 0.5 L Vcc

5 7
7
OFF
9
L
BASE: 0.5 R/W

ON
RELAY (WORK LAMP)
FUSE (FUEL PUMP) 6
BCN: 0.5
BASE: 3.0 R/W BASE: 0.5 Y/R 8

Null Null
4
FUSE (FRONT WORK LIGHT) J/C2 (TO W/H12) J/C2 (TO W/H00) FRONT WORK LIGHT J/C2 (TO W/H00) J/C2 (TO W/H12)
8 5 9
Null BASE: 3.0 R 30 87 BASE: 2.0 f Y BASE: 1.25 Y BASE: 1.25 f Y CA R(+) CB B(-) BASE: 1.25 f B BASE: 1.25 B
3
60
3 5
62 15 25 1 1
A-1 B-1
2 2
Null BASE: 0.5 R/W 86 85 BASE: 0.5 B
2
58
1 2
59 BONDER B
FUSE BOX BASE: 0.5 L LED(+) LED(GND) BASE: 0.5 B W/H12
4 10
3.9kohm
1
Null Null
5
FUSE (CAB WORK LIGHT)
BASE: 2.0 f Y BASE: 2.0 f Y
24 20 23
BONDER A BONDER B
FUSE BOX
RELAY (BEACON)
Null
4
BCN: 1.25 W 30 87 BCN: 1.25 Br
55 57
3 5
BCN: 0.3 R/B 86 85 BCN: 0.5 R/Y
53 54
1 2
RADIO
J/C6 (TO W/H19) J/C6 (TO W/H00) J/C12 (TO W/H21) J/C12 (TO W/H19) WORK LIGHT (CABIN RH F) J/C13 (TO W/H19) J/C13 (TO W/H21) BASE: 0.5 Or
BEACON SW BASE: 2.0 f Y BASE: 0.85 R BASE: 0.85 R BASE: 0.85 R BASE: 0.85 B BASE: 0.85 B
RADIO(+B)
4 4 1 1
LED(+) LED(-)
1 1 1
1 2 BASE: 1.25 Y RADIO(AC)
OFF ON BCN: 1.25 Br BASE: 1.25 Br 2
8 8 W/H21 BASE: 0.50 B RADIO(GND)
R
CAB: 0.5 Or BASE: 0.5 Or 3

BCN: 0.5 R/Y Vcc
3 3 J/C14 (TO W/H21) J/C14 (TO W/H19) WORK LIGHT (CABIN LH F) J/C15 (TO W/H19) J/C15 (TO W/H21) BASE: 1.25 B RADIOFRAME(GND)
BASE: 0.85
7 CAB: 1.25 G BASE: 1.25 Y BASE: 0.85 R BASE: 0.85 R LED(+) LED(-) BASE: 0.85 B BASE: 0.85 B 4
7 7 1 1 1 1 BASE: 0.5 W
OFF
9 CAB: 3.0 B BASE: 3 B
1 2 SPEAKER RH SPEAKER(R+)
5
ON BCN: 0.5 B 5 5 W/H21 (-) BASE: 0.5 W/B BASE: 0.5 W/B SPEAKER(R-)
6 CAB: 0.85 B BASE: 1.25 B 1 6
1 1 BASE: 0.5 W BASE: 0.5 Y
Null (+) SPEAKER(L+)
8 2 7
BASE: 0.5 Y/B
Null
GND3 SPEAKER(L-)
3 BONDER C J/C10 (TO W/H24) J/C10 (TO W/H19) BEACON J/C11 (TO W/H19) J/C11 (TO W/H24) 8
Null
BASE: 1.25 Br BASE: 0.5 R/L BASE: 0.5 B BASE: 0.85 B SPEAKER LH
BCN: 0.5 L LED(+) LED(GND)
2
BCN: 0.5 B 1 1
A-1
M3
M M3
B-1
1 1 (-) BASE: 0.5 Y/B CAB POWER SOURCE
4 10 1 GND(RADIO)
680ohm
Null Null
CAP (J/C6 (TO W/H19)) W/H24 (+) BASE: 0.5 Y 1
Br
1 5 2
Or
ROOMLIGHT BASE: 0.5 Or

2
BASE: 1.25
BASE: 0.50 B
1 ROOM LIGHT(+B)
BASE: 0.5
BASE: 0.5 Or com BASE: 1.25 B

FUSE (RADIO (AC)) 2 2
DOOR
1 BASE: 0.85 R
3
CAB WORK LIGHT
CAB: 1.25 G ON BASE: 1.25 B 4
15 34 BASE: 3 B
0.5 Or
3 3 GND (CABIN) GND(CAB)

BASE:
5
4
FUSE (WIPER / WASHER) 5 BASE: 1.25 Y
6
RADIO(AC)
CAB: 3.0 W CAB: 1.25 G/W 7
35 15 36 6 BASE: 1.25 Br BEACON
8
7 BASE: 1.25 Y
WASH2
WASH1
BASE: 3 B
OFF
ON
8
FUSE BOX WIPER SW GND (CABIN)
WASHER(B) CAB: 1.25 W
3 J/C9 (TO W/H20) J/C9 (TO W/H19) WIPER MOTOR
Vcc wash(Y/B) CAB: 1.25 G/W J/C7 (TO W/H19) J/C7 (TO W/H00) BASE: 0.85 G BASE: 0.75 G (+B)
CAB: 1.25 G/W BASE: 0.85 G 2 2
2 3 3 1
CAB: 1.25 G/W BASE: 0.75 R
Vcc(R)
1
J/C7 (TO W/H19) J/C7 (TO W/H00) J/C9 (TO W/H20) J/C9 (TO W/H19) 4
(S)
mo(+1)(G/R) CAB: 1.25 R/W CAB: 1.25 R/W BASE: 0.85 W BASE: 0.85 W BASE: 0.75 W M BASE: 0.75 B
BASE: 0.50 B
(+1) (-)
1 1 4 4
6 3 2
S(G/W) CAB: 1.25 L/W CAB: 1.25 L/W BASE: 0.85 R BASE: 0.85 R
2 2 3 3
5
J/C7 (TO W/H19) J/C7 (TO W/H00) WASHER MOTOR
Null
4 CAB: 1.25 W BASE: 0.5 W BASE: 0.5 W (-) (+) BASE: 0.50 B J/C9 (TO W/H20) J/C9 (TO W/H19)
4 4
1 M 2 BASE: 0.85 B BASE: 0.75 B
J/C7 (TO W/H19) J/C7 (TO W/H00) 1 1
W/H19 J/C9 (TO W/H20) J/C9 (TO W/H19) W/H20
CIGARETTE SOCKET
BASE: 1.25 G (+)
(+)
1
BASE: 2.0 B (-)
GND
2
BONDER C ELECTROMAGNETIC FUEL FEED PUMP

BASE: 0.5 Y/R + COMPRESSOR
1 ACD: 1.25 Y
BASE: 0.5 B - 1
2
BONDER A DIODE (COMPRESSOR)

FUSE (ELECTRICAL OUTLET) ACD: 0.5 Y C A ACD: 0.5 B
Y
BASE: 3.0 W BASE: 1.25 G 1 1 2 2

1 2
31 15
ACD: 0.5
RELAY (COMPRESSOR) BONDER A

Null
FUSE (COMPRESSOR) 4
ACD: 2.0 f W/R ACD: 2.0 f W/R 30 87 ACD: 1.25 Y
10 32 90
3 5
92
ACD: 0.5 L/B 86 85 ACD: 0.5 G/R
88 89
1 2
J/C8 (TO W/H06) J/C8 (TO W/H00) A/C PRESSURE SW J/C8 (TO W/H00) J/C8 (TO W/H06) THERMOSTAT A/C SW
W/R
W/R
FUSE BOX
ACD: 0.5 G/R
ACD: 0.5 G/R ACD: 0.5 G ACD: 0.5 G ACD: 0.5 L/W FREE LOCK
3 3 4 4
1 2 A-1 B-1
ACD: 0.5
ACD: 0.5
ACD: 0.5 W/R IG(L/R)

FUSE (BLOWER MOTOR) 4
ACD: 5.0 R/Y ACD: 3.0 R (L/B) ACD: 0.5 L/B
16 30 15 1
(W) ACD: 0.5 W
5
FUSE (CONDENSER MOTOR) BLOWER RESISTOR
L/B
OFF Lo Me Hi
ACD: 2.0 f R/W Me ACD: 1.25 L/Y
10 17
ACD: 0.5
1
3.0 L
ACD: 2.0 f L
RELAY (BLOWER MOTOR) D BLOWER(L)
ACD:
184 ±10℃ 0.65ohm 2 8

FUSE BOX Null HI ACD: 3.0 L ACD: 1.25 L/Y (L/Y)
4 0.85ohm 3 3
ACD: 3.0 R ACD: 3.0 B/Y ACD: 3.0 L/W ACD: 2.0 f L/W
100
3
30 87
5
102
LO
4 7
(L/W)
W/H00 W/H(MAIN,CAB,AC)
ACD: 0.5 W/R
98 86 85
99
ACD: 0.5 L/W GND(B) ACD: 2.0 f B W/H06 W/H(CONDENSOR,AC)
1 2 2
W/H12 W/H(FRONT)
L/W
null
6
ACD: 0.5 L/W W/H19 W/H(CAB,MAIN)
ACD: 0.5
W/H20 W/H(WIPERCODE)
DIODE (A/C SW) W/H21 W/H(CAB,WORKLIGHT)
BLOWER MOTOR ACD: 0.5 L/W
1 1
C A
2 2
ACD: 0.5 W
W/H30 CORD,BATTERY(+)
1 2
ACD: 3.0 B/Y + - ACD: 3.0 L
1
M
2 W/H33 CORD,BATTERY(-)
W/H34 CORD,BODY EARTH
RELAY(CONDENSER MOTOR)
Null
4
J/C8 (TO W/H06) J/C8 (TO W/H00) CONDENSER MOTOR J/C8 (TO W/H00) J/C8 (TO W/H06)
ACD: 2.0 f R/W 30 87 ACD: 2.0 f W ACD: 2.0 f W ACD: 2.0 f W ACD: 2.0 f B ACD: 2.0 f B
95 97 1 1 M 2 2
3 5 1 2
ACD: 0.5 L/B 86 85 ACD: 0.5 G/R
93 94
1 2
BONDER A
2RNNQ00003A01enUS
ELECTRICAL CIRCUIT DIAGRAM (U30-6S CABIN SPEC.)
INDEX
Symbols arm cylinder speed
measuring.......................................................... 6-64
5 V error arm limitation
handling............................................................. 7-71 fine adjustment...................................................7-42
arm limitation function setting
A operating............................................................ 7-26
abbreviation................................................................. xv AS
AI motor drive setting................................................................ 7-35
operating............................................................ 7-38 auto-idle signal circuit ............................................. 6-30
AI setting AUX
operating............................................................ 7-34 P-Q performance................................................. 9-7
AI system error (accelerator sensor) AUX control pedal
handling............................................................. 7-63 installing............................................................. 4-37
AI system error (AI motor) removing............................................................ 4-37
handling............................................................. 7-67 AUX flow rate
AI system error (governor sensor) measuring.......................................................... 6-73
handling............................................................. 7-65 AUX flow rate setting mode
air conditioning operating............................................................ 7-25
device layout........................................................ 8-1 AUX1
hose routing....................................................... 8-31 exchanging the switch operation........................7-38
air conditioning and heater system setting................................................................ 7-35
general description...............................................8-3 AUX2
air conditioning belt setting................................................................ 7-35
adjusting.............................................................3-49 AUX2/thumb
checking.............................................................3-49 exchanging the switch operation........................7-38
replacing............................................................ 3-51
air conditioning filter B
cleaning..............................................................3-50 battery
replacing............................................................ 3-52 checking.............................................................3-18
air conditioning hose handling............................................................... 2-5
checking.............................................................3-52 removing............................................................ 2-12
replacing............................................................ 3-53 battery charging error
air conditioning system handling............................................................. 7-53
service specifications......................................... 8-19 battery overcharging
air conditioning troubleshooting............................... 8-15 handling............................................................. 7-62
air conditioning unit blade.................................................................. 4-8,4-22
installing............................................................. 8-25 dimension.............................................................4-8
removing............................................................ 8-25 removing............................................................ 4-22
specifications....................................................... 8-7 blade control lever
alert installing............................................................. 4-34
list.......................................................................7-48 removing............................................................ 4-34
all error histories blade cylinder
reading............................................................... 7-43 assembling.......................................................6-159
alternator component....................................................... 6-154
checking.............................................................3-38 disassembling.................................................. 6-156
removing............................................................ 5-22 blade cylinder speed
arm.....................................................................4-4,4-18 measuring.......................................................... 6-64
dimension.............................................................4-4 blower........................................................................ 8-9
removing............................................................ 4-18 blower resister
arm cylinder checking.............................................................8-22
assembling.......................................................6-159 removing............................................................ 8-26
component....................................................... 6-154 blower resistor............................................................8-9
disassembling.................................................. 6-156 bolt and nut
tightening............................................................. 2-1
U30-6S I

bonnet compressor
removing............................................................ 2-14 installing............................................................. 8-23
boom..................................................................4-6,4-20 removing............................................................ 8-23
dimension.............................................................4-6 specifications....................................................... 8-4
removing............................................................ 4-20 working principle.................................................. 8-5
boom and arm regeneration.....................................6-28 condenser
boom cylinder cleaning..............................................................3-50
assembling.......................................................6-149 function and structure.........................................8-11
component....................................................... 6-145 installing............................................................. 8-28
disassembling.................................................. 6-146 removing............................................................ 8-28
boom cylinder speed specifications......................................................8-11
measuring.......................................................... 6-63 connector
boom holding valve.................................................. 6-21 diagram description............................................2-35
bucket................................................................ 4-3,4-17 handling............................................................... 2-7
dimension.............................................................4-3 handling precaution............................................2-35
removing............................................................ 4-17 control valve.....................................................6-15,6-98
bucket cylinder arm section...................................................... 6-103
assembling.......................................................6-159 assembling.......................................................6-106
component....................................................... 6-154 AUX section..................................................... 6-105
disassembling.................................................. 6-156 blade section....................................................6-105
bucket cylinder speed boom section....................................................6-104
measuring.......................................................... 6-64 bucket section.................................................. 6-103
bus components..................................................... 6-102
description..........................................................2-35 disassembling.................................................. 6-106
bushing hydraulic circuit.................................................. 6-18
dimension...........................................................4-10 inlet section...................................................... 6-106
installing............................................................. 6-98
C installing adapter..............................................6-107
outlet section....................................................6-102
cabin........................................................................ 4-25 removing............................................................ 6-98
installing............................................................. 4-25 section component...........................................6-102
removing............................................................ 4-25 specifications..................................................... 6-15
calender and clock setting spool shift performance......................................6-18
operating............................................................ 7-25 swing section......................................... 6-103,6-105
CAN communication error (main) travel LH section.............................................. 6-104
handling............................................................. 7-58 travel RH section..............................................6-104
canopy coolant
installing............................................................. 4-25 replacing............................................................ 3-46
removing............................................................ 4-25 coolant level
carrier roller checking............................................................. 3-11
dimension.............................................................4-9 counterweight...........................................................4-24
installing............................................................. 4-54 installing............................................................. 4-24
removing............................................................ 4-54 removing............................................................ 4-24
chain joint cover
handling............................................................... 2-2 removing............................................................ 2-14
charging hose.......................................................... 2-48 crane
check alert setting................................................................ 7-35
informing annual................................................ 7-40 crane function setting
circlip operating............................................................ 7-26
installing............................................................... 2-1 cylinder internal leakage
clock setting alert measuring.......................................................... 6-66
displaying........................................................... 7-41
clock setting mode
D
operating............................................................ 7-24
communication port default setting...........................................................9-12
layout................................................................... 7-7 description................................................................2-35
composite terminal...................................................2-35 diagnostic connector
connecting..........................................................2-13
II U30-6S

display mode............................................................7-22 reading............................................................... 7-33
dispose fluids correctly...............................................2-9 error warning
list.......................................................................7-46
E evaporator..................................................................8-9
excavator
elbow with male seat servicing (safety)..................................................1-7
installing............................................................... 2-4 excavator operation
electrical circuit diagram important information........................................... 1-4
accessory........................................................... 7-11 expansion valve....................................................... 8-10
AI........................................................................7-18
battery charge.................................................... 7-12
F
beacon............................................................... 7-20
description..........................................................2-33 fan belt
engine start........................................................ 7-13 adjusting.............................................................3-21
engine stop........................................................ 7-14 checking.....................................................3-13,3-21
lever lock............................................................7-15 replacing............................................................ 3-29
power supply........................................................7-9 fan switch
travel speed shift................................................7-16 checking.............................................................8-20
unit symbol.........................................................2-33 floating seal
washer motor..................................................... 7-19 replacing.............................................................. 2-3
wiper motor........................................................ 7-19 floor plate
work light............................................................7-17 removing............................................................ 2-14
electrical device flow control
layout................................................................... 7-1 load sensing control........................................... 6-12
electrical wiring front attachment horizontal play
checking.............................................................3-14 measuring.......................................................... 4-15
clamp................................................................. 2-34 front idler............................................................4-9,4-46
color coding........................................................2-34 assembling.........................................................4-48
electrical wiring and fuse component......................................................... 4-47
checking.............................................................3-43 dimension.............................................................4-9
engine disassembling.................................................... 4-47
device layout........................................................ 5-1 replacing the engine oil...................................... 3-37
dimension.............................................................5-6 fuel cooler
installing............................................................. 5-17 checking.............................................................3-13
performance curve............................................... 5-7 fuel filter
removing............................................................ 5-17 replacing............................................................ 3-27
service specifications................................... 5-11,9-3 fuel hose.................................................................. 5-12
specifications....................................................... 5-4 fuel injection pump
troubleshooting.................................................... 5-9 checking.............................................................3-41
engine air cleaner element fuel level
checking.............................................................3-23 checking............................................................. 3-11
cleaning..............................................................3-23 fuel level sensor error
replacing............................................................ 3-33 handling............................................................. 7-55
engine compression pressure fuel line
measuring.......................................................... 5-11 checking.............................................................3-24
engine oil replacing............................................................ 3-47
replacing............................................................ 3-25 fuel tank................................................................... 5-12
engine oil filter draining.............................................................. 3-17
replacing............................................................ 3-25 fuel hose routing................................................ 5-15
engine oil level installing............................................................. 5-12
engine oil pressure fuse
measuring.......................................................... 5-12 handling............................................................... 2-6
engine oil pressure error layout................................................................... 7-5
handling............................................................. 7-50
error history G
clearing.............................................................. 7-34
gain control.............................................................. 6-14
U30-6S III

general working precaution........................................2-1 installing adapter..............................................6-195
grease cylinder.........................................................4-51 removing.......................................................... 6-193
removing............................................................ 4-51 vacuuming..........................................................2-11
ground wiring hydraulic pump.................................................. 6-7,6-82
layout................................................................... 7-7 bleeding air........................................................ 2-21
component......................................................... 6-84
H hydraulic circuit.................................................... 6-8
installing............................................................. 6-82
heater installing adapter................................................6-97
hose routing....................................................... 8-31 removing............................................................ 6-82
heater core.................................................................8-9 specifications....................................................... 6-7
heater hose hydraulic system
checking.............................................................3-52 service specifications...................................6-61,9-3
replacing............................................................ 3-53 hydraulic troubleshooting
heater valve..............................................................8-11 front attachment................................................. 6-57
installing............................................................. 8-27 swivel................................................................. 6-59
removing............................................................ 8-27 traveling............................................................. 6-60
high hydraulic oil temperature warning
handling............................................................. 7-73
I
high pressure selector function................................ 6-26
horsepower control identification
piston pump........................................................6-11 engine model..................................................... 2-27
hydraulic circuit machine model...................................................2-27
diagram.............................................................. 9-15 injection nozzle
releasing residual pressure................................ 2-11 checking.............................................................3-35
hydraulic cylinder........................................... 6-45,6-145 installing............................................................. 5-24
bleeding air........................................................ 2-20 removing............................................................ 5-24
measuring........................................................ 6-163 inoperable machine
special jig........................................................... 2-46 towing.................................................................2-38
specifications..................................................... 6-45 intake air line
hydraulic cylinder bending checking.............................................................3-24
measuring........................................................ 6-163 replacing............................................................ 3-47
hydraulic cylinder rod and head clearance
measuring........................................................ 6-163 J
hydraulic cylinder tube and piston wear ring clearance
measuring........................................................ 6-164 jacking up the machine............................................ 2-16
hydraulic device layout...............................................6-1
hydraulic hose L
connecting............................................................2-4 language setting mode
delivery hose routing........................................6-197 operating............................................................ 7-25
drain hose routing............................................ 6-202 lever lock
front hose routing............................................. 6-198 installing............................................................. 4-32
length description.............................................6-196 removing............................................................ 4-32
metal fitting.......................................................6-196 lever lock system error
pilot hose routing (delivery, drain).................... 6-203 handling............................................................. 7-69
pilot hose routing (operation)........................... 6-206 liquid gasket
swivel and swing hose routing......................... 6-200 handling............................................................... 2-2
travel and blade hose routing...........................6-201 load sensing system
hydraulic lock cylinder general description...............................................6-3
removing............................................................ 4-39 lubricant quantity........................................................3-7
hydraulic oil lubrication point
replacing............................................................ 3-31 greasing............................................................. 3-15
hydraulic oil cooler
checking.............................................................3-13 M
hydraulic oil level
checking.............................................................3-12 machine
hydraulic oil tank.................................................... 6-193 device layout........................................................ 4-1
installing........................................................... 6-193 high pressure washer...........................................2-8
IV U30-6S

operating (safety)................................................. 1-2 measuring.......................................................... 6-77
washing................................................................2-8
working (safety)....................................................1-3 P
machine body
service specifications...................................4-13,9-1 periodic check alert
machine dimension.................................................. 2-30 informing............................................................ 7-39
machine mass table................................................. 2-31 periodic check information clearing method
machine on a truck operating............................................................ 7-39
loading............................................................... 2-37 periodic check mode
unloading........................................................... 2-37 operating............................................................ 7-23
magnetic clutch pulley................................................8-5 pilot control system
magnetic clutch pulley air gap general description...............................................6-5
measuring.......................................................... 8-21 pilot control valve........................................... 6-48,6-168
main relief valve....................................................... 6-18 assembling.......................................................6-172
main relief valve pressure component....................................................... 6-170
measuring.......................................................... 6-76 disassembling.................................................. 6-170
maintenance interval function and structure........................................ 6-49
table..................................................................... 3-1 installing........................................................... 6-168
manifold gauge........................................................ 2-48 installing adapter..............................................6-175
message performance diagram.........................................6-49
list.......................................................................7-49 removing.......................................................... 6-168
meter panel.............................................................. 7-21 specifications..................................................... 6-48
function.............................................................. 7-21 pilot filter
model setting replacing............................................................ 3-31
operating............................................................ 7-36 pilot primary pressure
muffler measuring.......................................................... 6-81
installing............................................................. 5-29 pilot secondary pressure
removing............................................................ 5-29 measuring.......................................................... 6-82
multi valve pin
component....................................................... 6-191 dimension...........................................................4-10
installing........................................................... 6-189 piston pump
installing adapter..............................................6-192 assembling.........................................................6-89
removing.......................................................... 6-189 disassembling.................................................... 6-85
specifications..................................................... 6-54 P-Q performance........................................... 6-9,9-6
multipurpose function working principle................................................ 6-10
setting................................................................ 7-42 piston pump P-Q performance
measuring.......................................................... 6-70
pressure compensator valve....................................6-27
N
pressure switch
normal mode function and structure........................................ 8-13
flow chart............................................................9-22 specifications..................................................... 8-13
pump coupling
O installing............................................................. 6-98
O-ring
Q
replacing.............................................................. 2-3
oil seal quick hose coupling
replacing.............................................................. 2-3 connecting............................................................2-5
opening screen disconnecting....................................................... 2-5
selecting.............................................................7-43
operating force for lever and pedal R
measuring.......................................................... 4-17
operation management radiator
confirming.......................................................... 7-22 checking.............................................................3-13
overheating installing............................................................. 5-25
handling............................................................. 7-52 removing............................................................ 5-25
overload alarm radiator hose and clamp
setting................................................................ 7-35 checking.............................................................3-22
overload relief valve................................................. 6-19 replacing............................................................ 3-45
U30-6S V

receiver slow blow fuse
function and structure........................................ 8-12 layout................................................................... 7-7
installing............................................................. 8-29 special jig and tool
removing............................................................ 8-29 engine compression pressure measuring kit..... 2-41
specifications..................................................... 8-12 overload relief valve measuring kit.....................2-41
recommended lubricant............................................. 3-9 travel motor special jig....................................... 2-42
red lamp universal joint tightening jig................................2-45
list.......................................................................7-46 specifications........................................................... 2-29
refrigerant split pin
checking.............................................................3-55 handling............................................................... 2-2
refrigerant gas spring pin
charging............................................................. 2-19 installing............................................................... 2-2
vacuuming..........................................................2-12 sprocket
refrigerant gas canister............................................ 2-49 dimension.............................................................4-9
refrigerant gas leak tester........................................ 2-49 standby flow............................................................. 6-13
refrigerant gas vacuum machine..............................2-49 starter motor
refrigerant pressure checking.............................................................3-39
measuring.......................................................... 8-19 removing............................................................ 5-24
relay steel track.......................................................... 4-8,4-44
layout................................................................... 7-5 dimension.............................................................4-8
return filter installing............................................................. 4-44
replacing............................................................ 3-28 removing............................................................ 4-44
rubber track straight traveling circuit............................................ 6-29
dimension.............................................................4-8 suction filter
installing............................................................. 4-42 replacing............................................................ 3-31
removing............................................................ 4-42 swing bracket........................................................... 4-22
removing............................................................ 4-22
S swing bracket vertical clearance
measuring.......................................................... 4-16
safety swing control pedal
general information.............................................. 1-1 installing............................................................. 4-36
loading the machine.............................................1-6 removing............................................................ 4-36
operating machine............................................... 1-2 swing cylinder
OPG..................................................................... 1-2 assembling.......................................................6-159
post-operation...................................................... 1-6 component....................................................... 6-154
ROPS...................................................................1-2 disassembling.................................................. 6-156
servicing the excavator........................................ 1-7 swing cylinder speed
starting to operate the machine........................... 1-2 measuring.......................................................... 6-65
transporting the machine..................................... 1-6 switch
working the machine............................................ 1-3 layout................................................................... 7-4
safety for children.......................................................1-6 swivel bearing.......................................................... 4-40
safety labels greasing............................................................. 3-22
taking care of the labels..................................... 1-17 installing............................................................. 4-40
safety labels (danger, warning and caution).............. 1-9 removing............................................................ 4-40
safety valve................................................................ 8-5 swivel bearing vertical play
seat measuring.......................................................... 4-15
removing............................................................ 4-24 swivel gear
seat support greasing............................................................. 3-19
installing............................................................. 4-27 swivel joint..................................................... 6-46,6-164
removing............................................................ 4-27 installing........................................................... 6-164
service dealer mode installing adapter..............................................6-167
flow chart............................................................9-23 removing.......................................................... 6-164
list.......................................................................7-28 specifications..................................................... 6-46
operating............................................................ 7-27 swivel motor...................................................6-31,6-109
servicing...................................................................7-45 assembling....................................................... 6-113
shim component....................................................... 6-110
dimension...........................................................4-10 disassembling...................................................6-111
hydraulic circuit.................................................. 6-32
VI U30-6S

installing........................................................... 6-109 disassembling.................................................. 6-179
installing adapter.............................................. 6-118 function and structure........................................ 6-51
make-up circuit...................................................6-33 installing........................................................... 6-176
parking brake..................................................... 6-33 installing adapter layout................................... 6-186
removing.......................................................... 6-109 performance diagram.........................................6-50
shockless function..............................................6-33 removing.......................................................... 6-176
specifications..................................................... 6-31 specifications..................................................... 6-50
working principle................................................ 6-32 travel motor.................................................... 6-34,6-118
swivel motor drain anti-cavitation valve........................................... 6-39
measuring.......................................................... 6-79 assembling.......................................................6-131
swivel motor internal leakage automatic deceleration.......................................6-43
measuring.......................................................... 6-68 component....................................................... 6-120
swivel motor overload relief valve pressure counterbalance valve......................................... 6-36
measuring.......................................................... 6-78 disassembling.................................................. 6-122
swivel prior circuit.....................................................6-30 hydraulic circuit.................................................. 6-36
swivel speed installing........................................................... 6-118
measuring.......................................................... 6-65 parking brake..................................................... 6-44
removing.......................................................... 6-118
T specifications..................................................... 6-34
working principle................................................ 6-36
temperature switch.....................................................8-6 travel motor drain
tension spring...........................................................4-50 measuring.......................................................... 6-80
installing............................................................. 4-50 travel motor gear oil
removing............................................................ 4-50 replacing............................................................ 3-27
tester mode................................................................ 9-9 travel motor internal leakage
operating............................................................ 7-30 measuring.......................................................... 6-67
thermostat................................................................ 8-10 travel speed
third line valve measuring.......................................................... 6-66
component....................................................... 6-193 travel speed shift system error
installing........................................................... 6-192 handling............................................................. 7-60
installing adapter..............................................6-193 travel straightness
removing.......................................................... 6-192 testing................................................................ 6-68
specifications..................................................... 6-55 troubleshooting
thread seal tape electrical.............................................................7-45
wrapping.............................................................. 2-4
thread-locking fluid
U
applying................................................................2-1
tightening torque unload valve...................................................6-24,6-186
adapter (taper thread)........................................ 2-25 assembling.......................................................6-187
bolt and nut........................................................ 2-23 component....................................................... 6-187
hose clamp.........................................................2-25 disassembling.................................................. 6-187
hydraulic hose (taper thread)............................. 2-24 installing........................................................... 6-186
hydraulic hose fitting.......................................... 2-24 installing adapter..............................................6-189
locknut of adapter with o-ring (straight thread).. 2-24 removing.......................................................... 6-186
stud bolt............................................................. 2-23 specifications..................................................... 6-52
time offset of periodic check working principle................................................ 6-53
adjusting.............................................................7-41 user setting mode.................................................... 7-22
track roller.......................................................... 4-9,4-51 flow chart............................................................9-22
assembling.........................................................4-53
component......................................................... 4-52 V
dimension.............................................................4-9
disassembling.................................................... 4-52 various setting mode
installing............................................................. 4-51 operating............................................................ 7-25
removing............................................................ 4-51
replacing the engine oil...................................... 3-37 W
travel control valve.........................................6-50,6-176 washer liquid level
assembling.......................................................6-182 checking.............................................................3-49
component....................................................... 6-179
U30-6S VII

water separator
draining.............................................................. 3-17
water temperature sensor error
handling............................................................. 7-56
wire harness.............................................................9-16
handling............................................................... 2-5
wiring
color..................................................................... 2-8
Y
yellow lamp
list.......................................................................7-48
VIII U30-6S

Editor : Kubota Corporation Construction Machinery Service Technical Support Dept.
Address : 1-1 Nakamiya-Ohike 1-Chome, Hirakata-City, Osaka, 573-8573, Japan
Phone : +81-72-840-1195
Fax : +81-72-890-2883
E-mail : kbt_g.ce-sv@kubota.com
KUBOTA Corporation Printed in Japan 2021. 06, H, EI, EI, engusa Code No. RY911-30320

Kubota Excavator: Workshop Manual

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WORKSHOP MANUAL

KiSC issued 06, 2021 A

KiSC issued 06, 2021 A

Manuals related to the engine (D1803-M-DI-E2-BH-TH1, D1803-M-DI-E2-BH-TH2)

WSM 03-M-DI-E2B SERIES 9Y011-0286△ (English)

KiSC issued 06, 2021 A

KiSC issued 06, 2021 A

KiSC issued 06, 2021 A

KiSC issued 06, 2021 A

KiSC issued 06, 2021 A

KiSC issued 06, 2021 A

KiSC issued 06, 2021 A

KiSC issued 06, 2021 A

KiSC issued 06, 2021 A

KiSC issued 06, 2021 A

KiSC issued 06, 2021 A

KiSC issued 06, 2021 A

KiSC issued 06, 2021 A

KiSC issued 06, 2021 A

A/C Air Conditioning ID Inner Diameter

AC Alternating Current ISO International Standards Organization

ACC Accessory J/C Joint Connector

AFS Air Flow Sensor JIS Japanese Industry Standard

AI Auto Idle LCD Liquid Crystal Display

API American Petroleum Institute LED Light Emitting Diode

Approx. Approximately LH Left Hand side

AS Auto Stop LSD Limited Slip Differential

ASSY. Assembly MAX Maximum

AUX Auxiliary MIN Minimum

C/V Control Valve NC Normally Closed

CAB Cabin NO Normally Opened

CAN Controller Area Network OD Outer Diameter

CCV Closed Crankcase Ventilation P/V Pilot Valve

Committee for European Construction Equip-

CNP Canopy RH Right Hand side

CRS Common Rail System RMS Root Mean Square

Deutsches Institut für Normung (German In-

DOC Diesel Oxidation Catalysts SAE Society of Automotive Engineers

DM Diagnostic Manual SBF Slow Blow Fuse

DPF Diesel Particulate Filters SCV Suction Control Valve

Système Internationale (International system

ECU Electronic Control Unit S/J Swivel Joint

EGR Exhaust Gas Recirculation SOL Solenoid

EN Europäische Norm (European standard) spec. Specification

Eng Engine SW Switch

FOPS Falling Object Protective Structure TEMP. Temperature

GND Ground TPSS Two Pattern Selection System

HST Hydraulic Static Transmission WSM Work Shop Manual

IAT Intake Air Temperature W/H Wire Harness

KiSC issued 06, 2021 A

KiSC issued 06, 2021 A

– While using the machine, do not allow any

KiSC issued 06, 2021 A

The OPG (top guard level I), in accordance with

KiSC issued 06, 2021 A

• Do not operate or idle engine in a non-ventilated Maximum drawbar pull at cou-

• Keep all safety equipment and covers in place.

KiSC issued 06, 2021 A

• When the machine is parked or left unattended on a

2.3 Important information on

– Excavation using the traveling power of the

• Under all circumstances, avoid the following

• Do not try to drop or shake off soil adhering to the