Procedure to Install Relief Valves in the 2nd Auxiliary Valve on Certain Next Gen Mini

Hydraulic Excavators {5051} (M0154449-01)

SMCS - 5051 i09627922

Mini Hydraulic Excavator
PSP
202 -0005
301.5 (S/N: MNH1-UP)
301.6 (S/N: MY61-UP)

301.7CR (S/N: JH71-UP) 4

03: /05/1 A93B
301.8 (S/N: H8X1-UP)

302.7CR (S/N: 3C31-UP; CZ61-UP)

2
M0 2:12+ 3
302CR (S/N: RHM1-UP) 1
© 2 5444 09:30
024 9
303.5CR (S/N: CE91-UP; RE91-UP; R2E1-UP)

Cat
303CR (S/N: MY31-UP; NXY1-UP)

304 (S/N: AN41-UP)

erp
304CR (S/N: AX41-UP)
illa
305 (S/N: AX51-UP)
r In
305 CR (S/N: 5G51-UP; 5X51-UP) c.
305.5 CR (S/N: AX61-UP)
306 (S/N: 6G61-UP; 6W61-UP)

307.5 (S/N: GW71-UP)

308 (S/N: GG81-UP; GK81-UP; GW81-UP; GX81-UP)

308.5 (S/N: GZ81-UP)

310 (S/N: GWT1-UP)

Revision History:
Table 1
Revision Summary of Changes
01 Corrected part number for 304 - 305.5 models.

Introduction
This Special Instruction contains the procedure to install relief valves in the 2nd auxiliary valve
on the machines listed above.

Verify the machine configuration to determine if the machine is equipped with a 2nd auxiliary
valve. Certain work tools that are connected to the 2nd auxiliary may need the ability to adjust
the pressure coming from the main control valve. This procedure only contains the instructions
for changing the relief valve in the main control valve.

If the machine is not equipped with a 2nd auxiliary valve from the factory, the following
installation instructions are available for Next Generation Mini Hydraulic Excavators:

Table 2

Model Machine Prefix Publication

306 (S/N: 6G6; 6W6) M0118777
307.5 (S/N: GW7) M0105049
308 (S/N: GG8; GW8) M0105045
310 (S/N: GWT) M0105047

If the machine is equipped with a 2nd auxiliary valve installed from the factory, determine if the
valve section already has relief valves installed. If relief valves were not installed in the valve
section from the factory, determine if relief valves can be fit directly into the 2nd auxiliary valve
section.

Be aware of the machine configuration. Some 301.5 to 305.5 machines have 2nd auxiliary run
through the boom swing valve section with a diverter valve. If 2nd auxiliary is run through the
boom swing valve and NOT an independent valve, the lower pressure setting will result in
reduced force output for the boom swing cylinder.

Do not perform any procedure in this Special Instruction until you have read the information and
you understand the information.

Reference Section
Reference: Special Instruction, M0118777 , "Installation Procedure for 581-3793 581-3794
Auxiliary Lines Kits (Second Auxiliary) on Certain 306 Mini Hydraulic Excavators"

Reference: Special Instruction, M0105049 , "Installation Procedure for 561-8198 Auxiliary Lines
Kit (Second Auxiliary) on Certain 307.5 Mini Hydraulic Excavators"

Reference: Special Instruction, M0105045 , "Installation Procedure for 561-8196 561-8197

Auxiliary Lines Kits (Second Auxiliary) on Certain 308 Mini Hydraulic Excavators"

Reference: Special Instruction, M0105047 , "Installation Procedure for 561-8199 Auxiliary Lines
Kit (Second Auxiliary) on Certain 310 Mini Hydraulic Excavators"

Reference: Operation and Maintenance Manual, M0088895 , "301.5 Mini Hydraulic Excavators"

Reference: Operation and Maintenance Manual, M0116093 , "302.7 CR, 303 CR, 303.5 CR,
and 304 CR Excavator"
Reference: Operation and Maintenance Manual, M0096944 , "308 CR and 308 SR Mini
Hydraulic Excavators"

Reference: Operation and Maintenance Manual, M0118365 , "304, 305 SR, 305 CR, 305.5 CR
Excavator"

Reference: Operation and Maintenance Manual, M0097987 , "306, 306 CR, and 306.5 Mini
Hydraulic Excavators" Prepare the Machine for Maintenance

Reference: Operation and Maintenance Manual, M0090571 , "307.5, 308 CR, 308.5, 309 CR,
and 310 Mini Hydraulic Excavators" Prepare the Machine for Maintenance

Reference: Specifications, SENR3130 , "Torque Specifications"

Safety Section
Work safely. Most accidents that involve product operation, maintenance, and repair are caused
by failure to observe basic safety rules or precautions. An accident can often be avoided by
recognizing potentially hazardous situations before an accident occurs.

A person must be alert to potential hazards. This person must also have the necessary training,
skills, and tools to perform these functions properly.

Safety precautions and warnings are provided in this instruction and on the product. If these
hazard warnings are not heeded, bodily injury or death could occur to you or to other persons.
Caterpillar cannot anticipate every possible circumstance of a potential hazard.

Therefore, the warnings in this publication and the warnings that are on the product are not all
inclusive. Avoid using a tool, a procedure, a work method, or operating technique that is not
recommended by Caterpillar.

Ensure that the product will not be damaged or the product will be made unsafe by the operation,
lubrication, maintenance, or the repair procedures.

Do not operate or work on this product unless you have read

and understood the instructions and warnings in the relevant
Operation and Maintenance Manuals and relevant service
literature. Failure to follow the instructions or heed the warnings
could result in injury or death. Proper care is your responsibility.
 Personal injury or death can result from improper maintenance
procedures. To avoid injury or death, follow the procedures
exactly as stated below.

Personal injury or death can result from sudden movement.

Prevent possible injury by performing the following procedures

before work begins:

Move the product or equipment to a smooth, level surface.

When applicable, lower equipment/work tools to the ground.

Engage the parking brake, system brakes and/or hydraulic

lockout control. When applicable, stop the engine and remove
the ignition key.

Release system pressure from pressurized systems.

If applicable, block the wheels/tracks.

Turn the battery disconnect switch to the OFF position and, if

applicable, remove the battery disconnect key. If not equipped
with a battery disconnect switch, disconnect all positive (+) and
negative (−) battery cables. Install an appropriate battery cable
lockout device and protect the battery posts to prevent
accidental contact and shorting.

Attach a “Do Not Operate” or similar warning tag at the battery

disconnect switch location and as defined by site rules and/or
local regulations.

Illustration 1 g06276183

Required Parts
Table 3
Required Parts
Part Part
Model Machine Prefix
Number Name
(S/N: MNH1-UP; MY61-UP; JH71-UP; H8X1-UP; RHM1-
301.5 - Relief
UP; CZ61-UP; 3C31-UP; MY31-UP; NXY1-UP; CE91- 479-0604
304 Valve Gp
UP; R2E1-UP; RE91-UP; AX41-UP)
304 - (S/N: AN41-UP; AX51-UP; 5G51-UP; 5X51-UP; AX61- Relief
594-1458
305.5 UP) Valve Gp
Relief
306 (S/N: 6G61-UP; 6W61-UP) 186-0907(1)
Valve Gp
Relief
307.5 (S/N: GW71-UP) 594-1458
Valve Gp
Relief
308 (S/N: GG81-UP; GW81-UP; GZ81-UP; GX81-UP) 456-1861
Valve Gp
Relief
310 (S/N: GWT1-UP) 594-1458
Valve Gp
(1) Factory installed.

Machine Preparation
Refer to Operation and Maintenance Manual, "Prepare the Machine for Maintenance" for your
machine.

301.5 - 305.5 Machines

1. Remove the plugs from the main control valve on the boom swing / 2nd auxiliary valve
section.

Illustration 2 g07489251
 For models (S/N: MNH) (S/N: MY6) (S/N: JH7) (S/N: H8X) (S/N: RHM) (S/N: CZ6) (S/N: 3C3) (S/N: MY3) (S/N:
NXY) (S/N: CE9) (S/N: R2E) (S/N: RE9) (S/N: AX4)
(1) 479-0604 Relief Valve Gp

Illustration 3 g07489253
For models (S/N: AN4) (S/N: AX5) (S/N: 5G5) (S/N: 5X5) (S/N: AX6)
(1) 594-1458 Relief Valve Gp
2. Directly install and torque the applicable relief valve groups from Table 3 into the boom
swing / 2nd auxiliary valve ports opened in Step 1.

306 and 308 Machines

1. Remove the plugs from the main control valve on the 2nd auxiliary valve section.
Note: 306 models are equipped with 186-0907 Relief Valve Gp from the factory.
Illustration 4 g06761489
For 306 machines
(3) 186-0907 Relief Valve Gp
 Illustration 5 g06737762
For 308 machines
(4) 456-1861 Relief Valve Gp
2. Directly install relief valve groups into the 2nd auxiliary valve.

307.5 and 310 Machines

Illustration 6 g06731460
(A) Main control valve
(B) Plugs

1. Remove two plugs (B) from main control valve (A).

 Illustration 7 g06738381
(5) 594-1458 Relief Valve Gp
(A) Main control valve
2. Install two relief valve groups (5) to main control valve (A). Tighten two relief valve groups
(5) to a torque of 47 ± 2 N·m (35 ± 1 lb ft).

Relief Valve Adjustment

Illustration 8 g07489245
Screw style relief valve
Illustration 9 g07489243
Allen head style relief valve
Relief valves may be a screw style or an Allen head, the locknut must be loosened to adjust
pressure. Turn the adjustment screw / allen head clockwise to increase the pressure setting.
Turn the adjustment screw counterclockwise to decrease the pressure.

Note: Do NOT adjust the relief valve with hydraulic flow going through the valve. The
relief valves are sensitive and can be damaged by over adjustment. Do not wind the relief
valve to the minimum or maximum adjustment.

Table 4
Relief Valve Adjustment
Part Factory Pressure
Adjustment Range Adjustment Rate
Number Setting
31000 kPa 10500 to 37000 kPa 12000 kPa
456-1861
(4496 psi) (1523 to 5366 psi) (1740 psi)/Turn
17500 kPa 17100 to 25000 kPa 8000 kPa
594-1458
(2538 psi) (2480 to 3626 psi) (1160 psi)/Turn
21400 kPa 10500 to 34500 kPa 12000 kPa
186-0907
(3104 psi) (1523 to 5004 psi) (1740 psi)/Turn
27500 kPa 16000 to 28000 kPa 7560 kPa
479-0604
(3989 psi) (2321 ± 4061 psi) (1097 psi)/Turn

1. Position the machine on level ground and stop the engine.

2. Release the pressure in the hydraulic system. Refer to Operation and Maintenance Manual,
"System Pressure - Release".

3. Record which relief valve is being installed and what the factory pressure setting is from
Table 4. Subtract the factory pressure from the desired work tool pressure. The result will be
the amount of adjustment that needs to be made.
 Example: 20000 kPa (2900 psi) (work tool requirement) - 27500 kPa (3989 psi) (factory
setting) = - 7500 kPa (1088 psi) (lower)
4. Divide the required adjustment by the adjustment rate given in Table 4.
Example: - 7500 kPa (1088 psi) / 7560 kPa (1097 psi)/Turn = approximately 1 full turn

Illustration 10 g07489241
(B) Adjustment screw
(C) Locknut

5. Loosen locknut (C).

6. Slowly turn adjustment screw (B) clockwise to increase the pressure setting. Slowly turn
adjustment screw (B) counterclockwise to decrease the pressure setting.
Example: To decrease the pressure to 20000 kPa (2900 psi), adjustment screw (B) should
be turned 1 full revolution counterclockwise

7. Test the pressure setting of the relief valve by stalling the 2nd auxiliary implement function
and measuring the pressure.

8. When the desired pressure for the work took has been achieved, tighten locknut (C) to a
torque of 8 N·m (70 lb in) for 594-1458 Relief Valve Gp and 479-0604 Relief Valve Gp.
Tighten locknut (C) to a torque of 13.5 N·m (120 lb in) for 456-1861 Relief Valve Gp and
186-0907 Relief Valve Gp.

PSP-0005A93B
2024/05/13
03:19:48+09:30
i09552815
© 2024 Caterpillar Inc.