305CR Mini Hydraulic Excavator DSA00001-UP (MACHINE) POWERED BY K4N ...

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Product: MINI HYD EXCAVATOR

Model: 305 MINI HYD EXCAVATOR DSA
Configuration: 305CR Mini Hydraulic Excavator DSA00001-UP (MACHINE) POWERED BY K4N Engine

Testing and Adjusting

305 CR Mini Hydraulic Excavator Hydraulic System
Media Number -RENR5556-05 Publication Date -01/07/2007 Date Updated -23/07/2007

i02139113

Relief Valve (Line) - Test and Adjust

SMCS - 5117-025-L9; 5117-081-L9

Personal injury can result from hydraulic oil pressure and hot oil.

Hydraulic oil pressure can remain in the hydraulic system after the
engine has been stopped. Serious injury can be caused if this pressure is
not released before any service is done on the hydraulic system.

Make sure all of the attachments have been lowered, oil is cool before
removing any components or lines. Remove the oil filler cap only when
the engine is stopped, and the filler cap is cool enough to touch with
your bare hand.

Do not check for leaks with your hands. Pin hole (very small) leaks can
result in a high velocity oil stream that will be invisible close to the hose.
This oil can penetrate the skin and cause personal injury. Use
cardboard or paper to locate pin hole leaks.

NOTICE

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Care must be taken to ensure that fluids are contained during

performance of inspection, maintenance, testing, adjusting and repair
of the product. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component
containing fluids.

Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop

Products Guide" for tools and supplies suitable to collect and contain
fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.

Test Procedure
Table 1
Required Tools
Part Number Description Quantity
8T-0860 Pressure Gauge 2
6V-3014 Hose 2
6V-4143 Coupler Assembly 4

Before you perform these procedures, refer to Testing and Adjusting, "Machine Preparation" for
the proper procedure to prepare the machine.

Note: The following tests require operating the engine at high idle. Refer to Testing and
Adjusting, "Engine Performance - Test".

Note: A temporary setting of the main relief valve is required before any line relief valve can be
tested. Temporarily adjust main relief valve (P1) in order to test the boom line relief valves and
the bucket line relief valve. Temporarily adjust main relief valve (P2) in order to test the stick line
relief valves. Refer to Testing and Adjusting, "Relief Valve (Main) - Test and Adjust".

1. Release the hydraulic system pressure. Refer to Testing and Adjusting, "Hydraulic System
Pressure - Release" for the proper procedure.

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Illustration 1 g00836560

Engine compartment

(1) Pressure tap (P1)

(2) Pressure tap (P2)

(3) Pressure tap (P3)

2. Open the engine hood in order to access the pressure taps for the main relief valves.

3. Connect a 40000 kPa (5800 psi) pressure gauge to pressure tap (1) .

4. Connect a 40000 kPa (5800 psi) pressure gauge to pressure tap (2) .

5. Start the engine. Be sure that the engine is at high idle.

6. Move the bucket's control lever to the CLOSE position and hold. Make a note of the reading
on the gauge attached to pressure tap (1) .

7. The pressure should be 27900 ± 1500 kPa (4050 ± 220 psi).

8. Move the boom's control lever forward to the LOWER position and hold. Make a note of
the reading on the gauge attached to the pressure tap (1) .

9. The pressure should be 27900 ± 1500 kPa (4050 ± 220 psi).

10. Move the stick's control lever forward to the OUT position and hold. Make a note of the
reading on the gauge attached to pressure tap (2) .

11. The pressure should be 27900 ± 1500 kPa (4050 ± 220 psi).

12. Move the stick's control lever backward to the IN position and hold. Make a note of the
reading on the gauge attached to the pressure tap (2) .

13. The pressure should be 27900 ± 1500 kPa (4050 ± 220 psi).

14. If any of the pressure readings are not set to the correct specifications, adjustment of that
line relief valve is necessary. Refer to the "Adjustment Procedure".

Adjustment Procedure

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Illustration 2 g00837781

Top view of main control valve

(4) Line relief valve (bucket cylinder head end)

(5) Line relief valve (boom cylinder rod end)

(6) Line relief valve (boom head)

(7) Line relief valve (stick cylinder head end)

(8) Line relief valve (stick cylinder rod end)

1. The following line relief valves are located on the right side of the main control valve: (4)
bucket cylinder head end, (5) boom cylinder rod end, (6) boom head and (7) stick cylinder
head end. Line relief valve (8) for the stick cylinder rod end is located on the left side of the
main control valve.

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Illustration 3 g00343372

Line relief valve (typical example)

(14) Locknut

(15) Adjustment screw

2. Determine the line relief valves that require adjustment. Loosen locknut (14). Turn
adjustment screw (15) in order to adjust the pressure. Turning adjustment screw (15)
clockwise increases the pressure. Turning adjustment screw (15) counterclockwise
decreases the pressure. Tighten locknut (14) .

Note: Always make final pressure adjustment on pressure rise.

Note: Adjust the main relief valve to the specifications. Refer to Testing and Adjusting,
"Relief Valve (Main) - Test and Adjust".

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