HKX Manual Parts 320D PDF

Some Components in this Kit
have been Partially Assembled

to Facilitate Installation
Please Note: Installer is
Responsible for Final
PRODUCT
Assembly; including O-ring
Condition and Tightening
of all Connections
INSTALLATION
AND
MAINTENANCE
MANUAL
HYDRAULIC KITS FOR EXCAVATORS
It is imperative to read, follow and

understand all safety precautions 320D CATERPILLAR EXCAVATOR
and installation procedures found
in this manual before attempting HYDRAULIC BREAKER KIT
any installation or operation of
product. Deviation from this manual KC1213-1 DATE: 10.08.10
may cause damage to machine,
attachment and product. Damage to
machine may cause serious injury or
death. Installation and maintenance
personnel must read this manual
before installation or maintenance of
this product on this machine. This
manual should be kept near the
machine for installation procedures
and reference while installing this
product. HKX, Inc. cannot anticipate
every possible circumstance that might
involve a potential hazard. The Hydraulic KITS
warnings in this publication and on the
product are therefore not all inclusive.
for Excavators
800.HYD.KITS
COPYRIGHT  2002. HKX, INCORPORATED. ALL RIGHTS RESERVED. (REV. 1 | 4/02).

INTRODUCTION
CONGRATULATIONS!
You have purchased a quality hydraulic piping kit our Technical Publications team at the information
designed specifically for your excavator. This kit was below:
designed by HKX, Incorporated and is optimized to
take full advantage of your excavator and maintain HKX, Incorporated
its high standard of quality. Attn.: Technical Publications Department
16761 - 146th Street SE, Suite 115
This manual contains specific technical drawings, Monroe, Washington 98272
step-by-step installation instructions, parts lists, Phone: (800) 493-5487
flow and pressure testing and troubleshooting Fax: (800) 353-5736
charts. We are confident that it will exceed your Email: support@hkx.com
requirements. http://www.hkx.com
HKX recommends that you read this manual thor- If the kit cannot be installed per manual, please
oughly before installing the kit. Follow the manual contact HKX before deviating from kit instructions
and drawings for proper installation. Deviation from and design. Our Technical Support team will assist
this manual may increase the installation time and/ you to correct the problem without affecting the
or cause damage to the machine or attachment. If HKX kit integrity or warranty.
the manual is followed precisely, the most efficient
installation in the shortest amount of time will be This information is to be used for the specific pur-
achieved. pose for which it was provided. It is provided on a
confidential basis and is the property of HKX. The
The kit is designed to fit the specific carrier. HKX has reproduction and use of this information without
endeavored to deliver the highest degree of accu- the express written consent from HKX, Incorporated
racy possible. However, continuous improvement is is strictly prohibited.
a HKX policy for all kits and manufacturers continu-
Copyright  2001 by HKX, Incorporated.
ally make improvement changes. Therefore product HKX is a registered trademark of HKX, Incorporated.
specifications are subject to change without notice.
Readers are encouraged to notify HKX and send in

suggestions for improvement. All communications
will be carefully considered for future printings of
this and other manuals.
Please write, call, email or fax your comments to
REV. 2 - 6.2003
TABLE OF CONTENTS
TABLE OF CONTENTS
I. INTRODUCTION XIII. FINALIZING INSTALLATION

A. Post Installation Inspection
II. TABLE OF CONTENTS B. Installation Clean-up
C. Installation and Maintenance Manual
III. SAFETY PRECAUTIONS
CAUTION WARNING DANGER XIV. FUNCTION TESTING
A. Foreword A. Before You Start Testing
B. Safety Alert Symbol B. Start-up Procedure
C. Signal Words & Symbols C. Setting Pressure (Port) Relief Cartridge (PRC)
D. Importance of Safety D. Setting Pilot Valve and Pressure Reducing
E. Precautions Valve (Flow Regulator) Pressure
F. Attachment Selection
G. Symbols Chart XV. AUXILIARY HYDRAULIC CIRCUIT SET-UP &
OPERATION CHECK LIST
IV. DECAL INSTALLATION A. Pressure
B. Flow
V. PREPARATION C. Excavator Settings
A. Before You Start D. Lock Out Valves & Switch Valves
B. Machine Preparation E. Decals & Lock Out Tags
C. Tips & Techniques
XVI. OPERATION & MAINTENANCE
VI. TORQUE SPECIFICATIONS A. Safety
A. Installation of O-ring Face Seal B. Operation of System Components
(ORFS) Fittings  Accumulator
B. Tightening Torque Chart -  Auxiliary Valve
Bolts/Screws (lock off ), 3-Way (lock-
 Ball Valve: 2-Way
C. Tightening Torque Chart - over)
Tubes/Manifolds and Adapter Fittings C. Periodic Inspections
VII. GROUP MAP XVII. TROUBLESHOOTING
A. Troubleshooting Chart
VIII. HYDRAULIC FLOW DIAGRAMS B. Troubleshooting Questionaire
(not applicable in some manuals)
IX. GROUP 1 - BOOM XVIII. GLOSSARY
A. GROUP 1 - Parts List
B. GROUP 1 - Installation Illustration XIX. PRODUCT WARRANTY
C. GROUP 1 - Support Documentation
X. GROUP 2 - ARM
A. GROUP 2 - Parts List
B. GROUP 2 - Installation Illustration NOTICE
XI. GROUP 3 - VALVE

A. GROUP 3 - Parts List INCLUDED WITH MANUAL:
B. GROUP 3 - Installation Illustration A. STOP! Read Before You Start! Safety First!
C. GROUP 3 - Support Documentation B. Customer Feedback Form
C. DANGER! Do Not Operate Tag
XII. GROUP 4 - CONTROLS D. CAUTION Auxiliary Circuit Flow and
A. GROUP 4 - Parts List Pressures need to be set to Attachment
B. GROUP 4 - Installation Illustration Specifications Tag
READ, UNDERSTAND AND FOLLOW ALL SAFETY PRECAUTIONS AND PROCEDURES

WARNING FOUND IN THE OPERATOR’S MANUAL FOR THE MACHINE AND INSTALLATION
INSTRUCTIONS OF HYDRAULIC KIT BEFORE ATTEMPTING ANY OPERATION, INSPEC-
TION OR MAINTENANCE OF THIS MACHINE, ATTACHMENTS AND/OR SYSTEMS.
No one can anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the
product are therefore not all inclusive. If a tool, procedure, work method or installation technique not specifically covered in this manual
is used, you must satisfy yourself that it is safe for you and others. You must also ensure that the product will not be damaged or made
unsafe by the installation, lubrication, maintenance and/or operation procedures you choose.
PROPERTY OF HKX,INCORPORATED PROPERTY OF HKX,INCORPORATED PROPERTY OF HKX,INCORPORATED PROPERTY OF HKX,INCORPORATED PROPERTY OF HKX,INCORPORATED PROPERTY OF HKX,INCORPORATED PROPERTY OF HKX,INCORPORATED
REV. 5 - 12.2007
DECAL INSTALLATION
DECAL INSTALLATION
APPLYING DECAL LABELS DECAL PLACEMENT
 Decal Placement
IMPORTANT : Before installation of DECALs,  ACCUMULATOR & BALL VALVE/ROCKER SWITCH DECAL
always ensure machine surface is clean and free of
dirt, oils, and any other debris.
 Applying Decal Labels

 DECAL LABEL SHEETS
These Decals have a variety of (peel and stick) labels
and (4) white labels for custom applications.
SINGLE DIRECTION DUAL DIRECTION
ATTACHMENT ATTACHMENT BREAKER BREAKER THUMB THUMB
ATTACHMENT ATTACHMENT BREAKER BREAKER THUMB THUMB
ATTACHMENT ATTACHMENT COMPACTOR COMPACTOR SHEAR SHEAR
ATTACHMENT ATTACHMENT
COMPACTOR COMPACTOR SHEAR SHEAR
ATTACHMENT ATTACHMENT OPEN OPEN
NOT NOT CLOSE CLOSE
USED USED INSIDE CAB

Ball Valve/Rocker Switch Decal Labels 850-0007 Rev.1 www.hkx.com *850-0007*
(RIGHT WINDOW)
The following examples show how the labels can be

used:
DUAL DIRECTION
OPEN LEFT ATTACHMENT
AUTO NOT
RIGHT USED
DECEL
SINGLE DIRECTION
CLOSED ATTACHMENT
OPEN
CLOSED
CLOSED
OPEN
GEN_DECAL INSTALLATION_MOD REV. 0 - 3.2007
DECAL INSTALLATION
 DECAL PLACEMENT CONTINUED

 BALL VALVE and KIT INFORMATION DECAL  BALL VALVE Point OF USE DECALs
INSIDE CAB
(RIGHT WINDOW)
Place Decal near Ball

Valve, visible with cover
open or place on cover
DECAL INSTALLATION
 DECAL PLACEMENT CONTINUED

 Control DECALS
INSIDE CAB
(RIGHT WINDOW)
SAFETY PRECAUTIONS
SAFETY PRECAUTIONS
FOREWORD | SAFETY ALERT SYMBOL | SIGNAL WORDS & SYMBOLS | IMPORTANCE OF SAFETY | PRECAUTIONS | ATTACHMENT SELECTION
n FOREWORD n IMPORTANCE OF SAFETY

This section is intended to point out some of the
basic situations, which may be encountered during
installation, operation and maintenance of a hydraulic Why is SAFETY
important to you?
kit and/or machine and to suggest possible ways of
dealing with these conditions. This is not a substitute for
the manufacturer’s manual(s). Additional precautions
may be necessary, depending on attachments used and Accidents Disable & Kill
conditions at the work site or in your service area.
IMPORTANT: IF YOU DO NOT HAVE THE MANUFAC-
3 BIG REASONS: Accidents Cost
Accidents Can Be Avoided
TURER’S MANUAL(S) FOR YOUR PARTICULAR MACHINE,
GET A REPLACEMENT MANUAL BEFORE ANY INSTALLA- It is YOUR responsibility to read and understand these
TIONS, OPERATIONS OR MAINTENANCE. safety precautions and the manufacturer’s manual(s). You are
the key to safety. Good safety practices not only protect you
but the people around you. So always Be Alert, Be Aware and
n SAFETY ALERT SYMBOL
Be Careful. Human error is caused by many factors. Damages
ATTENTION! BECOME ALERT! to machines can be fixed but injury, or death, has a lasting
YOUR SAFETY IS INVOLVED! effect. For your safety and the safety of others, encourage your
The Safety Alert Symbol identifies im- fellow workers to act safely.
portant safety messages on machine, safety Make sure a Safety Program is implemented at your service
signs, in manuals, or elsewhere. When you location. Follow all rules and regulations governing operation,
see this symbol, be alert to the possibility of installation and maintenance of equipment. Always check
personal injury or death. Follow the instruc- with your supervisor or the safety coordinator for regulations
tion in the safety message. and updates.
Protect yourself and others. Protective clothing and per-
n SIGNAL WORDS & SYMBOLS sonal safety devices should be issued to all service depart-
ment personnel.
DANGER Know your machine. Respect your machine. Study the
Operator’s Manual before starting the engine. Know how to
n DANGER | RED used to indicate the presence of an immi- operate all equipment on your machine.
nently hazardous situation which, if not avoided, will result For an industry standard Hydraulic Excavator “Safety
in death or serious injury. Manual” for operators and mechanics, visit the Equipment
Manufacturers Institute (EMI) website at www.emi.org or
WARNING write to them at address: 10 S. Riverside Plaza, Chicago, Il-
linois, 60606, USA.
n WARNING | ORANGE used to indicate the presence of a
potentially hazardous situation which, if not avoided, will n PRECAUTIONS
result in death or serious injury.
WARNING
CAUTION AVOID OIL SPILLS. USE CONTAINERS, RAGS AND/OR
ABSORBENT PADS TO CONTAIN ANY OIL LEAKAGE.
n CAUTION WITH SAFETY ALERT SYMBOL | YELLOW used DISPOSE OF ALL WASTE OILS, FLUIDS, LUBRICANTS
AND OTHER HAZARDOUS WASTE PROPERLY
to indicate the presence of a potentially hazardous situa-
tion which, if not avoided, may cause minor or moderate
injury. WARNING
USE PERSONAL PROTECTION EQUIPMENT
CAUTION SUCH AS: HARD HAT, SAFETY GLOVES,
SAFETY SHOES AND SAFETY GLASSES
NEEDED TO PERFORM THE JOB
n CAUTION WITHOUT SAFETY ALERT SYMBOL | YELLOW
used to indicate the presence of a potentially hazardous
situation which, if not avoided, may result in property dam- WARNING
age. NEVER USE GASOLINE, DIESEL FUEL OR OTHER FLAM-
MABLE LIQUIDS TO CLEAN PARTS. ALWAYS CLEAN
NOTICE
PARTS IN A WELL VENTILATED AREA
n NOTICE WITHOUT SAFETY ALERT SYMBOL | GREEN used

to indicate installation, operation or maintenance informa-
tion.
n CONTINUED
GEN_SAFETY PRECAUTIONS_MOD REV. 1 - 4.2003
SAFETY PRECAUTIONS
-PRECAUTIONS- continued
CAUTION
WARNING PROTECT ALL AREAS IN, ON AND AROUND THE MACHINE
NEVER WORK ON A MACHINE THAT HAS REACHED WITH A FLAME RETARDENT COVERING, DURING GRINDING
NORMAL OPERATING TEMPERATURE. ALLOW SUF- AND WELDING. THIS WILL PREVENT SPARKS AND WELD
FICIENT TIME FOR THE MACHINE TO COOL BEFORE SPLATTER THAT COULD CAUSE SHATTERING OF TEM-
PERFORMING ANY INSTALLATION OR MAINTE- PERED GLASS AND DAMAGE TO CYLINDERS, ELECTRICAL
NANCE. COMPONENTS, SEAT CUSHIONS, COSMETIC PARTS AND
OTHER COMPONENTS ON THE MACHINE. AFTER WELD-
WARNING ING, ALL SURFACES SHOULD BE TREATED AND PAINTED
THOROUGHLY TO PREVENT RUST AND CORROSION.
EXTRA CARE SHOULD BE TAKEN WHEN INSTALLING
COMPONENTS ON THE BOOM, ARM OR TOP OF THE
MACHINE, TO AVOID FALL HAZARDS. IF THE BOOM, CAUTION
ARM AND ATTACHMENT CYLINDERS ARE NOT IN
NEVER ALLOW A HYDRAULIC LINE OR COMPONENT TO
A RELAXED STATE ON THE GROUND, THEY COULD BECOME CONTAMINATED. THIS COULD CAUSE SEVERE
DROP RESULTING IN SERIOUS INJURY OR DEATH. SYSTEM DAMAGE. CONTACT YOUR MACHINE DEALER OR
MANUFACTURER FOR PROPER CAPS AND PLUGS TO BE
USED ON THE MACHINE.
WARNING
READ, UNDERSTAND AND FOLLOW WELDING CAUTION
SPECIFICATIONS IN THE OPERATOR’S MANUAL
BEFORE WELDING ON MACHINE. DISCONNECT WHEN CUTTING AND DRILLING, ALWAYS ENSURE ENOUGH
BATTERY, COMPUTER AND REMOVE ALL FLAM- CLEARANCE TO AVOID DAMAGE TO ELECTRICAL WIRING,
MABLE MATERIALS AND LIQUIDS FROM WORK
HOSES, COMPONENTS AND MACHINE.
AREA BEFORE WELDING.
WARNING CAUTION
ENGINE EXAUST GASES CAN FAILURE TO VERIFY, INSTALL AND SET FLOW CONTROL AND
CAUSE LOSS OF PRESSURE RELIEF CARTRIDGE REQUIREMENTS FOR THE
JUDGEMENT, LOSS OF ATTACHMENT MAY CAUSE SEVERE DAMAGE TO MACHINE
ALERTNESS AND LOSS OF AND VOID ATTACHMENT, MACHINE AND KIT WARRAN-
MOTOR CONTROL. THESE TIES. DO NOT EXCEED MAXIMUM OPERATING PRESSURE
GASES CAN ALSO CAUSE AND FLOW OF ATTACHMENT. CONTACT ATTACHMENT
UNCONSCIOUSNESS, MANUFACTURER FOR OPERATING PRESSURE AND FLOW
SERIOUS INJURY AND FATAL REQUIREMENTS. CONTACT MACHINE DEALER OR MANU-
FACTURER TO PURCHASE PORT RELIEF CARTRIDGES.
ACCIDENTS. MAKE SURE OF ADEQUATE VENTI-
LATION BEFORE STARTING THE ENGINE IN ANY
ENCLOSED AREA. YOU SHOULD ALSO BE AWARE
OF OPEN WINDOWS, DOORS OR DUCTWORK n ATTACHMENT SELECTION
INTO WHICH EXAUST FUMES MAY BE CARRIED,
OR BLOWN BY THE WIND, EXPOSING OTHERS TO When choosing an attachment, the following things
DANGER. are imperative:
n STABILITY.
CAUTION The attachment must fall within the excavator lift capac-
ity and tip-over weight limits.
IT IS IMPERATIVE TO FOLLOW THE MANUAL AND IL- n HYDRAULIC FLOW.
LUSTRATIONS FOR PROPER INSTALLATION. DEVIATION The excavator must be able to provide sufficient
FROM THIS MANUAL MAY CAUSE DAMAGE TO THE hydraulic flow (i.e. GPM, LPM, Etc.) to operate the at-
MACHINE, ATTACHMENTS AND COMPONENTS IN THE KIT, tachment.
AS WELL AS, HYDRAULIC SYSTEM PROBLEMS. CONTACT n HYDRAULIC PRESSURE.
KIT MANUFACTURER PRIOR TO INSTALLATION FOR AS- Similar to flow, sufficient hydraulic pressure (i.e. PSI, Bar,
SISTANCE IN EVALUATING MODIFICATIONS OR MACHINE/ Kg/cm², etc.) must be available at the required flow.
ATTACHMENT CHANGES. THE KIT MANUFACTURER
WILL NOT PAY FOR ANY INCIDENTAL CHARGES, LABOR
IMPORTANT: PLEASE NOTE ALL SECTIONS DEALING WITH
CHARGES OR MODIFICATIONS TO KITS WITHOUT PRIOR
SELECTION, MASS, OPERATION AND MAINTENANCE OF AT-
WRITTEN APPROVAL. UNAUTHORIZED MODIFICATIONS &
TACHMENTS FOR EXCAVATORS IN ALL MANUFACTURER’S
INCORRECT USE OF KIT WILL VOID ALL KIT WARRANTIES.
MANUAL(S).
CONTACT EXCAVATOR OR ATTACHMENT MANUFACTURER
FOR ASSISTANCE IN CORRECTLY SELECTING AN ATTACH-
MENT FOR A PARTICULAR MACHINE.
n CONTINUED
SAFETY PRECAUTIONS
n SYMBOLS CHART
The following symbols are used in this Installation Manual at important points dealing with installation, safety, quality, etc. to
make the data fully usable.
SYMBOL MEANING SYMBOL MEANING
SAFETY. MEASURE
Indicates procedures requiring special atten- Indicates items requiring measurement and
tion from a safety viewpoint. inspection by dimensions, etc.
010_SYM
WRENCH (Standard) MEASURE

Indicates tightening or loosening with a Indicates items requiring measurement and
Standard wrench. inspection by amperage, voltage, etc.
001_SYM 006_SYM
WRENCH (Socket) WELDING

Indicates tightening or loosening with a Indicates items that require welding.
Socket wrench.
013_SYM 017_SYM
WRENCH (Allen/HEX) ADHESIVE

Indicates tightening or loosening with an Indicates application of adhesive, locktite
Allen wrench/(HEX keys). and/or liquid gasket.
002_SYM 009_SYM
HAND LUBRICATION
Indicates tightening, loosening, pushing, pull- Indicates external parts to be lubricated with
ing, installation, etc. by hand. oil.
003_SYM 012_SYM
VISUAL CLEANING
Indicates items requiring visual inspection. Indicates items requiring cleaning for disas-
sembly and/or assembly.
004_SYM 005_SYM
READ ADJUSTMENTS
Indicates items that are required to read. Indicates components requiring adjustment
or precise settings.
015_SYM 016_SYM
TIPS & IDEAS SAFETY EQUIPMENT

Indicates tips, techniques and/or ideas for Indicates when protective clothing or gear
installation. needs to be worn for safety purposes.
008_SYM 014_SYM
NOTES
PREPARATION
PREPARATION
n BEFORE YOU START n MACHINE PREPARATION

q IS THE KIT CORRECT FOR THIS INSTALL? q REMOVE PANELS UNDER CAB
Check and make sure you have the correct instal- Remove
lation kit for your excavator and attachment. Check access
AB L
the excavator information against the kit descrip- panels T C NE
R ON PA
F OW
tion. All kits are designed for a specific excavator. from WI
ND
IF THERE ARE ANY DISCREPANCIES, IMMEDIATELY under-
CONTACT THE KIT MANUFACTURER. neath
CA
q INVENTORY PARTS and BE
NT
RA
NC
Open boxes and take inventory of parts received, behind E
while reviewing the parts lists and illustrations, the cab. ACCESS PANEL
before you begin. This will ensure there are no It is
missing or damaged parts, which may affect
installation time. Every precaution is taken to easier ACCESS PANEL
ensure every installation kit is shipped complete, to do

but sometimes errors can occur. IF THERE ARE this HKX_PREP_001_FIG
ANY DISCREPANCIES, IMMEDIATELY CONTACT before the machine is pulled into the shop, because
THE KIT MANUFACTURER. there is more room outside to swing the upper car-
riage to clear the tracks.
NOTICE
Take special care when removing parts from box and check-
ing off parts on list. All parts are marked with a part number
for ease of identification. Place checked parts in a clean area
to prevent damage and contamination. Do not remove
parts from protective packaging until ready for use.
HKX_PREP_002_FIG
q CLEANING SUPPLIES q POSITION MACHINE
Insure their are sufficient absorbent pads, rags or Move machine into a suitable bay, swing house so area
paper towels for cleaning purposes under cab is accessible for “G4-CONTROLS” installation and
q FLOW METER & PRESSURE GAUGE access to the lower side of the spare spool (there is a small
A flow meter and pressure gauge are needed for the opening under the frame for this purpose)
function testing process
q CLEAN & PAINT COMPONENTS NOTICE
Before painting, thoroughly clean any piping, Always park machine on a flat level surface. Lower
brackets and other components that need to be bucket or other working attachment to the ground or to
painted. Piping and components are provided in a an overnight support saddle and either tuck in the arm
grey primer or anodized finish and may be painted or extend out depending on available work space. Turn
before or after installation. auto-idle switch off.
q READ INSTALLATION INSTRUCTIONS
Read the entire installation instructions. Familiarize q ENGINE SHUTOFF
yourself with the installation process. Run the engine
at low idle speed
CAUTION without a load for
five minutes. Turn
IT IS IMPERATIVE TO FOLLOW THE MANUAL AND ILLUS- key switch OFF.
TRATIONS FOR PROPER INSTALLATION. DEVIATION FROM
THIS MANUAL MAY CAUSE DAMAGE TO THE MACHINE, Remove key from
ATTACHMENTS AND COMPONENTS IN THE KIT, AS WELL AS switch.
HYDRAULIC SYSTEM PROBLEMS, WHICH WILL INCREASE IN-
STALLATION TIME. IF THIS MANUAL IS FOLLOWED CLOSELY, HKX_PREP_003_FIG
THE MOST EFFICIENT INSTALLATION IN THE SHORTEST
AMOUNT OF TIME WILL BE ACHIEVED. WARNING
IF MAINTENANCE OR INSTALLATION MUST BE PER-
CAUTION FORMED WITH ENGINE RUNNING, DO NOT LEAVE
MACHINE UNATTENDED
IN ADDITION TO THE PIPING KIT INSTALLATION INSTRUC-
TIONS, HAVE ALL MANUFACTURER’S SERVICE MANUALS WARNING
AND BULLETINS ON HAND, INCLUDING ANY REPAIR AND
WELDING MANUALS. MAKE SURE YOU HAVE ALL MACHINE IF MAINTENANCE OR INSTALLATION IS TO TAKE
AND ATTACHMENT DOCUMENTATION HANDY FOR FLOW PLACE, BE AWARE THAT ACCUMULATOR(S) IN THE
AND PRESSURE SETTINGS. ALL PHASES OF THE INSTAL- SYSTEM STORE FLUID UNDER PRESSURE AFTER SYS-
LATION MUST BE IN ACCORDANCE WITH THE MANUFAC- TEM LOCK DOWN. RELEASE THE PRESSURE BY WORK-
TURER’S RECOMMENDATIONS. ING THE CONTROLS WITH THE ENGINE OFF, UNTIL
PRESSURE IN THE PILOT CIRCUIT HAS BEEN BLED OFF.
n CONTINUED
GEN_PREPARATION_MOD REV. 1 - 4.2003
PREPARATION
HKX_PREP_004_FIG HKX_PREP_008_FIG
q SAFETY LEVER IN LOCKED POSITION q REMOVE WINDOWS & PANELS
Pull the pilot control shut-off lever to the LOCKED You may find it helpful, if you remove tempered
and up position before leaving the cab. glass windows and panels around the cab for easier
access into areas during install and to decrease
chances for damage to machine.
DANGER
q DO NOT OPERATE TAG. n TIPS & TECHNIQUES
Before performing any in-
stallation or maintenance Here are some tips, bright ideas and pointers
on the machine, attach a we have gathered to better help you in install-
“Do Not Operate” tag on ing a hydraulic kit. If you have a great piece of
the operator’s cab controls advice not listed below, please email them to
to alert others that service support@hkx.com or fax at 800.353.5736 to be
or maintenance is being added to the list.
HKX_PREP_005_FIG
performed. A tag is sup- n A “DRY CONNECT” BY GROUP INSTALLATION

plied with this manual for The installation manuals are in the particular group
this purpose. order to do the “dry connects” first. Start with “G1-
BOOM” and follow in order the remaining groups.
HKX_PREP_009_FIG
q DISCONNECT A “dry connect” means that when a fitting or line is
removed or disconnected, there is not a continuous
BATTERY loss of oil (although there might be a small flow of
Disconnect the nega- oil buildup due to normal blowby). A “wet connect”
tive cable on the bat- involves a continuous flow of oil (such as a direct
tery to avoid damage flow-path to the reservoir). Wherever possible, make
to machine, computer all hydraulic connections of the “dry connect” type
and electrical devices first to minimize oil loss. When making “wet con-
and before doing any nects”, have plenty of oil absorbent pads on hand
if any oil is spilled. Sprinkle the floor with a liberal
installation, welding or
amount of “dry sand” or “oil absorbent pellets” to
maintenance.
prevent slipping on oil spills.
n OIL O-RINGS AND FACE SEALS
Apply oil to all face seal and O-ring boss fittings be-
fore connection to avoid “dry-spooling”. Please read
the Service Bulletin on correct O-ring installation
procedures.
n STANDARD AND DEEP SOCKETS
Standard sockets can be used to remove port plugs.
Deep sockets could be needed for installing some of
the adapters, cartridges, etc.
n FACTORY PAINT
Using factory paint is preferable when painting the
components and touch-up of weld locations.
HKX_PREP_006_FIG
q PRESS RESERVOIR CAP BUTTON
Press button on reservoir cap to relieve pressure,
remove cap and leave in place (loose) during instal-
lation to avoid pressure buildup due to temperature
changes.
n CONTINUED
GEN_PREPARATION_MOD REV. 1 - 4.2003
TORQUE SPECIFICATIONS
INSTALLATION OF O-RING FACE SEAL (ORFS) FITTINGS | TIGHTENINGTORQUE CHART - BOLTS / SCREWS | TIGHTENINGTORQUE CHART -TUBES / MANIFOLD AND ADAPTER FITTINGS
INSTALLATION OF O-RING FACE SEAL (ORFS) FITTINGS
Use two wrenches to hold fitting and hoses in
When installing ORFS fittings, the following steps
place while tightening, (see Fig. SB01-E).
must be followed:
FIG. SB01-E
Check O-ring and fittings for damage, (see Fig.
SB01-A & SB01-B). Replace either, if necessary.
FIG. SB01-A
FIG. SB01-B
CAUTION Start carrier and heat oil to operating tempera-

NOTE: Replacement O-rings ture (180o F). Re-tighten all fittings as per Torque
must have a 90 durometer Chart below.
hardness. Anything rated
lower will cause leaks). O-ring Face Seal
TUBE SIDE ASSEMBLY
TORQUE (+10% -0%)
DO NOT tighten tube or hose clamps until ORFS
connections are torqued. 220 18
Make sure the fitting face and the tube or hose 360 30
face are parallel, (see Fig. SB01-C). Apply a small 480 40
amount of grease 60
FIG. SB01-C 85
to the o-ring and
o-ring groove to -14 15/16-12 95
hold the o-ring in 110
place before 140
assembly, 180
360
(see Fig. SB01-D).
There is an alternative method of tightening fittings,
if a torque wrench is unavailable. This is known as
the Flats From Wrench Resistance (F.F.W.R.) method.
Wrench tighten the nut onto the fitting body until
FIG. SB01-D
wrench resistance is reached. Tighten further to the
appropriate F.F.W.R. value from the chart below.
O-ring Face Seal

FLATS FROM WRENCH
RESISTANCE (F.F.W.R.)
Tube Swivel &
Nuts Hose Ends
1/4 to 1/2 1/2 to 3/4
1/4 to 1/2 1/2 to 3/4
1/4 to 1/2 1/2 to 3/4
1/4 to 1/2 1/2 to 3/4
Torque fittings as tight as possible by hand with 1/4 to 1/2 1/3 to 1/2
standard wrenches. The face seal will not deform -14 15/16-12 1/4 to 1/2 1/3 to 1/2
with high torque. 1/4 to 1/2 1/3 to 1/2
1/4 to 1/2 1/3 to 1/2
1/4 to 1/2 1/3 to 1/2
C ONTINUED
PROPERTY OF HKX, INCORPORATED PROPERTY OF HKX, INCORPORATED PROPERTY OF HKX, INCORPORATED PROPERTY OF HKX, INCORPORATED PROPERTY OF HKX, INCORPORATED PROPERTY OF HKX, INCORPORATED PROPERTY OF HKX, INCORPORATE
GEN_TORQUE SPECIFICATIONS_MOD REV. 0 - 5.2003
TIGHTENING TORQUE CHART - BOLTS / SCREWS
The required torque is shown as kgf-m.

NOTICE
Ensure bolt and nut threads are clean before installation.
Apply lubricate to bolts and nuts, to stabilize their friction
coefficient, unless locktite or thread lock is being applied.
HXK_PREP_007_FIG
TIGHTENING TORQUE CHART - TUBE / MANIFOLD AND ADAPTER FITTINGS

ENSURE THAT THE CORRECT O-RING IS PROPERLY PLACED ON THE FITTING, FLUSH AGAINST THE MAIN (HEX)
BODY OF FITTING. THREAD THE FITTING BY HAND, THEN TIGHTEN IT TO THE RECOMMENDED TORQUE
SPECIFICATIONS FROM THE TABLES BELOW.
SAE O-ring Boss Port

(tube fitting - installed into Aluminum)
SAE Dash size Torque SAE Dash size Torque
-4 11 ft-lbs / 14.9 Nm -12 93 ft-lbs / 126.1 Nm
-6 23 ft-lbs / 31.2 Nm -16 139 ft-lbs / 188.5 Nm
-8 40 ft-lbs / 54.2 Nm -20 172 ft-lbs / 233.2 Nm
-10 69 ft-lbs / 93.6 Nm -24 208 ft-lbs / 282 Nm
SAE O-ring Boss Port

(tube fitting - installed into Steel)
-4 16 ft-lbs / 21.7 Nm -12 140 ft-lbs / 190 Nm
-6 35 ft-lbs / 47.5 Nm -16 210 ft-lbs / 284.7 Nm
-8 60 ft-lbs / 81.3 Nm -20 260 ft-lbs / 352.5 Nm
-10 105 ft-lbs / 142.4 Nm -24 315 ft-lbs / 427.1 Nm
Seal-Lok (NPT)
(Adapter Fittings)
-4 18 ft-lbs / 24.4 Nm -12 90 ft-lbs / 122 Nm
-6 27 ft-lbs / 36.6 Nm -16 120 ft-lbs / 162.7 Nm
-8 40 ft-lbs / 54.2 Nm -20 140 ft-lbs / 190 Nm
-10 63 ft-lbs / 85.4 Nm -24 165 ft-lbs / 223.7 Nm
PROPERTY OF HKX, INCORPORATED PROPERTY OF HKX, INCORPORATED PROPERTY OF HKX, INCORPORATED PROPERTY OF HKX, INCORPORATED PROPERTY OF HKX, INCORPORATED PROPERTY OF HKX, INCORPORATED PROPERTY OF HKX, INCORPORATE
GEN_TORQUE SPECIFICATIONS_MOD REV. 0 - 5.2003
INTRODUCTION
PARTS LIST
INSTALLATION ILLUSTRATION
STEP-BY-STEP INSTRUCTIONS
SUB-KIT MODULES AND OTHER SUPPORTING DOCUMENTATION
FIGURE ILLUSTRATION 1A FIGURE ILLUSTRATION 1B
FINAL ASSEMBLY OF FLANGE FINAL ASSEMBLY OF TUBE-TO-PORT

COUPLING FLANGE COUPLING
1) Oil bolt threads to reduce friction during assembly. It must be ensured that one of the O-rings used is
2) Position flange connections with its pre-mounted "Without groove".
O-ring on the bolt-on surface and manually tighten 1) Oil bolt threads to reduce friction during assembly.
bolts. The tube must be stress-free and at right angles 2) Align couplings flush with pre-mounted O-rings, join
to the bolt-on surface. and tighten bolts manually. Tubes must be stress-free
3) Carefully tighten bolts diagonally and evenly in and at right angles to each other.
several steps using a spanner; do not use a pneumatic 3) Carefully tighten bolts diagonally and evenly in
driver. several steps using a spanner; do not use a pneumatic
4) To complete the assembly process, tighten all 4 bolts driver.
in sequence 1, 2, 3, 4 (see figure illustration 1A) When 4) To complete the assembly process, tighten all 4 bolts
tightening bolts, make sure that the permissible in sequence 1, 2, 3, 4 (see figure illustration 1A) When
tightening torques for bolts are not exceeded (see tightening bolts, make sure that the permissible
figure illustration 1B). tightening torques for bolts are not exceeded (see
5) After final tightening, the flange must be parallel to figure illustration 1B).
the connection surface. Should the deviation from 5) After final tightening, the flange must be parallel to
parallel during checking (measure all 3 points) be the connection surface. Should the deviation from
greater than 0.5mm, a correction must be made with parallel during checking (measure all 3 points) be
reassembly. greater than 0.5mm, a correction must be made with
reassembly.
FLANGE TORQUE SPECS_TXT REV. 0 04.10

Reference Part Number Catalog Description Quantity
2 1 900-0166 Valve Assy Sec SGL/SGL 1
2 970-0044 2W -20 ORB w/mtg holes 1
3 970-0043 2W -16 ORB w/mtg holes 1
BREAKER 4 530-0008 Filter Return 60GPM 1
Reference Component Name Quantity
A Pilot Safety Shut-off Solenoid 1
3 ** - AUXILIARY RELIEF CARTRIDGES
4
1
T
P
S
900-0166
A1
A
** **
B1
B
ATTACHMENT SPOOL
T
P
S
LINES GROUP COLOR DESCRIPTIONS

HIGH PRESSURE LINE
LOW PRESSURE LINE
A
DRAIN LINE
LINES PATTERN DESCRIPTIONS

TO MAIN CONTROL PRESSURE LINE
VALVE (MCV)
PILOT/DRAIN LINES
COMPONENT GROUP LINE
CALLOUTS
1 COMPONENTS by number
A CONNECTIONS by letter
PILOT PUMP
ABC OEM COMPONENTS by letter

** OPTIONAL COMPONENT
Approvals Date
Drawn HKX, Inc.
PRIMARY PUMPS Ph:(800) 493-5487 Fx:(800) 353-5736 www.hkx.com
Checked
Description
- INITIAL RELEASE Eng. Mgr.
Date Rev. Change Description BY: DWG. No. Rev.
Purchasing
-
THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF HKX, INC. ANY REPRODUCTION IN PART OR IN
Production Size Scale File Name
WHOLE WITHOUT THE WRITTEN PERMISSION OF HKX, INC. IS PROHIBITED
GROUP 1 - BOOM
INTRODUCTION
PARTS LIST
SUB-KIT MODULES AND OTHER
SUPPORTING DOCUMENTATION
 The BOOM GROUP is part of the circuit

providing oil to the attachment from the
machine. This group may consist of boom
and hoses, tube adapters, interlocking
clamps and weld plates (if necessary).
G1_COVER_TEMPLATE_Rev1 REV. 1 - 09.2007

Excavator: CATERPILLAR 320D
Kit Code: 5
Kit No: KC1213-1
GROUP 1 : Parts List
ITEM NUMBER PART NUMBER QUANTITY DESCRIPTION
1.21 100-0103 1 Boom Tube Adp A

1.20 100-0110 1 Boom Tube Adp B
1.00 360-0556 1 G1-BOOM-OEM REPLACEMENT TUBES
1.00 360-0160 3 G1-BOOM-OEM REPLACEMENT TUBES
1.00 310-0250 2 Bolt Hex M12 x 1.75 x 40mm CAT
1.00 340-0033 2 Nut Hex M12 x 1.75 CAT
1.00 310-0116 2 Bolt Hex M12 x 1.75 x 80 Cl 10.9
1.00 350-0033 6 Washer Hardened Flat M12
1.13 750-0002 1 Boom Tube Clamp A (ESH)
1.14 750-0003 1 Boom Tube Clamp B (ESH)
1.12 360-0204 1 Boom Tube Clamp Mtg A & B
1.12 360-0137 1 Stack Spacer A & B
1.11 310-0116 1 Bolt Hex M12 x 1.75 x 80 Cl 10.9
1.11 350-0014 1 Washer Lock m12
1.13 750-0002 1 Boom Tube Clamp A (ESH)
1.12 360-0137 1 Stack Spacer A & B
1.11 310-0116 1 Bolt Hex M12 x 1.75 x 80 Cl 10.9
1.11 350-0014 1 Washer Lock m12
1.14 750-0003 1 Boom Tube Clamp B (ESH)
1.12 360-0137 1 Stack Spacer A & B
1.11 310-0116 1 Bolt Hex M12 x 1.75 x 80 Cl 10.9
1.11 350-0014 1 Washer Lock m12
1.15 750-0002 1 Boom Tube Clamp A (CS)
1.12 360-0137 1 Stack Spacer A & B
1.11 310-0116 1 Bolt Hex M12 x 1.75 x 80 Cl 10.9
1.11 350-0014 1 Washer Lock m12
1.16 750-0003 1 Boom Tube Clamp B (CS)
1.12 360-0137 1 Stack Spacer A & B
1.11 310-0116 1 Bolt Hex M12 x 1.75 x 80 Cl 10.9

1.11 350-0014 1 Washer Lock m12
1.17 750-0002 1 Boom Tube Clamp A (ESS)
1.12 360-0137 1 Stack Spacer A & B
1.12 360-0284 1 Stack Spacer A & B
1.11 310-0215 1 Bolt Hex M12 x 1.75 x 55 Gr 10.9
1.11 310-0125 1 Bolt Hex M12 x 1.75 x 70 Cl 10.9
1.11 350-0014 1 Washer Lock m12
1.18 750-0003 1 Boom Tube Clamp B (ESS)
1.12 360-0177 1 Stack Spacer A & B
1.12 360-0284 1 Stack Spacer A & B
1.11 310-0117 1 Bolt Hex M12 x 1.75 x 90 Cl 10.9
1.11 350-0014 1 Washer Lock m12
1.17 750-0002 1 Boom Tube Clamp A (ESS)
1.12 360-0408 1 Stack Spacer A & B
1.11 310-0209 1 Bolt Hex M14 x 2.0 x 130 Cl 10.9
1.11 350-0030 1 Washer Flat M14
1.11 350-0027 1 Washer Lock M14
1.11 340-0024 1 Nut Jam Hex M14 x 2 steel zinc
1.18 750-0003 1 Boom Tube Clamp B (ESS)
1.12 360-0408 1 Stack Spacer A & B
1.11 310-0128 1 Bolt Hex M14 x 2.0 x 140 Gr 10.9
1.11 350-0030 1 Washer Flat M14
1.11 350-0027 1 Washer Lock M14
1.11 340-0024 1 Nut Jam Hex M14 x 2 steel zinc
1.01 665-0369-B 1 ESH A
1.03 665-0367-B 1 CS A
1.05 661-2044-B 1 ESS2 A
1.07 665-0370-B 1 ESS1 A
1.02 666-0406-B 1 ESH B
1.04 665-0368-B 1 CS B
1.06 661-3044-B 1 ESS2 B
1.08 665-0371-B 1 ESS1 B
1.21 100-0103 3 Boom Tube Adp A
1.20 100-0110 3 Boom Tube Adp B
1.21 100-0103 1 Boom Tube Adp A
1.20 100-0110 1 Boom Tube Adp B
s = subkit
INTRODUCTION
PARTS LIST
INSTALLATION ILLUSTRATION Detail Bubbles (A, B, C, etc.) are in sequence
STEP-BY-STEP INSTRUCTIONS of Installation, unless otherwise specified,
SUB-KIT MODULES AND OTHER SUPPORTING DOCUMENTS Refer to Step-By-Step Instructions
either X.XX
or X.XX A = 4" Bar 1.11
B = 3.25" Bar
1.20 1.08
1.20 1.12
1.22
F 1.06 1.20
1.21
1.23 1.13
1.04 1.14
1.14
Nut to A
clamp appx. 1.13
5" B D
C 1.14
1.07 1.20
1.21
A1 1.05 1.13
1.11 1.21 1.11
1.03 1.02
1.17 D
1.18
1.21 1.12
1.12
1.11 1.11
1.01
1.17 1.12 1.20 E
1.18 A 1.11
1.18 A = 4" Bar 1.22
B = 3.25" Bar
E
1.12
F
1.11 1.15 1.21
1.16
1.12 1.23
1.12
1.17
C
1.11
CAT_1057-T-B-2-2_GI 04.21.10 R1
1
M. AHLES R. MacARTHUR
Existing components
B shown in gray
INTRODUCTION
PARTS LIST
1.00 ALTERNATE MOUNTING

FOR MACHINES WITH
Brackets
QUICK COUPLER LINES
& Hardware
Move OEM Lines to
Top of Kit Assembly
1.14
E2
1.13
1.11
1.12 Existing components

shown in gray
E2 CAT_1057-T-B-ALT_GI 07.29.09
1
M. AHLES C. CURFMAN
INTRODUCTION
PARTS LIST
CAUTION
Example of Boom Shrink Wrapped components: packaged
in sequence of installation (location where installed)
 READ “SAFETY PRECAUTIONS” AND “PREPARATION” SECTIONS E

OF THIS MANUAL PRIOR TO INSTALLATION
 REFER TO “G1-BOOM” INSTALLATION ILLUSTRATION, WHILE E
PROCEEDING WITH THE FOLLOWING STEPS ON THIS PAGE D
D E D
D
READ ALL NOTES PRIOR TO INSTALLATION D C
 NOTE: All O-rings should be lubricated with grease D C

before assembly to ensure a tight seal and long B
lasting connection. B B
 NOTE: When tightening hydraulic connections, turn nut B
not adapter/fitting or O-ring can get pinched. C A
 NOTE: Verify joint alignment faces are flat and O-rings
A
are properly seated. B
 NOTE: All connections should be assembled loose, until
directed to tighten and torque.
 NOTE: For best results, torque hydraulic connections B
with clamping hardware loose, (refer to Torque
Specifications Section). A
 NOTE: It is recommended to have a second person help
with installation. Example shown above is for REFERENCE ONLY and not
 NOTE: For simplicity and clarity of install - instructions intended to represent your kit packaging (Labels only
will show installation on left side of boom. Mirror shown on Pre-Assembled Kits)
installation on right side of boom, unless otherwise
specified. FIGURE ILLUSTRATION 1A
 NOTE: Slide clamp halves together, DO NOT hinge 3) Install clamp mounting brackets without clamps, refer
clamps together, see illustration below: to details (B), (C), (D), (E) and (F).
4) Using the Installation Illustration, install tubes, clamps
and spacer brackets on either left or right side (unless
otherwise specified) (right side may be easier to
access).
IMPORTANT- Check illustration for reference
locations (measurements) or starting points.
5) Check tube alignment throughout to ensure snug
connections (do not torque yet).
6) Install components on opposite side, using previous
side as a reference (unless otherwise specified). Most
kits have components that are mirrored images of
each other.
7) Verify alignment again and check both sides.
START HERE 8) Tighten and Torque all clamp hardware and
adapters in sequence from boom base to boom tip or
INSTALLATION STEPS (Refer to Detail Bubbles) visa versa, (refer to Torque Specifications Section).
* Pages following these Step-By-Step Instructions
 NOTES: _____________________________
1) Layout all Boom kit components (tubes, hoses, _____________________________________
adapters, etc.) and inspect for any damages or missing
components, which may have occurred during _____________________________________
shipping.
2) Orient Shrink Wrapped clamp and bracket package to _____________________________________
boom. Components are shrink wrapped in sequence
and order of installation. See Example of Boom Shrink _____________________________________
Wrap (Figure Illustration 1A). _____________________________________
_____________________________________
_____________________________________
CAT_1057-T-B-2-2_TXT REV. 0 01.08
HKX, INCORPORATED
16761 - 146th Street SE, Suite 115, Monroe, Washington 98272
(360) 805-8600 ~ (800) 493-5487 ~ www.hkx.com
ORFSJ 1 of 3 10-25-07
HKX, INCORPORATED
(360) 805-8600 ~ (800) 493-5487 ~ www.hkx.com
ORFSJ 2 of 3 10-25-07
There is an alternative method of tightening adapters, if a

torque wrench is unavailable. This is known as the Flats From
Wrench Resistance (F.F.W.R.) method. Wrench tighten the nut
onto the adapter body until wrench resistance is reached.
Tighten further to the appropriate F.F.W.R. value from the
chart to the right.
O-ring Face Seal O-ring Face Seal

SAE TUBE SIDE ASSEMBLY SAE FLATS FROM WRENCH
TUBE SIDE TORQUE (+10% - 0%) TUBE SIDE RESISTANCE (F.F.W.R.)
DASH DASH
THREAD SIZE THREAD SIZE Tube Swivel &
SIZE in. - lb. ft. - lb. SIZE Nuts Hose Ends
-4 9/16 - 18 220 18 -4 9/16 - 18 1/4 to 1/2 1/2 to 3/4
-6 11/16 - 16 360 30 -6 11/16 - 16 1/4 to 1/2 1/2 to 3/4
-8 13/16 - 16 480 40 -8 13/16 - 16 1/4 to 1/2 1/2 to 3/4
-10 1 - 14 60 -10 1 - 14 1/4 to 1/2 1/2 to 3/4
-12 1 3/16 - 12 85 -12 1 3/16 - 12 1/4 to 1/2 1/3 to 1/2
-14 1 5/16 - 12 95 -14 1 5/16 - 12 1/4 to 1/2 1/3 to 1/2
-16 1 7/16 - 12 110 -16 1 7/16 - 12 1/4 to 1/2 1/3 to 1/2
-20 1 11/16 - 12 140 -20 1 11/16 - 12 1/4 to 1/2 1/3 to 1/2
-24 2 - 12 180 -24 2 - 12 1/4 to 1/2 1/3 to 1/2
-32 2 1/2 - 12 360 -32 2 1/2 - 12 1/4 to 1/2 1/3 to 1/2
HKX, INCORPORATED
(360) 805-8600 ~ (800) 493-5487 ~ www.hkx.com
ORFSJ 3 of 3 10-29-07
GROUP 2 - ARM
INTRODUCTION
PARTS LIST
 The ARM GROUP is part of the circuit

providing oil to attachment from machine. This
group may consist of stick tubes and hoses,
tube adapters, interlocking clamps, ball valves,
weld plates (if necessary), and attachment
hoses (optional).

Kit Code: 5
Kit No: KC1213-1
2.05 100-0167 1 Stick Tube/Hose Adp A

2.05 180-0030 1 Stick Tube/Hose Adp A
2.06 100-0168 1 Stick Tube/Hose Adp B
2.06 180-0030 1 Stick Tube/Hose Adp B
2.11 750-0002 2 Stick Tube Clamps A
2.12 750-0003 2 Stick Tube Clamps B
2.13 360-0395 4 Stick Tube Clamp MTG
2.13 310-0076 4 Bolt Hex M12 x 1.75 x 40 Gr 10.9
2.13 350-0014 4 Washer Lock m12
2.07 970-0043 1 Shut-Off Valve A
2.07 360-0252 1 Shut-Off Valve Bracket A
2.07 310-0189 2 Bolt Socket M10 x 1.50 x 20
2.07 350-0015 2 Washer Lock M10
2.07 310-0202 2 Bolt Hex M10 x 1.5 x 30 Cl 10.9
2.07 350-0026 1 Washer Flat M10
2.09 100-0076 1 Shut-Off Valve Adaptor A
2.09 180-0003 1 Shut-Off Valve Adaptor A
2.08 970-0044 1 Shut-Off Valve B
2.08 360-0252 1 Shut-Off Valve Bracket B
2.08 310-0189 2 Bolt Socket M10 x 1.50 x 20
2.08 350-0015 2 Washer Lock M10
2.08 310-0202 2 Bolt Hex M10 x 1.5 x 30 Cl 10.9
2.08 350-0026 1 Washer Flat M10
2.10 100-0088 1 Shut-Off Valve Adaptor B
2.10 180-0004 1 Shut-Off Valve Adaptor B
2.01 642-0466-W 1 Stick Hose A ( - )
2.02 642-0467-W 1 Stick Hose B ( - )
2.03 667-0466-B 1 Stick Tube A ( - )
2.04 667-0467-B 1 Stick Tube B ( - )
s = subkit
INTRODUCTION
PARTS LIST
Brackets & Shutoff Circuit

Hardware A - "ON" Position
2.07 B - "OFF" Position
2.08
2.03 B 90˚
2.04
A
2.07
2.08
2.09
C Adapters 2.10
A C C B
B
2.11
2.12
2.01
2.02
2.11
2.12
2.05
2.06
2.13
2.03
2.04
A HKX, INCORPORATED
16761 - 146th Street SE, Suite 115
Monroe, Washington 98272
(360) 805-8600 ~ (800) 493-5487 ~ www.hkx.com
CAT_2018-2_GI 12.12.08 R2
J. Schmidt R. MacARTHUR
Existing components
shown in gray
INTRODUCTION
PARTS LIST
CAUTION
3) Place assembly on flat surface and check component
alignment, then Tighten and Torque all hydraulic
connections, (refer to Torque Specifications Section).
Keep hardware snug.
 READ “SAFETY PRECAUTIONS” AND “PREPARATION” SECTIONS 4) Installation can either be started on left or right side
OF THIS MANUAL PRIOR TO INSTALLATION (unless otherwise specified).
 REFER TO “G2-ARM” INSTALLATION ILLUSTRATION, WHILE 5) Position assembly on side of Arm and align to
PROCEEDING WITH THE FOLLOWING STEPS ON THIS PAGE existing clamp mounts or brackets.
IMPORTANT- Check illustration for reference
READ ALL NOTES PRIOR TO INSTALLATION locations (measurements) or starting points.
6) Tighten and Torque all hardware, (refer to Torque
 NOTE: All O-rings should be lubricated with grease Specifications Section).
before assembly to ensure a tight seal and long 7) Install stick hose between Boom and Arm
lasting connection. components. Stick hose should be positioned with "S"
 NOTE: When tightening hydraulic connections, turn nut curved shape of existing stick cylinder hose, refer to
not adapter or O-ring may get pinched. Figure Illustration 2A.
 NOTE: Verify joint alignment faces are flat and O-rings
are properly seated.
directed to tighten and torque.
 NOTE: For best results, torque hydraulic connections
with clamping hardware loose, (refer to Torque
Specifications Section).
 NOTE: It is recommended to have a second person help
with installation.
 NOTE: For simplicity and clarity of install - instructions
will show installation on left side of arm. Mirror
installation on right side of arm, unless otherwise
specified.
 NOTE: Slide clamp halves together, DO NOT hinge
clamps together, see illustration below:
FIGURE ILLUSTRATION 2A
8) Tighten and Torque stick hose connections, (refer to
Torque Specifications Section).
9) Install kit on opposite side, using previous side as a
reference (unless otherwise specified). Most kits have
components that are mirrored images of each other.
 NOTES: _______________________________
_____________________________________
START HERE _____________________________________
INSTALLATION STEPS (Refer to Detail Bubbles) _____________________________________
* Pages following these Step-By-Step Instructions _____________________________________
1) Layout all Arm (Stick) kit components (tubes, valves, _____________________________________
adapters, etc.) and inspect for any damages or
missing components, which may have occurred _____________________________________
during shipping.
2) Using the Installation Illustration, assemble
_____________________________________
components on stick tube at four locations, refer to _____________________________________
details (A), (B) and (C).
IMPORTANT- Remember to lubricate all O-rings _____________________________________
before assembly (see O-ring note).
_____________________________________
_____________________________________
CAT_2018-2_TXT REV. 0 09.07
GROUP 3 - VALVE
INTRODUCTION
PARTS LIST
 The VALVE GROUP is the source of flow and

pressure from spare valve section on the Main
Control Valve (MCV).

Kit Code: 5
Kit No: KC1213-1
3.80 900-0226 1 Auxiliary Relief Cartridge (ARC)

3.03 114-0003 1 Work Port Adaptor A
3.03 667-0464-B 1 Work Port Adaptor A
3.03 300-0028 1 BK Socket m10 x 1.5 x 30
3.01 642-0275 1 Work Port Hose A
3.71 360-0544 1 RF MTG
3.71 310-0202 2 Bolt Hex M10 x 1.5 x 30 Cl 10.9
3.71 350-0035 2 Washer Hardened Flat m10
3.09 642-0273 1 Boom Tube Jump Hose B
3.70 530-0008 1 Return Filter
3.71 360-0403 1 RF MTG
3.71 310-0071 2 Bolt Hex 3/8-24 x 1 Gr 8
3.71 350-0002 2 Washer Lock 3/8"
3.71 350-0001 2 Washer Flat 3/8"
3.71 310-0186 2 Bolt Hex M10 x 1.5 x 20 Gr 10.9
3.72 100-0088 1 RF Inlet Adaptor
3.73 100-0088 1 RF Outlet Adaptor
3.06 642-0529 1 Return Hose
3.05 101-0006 1 Return Port Adaptor
s = subkit
INTRODUCTION
PARTS LIST
CAUTION
_____________________________________
_____________________________________
 READ “SAFETY PRECAUTIONS” AND “PREPARATION” SECTIONS _____________________________________
 REFER TO “G3-VALVE” INSTALLATION ILLUSTRATION, WHILE _____________________________________
PROCEEDING WITH THE FOLLOWING STEPS ON THIS PAGE
 Before operating attachment(S), insure pressure _____________________________________
(port) relief cartridges (PRC's) have been installed
and adjusted to attachment specifications or _____________________________________
a potentially hazardous situation may occur,
resulting in property damage _____________________________________
READ ALL NOTES PRIOR TO INSTALLATION _____________________________________
 NOTE: All O-rings should be lubricated with grease _____________________________________
before assembly to ensure a tight seal and long _____________________________________
lasting connection.
 NOTE: When tightening hydraulic connections, turn nut _____________________________________
not adapter/fitting or O-ring can get pinched.
 NOTE: Verify joint alignment faces are flat and O-rings _____________________________________
are properly seated. _____________________________________
directed to tighten and torque. _____________________________________
 NOTE: There will be hydraulic fluid loss during
installation. Assure all necessary tools, components _____________________________________
and plenty of oil absorbing pads and rags are nearby.
_____________________________________
START HERE _____________________________________
INSTALLATION STEPS (Refer to Detail Bubbles) _____________________________________
_____________________________________
1) Layout all Valve kit components (clamps, hoses, _____________________________________
adapters, etc.) and inspect for any damage or missing
components, which may have occurred during _____________________________________
shipping.
2) Remove cover plate from upper work port on Main _____________________________________
Control Valve (MCV), install components and connect
work port hose A from left side of boom, refer to detail
_____________________________________
(A). Remember to lubricate all O-rings before _____________________________________
assembly (see O-ring note, above).
3) Pre-assemble Return Filter (RF) assembly, then _____________________________________
secure to hydraulic reservoir. Connect boom tube
jump hose B from right side of boom. Route return _____________________________________
hose to manifold behind (MCV), refer to details (A) _____________________________________
and (B).
 NOTE: Check (RF) arrows for direction of oil flow. _____________________________________
4) Remove plug from return port, install Return Port
Adapter (RPA) and connect return hose, refer to detail _____________________________________
(B).
5) Tighten and Torque all clamp hardware and hydraulic
_____________________________________
connections, (refer to Torque Specifications Section). _____________________________________
 NOTES: _______________________________ _____________________________________
_____________________________________ _____________________________________
_____________________________________ _____________________________________
_____________________________________ _____________________________________
CAT_3125-3-RF_TXT REV. 0 04.10

INTRODUCTION
PARTS LIST
Relief Valve Installation

1) Apply petroleum jelly to relief valve o-rings.
2) Install relief valves(1) for spare valve section (2) and
tighten to specification (refer to machine service
manual).
relief valve installation REV. 0 08.12

GROUP 4 - CONTROLS
INTRODUCTION
PARTS LIST
SUB-KIT MODULES, WIRING DIAGRAMS AND
OTHER SUPPORTING DOCUMENTATION
 The CONTROLS GROUP may consist of a foot

pedal, foot switch and/or joystick (operator
control) and pressure reducing valve options to
set the flow.

Kit Code: 5
Kit No: KC1213-1
4.09 400-0031 1 Footswitch

4.09 290-0126 1 Footswitch
4.09 290-0072 1 Footswitch
4.09 290-0037 4 Footswitch
4.09 290-0033 2 Footswitch
4.11 900-0166 1 Pilot Valve
4.11 160-0038 1 Pilot Valve
4.13 360-0488 1 Pilot Valve Mtg Kit
4.13 310-0260 2 Bolt Hex M10 x 1.5 x 30mm CAT
4.13 310-0192 2 Bolt Hex 5/16-18 x 2-1/2" Gr 8
4.13 350-0003 2 Washer Lock 5/16"
4.13 350-0006 2 Washer Flat 5/16"
4.04 641-1190 1 Pilot Supply Hose
4.04 641-1190 1 Pilot Return Hose
4.05 160-0013 1 Pilot Sup. & Ret. Adaptors
4.07 641-1191 1 Pilot Shift Hose A
4.07 641-1191 1 Pilot Shift Hose B
4.08 160-0013 1 Shift Port Adaptors
s = subkit
INTRODUCTION
PARTS LIST
SUB-KIT MODULES, WIRING DIAGRAMS AND OTHER SUPPORTING DOCUMENTS Refer to Step-By-Step Instructions
?
4.08
B
4.07
To (PV)
Main Control
Valve (MCV)
Machine
4.08 Connector
4.07 Machine
Floorboard
B To (PV)
B
4.13 Bracket &
Hardware
4.11 Pilot Valve (PV) 4.04 To (POS) "P" port

& Components
B1/BLUE 4.04
To (POS) "T" port
(For electrical installation, see A1/PURPLE P
Footswitch wiring circuit diagram) 4.09 S
T 4.07
AB
To (MCV)
Pilot Oil Source (POS) Manifold 4.07 To (MCV)
A
C
T
4.05
P Plug footswitch wiring harness
into existing connector A-C38 A
(Green and Black wires)
HKX, INCORPORATED
4.04 16761 - 146th Street SE, Suite 115
4.04 Monroe, Washington 98272
To (PV) "P" port (360) 805-8600 ~ (800) 493-5487 ~ www.hkx.com
To (PV) "T" port CAT_4241-FS_GI 10.08.10
C M. AHLES R. MacARTHUR
Ma rwa
Existing Components
ch rd
Fo
Shown in Gray
ine
INTRODUCTION
PARTS LIST
SUB-KIT MODULES, WIRING DIAGRAMS AND OTHER SUPPORTING-
DOCUMENTATION
CAUTION
_________________________________________
_________________________________________
 READ “SAFETY PRECAUTIONS” AND “PREPARATION” SECTIONS _________________________________________
 REFER TO “G4-CONTROLS” INSTALLATION ILLUSTRATION, _________________________________________
WHILE PROCEEDING WITH THE FOLLOWING STEPS ON THIS
PAGE _________________________________________
READ ALL NOTES PRIOR TO INSTALLATION _________________________________________
IMPORTANT: Pilot Valve (PV) and Pressure Reducing _________________________________________
Valve (PRV) (i.e. flow regulator) are NOT FACTORY SET, _________________________________________
refer to Machine and Attachment Manufacturer's
recommended flow settings and Function Testing _________________________________________
section of this manual.
 NOTE: All O-rings should be lubricated with grease _________________________________________
before assembly to ensure a tight seal and long
lasting connection. _________________________________________
 NOTE: When tightening hydraulic connections, turn nut _________________________________________
not adapter/fitting or O-ring can get pinched.
 NOTE: Verify joint alignment faces are flat and O-rings _________________________________________
are properly seated.
 NOTE: There will be hydraulic fluid loss during _________________________________________
installation. Assure all necessary tools, components _________________________________________
and plenty of oil absorbing pads and rags are nearby.
 NOTE: Pilot shift hoses can be swapped to change _________________________________________
actuation (reverse control direction) of controls.
 NOTE: Tap (PV/s) plug(s) firmly with ball pein hammer _________________________________________
before attempting to remove with allen wrench.
_________________________________________
START HERE _________________________________________
INSTALLATION STEPS (Refer to Detail Bubbles) _________________________________________
_________________________________________
1) Layout all Controls kit components (controls, hoses,
adapters, etc.) and inspect for any damage or missing _________________________________________
components, which may have occurred during _________________________________________
shipping.
2) Refer to Footswitch (FS) *Sub-Kit instructions for (FS) _________________________________________
installation.
3) Refer to detail (A) for Pilot Valve (PV) installation. _________________________________________
4) Connect hoses to (PV), route pilot shift hoses to Main _________________________________________
Control Valve (MCV) and route pilot supply and return
hoses to Pilot Oil Source (POS), refer to details (A), (B) _________________________________________
and (C).
5) Connect pilot shift hoses to (MCV), refer to detail (B). ________________________________________
6) Connect pilot supply and return hoses to (POS) "P"
and "T" port, refer to detail (C). _________________________________________
7) Tighten and Torque all hardware and hydraulic _________________________________________
connections, (refer to Torque Specifications Section).
_________________________________________
 NOTES: _________________________________
_________________________________________
_________________________________________
_________________________________________
_________________________________________
_________________________________________
_________________________________________
_________________________________________
_________________________________________
CAT_4241-FS_TXT REV. 0 10.10
GROUP 4 - INSTALLATION INSTRUCTIONS
Caterpillar "D" Series Monitor Programming D. Exit and return to Tool Installation Screen.
i. Change ATCH Valve #1 Type to Electrical , (refer to
 NOTE: For more detailed information, regarding Figure 4C).
monitor programming, please refer to the Cat
Service Information System (SIS). SMCS 5000,
5000-529, 5000-546, 5000-587, and 5000-0591
1. Install harnesses and connect joysticks per

"G4-CONTROLS" section of this manual.
A. Go to main menu on monitor and select service menu.
Enter password "FFF2".
B. Go into Configurations, Tool Installation.
i. Change from Bucket/CAPS to SPECIAL APPLI,
(refer to Figure 4A).
Figure 4C
E. Go back to Configurations menu and select Control

Inst. Change FOOT SW to installed, (refer to
Figure 4D).
Figure 4A
C. Change ATCH Valve #1 from not installed to ATT-ONE
WAY, (refer to Figure 4B).
Figure 4D
i. In same menu scroll down to:

a. FOOT SW.
1. Change to MOMENTARY A1 EXT
Figure 4B
Cat D Series Monitor Programming FOOT SWITCH Pg.1 REV. 0 08.09

These can be changed around to determine which

button controls whichever solenoid is desired, (refer
to Figures 4E and 4F).
Figure 4G
ii. It will read OFF next to it. Actuate

switch. This should change to ON, if setup
Figure 4E
is correct.
Figure 4F
F. Return to Service Menu and select Status, then

verify Foot Switch is working.
i. In Status, you will see FOOT SW).

G. Go back to Main Service Menu and select Tool

Program. Select TOOL #01.
i. Rename tool to match kit configuration,
(I.E. Thumb or Breaker), (refer to Figure 4H).
Figure 4J
2. Return to Main Menu and select SETTING

A. Go to WORK TOOL SELECT.
i. Select tool that you previously set up and return to
Figure 4H Home screen, (refer to Figure 4K).
ii. A1 & A2 Open & Close times can be adjusted to
offer smooth start and stop of tool, (refer to
Figure 4I). Typical breaker application set to 0.00
Figure 4K
3. Setup is complete.
Figure 4I
iii. Adjust A1 EXTND MAX PRESS
This adjustment will determine your max flow to

your implement, (see attachment specifications).

FINALIZING INSTALLATION
FINALIZING INSTALLATION
POST INSTALLATION INSPECTION | INSTALLATION CLEAN-UP | INSTALLATION AND MAINTENANCE MANUAL
DANGER CRUSHING HAZARD

At point of initial start up and/or hydraulic engagement beware of unexpected movement of
actuators. Be sure all personnel and equipment are clear of area around machine and attachments.
Failure to comply could result in serious injury or death.
IMPORTANT : Before operating attachment, insure

pressure (port) relief cartridges (PRC's) have been in-
stalled and adjusted to attachment specifications (read NOTICE
safety and function testing sections in this manual)
 POST INSTALLATION INSPECTION

 LEAKS
Again, check for any minor leaks after machine HIGH TO CHECK HYDRAULIC OIL
LEVEL
has cooled. Tighten and torque fittings, if
needed. OIL LEVEL 1. PARK MACHINE ON
 HOSE ROUTING LEVEL GRADE.
Check for any rubbing of hoses, adjust if needed. 2. WITH BUCKET CLOSED
LOW AND ARM IN, PLACE
 CLAMPS ATTACHMENT ON GRADE.
Make sure clamps have not loosened to where 3. TURN OFF ENGINE.
piping has shifted out of alignment. Use 4. ADD HYDRAULIC OIL AS
factory recommended Loctite on bolts that can NECESSARY TO BRING
LEVEL BETWEEN TOP
vibrate loose. AND BOTTOM LINES OF
 FLUID LEVELS SIGHT GAUGE.
Cycle machine and attachment through several
positions and functions, check hydraulic fluid
level, then add fluid, if needed. Hydraulic Reservoir Oil Check
 INSTALLATION CLEANUP
 SECURING OEM COMPONENTS  secure machine
After kit installation, inspection and testing, When satisfied with kit installation, reinstall all
reinstall cab floor mats and replace any cable covers, hatches and panels, which had been
ties or brackets, which may have been loosened removed previously.
or removed during installation.  touch-up
 FOREIGN OBJECT INSPECTION Inspect all outer tubes, clamps, brackets and
Look in and around machine for tools, rags, weld-on bases (if applicable) and ensure they
fasteners and extra parts, before closing covers, are completely covered 100% by paint, to
hatches or reinstalling panels. prevent rust and corrosion.
NOTICE
IT IS THE RESPONSIBILITY OF THE INSTALLER to perform a visual post installation inspection for leaks, fastener tightness, wear and
abrasion, within the first twenty (20) hours of operation or thirty (30) days from date of first use, whichever occurs first; and make any
adjustments as necessary. THE POST INSTALLATION INSPECTION IS NOT COVERED BY THE KIT MANUFACTURER.
 INSTALLATION AND MAINTENANCE MANUAL

 SAVING MANUAL
SAVE and FILE this Installation and Maintenance Manual for future reference. Please send any comments or
suggestions that you may have, concerning the instructions, to the kit manufacturer (see the Customer Feedback
Form, located in the back of this Manual). Also refer to the “Introduction” section of this manual for contact
information.
GEN_FINALIZING INSTALLATION_MOD REV. 4 - 3.2007
FUNCTION TESTING
FUNCTION TESTING
BEFORE YOU START TESTING | STARTUP PROCEDURE | SETTING (PRC) | SETTING PILOT VALVE AND (PRV)/FLOW REGULATOR PRESSURE
n BEFORE YOU START TESTING

q RECONNECT POWER SUPPLY
CAUTION Insure that battery and computer have been
q Verify all Installation Steps have been completed reconnected in accordance with the excavator
q Verify all hoses, piping, fittings and hardware have manufacturer’s recommended procedure.
been properly connected and torqued to specific-
ations
PUSH INDICATOR
q Have safety personnel available to verify operations
q Ensure all piping clamps and mounting brackets
are permanently welded into place or secured with
hardware, to torque specifications and do not inter-
fere with piping or hose end connections
q Hook up all electrical systems on machine, that
have been disconnected (Follow the manufacturer’s
instructions for reconnecting electrical components)
q Carefully reinstall battery and/or reconnect leads, as
Econo-mode
per the machine manufacturer’s instructions
q Remove any flame-retardant cloth (rags, drop q ECONOMY MODE
clothes, etc.) from window, cylinders, electrical If machine has an Economy Mode, activate E-
components, cosmetic items, fuel and oil tank fill mode switch. Although performance will
and vent ports and any other surfaces that may have decrease, fuel consumption and noise level will
been covered during welding also decrease.
q LEAK INSPECTION
WARNING Position personnel around machine, then turn
n USE A GAUGE OR FLOW METER TO VERIFY starter for 1-2 seconds, shut down and check
FLOW/PRESSURE REQUIREMENTS (PILOT, POWER, for leaks.
RETURN, CASE DRAIN) BEFORE OPERATION OF
ATTACHMENT q HOSE INSPECTION
If no leaks were found, start machine again,
n FAILURE TO DO THIS MAY VOID MACHINE, ATTACH- allow to run at low idle for 10-15 seconds, be
MENT AND KIT WARRANTIES
prepared to shut down machine, if any leaks
n PRESSURE RELIEF CARTRIDGES (PRC) MUST BE
are observed.
ADJUSTED TO SPECIFIED PRESSURE REQUIRE- If no leaks were found, allow machine to run at
MENTS FOR THE MACHINE AND ATTACHMENT. low idle and slowly move boom, stick, and
(REFER TO MACHINE AND ATTACHMENT SERVICE attachment through full range of motion to
MANUALS FOR CORRECT PRESSURE SETTINGS verify that all kit hoses are not stretched,
BEFORE OPERATION OF THE ATTACHMENT) kinked or obstructed.
n INITIAL STARTUP PROCEDURE AFTER KIT INSTALL n SETTING PRESSURE RELIEF CARTRIDGE (PRC)
CAUTION
PRESSURE RELIEF CARTRIDGES (PRC) LIMIT THE AMOUNT
OF PRESSURE ON EACH SIDE OF THE SPOOL AND ARE
REQUIRED FOR ALL HYDRAULIC KITS, WHETHER IN-
CLUDED IN KIT OR CUSTOMER SUPPLIED, THEY MUST BE
INSTALLED. ONE (PRC) IS USED FOR SINGLE DIRECTION
KITS, TWO (PRC’S) FOR DUAL DIRECTION KITS.
q (PRC’s) get installed into same section of Main

Control Valve (MCV), where (kit used) Work Ports
are located.
SETTING PRESSURE RELIEF CARTRIDGES
HKX_FT_FIGC
CAUTION
q CHECK OIL LEVEL
PRESSURE RELIEF CARTRIDGES MUST BE ADJUSTED TO
Open access door in front of main pump. Check oil ATTACHMENT SPECIFICATIONS
level on hydraulic tank. Oil must be between marks
on gauge. If necessary, add oil. n CONTINUED n CONTINUED
GEN_FUNCTION TESTING_MOD REV. 2 - 9.2002
FUNCTION TESTING
n SETTING PILOT VALVE AND PRESSURE REDUCING

-PRESSURE RELIEF CARTRIDGE (PRC)- continued VALVE (FLOW REGULATOR) PRESSURE
q The easiest way to set (PRC) pressure is with
two people. The first person attaches a pressure CAUTION
gauge/flow meter (in-line), between supply line PRESSURE REDUCING VALVES AND PILOT VALVES MUST
and Attachment or between supply line and BE SET AT OR BELOW THE FLOW RECOMMENDED BY
return line (in place of attachment). MACHINE MANUFACTURER
SINGLE GAUGE q Pilot Valves and Pressure Reducing Valves (PRV),

also known as Flow Regulators, are typically
installed under or behind the cab.
q SETUP TEST EQUIPMENT
Insure a flow meter is connected between
attachment hoses, at attachment.
ARM
q SET ENGINE IDLE
Increase engine speed to high idle. The pressure
should not increase by more than 200 psi.
PRESSURE GAUGE/
FLOW METER
q If using a single pressure gauge, then use a tee

fitting (in-line) with gauge or (if your kit configu- ��
ration included an Arm Manifold) use plugged
port on Arm Manifold to connect gauge.
��
q Start machine and bring engine to full RPM,
monitor the pressure at pressure gauge/flow ��
meter. Either “Dead Head” one of the functions � �
or adjust valve on pressure gauge/flow meter ��
to restrict flow, allowing pressure to build up,
then have second person at Main Control Valve
adjust (PRC) until pressure is set to Attachment HKX_FT_FIGG
specifications. q ADJUSTING FLOW
With engine speed at high idle, set flow to
manufacturer’s recommended setting, by
q For dual (PRC) configuration, swap hoses at adjusting pilot valve (flow regulator).
pressure gauge/flow meter or switch location of Adjust flow meter to set recommended
single pressure gauge to opposite side of arm, OPERATING pressure.
then follow the same proceedure to set second
(PRC). NOTICE
Note and verify that back pressure and temperature
q IF kit configuration included an Auxiliary Valve, readings are at or below the manufacturer’s
(PRC’s) have been pre-installed and will need to recommendations.
be adjusted to Attachment specifications.
NOTES
GEN_FUNCTION TESTING_MOD REV. 2 - 9.2002
OPERATION & MAINTENANCE
Auxiliary Hydraulic Circuit Set-Up & Operation Check List

Following items must be addressed by qualified personnel prior to initial attachment operation and
re-evaluated when ever there is an attachment change on the excavator.
DECALS & LOCK OUT TAGS

WARNING
 Be sure any and all relevant decals supplied with
PRESSURE the auxiliary circuit have been properly installed on
 Auxiliary circuit must have proper circuit relief the excavator or circuit component.
protection installed to prevent attachment damage  If any of the previous items have not been
and insure proper attachment operation. completed during auxiliary circuit installation, be
This is typically accomplished by adjusting auxiliary sure that ample lock out tags are installed to warn
spool circuit relief cartridge(s) on the Main Control and prevent improper operation.
Valve.
If external secondary relief block(s) are utilized on
the circuit they must be adjusted to correct
operating pressure also.
 Consult specific attachment manufacturer for correct
operating pressure specification.
FLOW
 Auxiliary circuit must have proper oil flow setting to
prevent attachment damage and insure proper
attachment operation.
This is typically accomplished by adjusting auxiliary
spool pilot shift pressure on the auxiliary spool pilot
valve.
If secondary pilot valve(s) are utilized on the circuit
they must be adjusted to attain the correct
operating flow also.
 Consult specific attachment manufacturer for correct
oil flow specification.
EXCAVATOR SETTINGS
 If Auxiliary circuit utilizes excavator components
(factory installed) during or to control attachment
operations, consult OEM documentation for proper
settings and operation for specific application.
These OEM components typically are excavator
monitor settings, excavator CPU programming,
and OEM supplied relief cartridges.
These OEM components typically control items
such as work mode, switch valves, and monitor
controlled pilot valves.
LOCK OUT VALVES & SWITCH VALVES

 Auxiliary circuits often use manual or automatically
controlled ball valves to control oil flow direction or
to lock out a specific attachment.
These valves must be in the correct position to
insure proper attachment operation and avoid
attachment damage.
GEN_O&M_AuxiliaryHyd_Circuit_Setup&Operation_CL_MOD REV. 0 - 4.2007
OPERATION AND MAINTENANCE

SAFETY | OPERATION OF SYSTEM COMPONENTS | PERIODIC INSPECTIONS
 SAFETY
ATTENTION! SAFETY IS FIRST! SETTING ACCUMULATOR CHARGE PRESSURES
REFER TO THE SAFETY PRECAUTION AND PREPA-  Use attachment Manufacturers recommended
RATION SECTIONS BEFORE PERFORMING ANY pressure for proper charging of hydraulic Accumulator.
OPERATION OR MAINTENANCE ON THE MACHINE If the Manufacturer does not specify an Accumulator
charge pressure, then the following recomendation
may be used:
 OPERATION OF SYSTEM COMPONENTS Charge Accumulator to 1/2 of the expected working
line pressure.
-ACCUMULATOR- If used in the attachment return line, then set to half of
the expected return line pressure (15 - 40 psi).
 If used in the attachment return line of a combination
(1-way/2way) kit, then during (1-way) operation mode,
verify that it is locked out with a hydraulic ball valve
(or other isolating valve) before the kit is used in
ACCUMULATOR
CHARGE PORT (2-way) operation mode.
 Regular exposure of the Accumulator working pres-
sures more than twice the nitrogen charge will dam-
age the internal diaphram.
 If the Accumulator is not isolated from an attachment
that it was not intended for, during (2-way) operation,
the attachment will exhibit diminished, unexpected,
and possibly unsafe acuation during operation.
CHARGING ACCUMULATOR
 Remove cap from charge port on Accumulator.
 Attach Nitrogen bottle and hose with an adapter that
is compatible with a Schrader valve.
WARNING
NOTICE
 ALWAYS WEAR SAFETY GLASSES
ALL CONNECTIONS SHOULD BE FREE OF DIRT AND
 ALWAYS FOLLOW MANUFACTURER’S GUIDELINES SHOULD BE SNUG
FOR CHARGING THE SPECIFIC TYPE AND MODEL
OF ACCUMULATOR  Open valve on Nitrogen bottle.
 Charge according to (OEM) specifications.
 FAILURE TO CHARGE ACCUMULATOR MAY RESULT  Close valve on Nitrogen tank after charging.
IN PERMANENT COMPONENT DAMAGE AND A  Disconnect charge hose from charge adapter.
POTENTIAL HAZARDOUS SITUATION THAT COULD  Remove charge adapter.
RESULT IN DEATH OR SERIOUS INJURY  Replace high pressure cap on charge port.
 FAILURE TO CHARGE ACCUMULATOR MAY VOID

MACHINE, ATTACHMENT AND KIT WARRANTIES  OPERATION OF SYSTEM COMPONENTS
-AUXILIARY VALVE-
 CHARGE ACCUMULATOR WITH NITROGEN GAS
ONLY, BECAUSE OIL IS FLAMMABLE AND CHARG-  Auxiliary Valves (AV) come in many different types and
ING WITH AIR WILL CREATE A POTENTIALLY EXPLO- models, the following is an example of a single (AV),
SIVE SITUATION which shows port, plug and cartridge locations:
Work Port A
 RELEASE ALL HYDRAULIC AND NITROGEN GAS Tank Port or Plug
PRESSURE FROM ACCUMULATOR BEFORE REMOV-
Inlet Port
ING OR DISASSEMBLING
Main Relief Cartridge
 CHECK ACCUMULATOR FOR PROPER AMOUNT OF Shift Port A
NITROGEN GAS, PERIODICALLY Work Port B
 NITROGEN UNDER PRESSURE! MAXIMUM PRES-

SURE IS 4800 PSI Port Relief Cartridge
Tank Port or Plug

Shift Port B
 CONTINUED  CONTINUED
GEN_OPERATION&MAINTENANCE_MOD REV. 1 - 5.2006
 OPERATION OF SYSTEM COMPONENTS

-BALL VALVES-
2-WAY (LOCK OFF)

 2-Way Ball Valves are designed CLOSED POSITION
to Allow hydraulic flow in the
OPEN position and Stop
flow in the CLOSED
position.
OPEN POSITION
 Insure 2-way ball valve is in the OPEN position and

locked into place for peak performance.
 Valve/handle direction can be changed, if needed.
To do this, you will need an adjustable wrench, 9/16”
wrench and snap ring pliers. Remove snap ring and
stop plate, then change valve/handle orientation as
desired. Replace stop plate in LOCKED position, then
reinstall snap ring.
3-WAY LOCK OVER
 3-Way Ball Valves are designed

to Change the direction of
hydraulic flow from one
path to another.
FLOW DIRECTION
FLOW DIRECTION
 Insure 3-way ball valve is locked into place for peak

performance.
 Valve/handle direction can be changed, if needed.
To do this, you will need an adjustable wrench, 9/16”
wrench and snap ring pliers. Remove snap ring and
stop plate, then change valve/handle orientation as
desired. Replace stop plate in LOCKED position, then
reinstall snap ring.
 PERIODIC INSPECTIONS
CAUTION
PERIODICALLY PERFORM A WALK-AROUND, INSPECTING
KIT HOSES, ADAPTER FITTINGS, VALVES AND MANIFOLDS
FOR LEAKS, CRACKS AND OTHER POTENTIAL PROBLEMS
CAUTION
PERIODICALLY CHECK NITROGEN GAS LEVEL IN ANY KIT
MOUNTED ACCUMULATOR
GEN_OPERATION&MAINTENANCE_MOD REV. 1 - 5.2006
TROUBLESHOOTING CHART
Problem Possible Cause Check Remedy

Cannot Obtain Carrier work mode setting Carrier work mode setting Set for maximum power
Required Flow
Carrier auxiliary valve work port Relief valve (Note: setting usually Reset relief pressure to
relief valve set below Breaker must be somewhat above Carrier and Attachment
or compactor/driver operating hammer operating pressure specifications
pressure. based on manufacturer’s
specification)
Insufficient carrier pump flow Carrier pump curve specifications Contact HKX
Optional shuttle valve pressure Hose routing and connections Refer to HKX
signal connections. schematics
Worn carrier pumps. Carrier pump output. Rebuild or replace
No flow or Auxiliary valve spool not Pilot pressure signal to auxiliary Refer to HKX
pressure shifting. valve pilot port. schematics.
readings at Pressure line connected to Auxiliary valve work port Reverse port
pressure line. wrong auxiliary valve work port. connections. connection(s)
Shut off valve closed on Shut off valves. Fully open both valves
pressure and/or return line. to ON position.
Plug, orifice, or obstruction in HKX Installation schematics. See Carrier Manual.

auxiliary valve work port. Auxiliary valve work port.
Pilot port connections to Hose routing and connections. Refer to HKX
auxiliary valve reversed. schematics. (Note:
Connect pilot pressure
to one side of auxiliary
valve spool and
opposite side of
auxiliary valve spool to
drain.)
Pressure and return hoses Hydraulic pressure at attachment Refer to HKX
reversed on installation. inlet port, hose routing and schematics.
connections. (Note: sitting in Reverse line
operators seat typically the connections.
pressure line is on the left side
and the return line is on the right
side.)
No pilot pump supply pressure Hose routing and connections. Refer to HKX
to pilot valve. schematics.
No pilot pressure signal to Hose routing and connections. Refer to HKX
auxiliary valve pilot port. Valve solenoid wiring. schematics.
Repair or replace
wiring.
No electrical power. Foot switch, Joystick, HKX valve Repair and/or replace
wiring. HKX “ON/OFF” toggle wiring.
switch. HKX circuit breaker.
Carrier power supply.
Solenoid coil operating voltage. Solenoid coil voltage compatibility Replace.
with carrier electrical system.
PROPERTY OF HKX, INCORPORATED PROPERTY OF HKX, INCORPORATED PROPERTY OF HKX, INCORPORATED PROPERTY OF HKX, INCORPORATED PROPERTY OF HKX, INCORPORATED PROPERTY OF HKX, INCORPORATED PROPERTY OF HKX, INCORPORATED
REV. 0 - 5.2001
TROUBLESHOOTING CHART continued
Problem Possible Cause Check Remedy

Flow delivery Low oil level in carrier Reservoir oil level. Add hydraulic oil.
does not hold reservoir.
steady. Auxiliary valve spool Pressure to auxiliary valve pilot Check valve.
throttling. port. (Note pressure should be Contact HKX.
at or below pilot pump
pressure)
Reduced pressure signal to Hose routing and connection. Connect to
pump swash plate angle HKX installation drawings. correct port.
control port is connected to
wrong port.
Reduced pressure signal to Reduced pressure signal to Contact HKX.
pump swash plate angle pump swash plate angle
control port is erratic. control port. (Note pressure
should steady and repeatable)
Hydraulic oil Low oil level in carrier Reservoir oil level. Add Hydraulic oil.
temperature reservoir.
is running hot. Carrier auxiliary valve work Relief valve (Note: setting Reset auxiliary
port relief valve set below usually must be somewhat relief valve
hammer or compactor/driver above hammer operating pressure per
operating pressure. pressure based on attachment carrier
manufacturer’s specification) specifications
Shut Off valve(s) are in a Shut Off valve spool position. Fully open both
partially closed position. valves to ON
position.
Flow setting exceeds Flow test at load pressure with Reset flow per
specifications. flow meter at attachment attachment
hoses and compare to requirements
attachment requirements.
Excessive flow for line size. Tube and hose ID. Call HKX
Tube crushed or hose kinked. All tubes and hoses. Replace.

Optional shuttle valve Shuttle valve (if present). Fully open both
malfunction. (Note: Internal ball should valves to ON
move freely) position.
Dirty carrier oil or filter. Oil cooler or filter of carrier. Clean cooler.
Change filter.
REV. 0 - 5.2001
HKX, INCORPORATED
(360) 805-8600 ~ (800) 493-5487 ~ www.hkx.com
TS_O-rings 1 of 4 11-01-07
Typical Causes
• Abrasives in system fluids
• Excessive temperatures
• Inadequate system lubrication due to gland surface being too smooth
• Incorrect lubrication by system fluid
• Rough gland surfaces
Typical Solutions
• Eliminate contamination; add or change filters
• Finish gland surface appropriately
• Select internally lubricated O-rings to reduce friction
Abrasion is typically a factor in dynamic seal applications. • Select material with better resistance to abrasion
Look for a flat area on one side only where the seal • Select material with better system compatibility
touches the moving surface. • Select system fluid to provide adequate lubrication
Typical Causes
• Chemical incompatibility
Typical Solutions
• Select chemically-compatible material
Chemical degradation can cause blisters, cracks, voids,

or discoloration.
Typical Causes
• Excessive squeeze from an over tight gland
• Excessive temperature as a result of system fluids, external environmental factors
or frictional heat build-up causing the O-ring to harden and lose elastic properties
• Improper gland design
• Incomplete curing (vulcanization) of material during production
• Introduction of an incompatible fluid
• Material has inherently poor compression set properties
• Volume swell due to system fluid
Typical Solutions
• Control frictional heat and/or control system operating temperature
Compression set is the single most common cause
• Inspect O-ring on shipment to match specified characteristics
of O-ring failure. Look for flat surfaces on both sides
• Use a material featuring low compression set characteristics
of the O-ring's cross section creating a flat-sided oval.
• Use a material that is compatible with actual conditions
Typical Causes
• Deposits from system process
• Seal degradation prior to assembly
• Inappropriate seal material
Typical Solutions
• Control seal manufacturing and packaging
• Select appropriate seal material
Contamination will result in foreign material on

the seal.
HKX, INCORPORATED
(360) 805-8600 ~ (800) 493-5487 ~ www.hkx.com
TS_O-rings 2 of 4 11-02-07
Typical Causes
• Chemical incompatibility
• Environmental incompatibility of material
• Excessive humidity
• The O-ring absorbs system fluids and swells
Typical Solutions
• Select a system-compatible material
Excessive swell is most common in high-friction

dynamic applications. Look for absorption of
system fluids, sponginess, swelling and unusual
wear.
Typical Causes
• Gas absorption
• Rapid system pressure drop traps gas in O-ring material micro-pores
Typical Solutions
• Increase decompression time
• Increase material hardness (+90 durometer)
• Reduce cross-section
• Select a decompression-compatible material (i.e. nitrile)
Explosive decompression can occur in systems featuring

gases under high pressure. Look for deep short splits or
ruptures in the cross section or small blisters on the
surface of the O-ring.
Typical Causes
• Degradation (swelling, softening, shrinking, cracking, etc.) caused by system fluid
• Excessive clearances/pressure
• Irregular clearance gaps caused by gland or seal eccentricity
• O-ring too large for groove
• Sharp edges on gland
• Too soft an elastomer
Typical Solutions
• Enhance rigidity of gland components
• Machine gland's sharp edges to an acceptable minimum radius (0.1 in)
Extrusion / nibbling is typical of O-rings installed in • Properly size O-rings
high-pressure systems. Look for chips taken out of • Reduce machining tolerances and decrease clearances
the edges of the O-ring, normally on the • Select harder material (90 derometer +), select system-compatible material
low-pressure (downstream) side of the gland. • Try different seal shape or use back-up rings
Typical Causes
• Evaporation of plasticizers caused by excessive temperatures
• Hardening caused by excessive temperatures
• Oxidative cracking caused by excessive temperatures
Typical Solutions
• Reduce operating temperatures
• Select high temperature material
• Select material with antioxidants
To identify heat hardening and oxidation, look for

pits and crack and possibly the flat edges as seen
in compression set.
HKX, INCORPORATED
(360) 805-8600 ~ (800) 493-5487 ~ www.hkx.com
TS_O-rings 3 of 4 11-02-07
Typical Causes
• Carelessness
• Contaminated O-ring, gland or system components
• Insufficient lead-in chamfer or lubrication prior to assembly
• O-ring twisted or pinched at assembly
• Sharp threads, edges on the gland or other system components
• Too large an O-ring on a piston or too small an O-ring on a rod
Typical Solutions
• Clean all components prior to assembly
• Install O-rings carefully
Installation damage usually causes short cuts, • Reduce edge sharpness; tape sharp threads and edges
notches, skinning, or peeling on the surface of • Select a system-compatible lubricant
the O-ring. • Specify an appropriate lead-in chamfer
• Use appropriate size and material
Typical Causes
• Eccentric component
• Flash or parting lines left on seal
• Improper sizing
• No compression
• Tolerance stack-up
Typical Solutions
• Allow for seal expansion
• Check for increased stretch
• Design to match tolerance stack-up for all system components
• Maintain appropriate compression
In some cases of failure, there is no evidence of • Remove flash and parting lines
failure visible on the seal.
Typical Causes
• Improper or improperly cured elastomer
• High vacuum levels
• Low hardness/plasticized elastomer
Typical Solutions
• Avoid plasticized elastomers
• Ensure all seals are properly post-cured to minimize outgassing
This failure is often very difficult to detect from

examination of the seal. The seal may exhibit a
decrease in cross-sectional size.
Typical Causes
• Improper design—failure to account for thermal or chemical volume changes,
or excessive compression
Typical Solutions
• Gland design should take into account material responses to chemical and thermal
environments
The seal exhibits parallel flat surfaces

(corresponding to the contact areas) and may
develop circumferential splits within the
flattened surfaces.
HKX, INCORPORATED
(360) 805-8600 ~ (800) 493-5487 ~ www.hkx.com
TS_O-rings 4 of 4 11-02-07
Typical Causes
• Ozone degrades O-ring material
• Pollutants degrade O-ring material
Typical Solutions
• Select ozone resistant material
• Select chemically-compatible material
This condition is typical when the seal is exposed

to air pollutants or ozone. Look for small surface
cracks running perpendicular to direction of stress.
Typical Causes
• Chemical reactivity of plasma
• Heat due to electron bombardment
• Inadequate gland design
• Ion bombardment (sputtering)
• System-incompatible material
Typical Solutions
• Minimize seal exposure to plasma
• Re- design gland
The seal often exhibits discoloration, as well as • Select plasma-compatible material
powdered residue on the surface and possible
erosion of elastomer in the exposed areas.
Typical Causes
• Eccentricity of components
• Incorrect lubrication
• O-ring pinched or rolled in assembly
• Rough surface finishes
• Side load applications with too wide a clearance
• Slow stroke speed
• Too soft an O-ring material
Typical Solutions
• Look for out-of-round eccentric components
Spiral failure is common to hydraulic piston • Proper surface finishes
(long stroke) and rod seal applications. Look • Select harder O-ring material
for deep, angled (45˚) cuts on the seal's surface. • Select proper lubricant
• Try different seal shape
Typical Causes
• Elastomer thermal properties
• Excessive temperature excursions or cycling
Typical Solutions
• Selection of an elastomer with improved thermal stability
• Evaluation of the possibility of cooling sealing surfaces
The seal may exhibit radial cracks located on the

highest temperature surfaces. In addition, certain
elastomers may exhibit signs of softening—a shiny
surface as a result of excessive temperatures.
TROUBLESHOOTING QUESTIONAIRE
TROUBLESHOOTING QUESTIONAIRE
DATE INSTALLED KIT NUMBER
Troubleshooting is always a challenge. To assist in solving any problems relating to this hydraulic kit, it is beneficial to have the
following information recorded. Please fill out this form and fax it to HKX at 1-800-353-5736 so we can pull the file for your kit,
review your settings and call the excavator and attachment technical representatives, if needed. An efficient troubleshooting
process can be achieved with the completion of this form.
FAILURE TO COMPLETE THIS FORM MAY AFFECT OR DELAY THE TROUBLESHOOTING PROCESS.
PERSONAL INFORMATION ADDITIONAL INFORMATION

Name __________________________________________ Does this attachment have a case drain? Yes No
Phone ( ) ______________ Fax ( ) ________________ If yes fill-in, Size Back Pressure psi.
Is this a dual-function kit? Yes No
COMPANY INFORMATION If yes, list attachments ___________________________
Name __________________________________________ _____________________________________________
Phone ( ) ______________ Fax ( ) ________________ Do you receive Installation Instructions? Yes No
This Kit was installed by ____________________________ Was kit installed per Installation Instructions? Yes No
Phone ( ) ______________ Fax ( ) ________________ Did the parts fit properly? Yes No
Were there any modifications to the kit? Yes No
EXCAVATOR INFORMATION Were any other problems encountered installing the kit?
Yes No - If yes, please list below.
Manufacturer ___________ Model _______ Series ____
_______________________________________________
Year ______ Serial # ____________ Hour Meter ______
_______________________________________________
Does this machine have a spare valve? Yes No
ATTACHMENT INFORMATION Does this machine have an Auxiliary Valve? Yes No
Manufacturer ___________ Model _______ Series ____ Does this machine have an Accumulator? Yes No
Type of Attachment _______________________________ Does this machine have a Return Filter? Yes No
Year ______ Serial # ____________ New (or) Used ___ External Port Relief Manifold? Yes No
- Record additional attachment(s) information, below. Please give descriptions on what seems to be the
Manufacturer ___________ Model _______ Series ____ problem(s), below.
Type of Attachment _______________________________ _______________________________________________
Year ______ Serial # ____________ New (or) Used ___ _______________________________________________
_______________________________________________
FUNCTION TESTING INFORMATION _______________________________________________
Port Relief Cartridge (A) setting __________ psi. _______________________________________________
Gauge location ____________________________ _______________________________________________
Port Relief Cartridge (B) setting __________ psi. _______________________________________________
Gauge location ____________________________ _______________________________________________
Flow Setting __________ gpm. _______________________________________________
Gauge location ____________________________ _______________________________________________
Pilot Pressure __________ psi. _______________________________________________
Gauge location ____________________________ _______________________________________________
Return Back Pressure (BP) __________ psi. _______________________________________________
Gauge location ____________________________ _______________________________________________
Auxiliary Valve main relief setting __________ psi. _______________________________________________
Gauge location ____________________________ _______________________________________________
Accumulator Charge __________ psi. _______________________________________________
Gauge location ____________________________ _______________________________________________
_______________________________________________
_______________________________________________
_______________________________________________
Problem Description continued on back? Yes No
REV. 0 - 5.2001
GLOSSARY
GLOSSARY
ABBREVIATION PARTNAME ABBREVIATION PARTNAME
ACC Accumulator Kg/cm² Kilogram/Centimeter²
ADP Adapter Kgf-m Kilogram Force Meter
ALUM Aluminum LBP Low Back Pressure
AMP Amperage LG Long/Length
AP Auxiliary Pump LN Lock Nut
ASSY Assembly M Male
AV Auxiliary Valve MAN Manifold
BH Bulk Head MCV Main Control Valve
BRKT Bracket MET Metric
BSPP British Standard Pipe Parallel MM Millimeters
BSPT British Standard Pipe Tapered MRC Main Relief Cartridge
BV2 2-way Ball Valve (Lockoff Valve) MTG Mounting
BV3 3-way Ball Valve NPT National Pipe Tapered
CB Circuit Breaker OC Open/Close
CCW Counter Clockwise OCR Open/Close & Rotate
CD Case Drain OD Outside Diameter
CD61 Code 61 OEM Original Equipment Manufacturer
CD62 Code 62 ORB O-ring Boss
CDSET Cordset ORFS O-ring Face Seal
CNV Conversion PFD Priority Flow Divider
CONN Connector PR Pilot Return
CS Center Section (Boom) PRC Pressure (Port) Relief Cartridge
CW Clockwise PRM Port Relief Manifold
CYLD Cylinder PRP Pressure Reducing Port
° or D Degree PRV Pressure Reducing Valve
DBL Double PS Pilot Supply
DC Direct Current PSI Pounds per Square Inch
DF Dual Function PSRA Pilot Supply & Return Adapters
DFH Dual Function House PSV Pilot Signal Valve
ELB Elbow PSW Pressure Switch
ELEC Electric PV Pilot Valve
EPC Electronic Pilot Control RED Reducer
ERGO Ergonomic RES Restricter
ESH End Section House (Boom) RF Return Filter
ESS End Section Stick (Boom) RL Return Line
F Female RPA Return Port Adapter
FC Fluid Controls RPM Revolutions Per Minute
Fig Figure RT Rotate
FIT Fitting RV Relief Valve
FL Fluid Lines SBP Standard Back Pressure
FLG Flange SF Split Flange
FP Foot Pedal SGL Single
FS Foot Switch SHC Socket Head Cap
G Grade SK Subkit
G1 Boom Group SLND Solenoid
G2 Arm Group SP Standard Pressure
G3 Valve Group SPA Shift Port Adapters
G4 Controls Group SS Spare/service spool ( accessory, option)
GA Gauge STD Standard
GPM Gallons Per Minute SV Shuttle Valve
HF High Flow TRPL Triple
HHC Hex Head Cap TS Terminal Strip
HP High Pressure TSW Toggle Switch
HPA Hard Plumbed Adapter V Volt
HYD Hydraulic VLV Valve
ID Inside Diameter WPA Work Port Adapter
JIC Joint Industrial Conference X Swivel
JS Joystick XHF Extra High Flow
REV. 1 - 4.2003
PRODUCT WARRANTY
 KIT WARRANTY
HKX, INCORPORATED (“HKX”) warrants any new hydraulic kits sold (except electrical components) by HKX, will be free
from defects in material and workmanship for a period of one (1) year from the date of shipment to the buyer,
if installed as per HKX installation manual. The HKX installation kit warranty does NOT cover labor, incidental costs
or travel expenses.
THIS WARRANTY DOES NOT APPLY TO:
Installation on carrier other than specified on the kit Bill of Materials.
 HKX RESPONSIBILITY
HKX will, at its discretion, repair or replace with a new or reconditioned part, any warranted part that fails by reason of
defective material or workmanship, free of charge.
NOTE: Parts replaced under warranty become the property of HKX.
 USER RESPONSIBILITY
 The installer, user, operator, repairer, assumes  All labor costs.
responsibility to READ, UNDERSTAND and COMPLY  Any expense incurred by field repair.
with HKX’s written INSTALLATION, OPERATION, SAFETY,  Returning completed Installation Feedback Form
PREPARATION, TESTING and SERVICE INSTRUCTIONS. to HKX after installation of kit.
 If the hydraulic kit has been in your inventory for over  Perform post-installation inspection within 20 hours
6 months, call HKX for upgrade information before of operation or 30 days from date of first use, which-
starting installation. ever occurs first, and make adjustments as necessary.
 THESE WARRANTIES DO NOT COVER FAILURES RESULTING FROM:

 Installation, alteration, modification, operation, maintenance, repair or storage which HKX judges improper.
 Not performing DAILY VISUAL INSPECTIONS and RETIGHTENING as specified in the HKX installation manual.
 Operation after discovery of defective or worn parts.
 Unreasonable delay in making a repair after being notified of a potential product problem.
 THESE WARRANTIES SPECIFICALLY EXCLUDE:

 Operation of products not sold by HKX.  Parts shipping charges in excess of those which
 Installations not approved by HKX. are usual and customary.
 Replacement due to normal wear.  Duties and local taxes.
 Use of parts not sold by HKX.
 LIMITATION AND EXCLUSIONS

Violation of any federal, provincial, state or local laws, ordinances, rules or regulations, or removal or alteration of product
serial numbers void HKX’s written product warranties. Application for warranty must be made within 60 days of
failure.
The written product warranties made by HKX set forth HKX’s only obligations with respect to any claims of
failure, defects or deficiencies in products sold by HKX. HKX MAKES NO OTHER WARRANTIES OR REP-
RESENTATIONS WHATSOEVER, EXPRESS OR IMPLIED, OF THE QUALITY, PERFORMANCE, DURABILITY,
MATERIALS, WORKMANSHIP, SUITABILITY, CONDITION, DESIGN OR UTILITY OF PRODUCTS SOLD BY
HKX, INCLUDING, WITHOUT LIMITATION, IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS,
ALL SUCH OTHER WARRANTIES AND REPRESENTATIONS BEING HEREBY EXPRESSLY EXCLUDED. HKX
SHALL NOT BE LIABLE FOR SPECIAL, INCIDENTAL OR CONSEQUENTIAL DAMAGES, INCLUDING,
WITHOUT LIMITATION, COSTS, LOSSES OR LIABILITIES ON ACCOUNT OF DELAY OR DOWNTIME.
As used in this warranty the term HKX means HKX, Incorporated, 16761 146th St. SE Suite 115, Monroe, WA 98272, USA.
PRODUCT WARRANTY
 DISCLAIMER REGARDING OTHER REPRESENTATIONS OR WARRANTIES
No person is authorized to grant any other warranties or to assume any other liability on HKX’s behalf
unless made or assumed in writing by an officer of HKX. No person is authorized to grant any warranties
or to assume any liabilities on the seller’s behalf unless made or assumed in writing by the seller.
IMPORTANT: MODIFICATIONS, ALTERATIONS, CHANGES, IMPROPER USAGE AND/OR USE OF PARTS NOT
SOLD OR AUTHORIZED BY HKX WILL VOID ANY AND ALL HKX WARRANTIES.
PRIOR WRITTEN AUTHORIZATION MUST BE OBTAINED FROM HKX FOR ANY OF THE ABOVE.
Please contact an HKX warranty coordinator immediately upon learning of a potential warranty claim at
1-800-493-5487 or 360-805-8600.
 WARRANTY CLAIMS
In response to your warranty claim, the Warranty Coordinator will, in a timely manner:
 Collect all pertinent information, including photos, if necessary.
 Evaluate the problem and promptly advise you verbally and in writing:
 What repairs are necessary  Parts required for repair
 The repair procedure  Time allowance for repairs
 Or, in certain instances, the Warranty Coordinator may request the return of parts to HKX for repairs.
 Where applicable, the Warranty Coordinator will immediately provide replacement parts, as required,
billing the claimant for the parts pending return and evaluation of the defective parts (also requiring an
RGA). If the returned parts are deemed defective, a credit will be issued against the parts invoice. All
defective parts must be returned to HKX freight prepaid.
 Preapproved dealer labor expense, including freight (where applicable) will be reimbursed with a credit
memo against future business with HKX.
IMPORTANT: Claims submitted 60 days past the repair date will not be considered for warranty.
 LEGAL STATEMENT
Any disagreements will have to be submitted to an arbitration company agreed upon by the buyer and HKX,
and a neutral arbitrator will resolve disputes in an informal private proceeding.

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HKX Manual Parts 320D PDF

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Some Components in this Kit

have been Partially Assembled

It is imperative to read, follow and

COPYRIGHT  2002. HKX, INCORPORATED. ALL RIGHTS RESERVED. (REV. 1 | 4/02).

Readers are encouraged to notify HKX and send in

I. INTRODUCTION XIII. FINALIZING INSTALLATION

XI. GROUP 3 - VALVE

READ, UNDERSTAND AND FOLLOW ALL SAFETY PRECAUTIONS AND PROCEDURES

 Applying Decal Labels

The following examples show how the labels can be

 DECAL PLACEMENT CONTINUED

Place Decal near Ball

 DECAL PLACEMENT CONTINUED

n FOREWORD n IMPORTANCE OF SAFETY

n NOTICE WITHOUT SAFETY ALERT SYMBOL | GREEN used

WRENCH (Standard) MEASURE

WRENCH (Socket) WELDING

WRENCH (Allen/HEX) ADHESIVE

TIPS & IDEAS SAFETY EQUIPMENT

n BEFORE YOU START n MACHINE PREPARATION

ensure every installation kit is shipped complete, to do

performed. A tag is sup- n A “DRY CONNECT” BY GROUP INSTALLATION

CAUTION Start carrier and heat oil to operating tempera-

O-ring Face Seal

TIGHTENING TORQUE CHART - BOLTS / SCREWS

The required torque is shown as kgf-m.

TIGHTENING TORQUE CHART - TUBE / MANIFOLD AND ADAPTER FITTINGS

SAE O-ring Boss Port

SAE O-ring Boss Port

FIGURE ILLUSTRATION 1A FIGURE ILLUSTRATION 1B

FINAL ASSEMBLY OF FLANGE FINAL ASSEMBLY OF TUBE-TO-PORT

FLANGE TORQUE SPECS_TXT REV. 0 04.10

LINES GROUP COLOR DESCRIPTIONS

LINES PATTERN DESCRIPTIONS

ABC OEM COMPONENTS by letter

 The BOOM GROUP is part of the circuit

G1_COVER_TEMPLATE_Rev1 REV. 1 - 09.2007

GROUP 1 : Parts List

ITEM NUMBER PART NUMBER QUANTITY DESCRIPTION

1.21 100-0103 1 Boom Tube Adp A

ITEM NUMBER PART NUMBER QUANTITY DESCRIPTION

1.11 310-0116 1 Bolt Hex M12 x 1.75 x 80 Cl 10.9

1.00 ALTERNATE MOUNTING

1.12 Existing components

 READ “SAFETY PRECAUTIONS” AND “PREPARATION” SECTIONS E

 NOTE: All O-rings should be lubricated with grease D C

There is an alternative method of tightening adapters, if a

O-ring Face Seal O-ring Face Seal

 The ARM GROUP is part of the circuit

G2_COVER_TEMPLATE_Rev1 REV. 1 - 09.2007

GROUP 2 : Parts List

ITEM NUMBER PART NUMBER QUANTITY DESCRIPTION

2.05 100-0167 1 Stick Tube/Hose Adp A

Brackets & Shutoff Circuit

 The VALVE GROUP is the source of flow and

G3_COVER_TEMPLATE_Rev1 REV. 1 - 09.2007

GROUP 3 : Parts List

ITEM NUMBER PART NUMBER QUANTITY DESCRIPTION

3.80 900-0226 1 Auxiliary Relief Cartridge (ARC)

CAT_3125-3-RF_TXT REV. 0 04.10

Relief Valve Installation

relief valve installation REV. 0 08.12

 The CONTROLS GROUP may consist of a foot

TROUBLESHOOTING CHART continued

PERSONAL INFORMATION ADDITIONAL INFORMATION