Manual de Instalacion PC200LC-8

Installation &
Maintenance Manual
AUXILIARY HYDRAULIC KITS
It is imperative to read, follow and

understand all safety precautions
and installation procedures found
PC200LC-8
in this manual before attempting
any installation or operation of
product. Deviation from this manual
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 HYDRAULIC EXCAVATOR
this product on this machine. This
manual should be kept near the
machine for installation procedures
and reference while installing this
product. Komatsu cannot anticipate
PC200(LC)-8 KOMATSU EXCAVATOR
every possible circumstance that might
involve a potential hazard. The
HYDRAULIC BREAKER KIT
warnings in this publication and on the
product are therefore not all inclusive.
H46928 DATE: 12.21.07
*H46928i*
COPYRIGHT  2002. KOMATSU AMERICA INTERNATIONAL COMPANY. ALL RIGHTS RESERVED. (REV. 0 | 4/02)
INSPECTED BY INSPECTED BY
TECH. PUBS. JS ENGINEERING DJ
INTRODUCTION
CONGRATULATIONS!
You have purchased a quality hydraulic piping kit de- Please write, call, email or fax your comments to our
signed specifically for your Komatsu excavator by Technical Publications team at the information below:
Komatsu America International Company (KAIC) and HKX,
Incorporated. This kit was designed to take full advantage Komatsu America International Company (KAIC)
of the Komatsu product and maintain its high standard of Attn: Technical Publications Department
quality. 16761 - 146th Street SE, Suite 115
Monroe, Washington 98272
This manual contains specific technical drawings, step-by- Phone: (800) 493-5487
step installation instructions, parts lists, flow and pressure Fax: (800) 353-5736
testing and troubleshooting charts. We are confident that Email: support@hkx.com
it will exceed your requirements. https://www.KomatsuAmerica.net
KAIC recommends that you read this manual thoroughly If the kit cannot be installed per manual, please call us at
before installing the kit. Follow the manual and drawings the contact information above, before deviating from kit
for proper installation. Deviation from this manual may instructions and design. Our Technical Support team will
increase the installation time and/or cause damage to the assist you to correct the problem without affecting the kit
machine or attachment. If the manual is followed pre- integrity or warranty.
cisely, the most efficient installation in the shortest
amount of time will be achieved. This information is to be used for the specific purpose for
which it was provided. It is provided on a confidential
The kit is designed to fit the specific carrier. KAIC has basis and is the property of KAIC. The reproduction and
endeavored to deliver the highest degree of accuracy use of this information without the express written
possible. However, continuous improvement is a KAIC consent from KAIC, Incorporated is strictly prohibited.
policy for all kits and manufacturers continually make
improvement changes. Therefore product specifications
are subject to change without notice.
Readers are encouraged to notify KAIC and send in

suggestions for improvement. All communications will be
HYDRAULIC KIT PROGRAM
Copyright 2002 by Komatsu America International
carefully considered for future printings of this and other Company (KAIC). KOMATSU  is a registered trademark
manuals. of Komatsu Ltd. Japan.
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. DECAL INSTALLATION
XIV. FUNCTION TESTING
IV. SAFETY PRECAUTIONS A. Before You Start Testing
CAUTION WARNING DANGER B. Start-up Procedure
A. Foreword C. Setting Pressure (Port) Relief Cartridge (PRC)
B. Safety Alert Symbol D. Setting Pilot Valve and Pressure Reducing
C. Signal Words & Symbols Valve (Flow Regulator) Pressure
D. Importance of Safety
E. Precautions XV. AUXILIARY HYDRAULIC CIRCUIT SET-UP &
F. Attachment Selection OPERATION CHECK LIST
G. Symbols Chart 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  Ball Valve: 2-Way (lock off ), 3-Way (lock-
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. WARRANTY POLICY
C. GROUP 1 - Support Documentation
XX. WARRANTY CANCELLATION & RETURN
PROCEDURES
X. GROUP 2 - ARM
A. GROUP 2 - Parts List
B. GROUP 2 - Installation Illustration NOTICE

INCLUDED WITH MANUAL:
XI. GROUP 3 - VALVE A. STOP! Read Before You Start! Safety First!
A. GROUP 3 - Parts List B. Customer Feedback Form
B. GROUP 3 - Installation Illustration C. DANGER! Do Not Operate Tag
C. GROUP 3 - Support Documentation D. CAUTION Auxiliary Circuit Flow and
Pressures need to be set to Attachment
XII. GROUP 4 - CONTROLS Specifications Tag
A. GROUP 4 - Parts List E. Decals - for Machine
B. GROUP 4 - Installation Illustration

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
GROUP 1 - BOOM
INTRODUCTION
PARTS LIST
INSTALLATION ILLUSTRATION
STEP-BY-STEP INSTRUCTIONS
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: KOMATSU PC200LC-8
Kit Code: 5
Order No: H46928
GROUP 1 : Parts List
ITEM NUMBER PART NUMBER QUANTITY DESCRIPTION
1.37 100-0168 1 ACC Boom Tube Adp B

1.36 100-0182 1 ACC Inlet Adp B
1.36 102-0002 1 ACC Inlet Adp B
1.38 645-1102 1 ACC Inlet Hose B
1.36 102-0049 1 ACC Inlet Adp B
1.35 510-0005 1 Accumulator B
1.13 750-0002 3 Boom Tube Clamp A (ESH)
1.14 750-0003 3 Boom Tube Clamp B (ESH)
1.12 360-0182 1 Boom Tube Clamp Mtg A & B
1.11 310-0164 6 Stacking Hardware A & B
1.17 750-0058 2 Boom Tube Clamp A (ESS)
1.18 750-0059 1 Boom Tube Clamp B (ESS)
1.11 310-0125 1 Stacking Hardware A
1.11 310-0116 1 Stacking Hardware B
1.01 667-0368-B 1 ESH A
1.03 645-1227 1 CS A
1.05 666-0456-B 1 ESS2 A
1.07 661-2076-B 1 ESS1 A
1.02 667-0370-B 1 ESH B
1.04 645-1467 1 CS B
1.06 661-3044-B 1 ESS2 B
1.08 661-3076-B 1 ESS1 B
1.21 100-0103 5 Boom Tube Adp A
1.20 100-0110 5 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
Nut to 1.20
clamp appx. 1.08
1.21 1.11 1.11
1" 1.13
1.20
A 1.14
B
1.11 1.06
A1 1.07
1.21 1.20 1.02

B 1.37
1.12
WELD
1.17 1.35
1.18 VIEW FROM BASE OF BOOM
1.05
C 1.36
D
3.09
1.04
1.21 1.38
1.20
1.36
1.17 1.03
1.12 1.18
1.02
F
D
1.21
1.11
1.11
A 1.17 1.13 1.14
1.18
D
1.01
1.17
1.18
1.12
1.12 1.12
1.11 E
1.11 VIEW FROM BASE OF BOOM
1.12
1.21 F
E
B
1.11
KOM_1047-H-B-ACC-8_GI 12.21.07
1
J. Schmidt R. MacARTHUR
C Existing components
shown in gray
INTRODUCTION
PARTS LIST
SUB-KIT MODULES AND OTHER SUPPORTING DOCUMENTATION
Example of Boom Shrink Wrapped components: packaged
CAUTION in sequence of installation (location where installed)
E
 READ “SAFETY PRECAUTIONS” AND “PREPARATION” SECTIONS
OF THIS MANUAL PRIOR TO INSTALLATION E
 REFER TO “G1-BOOM” INSTALLATION ILLUSTRATION, WHILE D
PROCEEDING WITH THE FOLLOWING STEPS ON THIS PAGE 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. B
 NOTE: For best results, torque hydraulic connections
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
will show installation on left side of boom. Mirror
installation on right side of boom, unless otherwise FIGURE ILLUSTRATION 1A
specified. 3) Install clamp mounting brackets without clamps, refer
 NOTE: Slide clamp halves together, DO NOT hinge to details (B), (D) and (E).
clamps together, see illustration below: 4) Using the Installation Illustration, install tubes and
clamps 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.
7) Verify alignment again and check both sides.
8) Tighten and Torque all clamp hardware and
adapters in sequence from boom base to boom tip or
visa versa, (refer to Torque Specifications Section).
9) Install components into union adapter(s) and
START HERE Accumulator(s) (ACC), then place (ACC) near union
adapter and install hose, refer to detail (F).
INSTALLATION STEPS (Refer to Detail Bubbles) 10) Mark location of (ACC) mounting bracket.
* Pages following these Step-By-Step Instructions 11) Remove paint from marked locations, reposition
(ACC), separate (ACC) from bracket and weld into
1) Layout all Boom kit components (tubes, hoses, place.
adapters, etc.) and inspect for any damages or missing 12) Clean-up welds and touch up bracket with factory
components, which may have occurred during color paint, then reinstall (ACC). Tighten and Torque
shipping. all hardware and hydraulic connections, (refer to
2) Orient Shrink Wrapped clamp and bracket package to Torque Specifications Section).
boom. Components are shrink wrapped in sequence
and order of installation. See Example of Boom Shrink  NOTES: _______________________________
Wrap (Figure Illustration 1A). _____________________________________
_____________________________________
_____________________________________
KOM_1047-H-B-ACC-8_TXT REV. 0 12.07
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
Order No: H46928
2.01 645-1262 1 Stick Hose A ( - )

2.02 645-1502 1 Stick Hose B ( - )
2.05 920-0042 1 Stick Manifold A
2.05 100-0076 2 Manifold Adaptor A
2.06 920-0065 1 Stick Manifold B
2.06 100-0088 2 Manifold Adaptor B
2.11 750-0002 1 Stick Tube Clamps A
2.12 750-0003 1 Stick Tube Clamps B
2.13 751-0002 2 Stick Tube Clamp MTG
2.03 667-0067-B 1 Stick Tube A ( - )9 - 7
2.04 667-0068-B 1 Stick Tube B ( - )9 - 7
2.07 970-0043 1 Shut-Off Valve A
2.07 360-0086 1 Shut-Off Valve Bracket A
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
2.08 360-0086 1 Shut-Off Valve Bracket B
2.10 100-0088 1 Shut-Off Valve Adaptor B
2.10 180-0004 1 Shut-Off Valve Adaptor B
s = subkit
INTRODUCTION
PARTS LIST
2.11
2.12
WELD
2.13
A Shutoff Circuit
2.11 A - "ON" Position
2.12
B - "OFF" Position
C B
2.07
C 2.03 90˚ 2.08
17" 2.04
A
From Center of Bucket Cylinder 2.09
Pin to End of Manifold 2.10
2.07
2.08 2.09
2.01 2.10
2.02
WELD
2.07
2.05 B 2.08
2.06
B
WELD
2.05
2.06
2.03
2.04
HKX_2102_17_GI 09.20.07
M. MELAND C. CURFMAN
Existing components
A shown in gray
INTRODUCTION
PARTS LIST
2) Using the Installation Illustration, assemble
CAUTION components on stick tube at three locations, refer

to details (A), (B) and (C) and refer to Ball Valve (BV)
*Sub-Kit. IMPORTANT- Remember to lubricate all
 READ “SAFETY PRECAUTIONS” AND “PREPARATION” SECTIONS O-rings before assembly (see O-ring note).
OF THIS MANUAL PRIOR TO INSTALLATION 3) Place assembly on flat surface and check component
 REFER TO “G2-ARM” INSTALLATION ILLUSTRATION, WHILE alignment, then Tighten and Torque all hydraulic
PROCEEDING WITH THE FOLLOWING STEPS ON THIS PAGE connections, (refer to Torque Specifications Section).
Keep hardware snug.
WARNING
4) Installation can either be started on left or right side
(unless otherwise specified).
5) Position assembly on side of Arm and mark location of
weld base(s).
 Read and follow all welding related items in the
“SAFETY PRECAUTIONS” AND “PREPARATION” sections OF
IMPORTANT- Check illustration for reference
THIS MANUAL PRIOR TO INSTALLATION locations (measurements) or starting points.
6) Remove paint from marked locations, reposition
READ ALL NOTES PRIOR TO INSTALLATION assembly on side of Arm and tack weld into place.
7) Remove assembly, finish welding brackets, clean-up
 NOTE: All O-rings should be lubricated with grease welds and touch up brackets with factory color paint,
before assembly to ensure a tight seal and long then reinstall assembly. Tighten and Torque all clamp
lasting connection. hardware, (refer to Torque Specifications Section).
 NOTE: When tightening hydraulic connections, turn nut 8) Install stick hose between Boom and Arm
not adapter or O-ring may get pinched. components. Stick hose should be positioned with "S"
 NOTE: Verify joint alignment faces are flat and O-rings curved shape of existing stick cylinder hose, refer to
are properly seated. Figure Illustration 2A.
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
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. _____________________________________
HKX_2102_17_TXT REV. 0
HKX, INCORPORATED
(360) 805-8600 ~ (800) 493-5487 ~ www.hkx.com
360-0086 5-12-07
ITEM# PART#
1 360-0241
2 360-0240
3 310-0189
4 350-0017
4
3
4
3 3
4
4
ITEM# PART# 2
1
1 360-0241 Weld
2 360-0240
3 310-0189
4 350-0017
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
Order No: H46928
3.50 910-0002 1 Auxiliary Valve (AV)

3.50 310-0225 4 Auxiliary Valve Mtg
3.03 110-0015 1 Work Port Adaptor A
3.03 100-0076 1 Work Port Adaptor A
3.01 645-1228 1 Work Port Hose A
3.09 645-1467 1 Boom Tube Jump Hose B
3.06 645-1469 1 Return Hose
3.70 645-1507 1 Return Filter Hose
3.14 102-0078 1 Bulkhead Adp B
3.12 360-0328 1 Mtg. Bracket B
3.18 750-0015 1 Hose Clamp
3.19 360-0176 1 Hose Clamp Mtg.
3.19 310-0076 1 Hose Clamp Mtg.
3.19 310-0121 1 Hose Clamp Mtg.
3.19 350-0014 2 Hose Clamp Mtg.
3.19 350-0019 1 Hose Clamp Mtg.
3.70 530-0008 1 Return Filter
3.71 360-0253 1 RF MTG
3.71 310-0098 2 RF MTG
3.71 350-0014 2 RF MTG
3.71 310-0071 2 RF MTG
3.71 350-0002 2 RF MTG
3.72 100-0088 1 RF Inlet Adaptor
3.73 100-0088 1 RF Outlet Adaptor
3.05 920-0129 1 Return Port Adaptor
3.18 750-0026 1 Hose Clamp
3.19 360-0103 1 Hose Clamp Mtg.
3.12 310-0123 1 Mtg. Hardware B
3.12 310-0098 1 Mtg. Hardware B

3.12 350-0019 1 Mtg. Hardware B
3.12 350-0014 2 Mtg. Hardware B
3.12 340-0022 1 Mtg. Hardware B
s = subkit
INTRODUCTION
PARTS LIST
To Bulkhead Adapter " P" Clamp 1

3.06 el
Pan
Side 3.19 Main Control Machine
Valve (MCV) Forward
3.19 B A
Side Panel
3.03 3.05
3.19 3.18 To (RF) To "P" Clamp
3.70 Return Port
C E Adapter (RPA)
3.01 E 3.71 3.71

To Boom Bulkhead
Piping (1.01) Adapter Existing Frame
3.12 C Mounting
A D
To Boom
Piping (1.02) 3.06 To "P" Clamp 1
3.14
3.09
E
F
B F
3.06 3.73
"P" Clamp 2 To (RF)
3.05
3.72
To "P" Clamp 2
3.70 3.70 3.70
To (RPA) Existing To "P" Clamp 1

Tapped 3.12 F1
Block 3.12
B1
KOM_3140-RF_GI 09.20.07 R2
J. Schmidt C. CURFMAN
Ma rwa
Existing components
ch rd
Fo
D shown in gray
ine
INTRODUCTION
PARTS LIST
 NOTES: _______________________________
CAUTION _____________________________________
_____________________________________
OF THIS MANUAL PRIOR TO INSTALLATION _____________________________________
 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) _____________________________________
* Pages following these Step-By-Step Instructions _____________________________________
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 left side work port on Main
Control Valve (MCV), install components, then connect _____________________________________
work port hose A, refer to details (A).
3) Pre-assemble bulkhead assembly, then remove cover _____________________________________
plate from right side work port on Main Control Valve _____________________________________
(MCV), install components and connect boom tube
jump hose B, refer to detail (B). _____________________________________
4) Refer to detail (F) and (F1) for Return Filter (RF)
installation. _____________________________________
5) Connect return hose between bulkhead adapter and
(RF), refer to details (B), (C) and (F1). _____________________________________
6) Connect (RF) hose to (RF), route through openings in _____________________________________
side panel to lower back side of (MCV), refer to details
(D), (E) and (F1). _____________________________________
7) Secure (RF) hose at two locations, refer to details (C)
and (D). _____________________________________
8) Remove cover plate from lower back side of (MCV), _____________________________________
install components, then connect return hose routed
from (RF), refer to details (E) and (F1). _____________________________________
9) Tighten and Torque all clamp hardware and hydraulic
connections, (refer to Torque Specifications Section). _____________________________________
_____________________________________
_____________________________________
KOM_3140-RF_TXT REV. 0 09.07
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
Order No: H46928
4.01 400-0051 1 Foot Pedal

4.03 460-0002 1 Foot Pedal Mtg Kit
4.02 900-0224 1 Flow Regulator Subkit
4.25 190-0121 1 Pressure Switch Adaptor
4.25 260-0021 1 Pressure Switch
4.27 200-0032 1 Pilot Signal Adaptor 2-Stage Relief
4.04 500-0005 1 Pilot Supply Hose
4.04 500-0005 1 Pilot Return Hose
4.05 130-0087 2 Pilot Sup. & Ret. Adaptors
4.05 100-0195 2 Pilot Sup. & Ret. Adaptors
4.07 641-1191 1 Pilot Shift Hose A
4.07 641-1191 1 Pilot Shift Hose B
4.08 160-0034 1 Shift Port Adaptors
s = subkit
INTRODUCTION
PARTS LIST
SUB-KIT MODULES, WIRING DIAGRAMS AND OTHER SUPPORTING DOCUMENTS Refer to Step-By-Step Instructions
Main Control
4.08 Valve (MCV) Main Control
C Valve (MCV)
4.08
E 4.27
4.07
C Solenoid
4.07 Valve Bank
To (FP) port "1"
To (FP) port "2" To CN-V06
C Connector
P-Block Existing Pressure
CN-V06 Connector 4.27
E
4.05
4.05 E
To P-Block
To (FP) "P" port 4.04

4.04
To (PRV) "P" port 4.02 Pressure
4.04 To (FP) "T" port
D Reducing
T-Block 4.02 Valve (PRV)
To (PRV) "T" port
D To T-Block
A
Foot Pedal (FP)
To (PRV) 4.04
4.02 "T" port
4.02
To (PRV) D
"R" Port
4.07 To Right side PR
B
T P
of (MCV) T
4.01
4.07 To Left side
of (MCV) B
4.25 Connect to existing
Pressure Switch Existing Pressure
connector P-13 Switch Connector TITLE: KOM_200Series8-FP-PRV-2SR-PS_GI
P-13 DRW: MM CHK'D: CC DATE: 09.20.07 REV: 3
Ma rwa
Existing components
ch rd
Fo
A shown in gray
ine
INTRODUCTION
PARTS LIST
SUB-KIT MODULES, WIRING DIAGRAMS AND OTHER SUPPORTING-
DOCUMENTATION
 NOTES: _________________________________
CAUTION _________________________________________
_________________________________________
OF THIS MANUAL PRIOR TO INSTALLATION _________________________________________
 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) _________________________________________
* Pages following these Step-By-Step Instructions _________________________________________
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 detail (A), Foot Pedal (FP) Cover *Sub-Kit and
(FP) *Sub-Kit instructions for (FP) installation. Connect _________________________________________
Pressure Switch to P-13 connector.
3) Refer to detail (B) and Pressure Reducing Valve (PRV) _________________________________________
*Sub-Kit instructions for (PRV) installation.
4) Connect hoses between (FP) and (PRV), route pilot _________________________________________
shift hoses to Main Control Valve (MCV) and route _________________________________________
pilot supply and return hoses to second compartment
under cab, refer to details (A), (B), (C) and (D). _________________________________________
5) Connect pilot shift hoses to (MCV), refer to detail (C).
6) Connect pilot supply and return hoses to "P" and "T" _________________________________________
Blocks, refer to detail (D). _________________________________________
7) Install two stage relief components and connect
signal hose from (MCV), refer to detail (E). _________________________________________
8) Tighten and Torque all hardware and hydraulic
connections, (refer to Torque Specifications Section). _________________________________________
_________________________________________
_________________________________________
_________________________________________
KOM_200Series8-FP-PRV-2SR-PS_TXT REV. 0 09.07
460-0001
460-0001
A
A
HKX, INCORPORATED
(360) 805-8600 ~ (800) 493-5487 ~ www.hkx.com
460-0002 (1of2) 4-22-07
460-0001
380 Black
Max
2 MIN. SET TIME
24 HR. CURE TIME
460-0001
380 Black
Max
2 MIN. SET TIME
24 HR. CURE TIME 580-0001
THIS CELL INTENTIONALLY LEFT BLANK
HKX, INCORPORATED
(360) 805-8600 ~ (800) 493-5487 ~ www.hkx.com
460-0002 (2 of 2) 4-22-07
HKX, INCORPORATED
(360) 805-8600 ~ (800) 493-5487 ~ www.hkx.com
400-0051 8-15-07 R2
ITEM# PART PART# QTY

Foot Pedal 400-0051 1
1 FP Pedal Rubber CAT 400-0058 1 1
2 FP Valve Kaw w/ Shuttle narrow 400-0060 1
3 FP Pedal Kaw w/Lock Upper Only 400-0062 1
4 Bolt Hex M8 x 1.25 x 10 310-0183 2
5 Pin, Spring Loaded, Quick Rele 390-0001 1
4 4
6 Kit PVA 7 Piece 6 ORBM 4 JICM 160-0001 1
6.1 Elb 4 JICM 4 JICX 102-0032 2
6.2 Elb 4 JICM 6 ORBM 102-0013 3
6.3 Adp 4 JICM 6 ORBM 100-0025 2
6.4 Plug 6 ORB SP 180-0024 1 3
7 BK Kaw FP Socket m10x1.5x30 300-0052 1
7.1 Bolt Socket M10 x 1.50 x 30 310-0029 2
7.2 Washer Lock M10 350-0015 2
8 Washer Flat M10 350-0026 3 7.1
7.1
7.2
8
7.2
8
3
6.3
2 6.3
6
6.3 6.1
6.4
6.2
6.2 6.4 6.2
5
FINALIZING INSTALLATION
FINALIZING INSTALLATION
POST INSTALLATION INSPECTION | INSTALLATION CLEAN-UP | INSTALLATION AND MAINTENANCE MANUAL
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
WARRANTY POLICY
 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, or 2,000
hours of use, whichever expires first, 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.
 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 AUTHORIZA-
TION MUST BE OBTAINED FROM HKX FOR ANY OF THE ABOVE. PLEASE READ THE WARRANTY, RETURN &
CANCELLATION PROCEDURES OR CONTACT A HKX WARRANTY COORDINATOR AT 1-800-493-5487.
As used in this warranty the term HKX means HKX, Incorporated, 16761 - 146th Street SE, Suite 115, Monroe, WA 98272, USA.
WARRANTY CANCELLATION & RETURN PROCEDURES
Call a HKX Warranty Coordinator at 800-493-5487 immediately upon learning of a potential
warranty claim, cancellation or return. Prior approval by HKX is required for all warranty claims,
cancellations and/or returns.
IMPORTANT: ANY 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 AFOREMENTIONED.
 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 the product to HKX for repairs.
In the event where an HKX product or component must be returned, HKX will send/fax a Return Goods
Authorization (RGA) to claimant. Please refer to the RGA number on all shipping documents and future
correspondence.
 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.
 Approved dealer labor expense at a rate of $25.00 per hour, 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.
 CANCELLATIONS
Please call HKX immediately, prior to shipment, for cancellation of order.
Cancellation of a Standard Kit will have a 10% processing and restock fee, if cancelled prior to being shipped.
Cancellation of any Custom Kit will have a 25% processing and restock fee, plus freight if applicable.
If a Custom Kit is cancelled within 24 hours of being ordered, the fee will be voided.
 RETURNS
Return of any kit(s) requires PRIOR approval and a Return Goods Authorization (RGA). Policy below applies
to complete kits. Partial kit returns are not authorized.
 HKX, Inc. will evaluate requests for returns on current design kits with a 35% restocking charge, for parts
that are unused. An additional fee will be charged for any items that need excessive cleaning, painting,
repackaging or any labor-intensive actions required making the return into a new re-sellable condition.
 Kits for noncurrent models may be allowed, with a restocking charge as determined on an individual
basis, except for custom components made specifically to order for the kit. Those restocking charges
will be based on 100% of whatever amount our component suppliers will allow.
 Non-kit components in a new, clean, re-sellable condition in the original package may be allowed a 10%
restocking charge.
 No kit or component will be approved for return after 90 days from the date of shipment.
 LEGAL STATEMENT
Any disagreements will have to be submitted to an arbitration company agreed upon by the buyer and
seller, and a neutral arbitrator will resolve disputes in an informal private proceeding.

Manual de Instalacion PC200LC-8

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Manual de Instalacion PC200LC-8

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Installation &

It is imperative to read, follow and

Readers are encouraged to notify KAIC and send in

I. INTRODUCTION XIII. FINALIZING INSTALLATION

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

 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

1.37 100-0168 1 ACC Boom Tube Adp B

ITEM NUMBER PART NUMBER QUANTITY DESCRIPTION

1.21 1.20 1.02

CAUTION in sequence of installation (location where installed)

 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

2.01 645-1262 1 Stick Hose A ( - )

CAUTION components on stick tube at three locations, refer

 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

3.50 910-0002 1 Auxiliary Valve (AV)

ITEM NUMBER PART NUMBER QUANTITY DESCRIPTION

3.12 310-0098 1 Mtg. Hardware B

To Bulkhead Adapter " P" Clamp 1

3.01 E 3.71 3.71

To (RPA) Existing To "P" Clamp 1

 The CONTROLS GROUP may consist of a foot

G4_COVER_TEMPLATE_Rev1 REV. 1 - 09.2007

GROUP 4 : Parts List

ITEM NUMBER PART NUMBER QUANTITY DESCRIPTION

4.01 400-0051 1 Foot Pedal

To (FP) "P" port 4.04

THIS CELL INTENTIONALLY LEFT BLANK

ITEM# PART PART# QTY

IMPORTANT : Before operating attachment, insure

 POST INSTALLATION INSPECTION

 INSTALLATION AND MAINTENANCE MANUAL

TROUBLESHOOTING CHART continued

PERSONAL INFORMATION ADDITIONAL INFORMATION