GROUP 4 - CONTROLS

INTRODUCTION
PARTS LIST
INSTALLATION ILLUSTRATION
STEP-BY-STEP INSTRUCTIONS
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.

G4_COVER_TEMPLATE_Rev1 REV. 1 - 09.2007

 Excavator: KOMATSU PC200/220LC-7
Kit Code: 2
Kit No: KC0462-1

GROUP 4 : Parts List

ITEM NUMBER PART NUMBER QUANTITY DESCRIPTION

4.01 400-0051 1 Foot Pedal(FC)

4.03 460-0002 1 Foot Pedal Mtg Kit
4.25 190-0121 1 Pressure Switch Adaptor(PS)
4.25 260-0021 1 Pressure Switch
4.26 290-0012 1 Pressure Switch Harness
4.04 500-0005 1 Pilot Supply Hose(PSR)
4.04 500-0005 1 Pilot Return Hose
4.07 641-1191 1 Pilot Shift Hose A
4.07 641-1191 1 Pilot Shift Hose B
4.05 130-0087 2 Pilot Sup. & Ret. Adaptors
4.05 100-0195 2 Pilot Sup. & Ret. Adaptors
4.08 160-0034 1 Shift Port Adaptors

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

Main Control
4.08 Valve (MCV)
B
Foot Pedal (FP)
To T-Block
4.04
4.08
4.04
To P-Block
4.07
4.07
To (MCV)
4.01 4.07
4.07 To (FP)
To (MCV)
To (FP)
4.25 B
4.26
Existing Pressure
Switch Connector
CN-S09
A
T-Block
C
4.05

4.05
4.04

To (FP) "T" port

4.04
C To (FP) "P" port
P-Block

A
C

HKX, INCORPORATED
16761 - 146th Street SE, Suite 115
Monroe, Washington 98272
(360) 805-8600 ~ (800) 493-5487 ~ www.hkx.com
TITLE: KOM_200Series7-FP-PS_GI
DRW: MM CHK'D: CC DATE: 10.15.07 REV: 1
Ma rwa

Existing components
ch rd
Fo

shown in gray
ine
INTRODUCTION
PARTS LIST
INSTALLATION ILLUSTRATION
STEP-BY-STEP INSTRUCTIONS
SUB-KIT MODULES, WIRING DIAGRAMS AND OTHER SUPPORTING-
DOCUMENTATION

CAUTION
 NOTES: _________________________________
_________________________________________
 READ “SAFETY PRECAUTIONS” AND “PREPARATION” SECTIONS _________________________________________
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 CN-S09 connector.
3) Connect pilot shift hoses and route to Main Control _________________________________________
Valve (MCV). Connect pilot supply and return hoses
and route to second conpartment under cab, refer to _________________________________________
details (A), (B) and (C).
4) Connect pilot shift hoses to (MCV), refer to detail (B).
_________________________________________
5) Connect pilot supply and return hoses to "P" and "T" _________________________________________
Blocks, refer to detail (C).
6) Tighten and Torque all hardware and hydraulic _________________________________________
connections, (refer to Torque Specifications Section).
_________________________________________
_________________________________________
_________________________________________
_________________________________________
_________________________________________
_________________________________________
KOM_200Series7-FP-PS_TXT REV. 0 10.07
 460-0001

460-0001

A
A

HKX, INCORPORATED
16761 - 146th Street SE, Suite 115, Monroe, Washington 98272
(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
16761 - 146th Street SE, Suite 115, Monroe, Washington 98272
(360) 805-8600 ~ (800) 493-5487 ~ www.hkx.com
460-0002 (2 of 2) 4-22-07
 HKX, INCORPORATED
16761 - 146th Street SE, Suite 115, Monroe, Washington 98272
(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