Kit Installation Manual

© 2018 HKX Inc. All Rights Reserved.

Kit Installation Manual Deere 250G LC

Hitachi ZX250LC-6

Shear

KA9224

2/1/2019

HKX Customer Support Technical Support: (800) 493-5487 x4701 toll-free, (360) 805-8600 x4701. Monday–Friday 7AM to 4PM (Pacific Time) fax: (800) 353-5736, email: [email protected]

HKX Technical Assistance is available to all customers; including application verification, kit selection, installation, and service. Please contact one of our hydraulic kit specialists if you have any questions, comments, problems, or suggestions regarding our hydraulic kit product.

Our Professional Service Team is staffed to provide immediate response to all your critical questions. No fumbling through an automated voice system, and no waiting on indefinite hold.

If the Kit cannot be installed following the instructions in this manual, you must contact HKX Technical Support before deviating from Kit’s instructions and design. Our Support team will assist you to correct the problem without affecting the HKX Kit integrity or warranty.

Before making ANY modifications to the HKX Kit, you MUST receive prior written approval from HKX. Unauthorized modifications & incorrect use of the HKX Kit will void the warranty.

Information in This Manual is Proprietary The information in this manual is to be used for the specific purpose for which it was provided. It is confidential and is the property of HKX. The reproduction of this information, in whole or in part, without the express written consent from HKX, Inc. is strictly prohibited. © 2018 HKX Inc. All Rights Reserved. HKX ® is a registered trademark of HKX, Incorporated.

mailto:[email protected]

HKX Kit Installation Manual

Page i

Table of Contents

Section A – Before Installing the HKX Kit • Read Th is Ent i re Manua l

• Expected Knowledge and Sk i l l s

• Warn ings are NOT A l l - Inc lus ive

• HKX Groups and Co lor Code

• Prepare to Insta l l the HKX Ki t

Section B – Installing the HKX Kit • Ki t Schemat ics and I l lus t rat ions

• G1 Boom

• G2 Arm

• G3 Va lve

• G4 Contro ls

Section C – After Installing the HKX Kit • Insta l l the HKX Deca ls

• F ina l i ze the Insta l la t ion

• Per form Funct ion Test ing

• Operat ion and Maintenance

Section D – Appendixes • Appendix 1 : Ins ta l l ing Deca ls

• Appendix 2 : K i t Ins ta l lat ion Gu idel ines

• Appendix 3 : Weld ing Gu ide l ines

• Appendix 4 : Assembl ing Connect ions

• Appendix 5 : Bo lt Torque Tab le

• Appendix 6 : Accumulators

• Appendix 7 : Ba l l Va lves

• Appendix 8 : Aux i l ia ry Va lves

• Appendix 9 : E lectronic Funct ion Se lector

• Appendix 10 : Troub leshoot ing — I ssues and Remedies

• Appendix 11 : HKX G lossary and Tab le o f Acronyms

HKX Product Warranty

HKX Kit Installation Manual

Page ii

About This Manual This HKX Kit Installation Manual contains the following sections:

Section A: Before Installing the HKX Kit

Section A delivers information on the HKX Kit and instructions on how to prepare to install the HKX Kit.

Section B: Installing the HKX Kit

Section B contains the information and instructions you need to install the HKX Kit. It is organized by

color-coded Group sections: G1 Boom, G2 Arm, G3 Valve, and G4 Controls. Each Group section includes

illustrations showing how the Kit goes together and how it is mounted on the machine. Where needed,

the illustration comes with written step-by-step instructions, parts lists, and other information that

describes how to assemble the Kit and install it.

Section C: After Installing the HKX Kit

Section C includes instructions for cleanup, setup and testing, troubleshooting, final inspection, and

operations and maintenance.

Section D: Appendixes

Section D: Appendixes contains references and technical information that is used to install and maintain

the HKX Kit. This includes items such as torque tables, general assembly instructions, special information

on components such as accumulators and ball valves, placement of Kit decals, etc.

If there are terms or acronyms used in this manual that are unfamiliar to you, please refer to

Appendix 11: HKX Glossary and Table of Acronyms.

HKX Kit Installation Manual Read This Entire Manual

Page A-1

Section A – Before Installing the HKX Kit

Read This Entire Manual

BEFORE attempting any installation or operation of this Kit, you MUST read, follow, and

understand ALL installation procedures and safety precautions described in this manual.

Deviation from the instructions in this manual could cause damage to the machine, attachments,

and Kit components; and could cause hydraulic system problems.

If the instructions in this manual are followed correctly, you will install the HKX Kit in the safest

and most efficient way.

Expected Knowledge and Skills

HKX assumes that the person installing the HKX Kit is fully qualified.

This includes:

• Has read and understood the machine OEM Service and Maintenance manuals, especially

the safety information.

• Has training, qualifications, knowledge, and experience on installing and maintaining

hydraulic systems.

• Knows, understands, and uses industry safety procedures.

Warnings are NOT All-Inclusive

HKX, Inc. cannot anticipate every possible hazard. The warnings and instructions in this

publication and on the Kit parts are NOT all-inclusive.

YOU are responsible for the safety of yourself and others. You must ensure that the parts in

the Kit will not be damaged or made unsafe by the installation, lubrication, maintenance, and/or

operation procedures that you choose.

HKX Kit Installation Manual Prepare to Install the HKX Kit

Page A-2

HKX Groups and Color Code

When you unpack the Kit, you will see color-coded stickers or tags showing you which Group

that piece or assembly belongs to, as follows:

•

Group 1 (G1) parts are

attached to the

excavator’s boom. G1

Boom stickers and tags

are green.

•

G2 parts are attached to

the excavator’s Arm (also

known as the Stick). G2

Arm stickers and tags are

red.

•

G3 parts are related to the

machine’s valve and/or

pump compartments. G3

Valve stickers and tags are

blue.

•

G4 parts are related to the controls and pilot system mounted in or under the cab. G4

Controls stickers and tags are yellow.

NOTE: HKX recommends that you install the parts in order of Group number; that is, install G1

first, then G2, then G3, then G4.

Prepare to Install the HKX Kit

Have Manuals for the Machine and Attachment On Hand

Before you start installing the Kit, make sure that you have the machine’s and attachment’s

manuals on hand. These could include manuals on operations, service and maintenance, repair,

and welding. Pay close attention to sections dealing with attachments, specifically; selection,

mass, operation, and maintenance. Also, ensure that you have the attachment’s documentation

on installation, operation, and maintenance.


Page A-3

Verify That Your Attachment Meets Requirements

Verify that the attachment you are installing does not exceed the specifications of your machine,

specifically:

• Stability

The attachment must fall within the machine’s lift capacity and tip-over weight limits.

• Hydraulic Flow

The machine must be able to provide sufficient hydraulic flow (GPM, LPM) to operate the

attachment.

• Hydraulic Pressure

The machine must be able to provide sufficient pressure (PSI, Bar, Kg/cm²) at the required

flow.

Verify that the Kit is Correct for your Machine and Attachment

Check that you have the correct HKX Kit for your machine and attachment. Check the machine’s

information against the Kit description. Kits are designed for a specific make and model of

machine. If there are any discrepancies, contact HKX Customer Service immediately.

About Individual Parts and Preassembled Parts

The parts in the HKX Kit can be an individual part or a preassembled part.

• Individual Part

An individual part is a single part on its own, not attached to any other parts.

• Preassembled Part

A preassembled part is assembled before shipping, to speed up installation. However, most

preassembled parts are not fully assembled and torqued to specification, and it needs

additional work before it is installed. At a minimum, you will need to torque the adaptors.

You are responsible for final assembly to specifications, including the condition of O-rings

and tightening of all connections to specified torque.

Other preassembled parts are ready for installation without additional work. All torqued

adaptors and fasteners on these preassembled parts are marked with a line, drawn to show

that they have been torqued to specifications. If a connection, nut, or bolt are not

marked, assume that it is NOT torqued to specifications.

About Shrink-Wrapped G1 Boom Brackets and Clamps

For ease of handling and installation, in most Kits, the brackets and clamps used on the G1

Boom are shrink-wrapped into one package, in the order of their location and sequence of

installation.

For more information, see Appendix 2: Kit Installation Guidelines.


Page A-4

Inventory the Parts

Open the HKX Kit boxes and take an inventory of parts while reviewing the packing list, parts

lists, and illustrations. Ensure that no parts are missing or damaged. HKX takes every precaution

to ensure that Kits are shipped complete. If there are any parts discrepancies, contact HKX

Customer Service immediately.

Take special care when removing parts from the box and checking off parts on the 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.

Prepare the Machine for Service per OEM Manual

Prepare the machine for servicing as described in OEM operation manual. This could include the

following:

• Position the machine, boom, and arm in a safe manner, that allows access to the areas in

which you will be working.

• Correctly shut off the machine.

• Remove access panels.

• Release pressure in the hydraulic system.

• Put the pilot control shut-off lever to the LOCKED position before leaving the cab.

• Disconnect the battery.

• Attach the “Do Not Operate” tags supplied in the Kit.

Prepare for Welding per OEM Manual

If the HKX installation instructions show that welding is required, check the machine

manufacturer’s operation and maintenance manuals for instructions on how to prepare the

machine for welding.

For guidelines on welding, see Appendix 3: Welding Guidelines.

Clean All Components to be Painted

Before painting, thoroughly clean all components to be painted. HKX components are delivered

with either zinc plating or a primer coat, and may be painted before or after installation.

HKX Kit Installation Manual Section B – Installing the HKX Kit

Section B – Installing the HKX Kit

• Kit Schematics and Illustrations

•

•

•

•


About This Section

This section, Section B – Installing the HKX Kit, describes how to install the HKX hydraulic Kit.

Each of the sections—Kit Schematics and Illustrations, G1 Boom, G2 Arm, G3 Valve, G4

Controls—contains one or more of these types of information:

• Schematic Flow Diagram

A hydraulic schematic diagram of the Kit.

• Technical Illustrations

One or more technical illustrations. In Kit Schematics and Illustrations, the illustration shows

the entire HKX Kit. In the other sub-sections, the illustration shows the parts for G1, G2, G3,

G4.

• Parts List

Each Group subsection could contain a list of HKX parts installed in that Group.

• Step-by-Step Instructions

The more complicated installation illustrations are followed by a text page giving step-by-

step instructions for installing the parts for that Group.

NOTE: HKX recommends that you install the parts in order of Group number; that is, install G1

first, then G2, then G3, then G4.

Before starting installation, be sure to study Appendix 2: Kit Installation Guidelines.

Technical I l lustrations: Item Numbers versus Part Numbers

In technical illustrations, HKX uses Item Numbers to reference the Kit components being

shown. In some illustrations, these Item Numbers are based on the location and type of the

components.

An Item Number can refer to one or more Part Numbers. Also, an Item Number can be used in

more than one place in a Kit’s technical illustration.

In some Kits—for example, where the same Item Number appears multiple times for Boom

mounting components—the same Item Number can contain a different list of parts. Please

keep this in mind as your review the technical illustrations and inventory the parts.


If the HKX Kit has parts to install for G4 Controls, this sub-section includes a hydraulic schematic

diagram of the entire Kit, and could include an illustration of the entire installed Kit.


BLANK PAGE

HKX, Inc.Ph:(800) 493-5487 Fx:(800) 353-5736 www.hkx.com

Description

Approvals Date

DWG. No. Rev.

Size Scale File Name

Drawn

Checked

Eng. Mgr.

Purchasing

Production

Date Rev. Change Description BY:

THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF HKX, INC. ANY REPRODUCTION IN PART OR IN

WHOLE WITHOUT THE WRITTEN PERMISSION OF HKX, INC. IS PROHIBITED

LINES GROUP COLOR DESCRIPTIONSHIGH PRESSURE LINE

LOW PRESSURE LINE

DRAIN LINE

LINES PATTERN DESCRIPTIONSPRESSURE LINE

PILOT/DRAIN LINES

COMPONENT GROUP LINE

CALLOUTSCOMPONENTS by number

CONNECTIONS by letter

OEM COMPONENTS by letter

1

A

** OPTIONAL COMPONENT

ABC

14

N PI

SM

13

SB

SP

SA

DF

M

DIG

RE

G

TR

. S

PE

ED

RE

LIE

F P

RE

S.

AR

M F

LO

W

PF

DZ

PD

DH

DS

DE

PE

DP

DK

DY

DN

DD

SC

SFSI

SG

DM

VA

LV

E S

OL

.

PILOT PUMP

P1

P2

PR

IMA

RY

PU

MP

S

SA

SB

SB SA

SW

ING

AU

X

B7

A7

AU

X B

(1

3)

AU

X A

(14

)

PR

IM. A

RM

SE

C. A

RM

SE

C. B

OO

MP

RIM

. B

OO

M

TR

AV

EL

; L

TR

AV

EL

; R

P1

DH

SJ

SJ2

T2

SM

SN

P2

A4

BU

CK

ET

AUX PUMP

900-0273

A B

INOUT

KA9224

ROTATE

A B

90

0-0

16

6T

PS S

PT

90

0-0

18

3-A

A BS

PT

SP

T


BLANK PAGE


The is part of the hydraulic circuit providing oil to the attachment from the

machine. This Group may consist of boom tubes and hoses, fittings, clamps, and brackets.

NOTE: Before installing anything in this Group, read and understand

Appendix 2: Kit Installation Guidelines.

Kit Code: 8

Kit No: KA9224

1GROUP : Parts List

ITEM NO PART NO QTY PART DESCRIPTION ITEM DESCRIPTION

1.13 750-0003 1 Clamp Set -20Boom Tube Clamp A (ESH)

1.14 750-0003 1 Clamp Set -20Boom Tube Clamp B (ESH)

1.11 310-0081 2 Bolt Hex M12 x 1.75 x 120 CL 10.9Stacking Hardware A & B

1.13 750-0060 2 Clamp, Double, -20 -20Boom Tube Clamp A (ESH)

1.14 750-0060 2 Clamp, Double, -20 -20Boom Tube Clamp B (ESH)

1.11 310-0115 4 Bolt Hex M12 x 1.75 x 65 Cl 10.9Stacking Hardware A & B

1.11 350-0019 4 Washer Flat M12Stacking Hardware A & B

1.17 750-0060 3 Clamp, Double, -20 -20Boom Tube Clamp A (ESS)

1.18 750-0060 3 Clamp, Double, -20 -20Boom Tube Clamp B (ESS)


1.11 350-0019 6 Washer Flat M12Stacking Hardware A & B

1.17 750-0003 1 Clamp Set -20Boom Tube Clamp A (ESS)

1.18 750-0003 1 Clamp Set -20Boom Tube Clamp B (ESS)


1.01 666-0083-B 1 Tube-20 FSX-20 Z 76 12x4 30ESH A

1.03 645-1351 1 Hose5K-16 FSX-16 FSX-16 60CS A

1.05 661-3048-B 1 Tube-20 FSX-20 S 48", Pwdr coatESS2 A

1.07 666-0034-B 1 Tube-20 FSX-20 Z 72 12x4 30ESS1 A

1.02 666-0083-B 1 Tube-20 FSX-20 Z 76 12x4 30ESH B

1.04 645-1591 1 Hose5K-20 FSX-20 FSX-20 60CS B

1.06 661-3048-B 1 Tube-20 FSX-20 S 48", Pwdr coatESS2 B

1.08 666-0034-B 1 Tube-20 FSX-20 Z 72 12x4 30ESS1 B

1.21 100-0110 3 Adp 20 FSM 20 FSM (GRN KB)Boom Tube Adp A

1.23 100-0135 2 Adp 16 FSM 20 FSM (GRN KB)Boom Tube Adp A Reducer

1.20 100-0110 4 Adp 20 FSM 20 FSM (GRN KB)Boom Tube Adp B

1.22 100-0135 1 Adp 16 FSM 20 FSM (GRN KB)Boom Tube Adp B Reducer

1.65 750-0001 1 Clamp Set -12Boom Tube Clamp RT A (ESH)

1.62 360-0114 1 Brkt Mtg Offset Riser PadStacking Spacer RT A&B

1.64 750-0001 1 Clamp Set -12Boom Tube Clamp RT B (ESH)


1.65 750-0001 2 Clamp Set -12Boom Tube Clamp RT A (ESH)


1GROUP : Parts List


1.64 750-0001 2 Clamp Set -12Boom Tube Clamp RT B (ESH)


1.67 750-0118 1 Mkit Clamp P type 0.98 in. IDBoom Tube Clamp RT A (CS)


1.61 310-0317 1 Bolt Hex M12 x 1.75 x 20mmStacking Hardware RT A

1.61 350-0019 1 Washer Flat M12Stacking Hardware RT A

1.66 750-0118 1 Mkit Clamp P type 0.98 in. IDBoom Tube Clamp RT B (CS)


1.61 310-0317 1 Bolt Hex M12 x 1.75 x 20mmStacking Hardware RT B

1.61 350-0019 1 Washer Flat M12Stacking Hardware RT B

1.69 750-0001 3 Clamp Set -12Boom Tube Clamp RT A (ESS)


1.68 750-0001 3 Clamp Set -12Boom Tube Clamp RT B (ESS)


1.69 750-0001 1 Clamp Set -12Boom Tube Clamp RT A (ESS)

1.62 360-0463 1 Mtg. Angle Bolt-On, 12MM, 4x3x1/2 AngleStacking Spacer RT A&B

1.61 310-0136 1 Bolt Hex M12 x 1.75 x 100 Cl 10.9Stacking Hardware RT A

1.61 350-0019 1 Washer Flat M12Stacking Hardware RT A

1.68 750-0001 1 Clamp Set -12Boom Tube Clamp RT B (ESS)

1.62 360-0463 1 Mtg. Angle Bolt-On, 12MM, 4x3x1/2 AngleStacking Spacer RT A&B

1.61 310-0136 1 Bolt Hex M12 x 1.75 x 100 Cl 10.9Stacking Hardware RT B

1.61 350-0019 1 Washer Flat M12Stacking Hardware RT B

1.51 666-0108-B 1 Tube-12 FSX-12 Z 76 12x4 30ESH RT A

1.53 645-5280 1 Hose5K-08 FSX-08 FSX-08 64CS RT A

1.55 661-1048-B 1 Tube-12 FSX-12 S 48, Pwdr coatESS2 RT A

1.57 666-0038-B 1 Tube-12 FSX-12 Z 72 12x4 30ESS1 RT A

1.52 666-0108-B 1 Tube-12 FSX-12 Z 76 12x4 30ESH RT B

1.54 645-5280 1 Hose5K-08 FSX-08 FSX-08 64CS RT B

1.56 661-1048-B 1 Tube-12 FSX-12 S 48, Pwdr coatESS2 RT B

1.58 666-0038-B 1 Tube-12 FSX-12 Z 72 12x4 30ESS1 RT B

1.60 100-0136 8 Adp 12 FSM 8 FSM (GRN KB)Boom Tube Adp RT A & B Reducer

1.59 100-0124 2 Adp 12 FSM 12 FSM (GRN KB)Boom Tube Adp RT A & B

s = subkit


BLANK PAGE

JDH_1547-H-B_GI

M. AHLES

06.08.11 R1

D. JOHNSON

1.08

1.03

1.04

1.02

B

A

1.061.20

1.211.05

1.01

1.07

B

CC

CD

INTRODUCTIONPARTS LISTINSTALLATION ILLUSTRATIONSTEP-BY-STEP INSTRUCTIONSSUB-KIT MODULES AND OTHER SUPPORTING DOCUMENTS

Existing componentsshown in gray

1Detail Bubbles (A, B, C, etc.) are in sequenceof Installation, unless otherwise specified,Refer to Step-By-Step Instructions

D

1.11

B

1.11

1.141.13

1.131.14

1.11

A

C

1.11

1.181.17

1.181.17

X.XXX.XX

either

or

1.201.22

1.211.23

1.201.22

1.211.23

1.201.22

1.211.23

1.201.22

1.211.23


BLANK PAGE


The is part of the circuit providing oil to the attachment from the machine. This

Group may consist of tubes and hoses, fittings, clamps, ball valves, and brackets.

NOTE: Before installing anything in this Group, read and understand

Appendix 2: Kit Installation Guidelines.

Kit Code: 8

Kit No: KA9224

2GROUP : Parts List


2.23 101-0018 2 Elb 12 FSM 12 FSX 45 deg (GRN KB)Cylinder Port Adaptors

2.01 645-1389 1 Hose5K-16 FSX-16 FSX90S-16 92Stick Hose A ( - )

2.02 645-1629 1 Hose5K-20 FSX-20 FSX90S-20 92Stick Hose B ( - )

2.05 100-0189 1 Adp20-16 Union Acc 20 FSM 16 FSM 12 ORBFStick Tube/Hose Adp A

2.05 180-0030 1 Plug 12 ORB SPStick Tube/Hose Adp A

2.06 100-0168 1 Adp 20 Union Acc. 20 FSM 20 FSM 12 ORBFStick Tube/Hose Adp B

2.06 180-0030 1 Plug 12 ORB SPStick Tube/Hose Adp B

2.11 750-0003 2 Clamp Set -20Stick Tube Clamps A

2.12 750-0003 2 Clamp Set -20Stick Tube Clamps B

2.13 310-0125 4 Bolt Hex M12 x 1.75 x 70 Cl 10.9Stick Tube Clamp MTG

2.03 667-0287-B 1 Tube-20 FSX-20 A 52 4 30Stick Tube A ( - )

2.04 667-0287-B 1 Tube-20 FSX-20 A 52 4 30Stick Tube B ( - )

2.07 970-0044 1 2W -20 ORB w/mtg holesShut-Off Valve A

2.07 360-0296 1 Brkt Mtg Stick LO ZX200Shut-Off Valve Bracket A

2.07 310-0202 2 Bolt Hex M10 x 1.5 x 30 Cl 10.9Shut-Off Valve Bracket Mtg. A

2.07 350-0015 2 Washer Lock M10Shut-Off Valve Bracket Mtg. A

2.07 310-0029 2 Bolt Socket M10 x 1.50 x 30 CL 12.9Shut-Off Valve Bracket Mtg. A

2.07 350-0017 2 Washer Lock m10 HiCollarShut-Off Valve Bracket Mtg. A

2.09 100-0088 1 Adp 20 FSM 20 ORBM (GRN KB)Shut-Off Valve Adaptor A

2.09 180-0004 1 Plug 20 ORB SPShut-Off Valve Adaptor A

2.08 970-0044 1 2W -20 ORB w/mtg holesShut-Off Valve B

2.08 360-0296 1 Brkt Mtg Stick LO ZX200Shut-Off Valve Bracket B

2.08 310-0202 2 Bolt Hex M10 x 1.5 x 30 Cl 10.9Shut-Off Valve Bracket Mtg. B

2.08 350-0015 2 Washer Lock M10Shut-Off Valve Bracket Mtg. B

2.08 310-0029 2 Bolt Socket M10 x 1.50 x 30 CL 12.9Shut-Off Valve Bracket Mtg. B

2.08 350-0017 2 Washer Lock m10 HiCollarShut-Off Valve Bracket Mtg. B

2.10 100-0088 1 Adp 20 FSM 20 ORBM (GRN KB)Shut-Off Valve Adaptor B

2.10 180-0004 1 Plug 20 ORB SPShut-Off Valve Adaptor B

2.51 645-5294 1 Hose5K-08 FSX-08 FSX90S-08 92Stick Hose A RT( - )

2.52 645-5294 1 Hose5K-08 FSX-08 FSX90S-08 92Stick Hose B RT( - )

2.05 100-0136 1 Adp 12 FSM 8 FSM (GRN KB)Stick Tube/Hose Adp A

2.06 100-0136 1 Adp 12 FSM 8 FSM (GRN KB)Stick Tube/Hose Adp B

2GROUP : Parts List


2.55 750-0001 2 Clamp Set -12Stick Tube Clamps A RT

2.56 750-0001 2 Clamp Set -12Stick Tube Clamps B RT

2.57 751-0002 4 Mtg, Pad, Weld, Stick, 12MMStick Tube Clamp MTG RT

2.53 667-0286-B 1 Tube-12 FSX-12 A 52 4 15Stick Tube A RT( - )

2.54 667-0286-B 1 Tube-12 FSX-12 A 52 4 15Stick Tube B RT( - )

2.58 970-0061 2 MKit Quick Disconnect -8Quick Disconnects A & B RT

s = subkit


BLANK PAGE

970-0061


BLANK PAGE


The is part of the hydraulic circuit providing high pressure oil to the attachment

from the machine. This Group may consist of valves, filters, harnesses, short tubes and hoses,

fittings, clamps, and brackets.

Kit Code: 8

Kit No: KA9224

3GROUP : Parts List


3.80 900-0209 2 Cartridge, Relief, KayabaAuxiliary Relief Cartridge (ARC)

3.03 110-0024 1 Flg 16 FL 16 FSM w/ grover CD 61Work Port Adaptor A

3.03 114-0003 1 Flg, Set, -16, CD 61Work Port Adaptor A

3.03 300-0028 1 BK Socket m10 x 1.5 x 30Work Port Adaptor A

3.01 645-1381 1 Hose5K-16 FSX-16 FSX90S-16 60Work Port Hose A

3.09 645-1348 1 Hose5K-16 FSX-16 FSX-16 48Boom Tube Jump Hose B

3.04 110-0015 1 Kit KF Block -16 cd 61 MaleWork Port Adaptor B

3.04 102-0044 1 Elb 16 FSM 16 ORBM 90 deg (GRN KB)Work Port Adaptor B

3.02 645-1347 1 Hose5K-16 FSX-16 FSX-16 44Work Port Hose B

3.14 102-0012 1 Elb 16 FSM 16 FSX 90 deg (GRN KB)Bulkhead Adp B

3.14 102-0077 1 Elb 16 FSM 16 FSM BULKHEAD/NutBulkhead Adp B

3.14 360-0147 1 Brkt Bulkhead -16 bolt onBulkhead Mtg. Bracket B

3.14 310-0202 4 Bolt Hex M10 x 1.5 x 30 Cl 10.9Bulkhead Mtg. Bolt B

3.14 350-0015 4 Washer Lock M10Bulkhead Mtg. Washer B

3.12 360-0308 1 Brkt. Mtg. Toshiba MCV, JDHMtg. Bracket B

3.12 360-0137 2 Spacer, 1 x 1 x 3/4, 9/16 ThruMtg. Hardware B

3.12 310-0142 2 Bolt Hex M14 x 2 x 60 CL 10.9Mtg. Hardware B

3.12 350-0027 2 Washer Lock M14Mtg. Hardware B

3.63 190-0153 1 Tee 12 BSPPM (ADJ.) 12 FSM 12 FSMGP Suction Adaptor - Machine

3.61 645-1195 1 Hose5K-12 FSX-12 FSX90M-12 36GP Suction Hose

3.63 190-0114 1 Adp 12 BSPPM 12 FSM with Ret/O RingGP Suction Adp - Pump

3.63 101-0018 1 Elb 12 FSM 12 FSX 45 deg (GRN KB)GP Suction Adp - Pump

3.66 900-0257 1 MKit Pump Gear DBL Hitachi RH (CCW) rotGear Pump

3.65 190-0115 1 Mkit Adp 08 BSPPM(30°) 08 FSMGP Outlet Adp

3.65 102-0042 1 Elb 8 FSM 8 FSX 90 deg (GRN KB)GP Outlet Adp

3.62 645-5208 1 Hose5K-08 FSX-08 FSX90S-08 36GP Pressure Hose

3.57 100-0154 1 Adp 8 FSM 10 ORBMAV Inlet Adaptor

3.50 900-0273 1 Mkit AV Single Husco5000Auxiliary Valve (AV)

3.50 102-0042 4 Elb 8 FSM 8 FSX 90 deg (GRN KB)Auxiliary Valve (AV)

3.50 360-0027 1 MKit Mtg AV Husco 5000Auxiliary Valve Mtg

3.51 100-0085 1 Adp 8 FSM 8 ORBM (GNR KB)AV Work Port Adaptor A

3GROUP : Parts List


3.53 645-5213 1 Hose5K-08 FSX-08 FSX-08 144AV Work Port Hose A

3.52 100-0085 1 Adp 8 FSM 8 ORBM (GNR KB)AV Work Port Adaptor B

3.54 645-5213 1 Hose5K-08 FSX-08 FSX-08 144AV Work Port Hose B

3.58 100-0154 1 Adp 8 FSM 10 ORBMAV Tank Port Adaptor

3.58 180-0030 1 Plug 12 ORB SPAV Tank Port Adaptor

3.55 645-5276 1 Hose5K-08 FSX-08 FSX-08 72AV Return Hose

3.60 190-0116 1 Adp 6 BSPPM 8 FSMAV Return Adaptor - Machine

3.60 102-0042 1 Elb 8 FSM 8 FSX 90 deg (GRN KB)AV Return Adaptor - Machine

s = subkit


BLANK PAGE

JDH_3555-10_GI

M. AHLES

01.23.09

R. MacARTHUR

B

A

Mach

ine

Forward

Mach

ine

Forward

INTRODUCTIONPARTS LISTINSTALLATION ILLUSTRATIONSTEP-BY-STEP INSTRUCTIONSSUB-KIT MODULES AND OTHER SUPPORTING DOCUMENTS

OEM componentsshown in gray

Detail Bubbles (A, B, C, etc.) are in sequenceof Installation, unless otherwise specified,Refer to Step-By-Step Instructions

To Left Side Boom Piping 3.01

3.03

B

Main ControlValve (MCV)

3.04

To Bulkhead Adapter

3.02

To Right Side Boom Piping

3.09

To (MCV)

Install Existing P-Clamp Assembly To This Bolt Hole Location

A

3.12

Bulkhead Adapter,Bulkhead Bracket &Hardware

Brackets &Hardware

3.14

3.02


BLANK PAGE


JDH_3555-10_TXT.doc.docx 1 of 1 11/13/2018 8:50 AM

These installation steps refer to illustration JDH_3555-10_GI.

Installation Steps 1. Lay out all G3 Valve kit components (clamps, hoses, adaptors, etc.) and inspect for any

damage or missing components. Remember to lubricate all O-rings before assembly.

2. Refer to detail (A) for Bulkhead Adaptor B installation.

a. Secure assembly to front of Main Control Valve (MCV).

b. Connect boom tube jump hose B between right-side boom piping and bulkhead adaptor.

c. Connect work port hose B to bulkhead adaptor B.

d. Route hose to underneath MCV.

3. Refer to detail (B) for MCV adaptor installation.

a. Connect work port hose A to left-side boom piping.

b. Route hose to MCV.

c. On MCV spare spool, remove cover plate from upper work port.

d. Install work port adaptor A.

e. Connect work port hose A, routed from left-side boom piping.

f. On MCV spare spool, remove cover plate from lower work port.

g. Install work port adaptor B.

h. Connect work port hose B, routed from bulkhead adaptor B.

4. Tighten and torque all hardware and hydraulic connections. (Refer to Appendix 3: Assembling Connections and Appendix 4: Bolt Torque Table.)


BLANK PAGE


JDH_3605-GP-5-9_TXT.doc.docx 1 of 2 2/1/2019 3:23 PM

These installation steps refer to illustration JDH_3605-GP-5-9_GI.

Installation Steps 1. Lay out all G3 Valve kit components (clamps, hoses, adaptors, etc.) and inspect for any


2. Refer to details (A), (A1), and (A2) for Auxiliary Valve (AV) installation.

a. Connect AV work port hose A to left-side boom piping.

b. Connect AV work port hose B to right-side boom piping.

c. Route hoses to rear of pump compartment.

d. On floor of compartment, mark location of hose end.

e. Remove paint from marked locations.

f. Reposition assembly, and tack weld into place.

g. Connect AV work port hose A to AV A port.

h. Connect AV work port hose B to AV B port.

i. Ensure there is enough slack in hoses for boom extend and retract functions.

j. Remove AV from bracket.

k. Weld bracket to marked location.

l. Reinstall AV.

m. Connect pressure hose to AV P port and route to pump compartment.

n. Connect AV return hose to AV T port and route to valve compartment. .

3. Refer to details (B) and (B1) for Gear Pump (GP) installation.

a. On pump, remove single GP, and replace with double GP.

a. Remove existing components from single GP.

b. Install existing components and elbow adaptor into rear ports on double GP.

c. Connect GP pressure hose to upper GP port.

d. Connect GP suction hose to lower GP port. Route hose to suction line.


JDH_3605-GP-5-9_TXT.doc.docx 2 of 2 2/1/2019 3:23 PM

e. Cap hose to minimize fluid loss.

4. Refer to detail (B) for suction line installation.

a. Disconnect existing suction hose from hydraulic reservoir.

b. Install GP suction adaptor, and reconnect hose.

c. Connect GP suction hose, routed from GP.

5. Refer to detail (C) for Drain Port Adaptor (DPA) installation.

a. Remove plug from return port.

b. Install DPA.

c. Connect return hose to DPA, routed from AV T port.

6. Tighten and Torque all clamp hardware and hydraulic connections. (Refer to Appendix 3: Assembling Connections and Appendix 4: Bolt Torque Table.)

900-0257

900-0273


The is part of the hydraulic circuit providing user-operated controls and

pilot oil to the high-pressure valves. This Group may consist of hoses, fittings, clamps, brackets,

foot pedals, foot switches, and/or joysticks (operator control).

Kit Code: 8

Kit No: KA9224

4GROUP : Parts List


4.10 400-0108 1 JS Cald type E 4-BU 1-TR, RHJoystick

4.10 340-0014 1 Nut Jam Hex m12x1.75 Steel zincJoystick Wiring

4.10 410-0006 1 Boot, Top Interface, CaldaroJoystick Wiring

4.10 290-0004 1 WS Field Wireable M, TurckJoystick Wiring

4.10 290-0001 1 WS Junction M FM FM, TurckJoystick Wiring

4.10 290-0003 1 WS DBL Harness M, TurckJoystick Wiring

4.10 290-0005 1 WS Receptacle FM, TurckJoystick Wiring

4.10 200-0036 1 Circuit breaker 4AJoystick Wiring

4.10 245-0002 1 MKit Double tie gasketJoystick Wiring

4.09 400-0031 1 FS Sm. Red w/PlugFootswitch

4.09 290-0008 1 Cord Extension 2 meter, TurckCord Extension 2 meter

4.09 290-0007 1 Tee, electric, TurckFootswitch TEE

4.11 900-0183-A 1 Valve Assy Sec DBL PRPilot Valve

4.11 160-0038 1 Kit PVA 8 Piece 4 ORBM 4 JICMPilot Valve Adaptors

4.13 360-0160 2 Spacer, 1 x 1 x 1/2, 9/16 ThruPilot Valve Mtg

4.13 360-0779 1 Brkt Mtg PV Hose Guard (4436124, 205mm)Pilot Valve Mtg

4.13 360-0298 1 Brkt Mtg PV SEC ZX/C SERIESPilot Valve Mtg

4.13 310-0186 2 Bolt Hex M10 x 1.5 x 20 CL 10.9Pilot Valve Mtg. Hardware

4.13 310-0309 2 Bolt Hex M10 x 1.5 x 45 CL 10.9Pilot Valve Mtg. Hardware

4.13 350-0026 4 Washer Flat M10Pilot Valve Mtg. Hardware

4.04 641-1190 1 Hose2K-04 JICX-04 JICX-04 24Pilot Supply Hose

4.04 641-1190 1 Hose2K-04 JICX-04 JICX-04 24Pilot Return Hose

4.24 641-0063 1 Hose2K-04 JICX-04 JICX-04 120Pilot Signal Hose

4.24 641-0063 1 Hose2K-04 JICX-04 JICX-04 120Pilot Signal Hose

4.23 190-0079 2 Adp 6 BSPPM 4 JICM w/o-ringPilot Signal Adaptor

4.23 180-0007 2 Cap 4 JICPilot Signal Adaptor

4.23 190-0079 2 Adp 6 BSPPM 4 JICM w/o-ringPilot Signal Adaptor

4.23 102-0032 2 Elb 4 JICM 4 JICXPilot Signal Adaptor

4.07 641-1190 1 Hose2K-04 JICX-04 JICX-04 24Pilot Shift Hose A

4.07 500-0005 1 Hose PSRA 48"Pilot Shift Hose B

4.05 130-0002 1 Tee 6 JICM 6 JICM 6 JICXPilot Supply Adaptors

4.05 102-0027 1 Elb 6 JICM 6 JICX 90 degPilot Supply Adaptors

4GROUP : Parts List


4.05 140-0001 1 Red 6 JICF 4 JICMPilot Supply Adaptors

4.06 130-0002 1 Tee 6 JICM 6 JICM 6 JICXPilot Return Adaptors

4.06 102-0027 1 Elb 6 JICM 6 JICX 90 degPilot Return Adaptors

4.06 140-0001 1 Red 6 JICF 4 JICMPilot Return Adaptors

4.08 160-0009 1 Kit SPA 6 BSPP Short/LongShift Port Adaptors

4.25 140-0065 1 Red 6 BSPPM 4 BSPPFPressure Switch Adaptor

4.25 540-0063 1 Oring 06 BSPPPressure Switch Adaptor

4.25 540-0025 1 Oring Crush -04Pressure Switch

4.25 260-0085 1 Switch Pressure Hitachi SensorPressure Switch

4.17 290-0080 1 Harness Control Main ZX-3/D SeriesHarness

4.40 400-0107 1 JS Cald Prop type B 1-RKR 3-BU 2-TR LHJoystick-Secondary

4.42 410-0006 1 Boot, Top Interface, CaldaroJoystick Adaptor-Secondary

4.42 340-0014 1 Nut Jam Hex m12x1.75 Steel zincJoystick Adaptor-Secondary

4.10 290-0162 1 Harness Adp, 400-0106/7 JDH_D/GJoystick Wiring

4.15 280-0030 1 Proportional Controller HED 03-00Proportional Controller

4.15 580-0002 10 VelcroProportional Controller Mtg.

4.16 290-0143 1 Harness, HED 03-00 (FLO 1/IMC)Proportional Control Harness

4.18 290-0056 1 Harness Power Hit/Deere "D" SeriesPV Power Harness

4.41 900-0166 1 Valve Assy Sec SGL/SGLPilot Valve-Secondary

4.42 160-0038 1 Kit PVA 8 Piece 4 ORBM 4 JICMPilot Valve-Adaptors

4.43 300-0047 1 BK Hex 5/16-18 x 5"Pilot Valve Mtg Kit-Secondary

4.37 641-0105 1 Hose2K-04 JICX-04 JICX-04 180Pilot Shift Hose A-Secondary

4.37 641-0105 1 Hose2K-04 JICX-04 JICX-04 180Pilot Shift Hose B-Secondary

4.38 160-0013 1 Kit SPA 4 JICM 6 ORBMShift Port Adaptors-Secondary

s = subkit


BLANK PAGE


JDH_4859-JSx2-PV2-AV_TXT.doc.docx 1 of 2 2/1/2019 11:08 AM

These installation steps refer to illustration JDH_4859-JSx2-PV2-AV_BGI.

Installation Steps 1. Lay out all G4 Controls kit components (controls, hoses, adaptors, etc.) and inspect for any


2. Refer to detail (A) for Pilot Valve (PV1) & (PV2) installation.

a. Connect pilot signal hose to PV1 A port.

b. Connect pilot signal hose to PV1 B port.

c. Connect secondary pilot shift hose A to PV2 A port.

d. Connect secondary pilot shift hose B to PV2 B port.

e. Tag hoses and route to valve compartment.

f. Connect pilot supply hose to PV1 P port.

g. Connect pilot return hose to PV1 T port.

h. Tag hoses and route to Pilot Shut-Off Valve (PSOV) under cab.

3. Refer to detail (B) for Pilot Signal Manifold (PSM) adaptor installation.

a. Install adaptor into M port. Connect pilot signal hose, routed from PV1 B port.

b. Install adaptor into N port. Connect pilot signal hose, routed from PV1 A port.

c. Install adaptors into port 13. Connect pilot shift hose B.

d. Route hose to Main Control Valve (MCV) lower spare spool shift port.

e. Install adaptors into port 14. Connect pilot shift hose A.

f. Route hose to MCV upper spare spool shift port.

g. Disconnect and plug hose from SM port. Install pressure switch assembly.

h. Disconnect and remove existing hose on MCV (this hose was disconnected from PSM). Install cap on existing adaptor. Refer to detail (C).

4. Refer to detail (D) for MCV adaptor installation.

a. Remove plug from upper spare spool shift port.

b. Install shift port adaptor.

c. Connect pilot shift hose A, routed from PSM port 14.


JDH_4859-JSx2-PV2-AV_TXT.doc.docx 2 of 2 2/1/2019 11:08 AM

d. Remove plug from lower spare spool shift port.

e. Install shift port adaptor.

f. Connect pilot shift hose B, routed from PSM port 13.

5. Refer to detail (E) for Auxiliary Valve (AV) adaptor installation.

a. Remove plug from AV shift port.

b. Install shift port adaptor.

c. Connect secondary pilot shift hose A, routed from PV2 A port.

d. Remove plug from AV shift port.

e. Install shift port adaptor.

f. Connect secondary pilot shift hose B, routed from PV2 B port.

6. Refer to detail (F) for PSOV adaptor installation.

a. Disconnect hose from P3 port on PSOV.

b. Install pilot supply adaptors, and reconnect hose.

c. Connect pilot supply hose, routed from PV1 P port.

d. Disconnect hose from T6 port on PSOV.

e. Install pilot return adaptors, and reconnect hose.

f. Connect pilot return hose, routed from PV1 T port.

7. Install proportional controller. Refer to detail (G).

8. Refer to Foot Switch (FS) wiring diagram for FS installation.

9. Refer to Joystick (JS) Sub-Kit instructions for JS installation.

10. Refer to wiring diagrams for wiring installation.

11. Tighten and torque all hardware and hydraulic connections. (Refer to Appendix 3: Assembling Connections and Appendix 4: Bolt Torque Table.)

M12 Joystick Stem

340-0014Nut Jam Hex M12

430-0027Coupler M12 - 1.75_M14 - 2

410-0006Rubber Boot

M12 Joystick Stem

340-0014Nut Jam Hex M12

410-0006Rubber Boot

TYPICAL:DEERE C Series Machines

HITACHI ZX Series Machinesalso,

FORESTRYWHEELED Excavators

DEERE D / G Series MachinesHITACHI ZX-3 / ZX-5 Series Machines

Existing JO stem M12

Existing JO stem M14

Existing

INTRODUCTIONPARTS LISTINSTALLATION ILLUSTRATIONSTEP-BY-STEP INSTRUCTIONSSUB-KIT MODULES AND OTHER SUPPORTING DOCUMENTATION

PSM PORTS REV. 0 05.11

290-0003

900-0183-A

290-0007

400-0031

290-0008

290-0005

290-0004

yellow

orange1234

orange

yellow

3

4

1

2

PRI-DD/JC/FS

WIRING DIAGRAM - CABLE ASSEMBLY

yellow

yellowFACEPB1

PB2

PB3

TRIGGER

PB4

*PB5

PB2

PB4

PB1

PB3

PB5

JOYSTICKSIDE VIEW

POWER RATINGFACE: PB1-4

3000 mA @ 24 VDC

*TRIGGER: PB550mA @ 24 VDC

MUST USE RELAY IF

POWERING COIL

400-0108JS Cald Type-E 4-BU 1-TR

orange

orange

blue

blue

green

green

violet

violet

+24V SOURCE

SOLENOID

POWER

CONTROL

290-0001

BLACK WIRE

BLUE WIRE

200-0036


BLANK PAGE

Monitor Set Up ZX-5_G Series Rev2 REV. 2 05.15

ZX-5 HITACHI / G SERIES IMC (IN MONITOR CONTROL)

ZX-5 HITACHI / G DEERE SERIES IMC

NOTE: If Applicable:When programming the Monitor for 470, 670 and 870, Auto Decel needs to be enabled to stroke the pumps bychanging the “Flag Used by ATT Pilot Pressure Sensor” from 0 to 1 with MpDr, see Operation and Test Manual. (Section 9015-16 Monitor Operation-List of Adjustment)

Attachment Control Circuit Theory of Operation

The main controller (MCZ) (A3) and monitor allow for the selection of up to five attachments plus the standard dig mode. Only one attachment mode may be selected at one time. The machine will return to dig mode when the machine is powered down and restarted; however, this can be changed with MPDr., Service ADVISOR™, and the monitor to return the machine to the attachment that was last selected when the machine was powered down. Each attachment selection (1 through 5) can be customized using MPDr., Service ADVISOR™, and the monitor. To customize options in the monitor, see Service Menu. (Group 9015-16.)

MPDr. and Service ADVISOR™ can adjust:

1 Attachment name 1 Attachment number 1 Pump flow 1 Engine speed 1 Secondary relief selection 1 Return oil flow selection 1 2-Speed selection 1 Accumulator selection

The monitor can slightly adjust pump 2 flow rate or boom-up, arm-in, swing and travel priority over attachment flow depending on the options selected. To view the attachment specifications on the monitor, select an attachment from the work mode menu. The monitor will display:

1 Attachment name (Breaker, Crusher, Pulverizer, Vibrating Hammer, Other) 1 Attachment number (1, 2, 3, 4, or 5) 1 Pump flow 1 Engine speed 1 Secondary relief selection (ON or OFF) 1 Return oil flow selection (O/T or C/V) 1 2-Speed selection (ON or OFF) 1 Accumulator selection (ON or OFF)



TX1088890A-UN: Work Mode Screen

LEGEND:

1 - Dig Mode 2 - ATT1 (attachment 1) 3 - ATT2 (attachment 2) 4 - ATT3 (attachment 3) 5 - ATT4 (attachment 4) 6 - Attachment Name 7 - Attachment Number Attachment Name - The available attachment names are as follows:

1 Breaker 1—Hydraulic Breaker 1 (BR) 1 Breaker 2—Hydraulic Breaker 2 (BR) 1 Crusher 1—Primary Crusher 1 (CR) 1 Pulverizer 1—Secondary Crusher 1 (PU) 1 Vibratory Hammer 1—Vibrating Hammer 1 (VI) 1 Other 1—Other Equipment (UN) 1 [Removal from monitor screen—(Non)]

Crusher 1—Primary Crusher 1 (CR) is considered a heavier crusher than Pulverizer 1—Secondary Crusher 1 (PU). When Crusher 1—Primary Crusher is selected, more priority is given to boom, arm, swing and travel functions over the attachment function in a combined arm-out, arm-out boom-up, swing or travel function and attachment function.



TX1088891A-UN: Attachment Type

LEGEND: 8 - ATT1 Type (attachment 1) Attachment Number— Each attachment can be assigned a number from 1 through 5.

Each attachment also has a dynamic number that is user defined to help differentiate attachments with the same name. For example, ATT1 (attachment 1) and ATT2 (attachment 2) could both be set up as breaker 1. The number associated with the attachment name can be changed to any number from 1 through 5. ATT2 (attachment 2) breaker 1 could be changed to ATT2 (attachment 2) breaker 2 (3, 4, or 5) to distinguish between the beakers for ATT1 (attachment 1) and ATT2 (attachment 2).

TX1088894A-UN: Attachment Adjustment—Pump Flow Rate

LEGEND: 9 - ATT 1 Pump 1 Maximum Flow Rate Maximum Pump Flow— The maximum pump flow can be adjusted using MPDr., Service ADVISOR™, and the monitor. Adjustments made to pump flow are only approximate values. The machine is not designed to measure pump flow and therefore the values in MPDr., Service ADVISOR™, and the monitor are calculated approximations. Actual flow must be measured using a flow meter to accurately adjust pump flow. See Pump Flow Test. (Group 9025-25.)



Pump 1 and pump 2 flow rates can be adjusted individually. If 2-speed is not selected (OFF), only pump 2 is used to run the attachment. In this mode, only adjustments to pump 2 will affect the flow to the attachment. Pump 2 flow rate adjustments are controlled by the main controller (MCZ) with the pump 2 flow rate limit solenoid. For more information see Main Controller (MCZ) Circuit Theory of Operation . (Group 9015-15.) If 2-speed is selected (ON), both pumps 1 and 2 are used to run the attachment. With 2-speed ON, flow from pump 1 is combined with flow from pump 2 in the control valve. In this mode, both pumps may be adjusted to control the flow of the attachment. The monitor will display the combined flow rates of pump 1 and pump 2. See Service Menu. (Group 9015-16.)

NOTE: 2-speed will not work properly unless appropriate kits are installed on machine. Pump flow or flow priority may also be finely adjusted in the monitor. If 2-speed is not selected (OFF), small adjustments can be made to the pump 2 flow rate. Adjustments are only approximate and relative to the overall selected flow. Actual flow must be measured using a flow meter to accurately set pump flow. If 2-speed is selected (ON), small adjustments can be made to the priority of oil flow. The priority can be adjusted to favor the attachment or the boom-up, arm-out, swing and travel functions. Adjustments are only approximate and relative to the overall selected flow. Actual flow must be measured using a flow meter to accurately set pump flow. See Pump Flow Test (Group 9025-25.) and See Service Menu. (Group 9015-16.)

TX1088895A-UN: ATT 1 Engine Speed

LEGEND: 10 - ATT 1 Engine Speed Maximum Engine Speed— The maximum engine speed for an attachment may be adjusted using MPDr., Service ADVISOR™, and the monitor. The engine will reduce speed when a work mode with reduced engine speed is selected on the monitor. The engine will run at the preset speed regardless if the attachment is operated or not. The maximum engine speed for an attachment cannot be set higher than the fast idle speed of the machine.



TX1088898A-UN: ATT 1 Selector Valve

LEGEND: 12 - ATT 1 Selector Valve Setting Valve Selector (Selector Valve)— The selector valve icon on the monitor controls the selector valve solenoid valve (Y40). The selector valve solenoid valve receives power from the travel alarm 5 A fuse (F5) and is grounded by the main controller (MCZ) by pin C4. When the monitor displays “1” the return oil from the attachment flows through the control valve before it returns to the hydraulic oil tank. When the monitor displays “0” the return oil from the attachment flows directly to the hydraulic oil tank, bypassing the control valve. The selector valve solenoid valve can be adjusted for each attachment using MPDr., Service ADVISOR™, and the monitor. The valve selector will default to “1” or control valve in dig mode (no attachment selected).

NOTE: Selector valve control will not work properly unless appropriate kits are installed on machine.

Accumulator— The accumulator controls the accumulator solenoid valve (Y42). The accumulator solenoid valve is powered by the travel alarm 5 A fuse (F5) and grounded by the main controller (MCZ) by pin C17. When the accumulator is ON, the accumulator solenoid valve is activated, pilot oil is sent to the accumulator control valve. The accumulator shutoff valve shifts, connecting the accumulators to the supply and return lines of the attachment hydraulic circuit. The accumulators help reduce the shock of oil pressure and buffers vibrations when certain types of attachments are used, such as breakers. When the accumulator is OFF, the accumulator solenoid valve is deactivated and the accumulators are isolated from the attachment hydraulic oil circuit. The accumulator status for each attachment can be adjusted using MPDr., Service ADVISOR™, and the monitor.

The accumulator solenoid valve diode (V42) suppresses voltage spikes created when the solenoid valve is activated or deactivated.

NOTE: Accumulator control will not work properly unless appropriate kits are installed on machine.



TX1088899A-UN: ATT1 Auxiliary Flow Combiner Valve

LEGEND: 13 - ATT1 Auxiliary Flow Combiner Valve Setting 2-Speed Selector and Auxiliary Flow Combiner Valve— The 2-speed selector icon on the monitor controls the 2-speed activation solenoid valve (Y43) and the flow rate adjustment solenoid valve (Y44). The 2-speed activation solenoid valve is powered by travel alarm 5 A fuse (F5) and grounded by the main controller (MCZ) pin C3. The flow rate adjustment solenoid valve is powered by the main controller (MCZ) pin A7 and grounded by pin A23. When activated, the 2-speed activation solenoid valve sends pilot oil to the bypass shutoff valve blocking hydraulic oil from pump 1 from returning to the hydraulic oil tank. The activated 2-speed activation solenoid valve also sends pilot oil to the auxiliary flow combiner valve to combine oil flow from pump 1 with that of pump 2. This allows for combined oil flow from pump 1 and pump 2 to operate the attachment.

When 2-speed is activated, the flow rate adjustment solenoid valve can also be activated. When an arm-out, boom-up, swing or travel function is actuated in combination with the attachment function, the flow rate adjustment solenoid valve is activated. When the flow rate adjustment solenoid valve is activated, pilot oil is routed to the auxiliary flow rate control valve. This adjusts the auxiliary flow rate control valve to provide more or less priority to the arm-out, boom-up, swing and travel functions over the attachment function. The main controller (MCZ) can vary the signal to the flow rate adjustment solenoid valve to vary the pilot oil pressure at the auxiliary flow rate control valve. This allows for adjustment of the priority of the attachment function over arm-out, boom-up, swing and travel. The 2-speed selector status can be adjusted for each attachment using MPDr., Service ADVISOR™, and the monitor. Adjustments to the priority level can be made in the monitor in the attachment adjustment menu. See Service Menu. (Group 9015-16.)

The 2-speed activation solenoid valve diode (V43) suppresses voltage spikes created when the solenoid valve is energized and de-energized.

NOTE: 2-speed control will not work properly unless appropriate kits are installed on machine.



TX1088896A-UN: ATT 1 Relief Valve

LEGEND: 11 - ATT 1 Relief Valve Setting Secondary Hydraulic Relief Selector— The secondary hydraulic relief selector icon in the monitor controls the secondary relief solenoid valve (Y41). The secondary relief solenoid valve receives power from the travel alarm 5 A fuse (F5) and is grounded by the main controller (MCZ) pin C16. When the secondary relief solenoid valve is activated, pilot oil shifts the secondary relief shutoff valve, routing hydraulic oil from the high pressure lines of the attachment to the secondary relief valve. The relief pressure of the circuit will then be equal to the lowest setting of the two relief valves in the circuit. The secondary hydraulic relief selector status can be adjusted for each attachment using MPDr., Service ADVISOR™, and the monitor. The secondary relief solenoid valve diode (V41) suppresses voltage spikes created when the solenoid valve is energized and de-energized.


BLANK PAGE

HKX Kit Installation Manual Install the HKX Decals

Page C-1

Section C – After Installing the HKX Kit

Install the HKX Decals

Install the decals that are included in your HKX Kit! The decals give important information

about safety, operation of the Kit, the Kit’s serial number, and other HKX data. Install the decals

as described in Appendix 1: Installing Decals.

Finalize the Installation

After you complete installing all HKX Kit components, finalize the installation by performing the

following steps:

• Verify Completion.

Verify that all HKX Kit installation steps have been completed.

• Verify Hoses, Tubes, Fittings, Brackets, and Hardware.

Verify that all hoses, tubes, fittings, brackets, and hardware have been properly connected,

secured, and torqued to specifications.

See Appendix 4: Assembling Connections, and Appendix 5: Bolt Torque Table.

• Verify Mounting.

Verify that all clamps and mounting brackets are permanently welded into place or bolted

into place with hardware torqued to specifications, and that they do not interfere with tube-

end or hose-end connections.

See Appendix 5: Bolt Torque Table.

• Paint Unprotected Areas.

To prevent rust and corrosion, ensure that all unprotected components and weld areas are

fully painted.

• Remove All Foreign Objects.

Look in and around the machine for foreign objects—tools, rags, fasteners, extra parts, etc.—

and remove them.

HKX Kit Installation Manual Perform Function Testing

Page C-2

• Reconnect Electrical Systems.

Reconnect all electrical systems on the machine that were disconnected for Kit installation,

including the battery. Follow the machine manufacturer’s instructions for reconnecting

electrical components.

• Reinstall Removed Machine Parts.

Re-install all machine parts that were loosened or removed during installation, for example;

covers, hatches, and panels.

• Clean Up.

Clean up the area in and around the machine, using the appropriate cleaning materials.

• Check Oil Level

Check the hydraulic oil level in the tank. If necessary, add oil.

• Apply Lock-Out Tags

If any of the previous items have not been completed during auxiliary circuit installation, be

sure that multiple lock out tags are installed to warn and prevent improper operation.

• Safely Store This Manual

Save and store this HKX Kit Installation Manual for future reference.

• Send HKX Your Suggestions

Please send any comments or suggestions that you may have concerning this HKX Kit and

Installation Manual to HKX Customer Support. See the back of the front cover for HKX

Customer Support contact information.

Perform Function Testing

After finalizing the Kit installation, the Kit must be fully tested. The following tests are to be

performed in sequence prior to the Kit being certified for duty:

1. Leak Test

2. Range of Motion Test

3. Pressure and Flow Setup and Test

At this point the machine will be fully pressurized for the first time after installing the new Kit. It

is imperative to take special care and precautions when looking for leaks, loose fittings, and

hose kinks and stretches.


Page C-3

CAUTION: High Pressure Hydraulics

Always check for leaks using a piece of cardboard or a mirror. Never use your hand – even if you

are wearing gloves. Always assume a hydraulic line is pressurized, even when the machine is not

running. A pinhole may emit a stream of high pressure hydraulic oil that may cause serious

injury or death.

WARNING: Crushing Hazard

Before operating the machine, make sure that all personnel and equipment are clear of the

machine and attachments!

When starting the machine or when engaging the hydraulics, beware of unexpected movement

of the actuators. Failure to watch for unexpected movements could result in serious injury

or death.

Leak Test

A leak test ensures the hydraulic integrity of the system. It ensures that fittings, hoses (including

hose connector crimps), and tubes are sealed, and that no hydraulic oil is leaking. To test for

leaks, perform the following steps:

WARNING: Be prepared to shut down the machine if any leaks are observed.

1. Position personnel around the machine, turn starter for 1-2 seconds, shut down, and then

inspect fittings, hoses, and tubes for leaks.

2. If no leaks were found, start machine again, allow it to run at low idle for 10-15 seconds, and

again check for leaks.

Range of Motion Test

A range of motion test is completed to ensure that hoses that connect lines between two

moving elements have the proper length and lay; to ensure that the hose is not pinched,

crimped, or pulled out. A range of motion test also ensures that rigidly mounted equipment

does not interfere with other elements throughout its range of motion.

If you encounter any operation problems while performing these tests, see Appendix 10:

Troubleshooting—Issues and Remedies.

To test for range of motion, perform the following steps:

1. Position the machine in an area where the boom and arm may be fully articulated; that is,

moved to their prospected end stops – both up/down and in/out.

2. Position personnel around the machine.

3. Start the machine and run it at low idle.

WARNING: Be prepared to shut down the machine if any leaks are observed.


Page C-4

4. Lift the boom just high enough to allow the arm to swing out and miss the ground.

5. Slowly extend the arm to its maximum out position. Watch for hose issues and interferences.

6. Reverse the arm, and slowly bring it all the way in. Again, watch for hose issues and

interferences.

7. Position an observer so they have a clear view of the boom base and all the jump hoses,

then slowly lift the boom until it stops. Watch for hose issues and interferences.

Note: If the Kit includes Load Hold Valves (LHVs), pay special attention to the clearance

between the boom LHV bodies and the swing frame.

8. Using a hole, embankment, or by pivoting the body on the tracks; slowly lower the boom

until it reaches its stops. Watch for hose issues and interferences.

Pressure and Flow Setup and Test

To ensure optimal operation of the attachment and to avoid damage, the auxiliary circuit must

be set to meet the Attachment Equipment Manufacturer’s (AEM) specifications for both pressure

and flow. Failure to set pressure and flow within the AEM specifications may cause severe

damage to the machine and/or attachment, and void warranties on the Kit, the

attachment, and the machine.

Pressure and flow are either set in the monitor (if your Kit utilizes In Monitor Control {IMC}) or

manually set using mechanical adjustments within the machine valves.

For pressure and flow setting through the monitor, see Section B, G4 Controls. For manually set

pressure and flow continue in this section.

The attachment circuit pressure is set one of two ways:

• by adjusting the directional control valve pressure relief cartridges,

• by adjusting the external secondary relief, typically located on a Pressure Relief Manifold

(PRM).

The attachment circuit flow is set by adjusting the pressure relief cartridges on the Pilot Valve(s)

(PVs), which in turn determines how far a spool valve shifts, which ultimately controls the flow in

that circuit.

To setup and test for pressure and flow, perform the following steps:

Note: Pressure gauge/flow meters are typically designed for one direction flow only;

therefore, the following process will need to be repeated if the auxiliary circuit is dual

direction.

1. Attach a flow meter at the end of the arm between the supply line and the return line (in

place of the attachment).


Page C-5

2. Using a tee fitting, install a pressure gauge on the supply line.

Optional: If backpressure is important to the attachment, tee in a second pressure gauge on

the return side, as a check only. There is no adjustment available to raise or lower the

backpressure, because it is a function of line size, distance, and fitting characteristics.

Figure 1: PRC Setting Gauges

3. Ensure that the flow meter load valve (i.e. needle valve) is fully open before proceeding.

4. Prepare the machine for operation per the manufacturer’s Operation Manual.

5. Start the machine and run at high idle.

6. When the hydraulic oil is up to operating temperature, proceed with setting the pressure

and flow adjustments.

Set the Pressure

Descr ipt ion

Pressure Relief Cartridges (PRCs) (also known as Port Relief Cartridges) limit the work oil

pressure that operates the attachment. Each auxiliary circuit should have its own PRC(s). A single

direction circuit will typically have one PRC, while a dual direction circuit will typically have two.

Some circuits that are designed to support multiple attachments may have more than two PRCs.

PRCs are typically located on the directional control valves for that circuit; however, if your Kit

comes with a Pressure Relief Manifold (PRM), the PRC(s) in that manifold will need to be

adjusted as well.

Pressure Gauge/ Flow Meter

Arm

Pressure Gauge


Page C-6

Figure 2: Pressure Relief Cartridges – Single Direction and Dual Direction

To Set the PRCs :

1. Start the machine and bring the engine to full RPM.

2. Monitor the pressure at the pressure gauge/flow meter.

3. Build up pressure in the circuit using either of these methods:

o “Dead Head” one of the lines (block the flow).

o Adjust the valve on the pressure gauge/flow meter to restrict the flow.

4. Adjust the PRC until the pressure is set to the attachment specifications.

Set the Flow

Descr ipt ion

Pilot Valves (PVs) control the movement of the directional control valves which determine the

direction and flow rate of work oil to the attachment. By adjusting the pilot oil pressure at the

PV, the work oil flow rate is adjusted.

To Set the P i lo t Va lve :

1. Ensure that the pressure gauge/flow meter is connected correctly for the flow direction that

is to be adjusted.

2. Start the engine, and increase the engine speed to high idle.

3. With engine speed at high idle, set the flow to the machine manufacturer’s recommended

setting by adjusting the Pilot Valve that controls the Flow Regulator.


Page C-7

Figure 3: Adjusting the Pilot Valve

4. Adjust the PV pressure relief until the recommended attachment flow is achieved.

5. Recheck that the auxiliary system pressure is still within the attachment manufacturer’s

specifications.

If the pressure is not within specifications, repeat the re-adjustments for pressure and flow

until both measurements are within the attachment manufacturer’s specifications. This may

take several iterations.

6. Verify that backpressure and temperature readings are at or below the manufacturer’s

recommendations.

If auxiliary circuit is dual directional, you will need to repeat the above steps after reversing the

connections to the pressure gauge/flow meter. To do that, follow these steps:

1. Shut off the machine.

2. Relieve the pressure in the work tool lines.

3. Allow the Hydraulic oil to cool.

4. Reverse the lines to the pressure gauge/flow meter.

5. Repeat the process for setting the pressure and flow.


Page C-8

Operation and Maintenance

20-hour Inspection

Within the first twenty (20) hours of operation or thirty (30) days from date of first use,

whichever occurs first, perform a visual inspection. Check for leaks, loose fasteners, and any

visible wear and abrasion. Make any adjustments or repairs as required.

• Hose Routing

Check for any rubbing of the hoses. Adjust the hose routing if needed.

• Oil levels

Cycle the machine and attachment through several positions and functions, then check the

hydraulic oil level. If needed, add oil according to the machine manufacturer’s instructions.

• Clamps

Inspect all clamps and ensure that they are tight and that no tubes have shifted out of

alignment. Use the Loctite recommended by the machine manufacturer on bolts that might

vibrate loose. See Appendix 5: Bolt Torque Table.

• Leaks

After running the machine and then allowing it to cool down, inspect all tubes, hoses, and

fittings for leaks. If needed, re-torque the fittings.

Regular Pre-Operation Inspections

Each day, before using the machine, perform a walk-around, inspecting Kit hoses, adaptor

fittings, valves, and manifolds for leaks, cracks, and other potential problems. Also, check that all

connections and mounting hardware is tight

If the Kit employs an accumulator, periodically check nitrogen gas level in the accumulator.

See Appendix 6: Accumulators.

After Making Changes to the Kit

Whenever there is change to the machine or the attachment, before operating the machine and

attachment, qualified and authorized personnel must check the items described in this

section.

Pressure

The auxiliary circuit that runs the attachment must have pressure relief protection that is

correctly installed, set up, and functioning. If not, the attachment will not function properly and

could be damaged.


Page C-9

Set the pressure relief(s) as described in the section Set the Pressure, above. Consult the

attachment’s documentation for the correct operating pressure settings, or contact the

manufacturer for them.

F low

The auxiliary circuit that runs the attachment must have the proper oil flow settings. If not, the

attachment will not function properly and could be damaged.

Set the flow as described in the section Set the Flow, above. Consult the attachment’s

documentation for the correct operating flow settings, or contact the manufacturer for them.

Mach ine Sett ings

If auxiliary circuit that runs the attachment uses OEM machine components (factory installed),

consult the machine’s OEM documentation for the correct settings and operation for this

specific application. These OEM machine components are things like 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 Va lves and Switch Valves

Auxiliary circuits often use ball valves, manual or automatically-controlled, to control the oil flow

direction or to lock out a specific attachment. To insure proper attachment operation and avoid

attachment damage, check that these valves are in the correct position.

See Appendix 7: Ball Valves.


Page C-10

BLANK PAGE

HKX Kit Installation Manual . Appendixes

Page D-1

Section D – Appendixes

• Appendix 1 : Ins ta l l ing Deca ls

• Appendix 2 : K i t Ins ta l lat ion Gu idel ines

• Appendix 3 : Weld ing Gu ide l ines

• Appendix 4 : Assembl ing Connect ions

• Appendix 5 : Bo lt Torque Tab le

• Appendix 6 : Accumulators

• Appendix 7 : Ba l l Va lves

• Appendix 8 : Aux i l ia ry Va lves

• Appendix 9 : E lectronic Funct ion Se lector

• Appendix 10 : Troub leshoot ing — I ssues and Remedies

• Appendix 10 : HKX G lossary and Tab le o f Acronyms

HKX Kit Installation Manual Appendix 1: Installing Decals

Page D-2

Appendix 1: Installing Decals

Decal Label Sheets

The HKX Kit includes two sheets of peel-and-stick labels to be used for various general labeling

tasks. These include four blank white labels on each for custom applications.


Page D-3

The following examples show how these labels can be used:


Page D-4

Decal Placement and Installation

Before you install a decal, make sure that the mounting surface is clean and free of dirt, oils, or

any other debris.

Ki t In format ion Deca l

Ba l l Va lve Deca l

Inside Cab

Right-hand Window

Inside Cab

Right-hand Window


Page D-5

Ba l l Va lve/Rocker Swi tch Decal

Ba l l Va lve Po in t -of-Use Deca ls

On Boom and Arm

Inside Cab

Right-hand Window


Page D-6

In the Cab

Accumulator Decal

Install the decals near

the ball valve, visible

with cover open, or

on the cover.

Inside Cab

Right-hand Window


Page D-7

Control Decals

Joyst ick and Funct ion Se lect Swi tch

Foot Swi tch and Foot Peda l

HKX Kit Installation Manual Appendix 2: Kit Installation Guidelines

Page D-8

Appendix 2: Kit Installation Guidelines

General Instal lation Guidelines

• Read Appendix 4: Assembling Connections.

Carefully read Appendix 4: Assembling Connections. That appendix gives detailed instructions

for proper alignment and assembly of the various hydraulic connections used in HKX Kits.

• Lubricate O-rings Before Assembly

Before assembling a connection, lubricate the O-ring with a silicone grease or hydraulic oil.

This helps to ensure a tight seal and long-lasting connection.

• Tap Pilot Valve Plugs Before Loosening

Before attempting to remove a plug from a Pilot Valve, tap the plug firmly with ball-peen

hammer. This helps loosen the plug to make removal easier.

• Accumulators

If your Kit includes any accumulators, before installing them, read Appendix 6: Accumulators.

That appendix provides important warnings and describes how to charge an accumulator.

• Electronic Function Selector

If your Kit includes an Electronic Function Selector (EFS), before installing, read Appendix 9:

Electronic Function Selector.

• To Reverse Control Directions

Pilot shift hoses can be swapped to change actuation (reverse control direction) of controls.

G1 Boom and G2 Arm Installation Instructions

1. Using the installation illustration as a guide, lay out all Kit components (tubes, hoses,

adaptors, clamps, etc.) in relative positions that show how they will be installed on the

machine. Inspect all parts for any damages or missing components.

If your Kit includes shrink-wrapped brackets and clamps, when laying out the components,

orient the shrink-wrapped bracket and clamp package to the boom or arm. Components are

shrink-wrapped in the sequence and order of installation.

The example shown in Figure 4: Example of G1 Boom Shrink-Wrapped Components is for

REFERENCE ONLY and is not intended to show your specific Kit packaging.


Page D-9

Figure 4: Example of G1 Boom Shrink-Wrapped Components

2. Install the mounting brackets or grommets as follows:

If the Kit uses grommets or the mounting brackets are all bolt-on, install the grommets

and/or bolt-on brackets onto the machine.

If the mounting brackets are a mix of bolt-on and weld-on, install the bolt-on brackets, and

then follow the instructions in Appendix 3: Welding Guidelines.

If the mounting brackets are all weld-on, follow the instructions in Appendix 3: Welding

Guidelines.

3. After the mounting brackets are installed, install the mounting clamps or other components

(manifold, valve, etc.) onto the brackets.

4. Clamp the tubes and/or hoses lightly into place, to allow for movement while tightening the

connections.

5. To ensure correct location and fit, before assembling connections:

If installing on G1 Boom, install the boom tube jump hose between the valve compartment

(See Section B, G3 Valve.) and the G1 Boom Kit components.


Page D-10

If installing on G2 Arm, connect the arm hose (“stick hose”) between the G1 Boom and G2

Arm Kit components. The stick hose should be positioned with an "S"-curved shape

matching the existing stick cylinder hose. See Figure 5: Arm “Stick Hose” S-Curve.

Figure 5: Arm “Stick Hose” S-Curve

6. Assemble all tube and/or hose connections loosely. Then go back and fully torque each

connection, and mark the connection with a line to show that it is fully torqued.

See Appendix 4: Assembling Connections.

7. After all connections on the line are torqued and marked, properly torque the mounting

clamps and bolts, or fasten the cables ties around the grommets.

See Appendix 5: Bolt Torque Table.

HKX Kit Installation Manual Appendix 3: Welding Guidelines

Page D-11

Appendix 3: Welding Guidelines

Before Welding

Before welding on the machine; read, understand, and follow the welding instructions in the

machine’s service manuals. Disconnect the battery, computer, and any other electronics.

Remove all flammable materials and liquids from work area.

During Welding

During welding and grinding, protect all areas in, on, and around the machine with a flame-

retardant covering.

Welding Instructions for Mounting Brackets

NOTE: When welding on the boom or arm, it is important to reduce stresses caused by

welding. The centerline of the sides of a boom or arm carry little or no stress, because

they are in the “neutral plane”. If possible, that is the best place to weld on the brackets

and spacers.

1. Prepare the machine for welding as instructed in the OEM Service Manual.

2. Determine where to weld the bracket(s), and mark the location(s), as follows:

If welding on a single bracket:

Use the measurements given in the Kit’s installation instructions and mark the welding

locations there.

If welding on multiple brackets:

a. Assemble the weld-on brackets to the components to be mounted—tubes, clamps,

manifolds, valves, etc.

b. Dry-assemble the tubes and/or hoses and connections.

c. Position the assembly onto the Boom or Arm, and secure it in place.

TIP: Use a ratcheting strap to hold the assembly in place.

3. Mark the weld locations.

4. Remove the assembly.

5. With a grinder or similar tool, remove paint from the marked weld location(s).

6. On the weld-on bracket, remove any paint or plating from the area(s) to be welded

7. Reposition the assembly on the boom or arm, and tack-weld the brackets sufficiently to hold

them in place.

8. Remove the assembly from the tack-welded brackets, and finish welding brackets into place.

Apply a weld sufficient to hold the entire assembly securely to the machine.

HKX Kit Installation Manual Appendix 3: Welding Guidelines

Page D-12

IMPORTANT: Follow these steps when welding on the boom or arm:

o Welds should run as closely as possible to parallel to the centerline of the length of the

boom or arm. Avoid welds that are between 45° - 90° to the centerline of the length.

o Welds should run the entire edge of the bracket.

o The ends of the weld should tail off with a 1-inch weld bead at a 45° angle away from

the bracket, that tapers down to nothing.

9. Finish the weld tail by grinding it to a taper.

It should be full-bead height at the bracket, and gradually taper into the surface of the

boom or arm. If bracket is at 45°, do not apply a tail that is perpendicular (90°) to the

centerline.

10. Clean and degrease the areas of bare or welded steel.

11. Apply paint as needed to protect bare areas from rust and corrosion.

After Welding

Remove any flame-retardant coverings.

To prevent rust and corrosion; touch up and inspect all outer tubes, clamps, brackets, and weld-

on bases, and ensure they are completely covered by paint.

HKX Kit Installation Manual Appendix 4: Assembling Connections

Page D-13

Appendix 4: Assembling Connections

This appendix describes how to assemble the types of connections used in HKX Kits:

• O-Ring Face Seal (ORFS)

• Flange

• O-ring Boss (ORB)

• Joint Industry Council (JIC)

• British Standard Pipe Parallel (BSPP)

After Assembling All Kit Connections

After you complete assembling and torqueing all Kit connections, re-check all connections and

verify that they are all marked with the correct dots and lines, showing that they are inspected

and properly torqued.

Insure that hoses are routed so they do not rub against anything, and so that they move freely

through the entire range of motion. Also, check the lay-line of the hose to ensure that it is

straight for its entire length and that no twist has been introduced.


Page D-14

O-Ring Face Seal (ORFS) Connections

About O-R ing Face Sea l (ORFS) Connect ions

HKX uses O-Ring Face Seal (ORFS) connections that have a nut (female) rotating around a collar.

Either the hose collar or the tube-end has a machined flat face. A two-ended adaptor (male) is

installed between the nuts. The adaptor has an O-ring on each face. The seal is created when

you tighten the treaded connection and compress the adaptor’s O-ring onto the flat face of the

collar or tube. The threads mechanically hold the connection together.

Figure 6: Sample O-Ring Face Seal – Hose to Tube

Notes on Assembl ing ORFS Connect ions

• Before assembling ORFS connections, mount tubes loosely in the clamps on the boom and

arm. Do not fully tighten the clamps until all connections are assembled and torqued to

specifications. While being assembled, sealing surfaces must be allowed to meet without any

restriction.

• When mounting a hydraulic hose, avoid introducing any amount of twist into the hose.

• If one end of a hose or tube (and the accompanying adaptor) is to be installed to a hard-

port location—such as a gear pump, return port, or valve—assemble the port connection

first. After hard-port connections are assembled, assemble any hose-to-tube or hose-to-

hose connections.

• When tightening ORFS connections, use two wrenches; one wrench to hold the adaptor in

place, and the second wrench to tighten the nut.

Rotate the nut, not the adaptor. This method prevents stretching, buckling, or otherwise

damaging the O-ring. It pulls the two sealing faces together without rotating them relative

to each other.

Hose

Nut

Collar Flat Face

Adaptor Nut

O-rings

Tube

Tube Flat Face


Page D-15

Figure 7: Hold adaptor in place and tighten nut.

To Assemble ORFS Connect ions :

1. Check the threads, faces, and O-rings for any damage.

If you find any damage, replace the parts.

NOTE: Replacement O-rings must have a 90-durometer hardness. Using a lower-rated O-ring

will cause leaks.

2. After you verify the condition of an O-ring, mark a dot on the connector-end to indicate that

the O-ring has been checked.

3. Lubricate the O-rings with a general-purpose grease or a high-viscosity oil specifically

intended for O-ring application.

This both lubricates the O-ring and helps hold it in place during assembly.

4. Ensure that the nut faces and the adaptor faces are parallel.

Figure 8: Nut face and the adaptor face are parallel.

Parallel

Hold in place.

Tighten


Page D-16

5. Hand-tighten the nuts onto the adaptor.

6. Slowly wrench-tighten the nuts onto the adaptor, using standard wrenches.

Torque the adaptors as tightly as possible by hand with the standard wrenches. When

rotating only the nut, the face seal will not deform with high torque.

If the connection is to a hard-port location (such as a gear pump, return port, or valve):

a. Tighten the adaptor into the port.

b. Then tighten the nut onto the adaptor.

If the connection is hose-to-tube:

a. Screw the adaptor into the hose end, and then tighten to the specified torque.

b. Attach the hose and adaptor to the tube, and then tighten to the specified torque.

7. Start the machine and heat the oil to operating temperature, about 180o F.

8. Re-tighten all ORFS connections to the following torque specifications:

O-Ring Face Seal Torque Specifications

SAE Dash

Size

Tube Side

Thread Size

Tube-Side Assembly

(Torque +10% to -0%)

in.-lbs. ft.-lbs

-4 9/16 – 18 220 18

-6 11/16 – 16 360 30

-8 13/16 – 16 480 40

-10 1 – 14 -- 60

-12 1 3/16 – 12 -- 85

-14 1 5/16 – 12 -- 120

-16 1 7/16 – 12 -- 150

-20 1 11/16 – 12 -- 190

-24 2 – 12 -- 230

-32 2 ½ - 12 -- 360

Seal-Lok (NPT) (Adaptor Fittings)

SAE Dash size Torque SAE Dash size Torque

-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


Page D-17

Alternative: FFWR Torqueing Method

If a torque wrench is unavailable, you can use the Flats From Wrench Resistance (FFWR)

method to torque the connections, as follows:

a. Wrench-tighten the nut onto the adaptor until wrench resistance is reached.

b. Tighten further to the appropriate FFWR value from the chart below.

O-Ring Face Seal, FFWR Method

SAE Dash Size

Tube Side Thread Size

Flats From Wrench Resistance (FFWR)

tube nuts swivel & hose ends

-4 9/16 – 18 ½ ¾

-6 11/16 – 16 ½ ¾

-8 13/16 – 16 ½ ¾

-10 1 – 13 ½ ¾

-12 1 3/16 – 12 ½ ½

-14 1 5/16 – 12 ½ ½

-16 1 7/16 – 12 ½ ½

-20 1 11/16 – 12 ½ ½

-24 2 – 12 ½ ½

-32 2 ½ - 12 ½ ½

9. After you properly torque a connection, mark a line across the adaptor and the nut and/or

port, to indicate that the connection has been properly torqued.

Flange Connections

About F lange Connect ions

HKX uses a four-bolt flange connection. The 4-Bolt Split Flange consists of these components:

• Flange

• Flange Head

• O-ring

• Flange Clamp (in two halves)

• Four bolts and washers

The flange has a hydraulic port in the center and four tapped bolt holes around the port. The

other side of the connection is the flange head, which is compressed against the flange face by

the flange clamp. The face of the flange head has an O-ring in a groove. Four bolts pass through

the untapped holes on the flange clamp and are tightened into the tapped holes in the flange.

When the flange clamp bolts are torqued, the flat surface of the flange compresses the O-ring

contained in the flange head groove, creating the hydraulic seal.


Page D-18

Figure 9: Four-Bolt Hydraulic Flange – Exploded View

Figure 10: An Assembled Flange Connection

Bolts

Washers

Flange Clamp

Flange Head

O-ring

Tapped Holes

Flange


Page D-19

To Assemble a F lange Connect ion :

To assemble a flange connection, perform the following steps:

1. Position the flange head, with the O-ring flat on the face of the flange.

2. Put the Flange Clamp(s) in place.

3. Put the lock washers on the bolts.

4. Apply Loctite to the bolt threads.

5. Insert the bolts through the clamp halves.

6. Hand-tighten the bolts.

7. Verify that the tube or hose is stress-free and at right angles to the bolt-on flange face.

8. Using a wrench (DO NOT use a pneumatic driver.), gradually tighten the bolts as shown in

Figure 11: Flange Bolt Tightening Sequence. Use four rounds of tightening to get to the

torque specified in Flange Bolt Torque Specification Tables, below.

a. First round - 30% of final torque

b. Second round- 60% of final torque

c. Third round - 100% of final torque

d. Last round – Verify the torque moving clockwise or counter clockwise sequentially

around the flange.

DO NOT exceed the specified torque.

Figure 11: Flange Bolt Tightening Sequence


Page D-20

Flange Bolt Torque Specification Tables

Connection Code 61 Flange Recommended Bolt Torque

Dash Size Size Inch Bolt

(J518)

Torque ft. lbs.

(+10%/-0%)

Metric Bolt

(ISO 6162)

Torque N-m

(+10%/-0%)

-8 1/2 5/16-18 17 M8 24

-12 3/4 3/8-16 31 M10 50

-16 1 3/8-16 31 M10 50

-20 1-

1/4

7/16-14 52 M10 50

-24 1-

1/2

1/2-13 77 M12 92

-32 2 1/2-13 77 M12* 92

Connection Code 62 Flange Recommended Bolt Torque

Dash Size Size Inch Bolt

(J518)

Torque ft. lbs.

(+10%/-0%)

Metric Bolt

(ISO 6162)

Torque N-m

(+10%/-0%)

-8 1/2 5/16-18 17 M8 24

-12 3/4 3/8-16 31 M10 50

-16 1 7/16-14 52 M12 92

-20 1-

1/4

1/2-13 77 M14 130

-24 1-

1/2

5/8-11 155 M16 210

-32 2 3/4-10 265 M20 400

9. Using a feeler gauge, check that the flange is parallel to the connection surface.

If the deviation from parallel is greater than 0.5mm, unassembled then reassemble the

connection.


Page D-21

O-Ring Boss (ORB) Connections

Figure 12: O-Ring Boss (ORB) Connection

O-Ring Boss Connect ion Descr ip t ion

An O-Ring Boss (ORB) connection has two sections.

• A male-to-female thread connection that mechanically holds the connection together. This

thread connection does not provide an oil seal.

• An O-ring and lock nut that produces an oil seal, preventing any hydraulic leaks.

Male Fitting

End

Female Port

O-Ring

Aligning Face

Seal made

by O-ring

Connection

held by

threads

Fitting and Port Assembled

Connection

Adjustable ORB

360°

Positioning

O-Ring

Washer

Nut


Page D-22

An ORB connection is tightened mechanically before the seal is made. Then, by tightening the

lock nut, the O-ring is compressed between the sealing surface of the female part and the

shoulder or back-up washer of the male part.

To Assemble an ORB Connect ion :

1. Lubricate the O-ring, and properly locate it on the male-end adaptor.

2. Thread the adaptor by hand and hand-tighten.

3. Tighten the adaptor to the torque specified in the tables below:

Aluminum:

SAE O-ring Boss Port (tube adaptor - installed into Aluminum)


-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

Steel:

SAE O-ring Boss Port (tube adaptor - 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

4. Tighten the lock nut to the same torque as the adaptor, to produce the oil seal.


Page D-23

Joint Industry Council (JIC) Connections

Figure 13: Joint Industry Council (JIC) Connection

J IC Connect ion Descr ipt ion

A Joint Industry Council (JIC) connection is a flare fitting with a 37-degree flare seating surface.

Tightening the nut on the tube compresses the tube’s flare against the angled sealing surface of

the male fitting.

To Assemble a J IC Connect ion :

1. Position the tube against the fitting.

2. Tighten the nut lightly with a wrench, clamping the tube flare between the fitting nose and

the sleeve.

3. Tighten the nut to the torque specified in the table below.

If you don’t have a torque wrench, use the Flats From Wrench Resistance (FFRW) method.

Starting at the Wrench Resistance position, tighten the nut further by the number of flats

shown in the Table below. A flat is one side of the hexagonal tube nut, and equals 1/6 of a

turn.


SAE

Dash

Size

Thread Size

Assembly Torque

(+10%/-0%)

Tube

Connection

FFWR

Swivel Nut or

Hose Connection

FFWR in. lb. ft. lb.

-2 5/16 - 24 72 6 -- --

-3 3/8 – 24 96 8 -- --

-4 7/16 – 20 132 11 2 1/2 2

-5 1/2 - 20 165 14 2 1/2 2

-6 9/16 – 18 235 20 2 1/2 2

-8 3/4 – 16 525 43 2 1/2 2

-10 7/8 – 14 650 55 1 1/2 1 1/2

-12 1 1/16 - 12 950 80 1 1/2 1 1/2

Fitting

Sleeve Nut Tube


Page D-24


SAE

Dash

Size

Thread Size

Assembly Torque

(+10%/-0%)

Tube

Connection

FFWR

Swivel Nut or

Hose Connection

FFWR in. lb. ft. lb.

-14 1 3/16 – 12 1200 100 1 1/2 1 1/2

-16 1 5/16 – 12 1400 115 1 1 1/2

-20 1 5/8 – 12 1900 160 1 1

-24 1 7/8 – 12 2250 185 1 1

-32 2 1/2 – 12 3000 250 1 1

-40 3 - 12 -- -- 1 1

Brit ish Standard Pipe Parallel (BSPP) Connections

HKX uses British Standard Pipe Parallel (BSPP) connections, not British Standard Pipe Tapered

connections. (BSPT). BSPP fitting are simple connections that thread directly together.

British Standard Parallel Pipe Thread (BSPP, ISO 1179)

SAE

Dash

Size

Pipe Thread

Torque ft-lbs

Torque N-m

Turns From

Finger Resistance

1/8" - 28 13 18 2-3

1/4" - 19 37 50 2-3

3/8" - 19 46 63 2-3

1/2" - 14 118 160 2-3

3/4" - 14 148 200 2-3

1" - 11 250 340 2-3

1 1/4" - 11 332 450 1 1/2 - 2 1/2

1 1/2" - 11 413 560 1 1/2-2 1/2

2" - 11 1 1/2-2 1/2

HKX Kit Installation Manual Appendix 5: Bolt Torque Table

Page D-25

Appendix 5: Bolt Torque Table

When tightening the bolts in HKX Kits, do not exceed the torque figures in the table below.

Ensure that bolt and nut threads are clean before installation.

NOTE: Torque values are for slightly lubricated bolts.

SAE Size Bolt Torque Table

Grade 5 Grade 8

Diameter Coarse Fine Coarse Fine

1/4" 6.3 lbs-ft 7.3 lbs-ft 9 lbs-ft 10 lbs-ft

5/16" 13 lbs-ft 14 lbs-ft 18 lbs-ft 20 lbs-ft








1"† 483 lbs-ft 541 lbs-ft 682 lbs-ft 764 lbs-ft

Metric Size Bolt Torque Table

Bolt

Dia.

Wrench

Size

Hexagon

Wrench

Size

Socket Bolt

Nm kgf m lbs ft Nm kgf m lbs ft Nm kgf m lbs ft

M8 13 6 29.5 3 22 19.5 2 14.5 9.8 1 7.2

M10 17 8 64 6.5 47 49 5 36 19.5 2 14.5

M12 19 10 108 11 80 88 9 65 34 3.5 25.5

M14 22 12 175 18 130 137 14 101 54 5.5 40

M16 24 14 265 27 195 205 21 152 78 8 58

M18 27 14 390 40 290 295 30 220 118 12 87

M20 30 17 540 55 400 390 40 290 167 17 123

HKX Kit Installation Manual Appendix 6: Accumulators

Page D-26

Appendix 6: Accumulators

An accumulator (ACC) is used in a hydraulic circuit to control pressure spikes, which could

damage the circuit. It acts as a hydraulic oil “shock absorber.” Any pressure spike in the Kit’s

hydraulic circuit is “smoothed out” by compressing gas in the accumulator.

This section gives warnings and instructions for handling, installing, and setting up accumulators

in HKX Kits.

Warnings

• Always follow the accumulator manufacturer’s guidelines for charging the specific type and

model of accumulator. Failure to charge accumulator can void warranties for the machine,

attachment, and Kit; cause permanent component damage; and create a hazardous situation

that could result in serious injury or death.

• Charge the accumulator with nitrogen gas only. Hydraulic oil is flammable and charging the

accumulator with air could create an explosion risk.

• Before removing or disassembling the accumulator, release all hydraulic and nitrogen

pressure.

• Periodically check the accumulator for proper nitrogen pressure.

• Do not expose the accumulator working pressures to more than twice the nitrogen charge,

as this will damage the internal diaphragm.

Setting accumulator charge pressures

For proper charging of the accumulator, pressurize the nitrogen to the level recommended by

the attachment manufacturer. If the manufacturer does not specify an accumulator charge

pressure, do the following:

• Charge the accumulator to 1/2 of the expected hydraulic circuit pressure.

• If used in the attachment return line, charge the accumulator to 1/2 of expected return line

pressure.

Combination 1-way/2way Kits

If an accumulator is installed in the attachment return line of a combination 1-way/2-way Kit, it

must be locked out of the circuit for 2-way operation. To do this, while still in 1-way mode, lock

out the accumulator with a hydraulic ball valve or other isolating valve. If the accumulator is

not isolated from an attachment that it is not intended for; during 2-way operation, the

attachment will have diminished, unexpected, and possibly unsafe operation.

HKX Kit Installation Manual Appendix 6: Accumulators

Page D-27

Charging the Accumulator

1. Check that all connections are free of dirt and are snug.

2. Remove the cap from the charge port on the accumulator.

Figure 14: Accumulator

3. Attach the nitrogen bottle and hose with an adaptor that is compatible with a Schrader

valve.

4. Open the valve on the nitrogen bottle.

5. Charge the accumulator to the attachment manufacturer’s specifications.

6. After charging, close the valve on the nitrogen tank.

7. Disconnect the charge hose from the charge adaptor.

8. Remove the charge adaptor.

9. Replace the cap on charge port.

Charge

Port

HKX Kit Installation Manual Appendix 7: Ball Valves

Page D-28

Appendix 7: Ball Valves

2-Way Ball Valve, Lock Off

2-Way Ball Valves (2BV) are designed to allow hydraulic flow in the Open Position and stop flow

in the Closed Position.

Figure 15: 2-Way Ball Valve Operation

If the circuit is in operation, ensure that the 2-way ball valve is in the Open Position and locked

into place.

3-Way Ball Valve, Lock Over

3-Way Ball Valves (3BV) can change the direction of hydraulic flow from one path to another.

Figure 16: 3-Way Ball Valve Operation

If the circuit is in operation, ensure that the 3-way ball valve is locked into place.

Open Position Closed Position

Flow Direction

Flow Direction

HKX Kit Installation Manual Appendix 8: Auxiliary Valves

Page D-29

Appendix 8: Auxiliary Valves

An Auxiliary Valve (AV) is used to control an auxiliary hydraulic circuit in applications where the

OEM Main Control Valve (MCV) does not have additional ports to control an auxiliary circuit.

AVs come in many different types and models. The following illustration shows an example of a

single AV, with port, plug, and cartridge locations:

Figure 17: Auxiliary Valve

HKX Kit Installation Manual Appendix 9: Electronic Function Selector

Page D-30

Appendix 9: Electronic Function Selector

To install an Electronic Function Selector (EFS):

1. Prepare the ball valve for EFS installation by removing unneeded hardware.

Figure 18: Prepare Ball Valve for Installation

2. Attach the EFS to the ball valve by aligning the grooves on the EFS rotator with the grooves

on the ball valve shaft.

Figure 19: Attach the EFS to the Ball Valve by Aligning the Grooves

3. Secure the EFS unit in position.

Remove Unneeded

Hardware

Alignment Grooves

Alignment Grooves

HKX Kit Installation Manual Appendix 10: Troubleshooting—Issues and Remedies

Page D-31

Appendix 10: Troubleshooting—Issues and

Remedies

Issue: Cannot obtain required f low.

Possible Cause Check This: Remedy

Machine work mode setting. Machine work mode setting. Set for maximum power.

Machine auxiliary valve work

port relief valve is set below

breaker or compactor/driver

operating pressure.

Relief valve

(Note: The pressure setting

usually must be somewhat

above the breaker operating

pressure, based on

manufacturer’s specification).

Reset relief pressure to

machine and attachment

specifications.

Insufficient machine pump

flow.

Machine pump curve

specifications.

Contact HKX Customer

Service.

Optional shuttle valve

pressure signal connections.

Hose routing and

connections.

Refer to HKX schematics.

Issue: No flow or pressure readings at pressure line .


Auxiliary valve spool not

shifting.

Pilot pressure signal to

auxiliary valve pilot port.


Pressure line connected to

wrong auxiliary valve work

port.

Auxiliary valve work port

connections.

Reverse port connection(s).

Shut-off valve is closed on

pressure and/or return line.

Shut-off valves. Fully open both valves to ON

position.

Plug, orifice, or obstruction in

auxiliary valve work port.

HKX Installation schematics.

Auxiliary valve work port.

See machine manual.

Pilot port connections to

auxiliary valve reversed.

Hose routing and

connections.


(Note: Connect pilot pressure

to one side of the auxiliary

valve spool and connect the

opposite side of auxiliary

valve spool to the drain.)


Page D-32


Pressure and return hoses

reversed on installation.

Hydraulic pressure at

attachment inlet port.

Hose routing and

connections.

(Note: From the view of

sitting in operator’s seat, the

pressure line is typically on

the left side and the return

line is on the right side.)


Reverse line connections.

No pilot pump supply

pressure to pilot valve.

Hose routing and

connections.


No pilot pressure signal to

auxiliary valve pilot port.

Hose routing and

connections.

Valve solenoid wiring.


Repair or replace wiring.

No electrical power. Foot switch, Joystick, HKX

valve wiring.

HKX “ON/OFF” toggle switch.

HKX circuit breaker.

Machine power supply.

Repair and/or replace wiring.

Solenoid coil operating

voltage.

Solenoid coil voltage

compatibility with machine

electrical system.

Replace solenoid.

Issue: Flow delivery does not hold steady .


Low oil level in machine

reservoir.

Reservoir oil level. Add hydraulic oil.

Auxiliary valve spool

throttling.

Pressure to auxiliary valve

pilot port.

(Note pressure should be at

or below pilot pump

pressure.)

Check the valve.


Support.

Reduced pressure signal to

pump swash plate angle

control port is connected to

wrong port.

Hose routing and connection.

HKX installation drawings.

Connect hose to correct port.


Page D-33




control port is erratic.



control port.

(Note pressure should steady

and repeatable.)


Support.

Issue: Hydraulic oi l temperature is running hot .


Low oil level in machine

reservoir.

Reservoir oil level. Add Hydraulic oil.

Machine auxiliary valve work

port relief valve set below

hammer or compactor/driver

operating pressure.

Relief valve.

(Note: The pressure setting

usually must be somewhat

above the hammer operating

pressure, based on

manufacturer’s specification).

Reset auxiliary relief valve

pressure per machine

specifications.

Shut-off valve(s) are in a

partially closed position.

Shut-off valve spool position. Fully open both valves to ON

position.

Flow setting exceeds

specifications.

Perform flow test at load

pressure with flow meter at

attachment hoses and

compare to attachment

requirements.

Reset flow per attachment

requirements.

Excessive flow for line size. Tube and hose inner diameter

(ID).

Call HKX Customer Support.

Tube crushed or hose kinked. All tubes and hoses. Replace crushed or kinked

parts.

Optional shuttle valve

malfunction.

Shuttle valve (if present).

(Note: Internal ball should

move freely)

Fully open both valves to ON

position.

Dirty machine oil or filter. Oil cooler or filter of machine. Clean cooler. Change filter.

Change oil.

HKX Kit Installation Manual Appendix 11: HKX Glossary and Table of Acronyms

Page D-34

Appendix 11: HKX Glossary and Table of Acronyms

HKX Glossary

Term Description

Accumulator A hydraulic Accumulator reduces hydraulic shock in the circuit.

An accumulator enables a hydraulic system to cope with extremes

of demand using a less powerful pump, to respond more quickly

to a temporary demand, and to smooth out pulsations.

Active Control

Technology (ACT)

The ACT monitor displays, stores and transmits attachment

specifications which, when selected, electronically adjusts the

excavator’s auxiliary hydraulic system parameters accordingly.

Arm The Arm (also called Stick)

is the second of three

members that make up the

digging function of an

excavator. It is attached to

the end of the boom and the bucket is attached to its tip.

Attachment Equipment

Manufacturer (AEM)

The Attachment Equipment Manufacturer is the company that

built the attachment and defined the attachment’s requirements

and limitations.

Auxiliary Circuit An Auxiliary Circuit is a hydraulic circuit, separate from the

machine’s Primary Circuit. It is usually used to power attachments

added to the machine. For example, on an excavator, the Primary

Circuit operates the Bucket, while the Auxiliary Circuit operates an

attachment or other function on the excavator.

Auxiliary Relief Valve An Auxiliary Relief Valve is a Cartridge valve that screws into the

auxiliary valve, to set the pressure on the circuit. It reduces

pressure to attachment.

Auxiliary Valve The Auxiliary Valve controls the auxiliary hydraulic circuit.

Ball Valve Ball Valves (BVs) are used to shut off oil flow to a hydraulic

circuit (2-way) or to control the direction of oil flow (3-way).

Boom The Boom is the first of

three members that make

up the digging function of

an excavator. It is attached

to the swing frame and the

arm is attached to the other end.

Arm

Boom


Page D-35

Term Description

Bucket The Bucket (also call

“scoop”) is the third of

three members that make

up the digging function of

an excavator. It is attached

to the end of the arm and digs up then transports soil.

Bulkhead A Bulkhead is a panel, suface, or bracket that a hydraulic line

passes through. See Bulkhead Fitting.

Bulkhead Fitting A Bulkhead Fitting is an adaptor designed to pass a hydraulic

line through a bulkhead. It is secured in place by a locknut.

Cab See House.

Case Drain A Case Drain is a return line that returns slippage hydraulic oil

from a rotary device (motor or pump).

Check Valve A Check Valve allows oil to flow through it in only one direction.

Combination Selector

Valve (CSV)

A Combination Selector Valve (CSV) enables manual selection

between single direction or double direction oil flow through the

auxiliary circuit. The Electronic Function Select (EFS) option

enables in-cab control of this selector valve.

Combiner Valve A Combiner Valve combines hydraulic flow from two sources

into one flow.

Connection A Connection is the hardware that connects hydraulic

components.

Control Valve A Control Valve directs hydraulic oil flow into different paths

from one or more sources.

Double Acting See Dual Acting.

Dual Acting Also called Dual Direction or Double Acting.

Dual Acting hydraulic components work in a system that can

exert force is two directions. E.g.; dual acting cylinder, dual acting

valve.

Dual Direction See Dual Acting.

Bucket

Bulkhead Fitting

Locknuts

Bulkhead (Bracket)


Page D-36

Term Description

Electronic Function Select

(EFS)

The Electronic Function Select system enables a machine

operator to change the position of a ball valve using an electronic

control switch in the cab, instead of having to leave the cab and

manually change the ball valve setting. An EFS actuator is a pilot

oil actuated rotary device that rotates a ball valve. An EFS system

is primarily used to switch between single direction circuits (such

as those used for breakers), and dual direction attachments (such

as those used for shears or thumbs).

Electronic Pressure Select An Electronic Pressure Select valve adjusts the relief pressure for

specific attachments, set increments.

Electronic Pilot Control

(EPC)

An Electronic Pilot Control (EPC) is a component that enables

remote electronic operation of a Pilot Valve.

Flange A Flange is part of a Flange Connection.

(See Appendix 4: Assembling Connections.)

Flange Connection A Flange Connection is a hydraulic connection that is held

together by two or more bolts.

(See Appendix 4: Assembling Connections.)

Foot Pedal A Foot Pedal is primarily used to vary hydraulic flow to an

attachment. Pressing down harder on the pedal results in higher

flows at the attachment. Recommended for use with breaker Kits.

Foot Switch A Foot Switch provides on/off functionality for the attachment.

Best used with breaker Kits and combination Kits that include a

breaker.

House The House is the cab on

the swing frame of an

excavator, from which the

operator controls the

machine.

Isolating Valve Also “Isolation Valve.” An Isolating Valve is used to stop the flow

of hydraulic oil through a circuit.

Joint See Connection.

Joystick A Joystick is a four-way input device that controls a hydraulic

attachment by responding to the motion of the operator's hand.

Joysticks can also include buttons and sliders that control more

functions.

Line A Line is a passage through which hydraulic oil flows. Can refer to

any combination of tubes, hoses, manifolds, connections, etc.

House


Page D-37

Term Description

Load Hold Valve A Load Hold Valve is a type of Shut-Off Valve used to hold the

hydraulic oil in a hydraulic cylinder. They provide anti-drift

capability in instances where the load needs to be held for

extended periods of time.

Lock-Out Valve A Lock-Out Valve is a 2-Way Ball Valve used to shut off oil flow

in a hydraulic circuit.

Main Control Valve

(MCV)

The Main Control Valve is the primary control valve on a

machine. It can have multiple sections, each controlling a

separate hydraulic circuit. If the MCV does not have enough

sections to control all attachment functions, Auxiliary Valve(s)

can be added to the circuit(s) that control the attachment.

Monitor-Controlled Valve A Monitor-Controlled Valve is a valve that is electronically

controlled by a digital monitor system.

Original Equipment

Manufacturer

(OEM)

The Original Equipment Manufacturer is the company that built

the excavator or machine and defined the machine’s

requirements and limitations.

O-Ring Face Seal (ORFS) O-Ring Face Seal connections have a nut (female) rotating around a collar. Either the hose collar or the tube-end has a machined flat face. A two-ended adaptor (male) is installed between the nuts. The adaptor has an O-ring on each face. The seal is created when you tighten the threaded connection and compress the adaptor’s O-ring onto the flat face of the collar or tube. The threads mechanically hold the connection together. See Appendix 4: Assembling Connections.

Pilot Circuit A Pilot Circuit is a low-pressure and easily-controlled hydraulic

circuit used to control valves, actuators, and other control

components, which in turn control the high-pressure circuit that

powers the boom, arm, and attachment.

Pilot Shut-Off Valve

(PSOV)

A Pilot Shut-Off Valve is a ball valve that shuts off flow in a Pilot

Circuit.

Pilot Signal Manifold

(PSM)

A Pilot Signal Manifold has inputs and outputs for Pilot

Circuits. Using either hydraulic or electronic control inputs, it can

turn on/off individual flows. With an installed sensor, it can

provide electronic signals.

Pilot Valve A Pilot Valve controls the oil flow in a Pilot Circuit.

Port A Port is a hole that hydraulic oil flows through.

Pressure Reducing Valve A Pressure Reducing Valve reduces the pressure in a hydraulic

circuit, so it does not go over a set maximum, by sensing the

downstream pressure in the system.


Page D-38

Term Description

Pressure Relief Valve A Pressure Relief Valve relieves the pressure in a hydraulic

circuit, so it does not go over a set maximum by sensing the

upstream pressure in the system.

Pressure Relief Cartridge

(PRC)

A Pressure Relief Cartridge (PRC) is a Pressure Relief Valve in

cartridge form. Typically, one PRC is used for single direction Kits,

two PRCs for dual direction Kits. PRCs are installed onto the same

section of Main Control Valve (MCV) as the work ports that are

connected to the Kit.

Pressure Switch A Pressure Switch senses hydraulic pressure and, depending on

the pressure level, generates an electronic signal.

Primary Circuit The Primary Circuit powers the basic hydraulic functions on the

machine: boom, arm, and bucket. Though not common, it can be

used to power other functions and attachments.

Priority Flow Divider

(PFD)

A Priority Flow Divider is a valve that controls the flow on two

separate hydraulic circuits that are powered by a single pump.

However, when maximum flow demand is exceeded, it gives

priority to one circuit over the other.

Proportional Joystick A Proportional Joystick has a slider switch on it that produces

electronic outputs proportional to the position of the slider.

Quick Disconnect A Quick Disconnect is a hydraulic coupler that requires no tools

to connect or disconnect, enabling easy hook-up or removal

without using ball valves.

Reducer A Reducer is a 2-sided adaptor with different diameters on each

side. It “reduces” the hydraulic line size from a larger to a smaller

inner diameter, or vice versa.

Relief Valve See Pressure Relief Valve.

Return Filter A Return Filter filters oil returning to the tank.

Secondary Circuit See Auxiliary Circuit.

Selector Valve A Selector Valve directs hydraulic oil flow from one source to

one of multiple hydraulic circuits.

Shut-Off Valve See Lock-Out Valve.

Shuttle Valve A Shuttle Valve directs pilot hydraulic oil flow input from one of

multiple sources to one hydraulic circuit, while blocking reverse

flow to the unused input. It is a type of Signal Valve.

Signal Valve A Signal Valve signals produces and electronic signal dependent

on the incoming pilot oil pressure.

It can be used to signal the factory auxiliary valve and the bucket

spool simultaneously for two-pump flow.

Single Direction A Single Direction Kit has hydraulic oil flow in one direction only.


Page D-39

Term Description

Solenoid Valve A Solenoid Valve is a valve controlled by an electric current

through a solenoid. A two-port Solenoid Valve switches flow on

and off. A three-port Solenoid Valve switches between two

outlet ports.

Spool Pilot Valve A Spool Pilot Valve is used to control (pilot) other full-flow

valves.

Stick See Arm.

Sub-Kit A Sub-Kit is a pre-assembled sub-assembly of parts delivered in

an HKX Kit.

Swing Control Valve A Swing Control Valve controls the rotation of the excavator’s

frame.

Three-Way Ball Valve See Ball Valve.

Thumb Lock A Thumb Lock is a Shut-Off Valve used to lock the thumb

circuit. It prevents the thumb from drifting when using breakers

and compactors on the same circuit.

Two-Way Ball Valve See Ball Valve.


Page D-40

Table of Acronyms

Acronym Meaning

2BV 2-Way Ball Valve

(Lock-off Valve)

3BV 3-Way Ball Valve

ACC Accumulator

ACT Active Control Technology

ADP Adaptor

AFC Auxiliary Flow Combiner

ALUM Aluminum

AMP Amperage

AP Auxiliary Pump

ASSY Assembly

AV Auxiliary Valve

BH Bulk Head

BRKT Bracket

BSPP British Standard Pipe Parallel

BSPT British Standard Pipe

Tapered

CB Circuit Breaker

CCW Counter Clockwise

CD Case Drain

CD61 SAE Code 62 (6000 PSI)

CD62 SAE Code 61 (3000 PSI)

CDSET Cordset

CNV Conversion

CONN Connector

CS Center Section (Boom)

CSV Combination Selector Valve

CW Clockwise

CYLD Cylinder

D or ° Degree

DBL Double

DC Direct Current

DF Dual Function

DFH Dual Function House

DPA Drain Port Adaptor

EBSV Electric Bucket Signal Valve

ELB Elbow

Acronym Meaning

ELEC Electric

EPC Electronic Pilot Control

ERGO Ergonomic

ESH End Section House (Boom)

ESS End Section Stick (Boom)

F Female

FC Fluid Controls

Fig Figure

FIT Fitting (Adaptor)

FL Fluid Lines

FLG Flange

FP Foot Pedal

FS Foot Switch

G Grade

G1 Boom Group

G2 Arm Group

G3 Valve Group

G4 Controls Group

GA Gauge

GPM Gallons Per Minute

HF High Flow

HHC Hex Head Cap

HP High Pressure

HPA Hard Plumbed Adaptor

HYD Hydraulic

ID Inside Diameter

JIC Joint Industry Council

JS Joystick

Kg/cm² Kilogram/Centimeter²

Kgf-m Kilogram Force Meter

LBP Low Back Pressure

LG Long/Length

LN Lock Nut

LS Load Sensing

M Male

MAN Manifold

MCV Main Control Valve


Page D-41

Acronym Meaning

MET Metric

MM Millimeters

MRC Main Relief Cartridge

MTG Mounting

NPT National Pipe Tapered

OC Open/Close

OCR Open/Close & Rotate

OD Outside Diameter

OEM Original Equipment

Manufacturer

ORB O-ring Boss

ORFS O-ring Face Seal

PFD Priority Flow Divider

POS Pilot Oil Source

PR Pilot Return

PRC Pressure (Port) Relief

Cartridge

PRM Port Relief Manifold

PRP Pressure Reducing Port

PRV Pressure Reducing Valve

PS Pilot Supply

PSI Pounds per Square Inch

PSOV Pilot Shut-Off Valve

PSRA Pilot Supply & Return

Adaptors

PSV Pilot Signal Valve

PSW Pressure Switch

PV Pilot Valve

RED Reducer

RES Restrictor

RF Return Filter

RL Return Line

Acronym Meaning

RPA Return Port Adaptor

RPM Revolutions Per Minute

RT Rotate

RV Relief Valve

SBP Standard Back Pressure

SCV Swing Control Valve

SF Split Flange

SGL Single

SHC Socket Head Cap

SK Sub-Kit

SLND Solenoid

SP Standard Pressure

SPA Shift Port Adaptors

SS Spare/Service spool

(accessory, option)

STD Standard

SV Signal Valve

SV Shuttle Valve

TP Travel Pedal

TRPL Triple

TS Terminal Strip

TSW Toggle Switch

V Volt

VLV Valve

WPA Work Port Adaptor

X Swivel

XHF Extra High Flow


Page D-42

BLANK PAGE

W-1


As used in this warranty the term HKX means:

HKX, Incorporated, 16761 146th St. SE Suite 115, Monroe, WA 98272, USA.

KIT WARRANTY

HKX, INCORPORATED (“HKX”) warrants any new hydraulic kits sold (except electrical

components) by HKX, will be free from defects in material and workmanship for a period of one

(1) year from the date of shipment to the buyer, if installed as per HKX installation manual. The

HKX installation kit warranty does NOT cover labor, incidental costs, or travel expenses.

THIS WARRANTY DOES NOT APPLY TO:

Installation on carrier other than specified on the kit Bill of Materials.

HKX RESPONSIBILITY

HKX will, at its discretion, repair or replace with a new or reconditioned part, any warranted part

that fails by reason of defective material or workmanship, free of charge.

NOTE: Parts replaced under warranty become the property of HKX.

USER RESPONSIBILITY

• The installer, user, operator, repairer, assumes responsibility to READ, UNDERSTAND and

COMPLY with HKX’s written INSTALLATION, OPERATION, SAFETY, PREPARATION, TESTING,

and SERVICE INSTRUCTIONS.

• If the hydraulic kit has been in your inventory for over 6 months, call HKX for upgrade

information before starting installation.

• All labor costs.

• Any expense incurred by field repair.

• Returning completed Installation Feedback Form to HKX after installation of kit.

• Perform post-installation inspection within 20 hours of operation or 30 days from date of

first use, whichever 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.


W-2

• 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.

• Installations not approved by HKX.

• Replacement due to normal wear.

• Use of parts not sold by HKX.

• Parts shipping charges in excess of those which are usual and customary.

• Duties and local taxes.

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 representations 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 AUTHORIZATION MUST BE OBTAINED FROM HKX FOR ANY OF

THE ABOVE.


W-3

Please contact an HKX warranty coordinator immediately upon learning of a potential warranty

claim at 1-800-493-5487 or 360-805-8600.

WARRANTY CLAIMS

In response to your warranty claim, the Warranty Coordinator will, in a timely manner:

• Collect all pertinent information, including photos, if necessary.

• Evaluate the problem and promptly advise you verbally and in writing:

o What repairs are necessary.

o The repair procedure.

o Parts required for repair.

o Time allowance for repairs.

• Or, in certain instances, the Warranty Coordinator may request the return of parts to HKX for

repairs.

• Where applicable, the Warranty Coordinator will immediately provide replacement parts, as

required, billing the claimant for the parts pending return and evaluation of the defective

parts (also requiring an RGA). If the returned parts are deemed defective, a credit will be

issued against the parts invoice. All defective parts must be returned to HKX freight prepaid.

• Preapproved dealer labor expense, including freight (where applicable) will be reimbursed

with a credit memo against future business with HKX.

IMPORTANT: Claims submitted 60 days past the repair date will not be considered for warranty.

LEGAL STATEMENT

Any disagreements will have to be submitted to an arbitration company agreed upon by the

buyer and HKX, and a neutral arbitrator will resolve disputes in an informal private proceeding.


W-4

BLANK PAGE

Total Support Total Response Our goal is to help you stay ahead of the competition. One way we do that is by investing a great deal into research and development of our hydraulic kits.

More than anything, we listen to your suggestions for product improvements. By integrating your ideas into new product designs, we're confident that our equipment is on the cutting edge of productivity and reliability.

So, we encourage you to notify us and send in suggestions for improvements on our auxiliary hydraulic kit product.

Technical Support: (800) 493-5487 x4701 toll-free, (360) 805-8600 x4701. Monday–Friday 7AM to 4PM (Pacific Time) fax: (800) 353-5736, email: [email protected]

If the Kit cannot be installed following the instructions in this manual, you must contact HKX Technical Support before deviating from Kit’s instructions and design. Our Support team will assist you to correct the problem without affecting the HKX Kit integrity or warranty.

mailto:[email protected]

Kit Installation Manual

Documents

Transcript of Kit Installation Manual