160 BOOM ELECTICAL INSTALLATION 160 BOOM CAB INSTALL
160 BOOM ELECTICAL INSTALLATION
160 BOOM CAB INSTALL INVERTER HARDWARE KIT (4) (8) (4) (2) 10 -32 X 3/4 #10 Lock Washers #10 Flat Washers 10 -32 Nuts 10” ½ black loom 71/2” ½ black loom BACK-UP HORN KIT K 1 RELAY (1) (1) ¼ -20 Fender Washer ¼ -20 Nut 800457 back-up horn (BT 0043) (1) 87541 (FI 0130) 160 CAB ELECTRCAL PARTS (1) (1) (11) (2) 72963 PTO switch (EL 0004) 800414 -1 PTO light (W-101731 24 V bulb)-(WH 0469) 800051 PTO on/off plate (BT CELL 1) 803220 Inverter 24 V on/off plate (WH 0221) 85355 Green light (12 V)-(EL 0003) 72963 On/off switch (EL 0004) ? ? ? 5” Terminal strip 72820 Terminal block (EL 0005) 75654 Terminal block end (EL 0005)
160 BOOM HARNESS Find # Qty 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Part# 17 ft 2 4 2 3 3 1 30” 2 1 1 Description 86531 800042 800044 800043 800035 800040 800036 800037 800041 800348 Wire 5 Cx 14 AWG Turn/tail connector Clearance connector Back-Up connector Tail light Boot Back-up light Red clearance lights Boot License plate light ¼” Black Loom 652085 Blue ring lug 634005 Male conn 694005 Female conn R/H 3 HEAT SHRINK TAIL LIGHT 3” 11 SIDE VIEW 6. 00” L / TURN BRAKE RUNLIGHTS. . GROUND…. . BACK-UP… ALARM 13 12 R / TURN BRAKE A B D C FRONT VIEW MAC PLUG BACK -UP 5 6 6 7 8 9 BLK-#4 WHT-GND 5 6 7 6 L/H TAIL LIGHT 2 BLK LOOM 30” MACK LIGHT HARNESS BLK- #2 RED- #3 WHT-GND BACK-UP 4 MARKING LIGHTS 4 RED-#1 WHT-GND 3 BLK-#4 WHT-GND HEAT SHRINK 3” 1 BACK-UP 86531 cut wire 17’ 2 BLK- #4 RED-#3 WHT-GND RED-#1 WHT-GND #1 #2 #3 #4 GRN/YELL
160 BOOM HARNESS Find # Qty 1 2 3 4 3 3 3 Part# Description ? ? ? 800037 800041 800044 Wire 2 CX 16 AWG BLK 600 V Red clearance lights Boots Clearance light conn. MARKER LIGHT HARNESS (TOP) NOTE* Drill 7/8” hole into the Bulkhead plate. 2 160/37 M -30 FT X 3 6” 3 42 M -35 FT 3” 6” Yell 12 -10 AWG Butt splice 4 X 3 1 STRESS RELIEF 3/8 P/N 73783 WH 527 NOTE* Cut flex grey conduit 12 FT 12 FT 15 FT
160 BOOM HARNESS Find # Qty 1 2 3 4 4 1 Part# 800037 800041 800044 75756 Description Red lights Boot Light conn. Wire 16 AWG 2 C (600 V) MARKER LIGHT HARNESS (FRAME) 1 1 2 2 3 3 WHT WIRE GND BLK WIRE +12 V NOTE* Connect to Boom wire Harness (TOP) 8 1/ 2 FT STRIP 3” 15 FT T /2 F 1” black heat shrink cut 10” lengths 2 layers on each side 18 FT 1 FT STRIP 3” T /2 F 81 8 FT 81 16 AWG 2 C (600 V) P/N 75756 1 2 1 3 2 3
160 BOOM HARNESS Find # 1 2 3 4 BOOM POWER HARNESS Parts qty 801359 fuse holder WH 0452 1 801360 50 A fuse WH 0452 1 85614 cable 8 AWGX 4 C 256125 ½ Ring lug 4 AWG Del city Instructions: Cut cable as directed for appropriate boom size. 25 FT BLK, GRY 160 37 M Boom 1 2 CUT OFF 12 IN WIRE 6” Shrink + - 3 1 FT Shrink 54” Loom 32” 4 X 2 NOTE* Crimp and solder ring lugs BRN, YELL 30 FT BLK, GRY 42 M Boom + - CUT OFF 12 IN WIRE 3 1 2 6” Shrink 32” 1 FT Shrink 54” Loom 42” 4 BRN, YELL X 2 NOTE* Crimp and solder ring lugs
160 RADIO REMOTE NBB RADIO INSTALLATION NOTE* Radio bracket is supplied with radio kit Install battery into radio remote. Install battery charger In cab. NBB 160 Bracket Install using (3) 5/16 X 11/4 Bolt (6) 5/16 Flat washers (3) 5/16 Nylon lock washers Install whip antenna W-104744 PW-0065 WAI 108573 NBB radio receiver remote kit Reed P/N 206296 BOOM DECK NBB BOOM DECK Plug cable into “D” Junction box
160 BOOM INVERTER INSTALLATION INSTRUCTION: Remove seat and seat Belt bracket using 5/8 socket. Cut out hole using die grinder with cutting wheel. PART 1 SIDE OF CAB After hole is cut out, Debur and apply Black trim P/N 10196 to edges. INSIDE CAB 9” INVERTER TEMPLATE 1 ¾” REMOVE SEAT BELT BRACKET
160 BOOM INVERTER INSTALLATION INSTRUCTION: Lift cab Up. Use Inverter template and place under cab 5” from the latch, Drill 4 holes. 261 drill bit. PART 2 BOTTOM SIDE LATCH 5” BOTTOM SIDE INVERTER TEMPLATE RIGHT SIDE OF CAB
160 BOOM INVERTER INSTALLATION PART 3 INSTRUCTION: Install hardware as shown below. Wire and install into compartment behind the seat. INVERTER MOUNT LEG (4) #10 -32 X 3/4” SCREW (8) #10 LOCK WASHER (8) #10 FLAT WASHER (8) #10 -32 NUT SCREW LOCK WASHER FLAT WASHER +24 V +12 V NUT FLAT WASHER LOCK WASHER NUT GND
160 BOOM CLUTCH SWITCH INSTALL INSTRUCTION: Install clutch switch onto bracket. Mark and pre drill holes For switch bracket using self taping screws CLUTCH SWITCH CUT 4” MAC CLUTCH PETAL BRACKET 4 1/2” SELF TAP SCREWS BRACKET
160 BOOM HARNESS IN CAB PANEL MODIFICATION 160 PART 1 1. 00” OFF 24 V DC + 5/8” 1. 0 0” + + ON PTO + 1. 50” USE HOLE TEMPLATE, CENTER OVER 24 V DC PLATE. 15/32”. 877” HOLE LAYOUT PRE DRILL PILOT HOLES IN TEMPLATE. THEN DRILL 7/8 HOLE TO PLACE HYDRALIC PUNCH TOOL.
160 BOOM HARNESS HYDRALIC PUNCH TOOL IN CAB PANEL MODIFICATION 160 PART 2
160 BOOM HARNESS NOTE: install panel into MAC cab NOTE: Install Reed marker light harness and 12 V battery harness in MAC frame rail using tie wraps. NOTE: Connect 12 V power cable to (+) 12 V fused side on Mac battery tray NOTE: Connect (-) 12 V to the battery on off selector switch, Off side as shown.
160 BOOM HARNESS IN CAB WIRING 160 ON/OFF INVERTER LIGHT PTO LIGHT X 1 CLUTCH SWITCH +- BLK (+12 V) BRN (GND) BLU (+24 v) X 2 + - MAC CAB IGN CB 23 FUSE BLOCK KEY SWITCH N/C BOTTOM TOP N/O 7 6 5 A 30 A 5 A 5 3 4 5 A 2 1 5 A 30 A REV IGN CB 43 SPARE BATT CB 38 N/O #2 J 1 -7 MAC ECM J 2 -10 YELL/GRN J 1 -6 #1 1 2 3 4 5 6 7 8 9 G G 2 WIRES BLU (+24) (BOOM HARNESS) BLK/GRY +12 RED/TELL BRN/BLU GRY/RED GRN WHT -24 V BLU/WHT Y 1 RED 10 AWG +24 V BLK/WHT Y 2 2 BLK (+12) VIBRATOR INVERTER +12 V NEUT #3 J 1 -8 N/O 8 (BOOM HARNESS) CHASSIE GROUND BLK/GRY +12 -12 V GRN/YELL BRN -12 V P/N 85614 8 AWG-4 C GRN/YELL BRN -12 V
160 BOOM HARNESS Find # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 Parts 800369 -1 800864 -1 800865 -1 800414 -1 802408 800909 85354 90392 ? ? ? 72820 75654 72821 85355 72963 87541 W-108574 800051 803220 Description qty Key switch 1 N/O contact block 1 N/C contact block 2 PTO Light 1 Clutch bracket 1 Clutch switch 1 Fuse Block 8 way 1 Fuse, 5 A 4 Fuse, 30 A 2 Terminal block 11 Terminal ends 2 Jumper 1 Rail 5 Inches Inverter light 1 Inverter switch 1 Relay 1 Inverter 12 V – 24 V 1 PTO switch plate 1 24 V switch plate 1 IN CAB PARTS 160 Loc WH 514 WH 469 WH 1158 WH 829 EL 0005 16 6 INVERTER EL 0005 EL 0003 FI 0130 WH 478 ? ? ? WH 221 +24 V +12 V -12 V FUSE BLOCK 7 INVERTER LIGHT 14 8 X 4 9 X 2 8 7 6 5 A 30 A 5 A 5 4 3 5 A 2 1 5 A 30 A 4 18 1 PTO LIGHT + - 2 +19 17 -24 V 15 ON/OFF 5 11 X 2 10 12 13 X 2 3 KEY SWITCH N/O OFF/ON N/C BOTTOM 24 VDC 1 2 3 4 5 6 7 8 9 G G PTO TOP N/O
160 BOOM HARNESS PART 1 IN CAB HARNESS 160 85617 Wire DOUBLE RED FERRULE Wire 16 AWG-4 C 34” Mach ECM. . . SINGLE BLK FERRULE INVERTER (+) GRN LIGHT 653105 RING YELL Wire 16 AWG BLUE 53”…………………. . K 1 ON/OFF SWITCH 692115 PUSH-ON BLU Wire 16 AWG BRN 11”…………… K 1 TB GROUND 652105 #10 RING BLU Wire 16 AWG BLU 48”…………… CB-23 F-7 Wire 16 AWG BLU 49”…………… CB-23 F-8 692005 PUSH-ON BLU 693005 PUSH-ON YEL 653385 RING LUG 3” 1 1/2” Heat shrink +24 V Wire 10 AWG RED 72”……………… Inverter F 1/F 3/F 6 Solder all connections 3” Wire 16 AWG BLU 46”…………………. . CB 43 F 2 Wire 10 AWG RED 12”…………………. TB 1 #1 F 4
160 BOOM HARNESS IN CAB HARNESS 160 PART 2 DOUBLE RED FERRULE Wire 16 AWG BRN 13”……………. GND Wire 16 AWG BLU 8”…………. PTO Light (+) Inverter Light (-) 692115 PUSH-ON BLU TB 2 GROUND PTO Wire 16 AWG BRN 11”…………. Light (+) 5” Heat shrink PTO Key Switch Wire 16 AWG BLU 16”……………. . . TB 3 Solder all connections 5” Heat shrink Wire 16 AWG BLU 16”……………. TB 4 Solder all connections Wire 16 AWG BRN 36”………………. . CB GND PTO Key Switch TB GND Wire 16 AWG BLU 14”……………. . TB 5 PTO Key Switch Wire 16 AWG BLU 14”……………. . TB 6 PTO Key Switch 652105 #10 RING BLU
160 BOOM HARNESS IN CAB HARNESS 160 PART 3 DOUBLE RED FERRULE Wire 16 AWG BLU 9”…………………. ON/OFF SWITCH Wire 16 AWG BLU 12”…………. …. TB 5 Wire 16 AWG BLU 12”……………. TB 6 F 7 PTO KEY SWITCH NO/(GRN) PTO KEY SWITCH NC/(RED) Wire 16 AWG BLU 12”……………. . . TB 9 F 8 Wire 16 AWG BLU 14”……………. . TB 3 F 2 692115 PUSH-ON BLU 400677 DOUBLE LUG 652065 #6 RING LUG BLU
160 BOOM HARNESS INVERTER ON/OFF +8 7 IN CAB HARNESS LAYOUT FUSE BLOCK PART 4 6 5 5 A 30 A 5 A 3 4 5 A 2 652105 #10 RING LUG 1 GROUND 5 A 30 A MAC PANEL 1 2 3 4 5 6 7 8 9 G G K 1 RELAY 1 FT 24” 19” 2” 8” +24 V -24 V +12 V -12 V J 1 -8 J 1 -6 J 2 -10 MAC ECM 26” CB 23 IGN J 1 -7 CB 43 INVERTER 8”
160 BOOM HARNESS BATTERY CHARGER INSTALLATION INSTALL HERE AS SHOWN + 71/2” Drill 7/16 Install grommet and cable B 9115 Black grommet - Apply Velcro to back side of battery charger Place on top of cover as shown. BATTERY CHARGER WIRE HOOK-UP BLK------GND BLK/WHT---CB 38
160 BOOM HARNESS HOPPER GRATE SAFTEY SWITCH NOTE: The grate cam may need to be Adjusted. When the grate is closed the switch needs to be closed. BLACK WIRE HOPPER GRATE SAFTY SWITCH W-109027 (WH 0511) + + BROWN WIRE PROXY BOX S 15 Silicone cable in side of box. HEADSIDE S 10 SAFETY SWITCH S 16 P/N 803105 Cable 802700 (WH 0467) Connect to prox switch box S 10 (3) RODSIDE NOT USED
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