New Holland EH160LC Excavator 2-Way Hand Control with boom & Standard arm Piping Instruction Manual

INSTRUCTION SHEET INSTRUCTIONS FOR INSTALLING YM32TU1038F2 2-WAY HAND CONTROL WITH BOOM AND STANDARD ARM PIPING ON EH160LC EXCAVATOR PARTS LIST REF. PART NO. 1.

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DESCRIPTION

QTY.

24100P1005F1 .............. SELECTOR VALVE........................................................................................................................

24100P1006F1 .............. VALVE, STOP ................................................................................................................................

2414Z199D100 .............. GUARD, HOSE ..............................................................................................................................

2416N6141 .................... BLOCK...........................................................................................................................................

2418T10357................... WASHER .......................................................................................................................................

2420R349D110 .............. HOSE.............................................................................................................................................

2420R349D280 .............. HOSE.............................................................................................................................................

2420R349D315 .............. HOSE.............................................................................................................................................

2420T4404 .................... PLUG .............................................................................................................................................

2432T2434 .................... CLAMP ..........................................................................................................................................

2432T5924 .................... CLAMP ..........................................................................................................................................

2432T6122 .................... CLAMP ..........................................................................................................................................

2444P1744D2 ................ CONNECTOR ................................................................................................................................

2444R1120D110 ............ HOSE.............................................................................................................................................

2444R399D7.................. ELBOW ..........................................................................................................................................

2444Z2760 .................... CONNECTOR ................................................................................................................................

2444Z2894 .................... ELBOW ..........................................................................................................................................

2444Z3722D4 ................ HOSE.............................................................................................................................................

2479U1190F32 .............. SWITCH.........................................................................................................................................

EN24S00008P1 ............. RELAY ...........................................................................................................................................

HG23H12012G1 ............ CONNECTOR ................................................................................................................................

HG23H12016G1 ............ CONNECTOR ................................................................................................................................

HG24F10012G3............. CONNECTOR ................................................................................................................................

HG33F10016G1............. ELBOW ..........................................................................................................................................

HG33H16012G1 ............ ELBOW ..........................................................................................................................................

HH25R04004G5............. CONNECTOR ................................................................................................................................

LB42H01001P1.............. CLAMP ..........................................................................................................................................

LB42H01004P1.............. BUSHING.......................................................................................................................................

LC35V00004F2 .............. SOLENOID VALVE ........................................................................................................................

LC42H01020P1 ............. BUSHING.......................................................................................................................................

LS43H01005P1.............. CLAMP ..........................................................................................................................................

PY01P01043D3 ............. PLASTIC TIES ...............................................................................................................................

PY20T01062P1.............. LABEL............................................................................................................................................

YB03M01003F2 .............LH GRIP ASSEMBLY ......................................................................................................................

YB03M01003F3 .............RH GRIP ASSEMBLY .....................................................................................................................

YM03H01015P1............. TUBE .............................................................................................................................................

YM03H01041P2............. BRACKET ......................................................................................................................................

YM03H01042P1............. TUBE .............................................................................................................................................

YM03H01043P1............. SUPPORT......................................................................................................................................

YM12B01041P1 ............. LINK...............................................................................................................................................

YM12B01042P1 ............. LINK...............................................................................................................................................

YM42H01056P1............. O-RING ..........................................................................................................................................

YM42H01105P1............. TUBE .............................................................................................................................................

IS04-013A-NH NA Cst Issued 08-04 Copyright © 2004 CNH America LLC. All Rights Reserved.

Printed in U.S.A.

1 2 4 1 4 1 1 1 2 1 5 5 2 1 1 1 1 1 1 2 2 1 1 1 1 1 4 2 1 2 4 5 1 1 1 1 1 1 1 1 1 1 1

Page 1 of 39

INSTRUCTION SHEET FOR EH160LC 2 WAY - HAND CONTROL (W/BOOM and STD ARM PIPING) REF. PART NO.

DESCRIPTION

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TUBE ............................................................................................................................................. 1 TUBE ............................................................................................................................................. 1 TUBE ............................................................................................................................................. 1 TUBE ............................................................................................................................................. 1 TUBE ............................................................................................................................................. 1 SPACER ........................................................................................................................................ 1 BLOCK........................................................................................................................................... 1 HARNESS...................................................................................................................................... 1 HARNESS...................................................................................................................................... 1 LABEL............................................................................................................................................ 1 CLAMP .......................................................................................................................................... 1 CLAMP .......................................................................................................................................... 2 SUPPORT...................................................................................................................................... 1 BRACKET ...................................................................................................................................... 1 LABEL............................................................................................................................................ 1 BRACKET ...................................................................................................................................... 2 LABEL............................................................................................................................................ 1 O-RING .......................................................................................................................................... 4 O-RING .......................................................................................................................................... 9 O-RING .......................................................................................................................................... 4 O-RING .......................................................................................................................................... 2 PLUG ............................................................................................................................................. 1 PLUG ............................................................................................................................................. 1 PLUG ............................................................................................................................................. 2 CONNECTOR ................................................................................................................................ 1 ELBOW .......................................................................................................................................... 1 CONNECTOR ............................................................................................................................... 3 CONNECTOR ................................................................................................................................ 1 ELBOW, 90°................................................................................................................................... 2 ELBOW, 90°................................................................................................................................... 2 ELBOW, 45°................................................................................................................................... 1 SEMS-BOLT .................................................................................................................................. 2 NUT ............................................................................................................................................... 1 CAPSCREW ................................................................................................................................. 8 CAPSCREW .................................................................................................................................. 8 CAPSCREW .................................................................................................................................. 4 CAPSCREW .................................................................................................................................. 4 CAPSCREW .................................................................................................................................. 8 CAPSCREW .................................................................................................................................. 4 CAPSCREW .................................................................................................................................. 4 CAPSCREW ................................................................................................................................ 20 CAPSCREW .................................................................................................................................. 3 WASHER ..................................................................................................................................... 16 WASHER ....................................................................................................................................... 8 WASHER ....................................................................................................................................... 6 WASHER ....................................................................................................................................... 4 WASHER ....................................................................................................................................... 4 LOCK WASHER ........................................................................................................................... 26 HOSE............................................................................................................................................. 2 HOSE............................................................................................................................................. 1 HOSE ............................................................................................................................................ 1 HOSE............................................................................................................................................. 1 HOSE............................................................................................................................................. 1 VALVE ASSEMBLY, N&B CONTROL ............................................................................................. 1 CAPSCREW .................................................................................................................................. 4

YM42H01106P1.............

YM42H01117P1.............

YM42H01118P1.............

YM43H01040P1.............

YM43H01041P1.............

YN02B01031D2 .............

YN03H01489P1 .............

YN11E01111P1 .............

YN11E01112P1 .............

YN20T01414P1 .............

YN42H01366P1 .............

YN68H01035P1 .............

YN68H01071P1 .............

YN68H01073P1 .............

YT20T01054P1 ..............

YW43H01044P1 ............

YY20T01039P1..............

ZD12A01600..................

ZD12A01800..................

ZD12A02100..................

ZD12P02400..................

ZE72X04000 ..................

ZE72X06000 ..................

ZE72X16000 ..................

ZG23F10012..................

ZG33F10012..................

ZH22X04000..................

ZH22X04006..................

ZH32X04000..................

ZH32X04006..................

ZH42X04000..................

ZM61C06016 .................

ZN18C12010 .................

ZS18C08020..................

ZS18C08025..................

ZS18C08065..................

ZS18C10020..................

ZS18C10030..................

ZS18C12030..................

ZS18C12045..................

ZS18C12060..................

ZS18C12065..................

ZW16H08000.................

ZW16H10000.................

ZW16H12000.................

ZW16X08000 .................

ZW16X10000 .................

ZW26X12000 .................

ZX20H12105..................

ZX30H10058..................

ZX30H10066..................

ZX50H12185..................

ZX50H16185..................

YN30V00075F1 .............

ZS23C12090..................

Page 2 of 39

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INSTRUCTION SHEET FOR EH160LC 2 WAY - HAND CONTROL (W/BOOM and STD ARM PIPING) REF. PART NO.

DESCRIPTION

QTY.

99. YN03M01503P1.............HARD RUBBER BOOT.................................................................................................................... 2 100. YN03M01505P1.............FLEXIBLE RUBBER BOOT ............................................................................................................. 2 101. PY01P01043D6 ............. PLASTIC TIES ................................................................................................................................6

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Page 3 of 39

INSTRUCTION SHEET FOR EH160LC 2 WAY - HAND CONTROL (W/BOOM and STD ARM PIPING)

GENERAL INFORMATION When used in the instructions, reference numbers from the parts list are in parenthesis.

NOTE: Unless otherwise noted, all dimensions are in millimeters.

MACHINE PREPARATION WARNING: Never work on a machine that has just finished working. Allow the machine to cool until oils and fluids are warm, not hot.

Release hydraulic tank pressure before working with any hydraulic components.

Figure 3

DC04E123

6. Move the control levers forward, backward, right, and left several times to release pressure in the hydraulic system components.

Figure 1

DC04E121

1. Park the machine on a level surface.

2. Turn the upper structure at right angle to the undercarriage.

3. Extend the attachment to the maximum and lower it to the floor.

4. Stop the engine. Put the ignition key in the ON position.

1 2 Figure 4

DC04A002

1. AIR RELEASE BUTTON 2. HYDRAULIC TANK BREATHER

NOTE: The hydraulic tank breather is located on top of the tank.

WARNING: Gasses from the hydraulic tank may be hot. Wear safety equipment.

7. Remove the cap on the hydraulic tank breather and push the air release button down to release the pressure in the hydraulic tank.

1 Figure 2

DC04E122

1. FUNCTION CANCELLATION LEVER

5. Lower the function cancellation lever to the down position to unlock the hydraulic system.

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INSTRUCTION SHEET FOR EH160LC 2 WAY - HAND CONTROL (W/BOOM and STD ARM PIPING) VACUUM PUMP USAGE NOTE: To minimize oil loss during installation of the kit, it is highly recommended the use of a vacuum pump on the hydraulic tank capable to vacuum 762 mm Hg (30 in Hg).

1

Figure 5

DC04E124

1. FUNCTION CANCELLATION LEVER

8. Put the function cancellation lever in the up position to lock the hydraulic system.

9. Put the ignition key in the OFF position and remove the ignition key.

10. Put a DO NOT OPERATE tag on the Operator’s console.

1 Figure 7

DC04A004

1. HYDRAULIC TANK BREATHER

1. Remove the hydraulic tank breather. Do not remove the rubber gasket.

2 1

1

Ø7 MM X 4

Ø75 MM

10 MM

2

Figure 8

DC04B329

Figure 6

DC04E125

1. NEGATIVE (-) BATTERY CABLE 2. POSITIVE (+) BATTERY CABLE

11. Disconnect the negative (-) battery cable from the battery terminal.

INSTALLATION

Ø90 MM

1. ADAPTER PLATE 2. CONNECTOR

2. Fabricate an adapter plate for the installation of the vacuum pump. Drill and thread this plate to accept the connector to be used with the vacuum pump connection. Use existing breather bolts removed in the previous step to install this plate on the opening for the tank breather.

IMPORTANT: Make sure the Machine Preparation instructions are completed before doing the following procedures.

WARNING: Avoid oil spills. Use container, rags, and/or paper towels to contain any oil leakage. Dispose all waste oils and other hazardous waste in accordance with government environmental regulations.

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INSTRUCTION SHEET FOR EH160LC 2 WAY - HAND CONTROL (W/BOOM and STD ARM PIPING)

1

2 1 Figure 9

DC04B330

1. CONNECTOR 2. VACUUM PUMP

3. Install vacuum pump connector on the adapter plate and install vacuum pump.

4. Operate the vacuum pump whenever a hose and/or tube is to be disconnected.

REMOVE COVERS TO GAIN ACCESS TO THE AREAS WHERE THE KIT PARTS WILL BE INSTALLED

2

1

Figure 11

DC04C626

1. AIR CLEANER COMPARTMENT FRONT PANEL

2. Remove the air cleaner compartment front panel to gain access to the control hoses clamps at the rear of the cab.

Steps in removing the front panel:

Figure 10

DC04C632

1. MAIN CONTROL VALVE COVER 2. MOUNTING BOLTS

1 Figure 12

DC04C627

1. Remove the main control valve cover to gain access to the control valve.

1. LEFT REAR COMPARTMENT DOORS

a. Open left rear compartment doors. Secure doors open.

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INSTRUCTION SHEET FOR EH160LC 2 WAY - HAND CONTROL (W/BOOM and STD ARM PIPING)

1 Figure 15

DC04C629

1. AIR CLEANER COMPARTMENT TOP COVER

e. Remove the air cleaner compartment top cover.

1

3 Figure 13

DC04C626

1

1. AIR CLEANER COMPARTMENT DOOR

NOTE: The air cleaner compartment door weights 15 Kg (33 lbs). Have somebody to hold it while removing the mounting bolts. b. Remove the air cleaner compartment door.

1 2 Figure 16

DC04C630

2

1. WASHER PUMP HARNESS 2. WASHER PUMP HOSE 3. PLASTIC TIES

f. Cut the plastic ties that hold the washer pump harness to the panel. Remove the harness and hose from the panel.

3 Figure 14

DC04C628

1. WINDSHIELD WASHER FLUID RESERVOIR 2. WASHER PUMP HARNESS 3. WASHER FLUID HOSE

c. Remove the washer pump harness and washer fluid hose from the reservoir. d. Push reservoir upward and remove it from the bracket.

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Page 7 of 39

INSTRUCTION SHEET FOR EH160LC 2 WAY - HAND CONTROL (W/BOOM and STD ARM PIPING)

1

2

2

1 Figure 19

DC04E129

1. MIDDLE LOWER COVER 2. MOUNTING BOLTS

Figure 17

DC04C631

4. Remove the middle lower cover under the cab to gain access to the pilot block.

1. AIR CLEANER COMPARTMENT FRONT PANEL 2. MOUNTING BOLTS

NOTE: The front panel weights 15 Kg (33 lbs). Have somebody to hold it while removing the mounting bolts. g. Remove the cap screws that mount the front panel to the upper structure. Remove the front panel.

2

1 Figure 18

DC04E128

1. FRONT LOWER COVER 2. MOUNTING BOLTS

3. Remove the front lower cover under the cab to gain access to the pilot control valve.

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INSTRUCTION SHEET FOR EH160LC 2 WAY - HAND CONTROL (W/BOOM and STD ARM PIPING) INSTALL THE N&B CONTROL VALVE NOTE: Number in parenthesis in the instruction refer to the reference number in the Parts List.

NOTE: Lubricate O-rings with hydraulic oil prior to installation.

Never use thread locking adhesive on pilot block connectors and pilot hoses.

3

2. Position the end cover and YN30V00075F1 N&B Control Valve (97). Make sure that the O-rings in the N&B control valve and main control valve body are properly seated in the O-ring grooves.

3. Use one of the ZS23C12090 Allen Head Capscrews (98) as a guide to hold the end cover and the N&B control valve together during installation. Secure the valve group with another capscrew to the main control valve. Use care during the installation to avoid damaging the O-rings.

4. Install the rest of the four ZS23C12090 Allen Head Capscrews (98) in securing the end cover and the N&B control valve to the main control valve. Tighten the capscrews in opposite angle to 98~118 N.m (72~87 lbf-ft) torque.

WARNING: Clean all spilled oil to prevent fire. Dispose of hazardous waste according to environmental laws and regulations.

2

1

INSTALL THE HYDRAULIC CONTROL LINES Figure 20

DC04F040

1. EXISTING ALLEN HEAD CAPSCREWS 2. END COVER 3. MAIN CONTROL VALVE

NOTE: Lubricate O-rings with hydraulic oil prior to installation.

1. Remove the existing allen head capscrews that secure the end cover to the LH valve bank of the control valve and remove the end cover. These capscrews will not be reused. The O-rings between the end cover and valve body will be reused.

3 1

NOTE: Number in parenthesis in the instruction refer to the reference number in the Parts List.

NOTE: Never use thread locking adhesive on pilot block connectors and pilot hoses.

1

2

4

Figure 22

DC04A178

1. FLOOR MAT

6

1. Remove cab floor mat. The floor mat is not bolted to the floor plate. The floor mat will be reused.

5 DC04F041

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2.

3.

4.

5.

6.

Figure 21

ZS23C12090 - ALLEN HEAD CAPSCREWS YN30V00075F1 - N&B CONTROL VALVE O-RINGS - PART OF N&B CONTROL VALVE END COVER O-RINGS -EXISTING IN MAIN CONTROL VALVE BODY MAIN CONTROL VALVE

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INSTRUCTION SHEET FOR EH160LC 2 WAY - HAND CONTROL (W/BOOM and STD ARM PIPING)

1

5 1

4

2

2

FRONT VIEW

Figure 23

DC04B303

2 3

3

SIDE VIEW

Figure 25

DC04G002

1. RH FOOT REST 2. MOUNTING BOLT

2. Remove the sems bolts that mount the RH foot rest.

3 2

1.

2.

3.

4.

5.

YN68H01073P1 - SOLENOID VALVE BRACKET ZS18C10020 - CAPSCREW ZW16X10000 - WASHER LC35V00004F2 - SOLENOID VALVE ASSY. SOLENOID VALVE SUPPORT

5. Install YN68H01073P1 Solenoid Valve Bracket (57) to the valve support. Secure the bracket to the support with two ZS18C10020 Capscrews (80) and two ZW16X10000 Washers (90).

6. Install the LC35V00004F2 Solenoid Valve (29) to the solenoid valve bracket. Secure the valve to the bracket with two ZS18C10020 Capscrews (80) and two ZW16X10000 Washers (90).

Tighten the capscrews to 22 ± 2 N.m (16 ± 2 lbf-ft).

1 DC04G001

Figure 24

1. YN68H01071P1 - SOLENOID VALVE SUPPORT 2. EXISTING RH FOOT REST 3. EXISTING SEMS BOLTS

3. Mount YN68H01071P1 Solenoid Valve Support (56) under the RH foot rest and install back the foot rest using the same sems bolt that were removed. Tighten the bolts to 46 ± 5 N.m (34 ± 4 lbf-ft) torque.

1

6

2

4

4. Install back the floor mat.

3

5

5 Figure 26

DC04G003

1.

2.

3.

4.

5.

6.

HH25R04004G5 - CONNECTOR 2444Z2894 - ELBOW ZH42X04000 - ELBOW ZH22X04000 - CONNECTOR ZH32X04000 - ELBOW SOLENOID VALVE

7. Install HH25R04004G5 Connector (26) to the “P” port of the solenoid valve. Tighten the connector to 29 ± 2 N.m (21 ± 2 lbf-ft) torque.

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INSTRUCTION SHEET FOR EH160LC 2 WAY - HAND CONTROL (W/BOOM and STD ARM PIPING) 8. Install 2444Z2894 Elbow (17) to the connector at “P” port of solenoid valve.

9. Install ZH42X04000 Elbow (74) to the elbow that is connected to the connector in port “P” of the solenoid valve. Position the elbow as shown in Figure 26.

16. Tighten the hoses to the fittings.

NOTE: Make sure that the other end of the pilot hoses are plugged and/or covered to prevent dirt from getting inside the hose during routing.

10. Install ZH22X04000 Connector (70) to the “T” port of the solenoid valve. Tighten the connector to 29 ± 2 N.m (21 ± 2 lbf-ft) torque.

11. Assemble the two ZH32X04000 Elbow (72) to the bottom ports of the solenoid valve (one on port “A” and one on port “B”). Position the elbows as shown in Figure 26. Tighten the elbows to 29 ± 2 N.m (21 ± 2 lbf-ft) torque.

1 Figure 28

DC04A214

1. RH PILOT HOSE CLAMP

2

17. Locate the RH pilot hose clamp under the cab.

Remove the clamp bolts and washers. Lower the clamp with the hoses.

5

4

5

6

7

1 1

4

3 Figure 27

DC04G005

1.

2.

3.

4.

5.

2420R349D110 - HOSE (S/V P) 2444R1120D110 - HOSE (S/V T) 2420R349D280 - HOSE (S/V B) 2420R349D315 - HOSE (S/V A) SOLENOID VALVE

2

8 9

Figure 29

DC04C636

NOTE: Label the pilot hoses for ease of installation and routing.

12. Install 2444R1120D110 Hose (14) to the “T” port of the solenoid valve.

13. Install 2420R349D110 Hose (6) to the “P” port of the solenoid valve.

14. Install 2420R349D315 Hose (8) to the “A” port of the solenoid valve.

3

1.

2.

3.

4.

5.

6.

7.

8.

9.

YN68H1035P1 - CLAMP ZW16X08000 - WASHER ZS18C08065 - CAPSCREW 2420R349D280 - HOSE (S/V B) 2420R349D315 - HOSE (S/V A) 2444R1120D110 - HOSE (S/V T) 2420R349D110 - HOSE (S/V P) EXISTING CLAMP EXISTING HOSES

18. Insert the new YN68H01035P1 Clamp (55) on top of the existing clamp.

15. Install 2420R349D280 Hose (7) to the “B” port of the solenoid valve.

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Page 11 of 39

INSTRUCTION SHEET FOR EH160LC 2 WAY - HAND CONTROL (W/BOOM and STD ARM PIPING) 19. Place the pilot hoses through the slots of the new clamp as indicated in Figure 29 (view looking from the front of the cab).

NOTE: Make sure to place the pilot hoses (S/V B), (S/V A), (S/V T), and (S/V P) respectively from right to left through the plastic clamp.

20. With the new clamp on top of the existing clamp, fastened the clamps with two ZS18C08065 Capscrews (79) and two ZW16X08000 Washers (89). Use medium strength thread locking adhesive on the capscrews and tighten to 10 ± 1 N.m (7 ± 0.7 lbf-ft) torque.

21. Continue routing the pilot hoses towards the rear of the cab.

3

2

3

1

4

5

Figure 31

DC04C637

1.

2.

3.

4.

5.

ZH32X06000 - ELBOW FITTING 90° 2444Z2336 - TEE FITTING ZH22X06000 - STRAIGHT FITTING 2444Z2359 - TEE FITTING EXISTING PILOT BLOCK

25. Remove ZH32X0600 90° elbow fitting from the existing pilot block. This fitting will be reused in the new pilot block.

26. Remove 2444Z2336 Tee fitting from the existing pilot block. This fitting will be reused in the new pilot block.

27. Remove the two ZH22X06000 straight fittings from the existing pilot block. These fittings will be reused in the new pilot block.

28. Remove 2444Z2359 Tee fitting from the existing pilot block. This fitting will be reused in the new pilot block.

1

29. Remove the existing pilot block from the block bracket.

Figure 30

DC04B331

1. EXISTING STANDARD PILOT BLOCK

22. Locate the pilot block under the cab where the middle lower cover was removed.

23. Label each one of the pilot hoses connected to the existing standard block and take note of their locations.

NOTE: Put a wooden block between the pilot block and the cab floor to avoid over stressing the pilot block bracket while disconnecting the pilot hoses and removing the connector fittings.

24. Disconnect all hoses from the existing standard block.

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INSTRUCTION SHEET FOR EH160LC 2 WAY - HAND CONTROL (W/BOOM and STD ARM PIPING) C

5

30. Clean the capscrews that were removed from the old pilot block. Apply medium strength thread locking adhesive to the capscrews. Install the new 2416N6141 pilot block (4) to the block bracket using these capscrews and washers.

Tighten capscrews to torque specification.

6

4

6

B

7

3

NOTE: Put a wooden block between the pilot block and the cab floor to avoid over stressing the pilot block bracket while installing the fittings and hoses.

8

2 1 10

31. Install ZE72X04000 Plug (65) to the front LH “P” port of the new pilot block.

9

32. Install ZH32X06000 90° Elbow Fitting that was removed from the old pilot block to the front middle “P” port of the new block. Position elbow as shown in VIEW B. Inspect fitting O-ring.

Replace O-ring if damaged before installing fitting.

A

33. Install ZH22X04000 Straight Fitting (70) to the front RH “P” port of the new pilot block.

VIEW

A

34. Install 2444Z2336 Tee Fitting that was removed from the old pilot block to the RH side “P” port of the new pilot block. Position the tee as shown in VIEW C. Inspect fitting O-ring. Replace O-ring if damaged before installing fitting.

11 VIEW

35. Install the two ZH22X06000 Straight Fittings that were removed from the old pilot block. One fitting to the RH side “T” port and one to the rear RH “T” port. Inspect fitting O-ring. Replace O-ring if damaged before installing fittings.

B

36. Install ZH32X04006 90° Elbow Fitting (73) to the rear middle “T” port of the new pilot block.

37. Install ZE72X06000 Plug (66) to the rear LH “T” port of the new pilot block.

VIEW

C Figure 32

DC04A210

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

2416N6141 - PILOT BLOCK (NEW) ZE72X04000 - PLUG ZH32X06000 - ELBOW FITTING 90° ZH22X04000 - STRAIGHT FITTING 2444Z2336 - TEE FITTING ZH22X06000 - STRAIGHT FITTING ZH32X04006 - ELBOW FITTING 90° ZE72X06000 - PLUG 2444Z2359 - TEE FITTING ZH22X04000 - STRAIGHT FITTING CAPSCREW & WASHER

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38. Install 2444Z2359 Tee Fitting that was removed from the old pilot block to the LH side “T” port of the new pilot block. Position the tee as shown in VIEW A. Inspect fitting O-ring. Replace O-ring if damaged before installing fitting.

39. Install ZH22X04000 Straight Fitting (70) to the LH side “P” port of the new pilot block.

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Page 13 of 39

INSTRUCTION SHEET FOR EH160LC 2 WAY - HAND CONTROL (W/BOOM and STD ARM PIPING)

4

5

1 1 2

2

6 7 Figure 33

DC04B332

1. 2420R349D110 - HOSE (S/V P) 2. 2444R1120D110 - HOSE (S/V T)

40. Connect 2420R349D110 (S/V P) hose connected from the “P” port of the solenoid valve to the front RH “P” port of the new pilot block.

41. Connect 2444R1120D110 (S/V T) hose connected from the “T” port of the solenoid valve to the rear middle “T” port of the new pilot block.

42. Reconnect all the hoses that were disconnected from the old pilot block to the new pilot block.

Make sure that the hoses are connected to their proper ports.

43. Continue routing the 2420R349D280 (S/V B) and 2420R349D315 (S/V A) hoses through the structure opening under the cab towards the rear of the cab.

3 Figure 35

DC04C639

1.

2.

3.

4.

5.

6.

7.

YN68H01035P1 - CLAMP ZW16X08000 - WASHER ZS18C08065 - CAPSCREW 2420R349D280 - HOSE (S/V B) 2420R349D315 - HOSE (S/V A) EXISTING CLAMP EXISTING HOSES

46. Insert the new YN68H01035P1 Clamp (55) on top of the existing clamp.

47. Place the pilot hoses through the slots of the new clamp as indicated in Figure 35 (view looking from the front of the cab).

NOTE: Make sure to place the pilot hoses S/V B and S/V A respectively from right to left through the plastic clamp.

48. With the new clamp on top of the existing clamp, fastened the clamps with two ZS18C08065 Capscrews (79) and two ZW16X08000 Washers (89). Use medium strength thread locking adhesive on the capscrews and tighten to 10 ± 1 N.m (7 ± 0.7 lbf-ft) torque.

49. Continue routing the S/V B and S/V A hoses toward the control valve.

1

Figure 34

DC04C638

1. PILOT HOSES CENTER CLAMP

44. Locate the pilot hoses center clamp behind the operator’s cab.

45. Remove the clamp bolts and washers. Lower the clamp with the hoses.

Page 14 of 39

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INSTRUCTION SHEET FOR EH160LC 2 WAY - HAND CONTROL (W/BOOM and STD ARM PIPING)

1

53. Continue routing the 2420R349D315 (S/V A) hose and pass it through the pilot hose rubber protector. You may have to cut the plastic ties that secured the rubber protector to facilitate the routing of the hose toward the top PA02 port of the N&B control valve. Make sure to wrap the hoses with the rubber protector and secure the protector with plastic ties after routing the hoses.

2

NOTE: (S/V A) hose connected from the “A” port of the solenoid valve will be connected to the top PA02 port of the N&B control valve and the (S/V B) hose connected from “B” port of the solenoid valve will be connected to the bottom PB02 port.

2

Figure 36

DC04C638

1. RUBBER WRAPPING 2. PLASTIC TIES

50. Cut the plastic ties that secured the rubber wrapping.

1

51. Unwrapped the pilot hoses and route the S/V B and S/V A hoses with the old hoses.

52. Wrap the control hoses with the rubber wrapping.

Secure the rubber wrapping with plastic ties.

3 Figure 38

DC04B327

1

1. N&B CONTROL VALVE 2. ZH32X04006 - ELBOW FITTING 90° 3. ZH22X04006 - STRAIGHT FITTING

54. Remove the plug on top “PA02” port of the N&B control valve and install ZH32X04006 Elbow fitting (73).

55. Remove the plug on the bottom “PB02” port of the N&B control valve and install ZH22X04006 Straight fitting (71).

2 3

1

Figure 37

DC04B326

1. 2420R349D315 - HOSE (S/V A) 2. RUBBER PROTECTOR WRAPPING 3. PLASTIC TIE

2 Figure 39

DC04B328

1. 2420R349D315 - HOSE S/V A) 2. 2420R349D280 - HOSE (S/V B)

56. Connect the (S/V A) hose to the elbow fitting in the “PA02” port of the N&B control valve.

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Page 15 of 39

INSTRUCTION SHEET FOR EH160LC 2 WAY - HAND CONTROL (W/BOOM and STD ARM PIPING) 57. Connect the (S/V B) hose to the straight fitting in the “PB02” port of the N&B control valve.

58. Tighten hoses to the fittings.

INSTALLATION OF THE HYDRAULIC CONTROL HAND GRIPS AND ELECTRICAL HARNESSES

3

Replacing the LH Hand Grip

1 2 Figure 42

DC04G008

1. SEMS BOLTS 2. OUTER COVER 3. INNER COVER

1

4. Raise the boot from the tower.

2 Figure 40

DC04G007

5. Remove the three sems bolts (one on top front, one in the bottom front, and one in the middle rear) that retain the side covers to the control box.

1. LH CONSOLE INSTRUMENT PANEL 2. LH CONTROL BOX

1. Remove the screw caps and remove the screws that fastened the LH console instrument panel to the control box.

2. Lift the panel and flip it toward the seat.

1

2 Figure 43

DC04G009

1. ELECTRICAL HARNESS 2. HAND GRIP ELECTRICAL WIRE PLUG

1

6. Remove the outer cover to gain access to the electrical harness that connects to the hand grip electrical wires.

2 Figure 41

DC04G006

1. FLEXIBLE RUBBER BOOT 2. BOOT RETAINER LOCK

3. Using a small flat screw driver push the flexible boot retainer lock on each corner to release the boot from the control box.

Page 16 of 39

7. Unplug the hand grip electrical wire from the harness. For ease of unplugging, insert the tip of a small flat screw driver into the slot of the male plug and push it away from the female plug.

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INSTRUCTION SHEET FOR EH160LC 2 WAY - HAND CONTROL (W/BOOM and STD ARM PIPING) 12. Transfer the jam nut from the old hand grip to the new hand grip assembly.

1

1 2

3

4

4

3

Figure 46

DC04G012

Figure 44

DC04G010

1.

2.

3.

4.

1.

2.

3.

4.

HAND GRIP JAM NUT PILOT VALVE NUT WRENCHES

8. Using two wrenches, loosen the jam nut that lock the hand grip to the pilot valve. Unscrew the hand grip from the pilot valve.

1 3

4 DC04G011

LH HAND GRIP ASSEMBLY JAM NUT PILOT VALVE NUT CONTROL PIVOT POINT

13. Assemble the new hand grip to the pilot valve.

Screw the hand grip lever until the top of the hand grip is about 250 mm (9.8 inches) from the pilot valve control pivot point as shown in Figure 46.

14. Position the hand grip with the switch buttons facing toward the operator. Lock the hand grip to the pilot valve by tightening the jam nut against the pilot valve nut to 58 ± 6 N.m (43 ± 4 lbf-ft) torque.

2

1.

2.

3.

4.

5.

2

5 Figure 45

YB03M01003F2 - LH GRIP ASSEMBLY YN03M01503P1 - HARD RUBBER BOOT YN03M01505P1 - FLEXIBLE RUBBER BOOT JAM NUT FROM THE OLD GRIP ASSEMBLY RETAINER PLATE FROM THE OLD FLEXIBLE BOOT

9. Disassemble the retaining plate from the old flexible rubber boot and assemble it to the new YN03M01505P1 Flexible Rubber Boot (100).

10. Assemble the new YN03M01503P1 Hard Rubber Boot (99) to the new flexible rubber boot.

Make sure that the flexible boot is properly inserted to the hard rubber boot groove.

11. Assemble the new YB03M01003F2 LH Grip Assembly (34) to the boot assembly. Make sure that the hard rubber boot is properly inserted to the hand grip handle groove.

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Page 17 of 39

INSTRUCTION SHEET FOR EH160LC 2 WAY - HAND CONTROL (W/BOOM and STD ARM PIPING)

3

4 1

1

6 2

Figure 47

DC04G027

1. LH STANDARD ELECTRICAL HARNESS

5

15. Connect the Horn switch electrical wiring connector (with yellow & green wires) to the standard harness wiring connector (with blue taping) where the old hand grip wiring was disconnected.

16. Leave the control box open until the auxiliary (N&B) wiring harness has been routed.

Replacing the RH Hand Grip

Figure 49

DC04G026

1.

2.

3.

4.

5.

6.

FLEXIBLE BOOT RETAINER LOCK JAM NUT PILOT VALVE NUT SEMS BOLT INNER COVER OUTER COVER

19. Using a small flat screw driver push the flexible boot retainer on each corner to release the boot from the control box.

20. Raise the boot from the tower.

21. Remove the three sems bolts (one on top front, one in the bottom front, and one in the middle rear) that retain the side covers to the control box.

1

22. Remove the inner cover to gain access to the electrical harness that connects to the hand grip electrical wires.

Figure 48

23. Unplug the hand grip electrical wire from the harness. For ease of unplugging, insert the tip of a small flat screw driver into the slot of the male plug and push it away from the female plug.

17. Remove the screw caps and remove the screws that fastened the RH console instrument panel to the control box.

24. Using two wrenches, loosen the jam nut that lock the hand grip to the pilot valve. Unscrew the hand grip from the pilot valve.

DC04G025

1. RH CONSOLE INSTRUMENT PANEL

18. Lift the panel and flip it toward the wall.

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INSTRUCTION SHEET FOR EH160LC 2 WAY - HAND CONTROL (W/BOOM and STD ARM PIPING)

1 2 3

5 1

4 Figure 50

DC04G011

1.

2.

3.

4.

5.

YB03M01003F3 - RH GRIP ASSEMBLY YN03M01503P1 - HARD RUBBER BOOT YN03M01505P1 - FLEXIBLE RUBBER BOOT JAM NUT FROM OLD GRIP ASSEMBLY RETAINER PLATE FROM OLD FLEXIBLE BOOT

Figure 51

DC04G028

1. RH STANDARD ELECTRICAL HARNESS

25. Disassemble the retaining plate from the old flexible rubber boot and assemble it to the new YN03M01505P1 Flexible Rubber Boot (100).

26. Assemble the new YN03M01503P1 Hard Rubber Boot (99) to the new flexible rubber boot. Make sure that the flexible boot is properly inserted to the hard rubber boot groove.

31. Connect the Power Boost switch electrical wiring connector (with yellow & green wires) to the standard harness wiring connector (with yellow taping) where the old hand grip wiring was disconnected.

32. Leave the control box open until the auxiliary (N&B) wiring harness has been installed.

27. Assemble the new YB03M01003F3 RH Grip Assembly (35) to the boot assembly. make sure that the hard rubber boot is properly inserted to the hand grip handle groove.

28. Transfer the jam nut from the old hand grip to the new hand grip assembly.

29. Assemble the new hand grip to the pilot valve.

Screw the hand grip lever until the top of the hand grip is about 250 mm (9.8 inches) from the pilot valve control pivot point.

30. Position the hand grip with the switch buttons facing toward the operator. Lock the hand grip to the pilot valve by tightening the jam nut against the pilot valve nut to 58 ± 6 N.m (43 ± 4 lbf-ft) torque.

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Page 19 of 39

INSTRUCTION SHEET FOR EH160LC 2 WAY - HAND CONTROL (W/BOOM and STD ARM PIPING) INSTALLING THE AUXILIARY (N&B) ELECTRICAL WIRING HARNESS INSIDE THE CAB

YN11E01111P1 - AUXILIARY (N&B) HARNESS Figure 52

DC04G029

1. SEAT BACK RECLINING ADJUSTMENT LEVER 2. SEAT STAND FORWARD & BACKWARD ADJUSTMENT BAIL 3. SEAT FORWARD & BACKWARD ADJUSTMENT BAIL 4. SEAT

1

33. For easy access to the rear panel: a. Raise the seat arm rests all the way up. b. Position the seat back all the way to the front by pulling the reclining adjustment lever. c. Move the seat stand all the way forward by pulling up the bottom bail and pulling the seat stand forward.

2

d. Move the seat all the way forward by pulling up the top bail and pulling the seat forward.

4

3 DC04G033

Page 20 of 39

Figure 53

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INSTRUCTION SHEET FOR EH160LC 2 WAY - HAND CONTROL (W/BOOM and STD ARM PIPING)

2

1

2

39. Remove the Controller and Relays Cover mounting screws and flip both the controller and cover towards the front to gain access to the relays under the controller.

2

2

3 3

3

5

5 1 6

6

4

Figure 54

DC04D556

1.

2.

3.

4.

5.

6.

2

REAR PANEL UPPER COVER UPPER COVER TOP MOUNTING SCREWS UPPER COVER BOTTOM LOCKS REAR PANEL LOWER COVER LOWER COVER TOP LOCKS LOWER COVER BOTTOM LOCKS

Figure 56

DC04G036

1. EN24S00008P1 - NIBBLER OPEN RELAY 2. EN24S00008P1 - NIBBLER CLOSE RELAY 3. ZM61C06016 - SEMS BOLTS

34. Remove the rear panel upper cover top mounting screws and press the bottom locks to release the cover.

35. Tilt the cover towards the seat and pull out the speaker wires and 12V adapter wires.

40. Install two EN24S00008P1 Relays (20) into the relay plate and secure each with ZM61C06016 Sems Bolt (75) to the plate. Mark the RH relay “Nibbler Open Relay” and the LH relay “Nibbler Close Relay” for identification.

36. Remove the upper cover.

1

37. Press the rear panel lower cover top locks to release the top side of the lower cover, then press the bottom locks to release the bottom side of the cover to remove it.

2

38. Remove the lower cover.

3

2 3

3 DC04G038

Figure 57

1. YN11E01111P1 - N&B ELECTRICAL HARNESS 2. RH CONTROL BOX 3. LH CONTROL BOX

1 3 Figure 55

DC04G035

1. CONTROLLER 2. RELAYS COVER 3. MOUNTING SCREWS

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41. Install YN11E01111P1 Auxiliary (N&B) Electrical Harness (51) (see Figure 52 for harness identification) by threading first the pigtails with white tape (BrW - B wires) and red tape (VW - B wires) to the right console following the standard harness that is already installed in the control box. Clip the wiring with the standard harness.

Page 21 of 39

INSTRUCTION SHEET FOR EH160LC 2 WAY - HAND CONTROL (W/BOOM and STD ARM PIPING) 42. Continue routing the harness following the standard harness. Position the pigtail with connector marked “NIBBLER” in the right corner where the standard harness is routed down under the floor plate.

1

2

1 3

2

RH CONTROL BOX Figure 59

DC04G040

1. RH GRIP ASSEMBLY 2. GRIP WIRING 3. AUXILIARY HARNESS WIRING

3 Figure 58

DC04G039

1. NIBBLER OPEN RELAY 2. NIBBLER CLOSE RELAY 3. PY01P01043D3 - PLASTIC TIES

43. Continue routing the harness under the control box. Connect the connector with “OPEN” tag to the RH nibbler “open” relay and the connector with “CLOSE” tag to the LH nibbler “close” relay.

44. Connect the harness connector with “INST” tag to the standard harness connector under the controller. Match the connectors.

48. In the RH control box with the RH grip installed and the auxiliary harness wiring in place, connect the Nibbler Open Switch wiring (white taping) to the auxiliary harness wiring with white taping.

Connect the Nibbler Close Switch wiring (red taping) to the auxiliary harness wiring with red taping. The Power Boost switch wiring is connected to the standard harness wiring with yellow taping.

1

45. Tie the harness to the standard harness with PY01P01043D3 Plastic Ties (32).

46. Continue routing the harness through the hole in the relay plate down to the LH control box.

3

47. Thread the pigtails with white tape (LO - B wires) and red tape (GY - B wires) inside the LH console following the standard harness that is already installed in the control box. Clip the wiring with the standard harness.

2

LH CONTROL BOX Figure 60

DC04G042

1. LH GRIP ASSEMBLY 2. GRIP WIRING 3. AUXILIARY HARNESS WIRING

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INSTRUCTION SHEET FOR EH160LC 2 WAY - HAND CONTROL (W/BOOM and STD ARM PIPING) 49. In the LH control box with the LH grip installed and the auxiliary harness wiring in place, connect the Clockwise Switch wiring (white taping) to the auxiliary harness wiring with white taping.

Connect the Counterclockwise Switch wiring (red taping) to the auxiliary harness wiring with red taping. The Horn switch wiring is connected to the standard harness wiring with Blue taping.

1

2

NOTE: Clockwise and Counterclockwise Switches will be connected but will not be powered and used.

They are use only on machine with Rotation Attachment.

3 Figure 63

DC04G046

1. EXISTING STANDARD HARNESS 2. HARNESS CLIP 3. RH REAR CORNER TUNNEL

51. Following the routing of the existing standard harness route the harness from the solenoid valve to the right rear corner tunnel where the standard harness is threaded up inside the cab.

Thread the end of the harness with single connector up inside the cab.

DC04G043

Figure 61

52. Clip the solenoid harness with the standard harness.

NOTE: Figure 61 shows correct location of the grip switches.

Installing the Solenoid Valve Electrical Harness

1

2 Figure 64

DC04G045

1. N&B SOLENOID VALVE UNDER THE RH FOOT REST 2. N&B SOLENOID VALVE HARNESS

YN11E01112P1 - N&B SOLENOID HARNESS DC04G044

Figure 62

50. Install YN11E01112P1 N&B Solenoid Valve Harness (52) under the cab floor plate.

53. Connect harness wire connector tagged “OPEN” to solenoid “B”.

54. Connect harness wire “CLOSE” to solenoid “A”.

connector

tagged

55. Connect harness single connector to the a u x i l i a r y h a r n e s s w i r e c o n n e c t or t a g g e d “NIBBLER”.

56. Recheck all electrical wiring connections.

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Page 23 of 39

INSTRUCTION SHEET FOR EH160LC 2 WAY - HAND CONTROL (W/BOOM and STD ARM PIPING) 57. Install back the Controller and covers that were removed in facilitating the grips, auxiliary harness, and solenoid valve harness installation.

INSTALL THE UPPER HYDRAULIC LINES

2

NOTE 1: Number in parenthesis in the instructions refer to the reference number in the Parts List.

3

NOTE 2: Lubricate O-rings with hydraulic oil prior to installation.

NOTE 3: Apply medium strength thread locking adhesive to the mounting bolts (cap screws).

1 4

NOTE 4: Tightening Torques for M-Threads: Thread Size

Tightening Torques

M8

35 ± 4 N.m (26 ± 3 lbf-ft)

M 12

121 ± 12 N.m (89 ± 9 lbf-ft)

Figure 66

DC04C640

1.

2.

3.

4.

NOTE 5: Tightening Torques for PF, PT - Threads: Thread Size

Tightening Torques

3/4

162 ± 15 N.m (119 ± 11 lbf-ft)

1

255 ± 10 N.m (188 ± 7 lbf-ft)

NOTE 6: Tightening Torques for ORS - Joint Nut: Thread Size

Tightening Torques

1 - 14 UNS

137 ± 14 N.m (101 ± 10 lbf-ft)

1 3/16 - 12UNS

177 ± 18 N.m (131 ± 13 lbf-ft)

1 7/16 - 12UNS

206 ± 21 N.m (152 ± 15 lbf-ft)

YM03H01043P1 - TUBE SUPPORT ZS18C12030 - CAPSCREW ZW16H12000 - WASHER ANGLE BRACKET

2. Install YM03H01043P1 Tube Support (39) to the angle bracket with two ZS18C12030 Capscrews (82) and two ZW16H12000 Washers (88).

Tighten the capscrew to torque specification.

1 1

Figure 67

DC04C642

1. TAPPED BLOCK

3. Locate the tapped block welded to the frame at the LH side of the swing motor.

Figure 65

DC04C641

1. ANGLE BRACKET

1. Locate the angle bracket welded to the frame at the LH side of the control valve.

Page 24 of 39

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INSTRUCTION SHEET FOR EH160LC 2 WAY - HAND CONTROL (W/BOOM and STD ARM PIPING) 1.

2.

3.

4.

5.

6.

7.

8.

9.

1

A

3

4

2

VIEW A Figure 68

DC04C643

24100P1005F1 - SELECTOR VALVE ZS18C08020 - CAPSCREW ZW16H08000 - WASHER YN03H01489P1 - TERMINAL BLOCK 2444R399D7 - ELBOW ZG33F10012 - ELBOW HG33H16012G1 - ELBOW HG23H12016G1 - CONNECTOR HG33F10016G1 - ELBOW

5. Install 24100P1005F1 Selector Valve (1) to the valve bracket using four ZS18C08020 Capscrews (77) and four ZW16H08000 Washers (86). Tighten cap screws to torque specification.

YM03H01041P2 - SELECTOR VALVE BRACKET ZS18C12030 - CAPSCREW ZW16H12000 - WASHER TAPPED BLOCK

6. Install YN03H01489P1 Terminal Block (50) to the valve bracket using four ZS18C08020 Capscrews (77) and four ZW16H08000 Washers (86). Tighten cap screws to torque specification.

4. Install YM03H01041P2 Selector Valve Bracket (37) to the tapped block with two ZS18C12030 Capscrews (82) and two ZW16H12000 Washers (88). Tighten capscrews to torque specification.

7. Install 2444R399D7 Elbow (15) to the outer port of the selector valve.

1.

2.

3.

4.

5

9. Install HG33H16012G1 Elbow (25) to the inner port of the selector valve.

10. Install HG23H12016G1 Connector (22) to the face port of the terminal block.

6

1

8. Install the ZG33F10012 Elbow (69) to the top port of the selector valve. Position the elbow as shown.

11. Install HG33F10016G1 Elbow (24) to the top port of the terminal block.

7 A 8

3

3 2

2

2

9 4 1

View A

Figure 70

DC04A175

1. PLUG 2. HYDRAULIC TANK

12. Remove the Plug from the Hydraulic tank.

DC04A174

IS04-013A-NH NA

Figure 69

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Page 25 of 39

INSTRUCTION SHEET FOR EH160LC 2 WAY - HAND CONTROL (W/BOOM and STD ARM PIPING)

1

3 1

2

3

A

1

2 3 Figure 71

DC04A177

1. 2444Z2760 - CONNECTOR 2. 2444Z3722D4 - HOSE

13. Install the 2444Z2760 Connector (16) to the hydraulic tank where the plug was removed.

14. Install 2444Z3722D4 Hose (18) from the selector valve outer elbow to the hydraulic tank connector. Position the hose and tighten to torque specification.

A

1

3

2

3

VIEW A Figure 73

DC04B355

1. ZX30H10058 - HOSE 2. ZX30H10066 - HOSE 3. ZD12A01600 - O-RING

17. Install ZX30H10058 Hose (93) from the selector valve top port to the control valve upper “A02” port. Make sure that ZD12A01600 O-rings (61) are inserted between the connectors on both ends and are in the O-ring grooves before tightening the joint nuts. Position the hose and tighten joint nuts to torque specification.

18. Install ZX30H10066 Hose (94) from the terminal block top port to the control valve lower “B02” port. Make sure that ZD12A01600 O-rings (61) are inserted between the connectors on both ends and are in O-ring grooves before tightening the joint nuts. Position hose and tighten the joint nuts to torque specification.

4

2 VIEW A

Figure 72

DC04A176

1.

2.

3.

4.

UPPER “A02” PORT PLUG LOWER “B02” PORT PLUG ZG23F10012 - CONNECTOR HG24F10012G3 - CONNECTOR

15. Remove the plug from the upper “A02” port of the N&B control valve. Install ZG23F10012 Connector (68) in this port.

16. Remove the plug from the lower “B02” port of the control valve. Install HG24F10012G3 Connector (23) in this port.

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INSTRUCTION SHEET FOR EH160LC 2 WAY - HAND CONTROL (W/BOOM and STD ARM PIPING) 19. Insert ZD12A02100 O-ring (63) to the selector valve inner elbow and install the YM03H01042P1 Tube (38) from this elbow down to the tube support. Make sure that the O-ring is in the O-ring groove. Don’t tighten the joint nut at this time.

20. Insert ZD12A01800 O-ring (62) to the terminal block face connector and install YM03H01015P1 Tube (36) from this connector down to the tube support. Make sure that the O-ring is in the O-ring groove. Don’t tighten the joint nut at this time.

21. Secure the two tubes at the tube support with 2432T2434 Clamp (10), YN02B01031D2 Spacer (49), ZS18C12065 Capscrew (85), two ZW16H12000 Washers (88), and ZN18C12010 Nut (76). Don’t tighten the clamp at this time.

2

1

3

4

22. Position the tubes and tighten the joint nuts to torque specification.

23. Tighten the tube clamp capscrew to torque specification after positioning the tubes.

A

A

4 2

5

8

7 9

8

SECTION A-A Figure 74

DC04B356

ZD12A02100 - O-RING YM03H01042P1 - TUBE ZD12A01800 - O-RING YM03H01015P1 - TUBE 2432T2434 - CLAMP YN02B01031D2 - SPACER ZS18C12065 - CAPSCREW ZW16H12000 - WASHER ZN18C12010 - NUT

IS04-013A-NH NA

Figure 75

DC04B300

6

1.

2.

3.

4.

5.

6.

7.

8.

9.

1

3

1.

2.

3.

4.

ZD12A01800 - O-RING ZX20H12105 - HOSE 2414Z199D100 - HOSE GUARD EXISTING ARM HOSES

24. Insert ZD12A01800 O-rings (62) to the attachment tubes (one on each tube) and connect ZX20H12105 Hoses (92) to each tube.

Make sure that the O-rings are in the O-ring g roo ve s. T igh te n th e jo int nut s to torque specification.

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Page 27 of 39

INSTRUCTION SHEET FOR EH160LC 2 WAY - HAND CONTROL (W/BOOM and STD ARM PIPING) 25. Route the two hoses from the tube support to the boom.

INSTALL THE DOUBLE PUMP FLOW SELECTOR SWITCH

26. If the attachment tubes are already installed in the boom, connect the attachment hoses to the tubes. If not, plug the end of the hoses to prevent dirt from entering the hoses.

27. In connecting the hoses to the tubes, connect the LH hose to the LH tube and RH hose to the RH tube. Make sure that ZD12A01800 O-rings (62) are inserted in between the connectors and are in the O-ring grooves before tightening the connector nuts.

1 2

6

7 2 5

3

28. Assemble the four 2414Z199D100 (3) Hose Guards to the attachment hoses and to the existing arm hoses. These guards are of spiral wrap and can be assembled to the hoses without disconnecting the hoses.

4

Figure 76

DC04B351

1.

2.

3.

4.

5.

6.

7.

SCREW CAP SCREW LH SIDE PANEL CONSOLE HARNESS CONNECTOR MARKED “CONFLUX” PANEL COVER COVER SWITCH CAP 2479U1190F32 - DOUBLE FLOW SWITCH

1. Remove the screw caps and remove the screws that fastened the panel cover.

2. Carefully lift the panel cover and locate the harness connector marked “CONFLUX”. The color of wires for this connector are: B (black), and LY (blue wire with yellow stripe).

3. Remove the cover switch cap and install 2479U1190F32 Double Flow Switch (19) to this opening. Connect the flow switch wire to the harness connector marked “CONFLUX”.

4. Reassemble the panel cover to the console.

NOTE: The flow switch is a two position rocker switch. Press it Forward to activate the double pump flow for the auxiliary system. Press it Backward to cancel the double pump flow and activate the single pump flow for the auxiliary system.

Page 28 of 39

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INSTRUCTION SHEET FOR EH160LC 2 WAY - HAND CONTROL (W/BOOM and STD ARM PIPING) INSTALL THE LABELS

2

1 1

2

Figure 79

DC04B354

Figure 77

DC04B352

1. YT20T01054P1 - CAUTION DECAL 2. OPERATOR’S LH INSTRUMENT PANEL

1. Clean the top area of the operator’s left panel and install YT20T01054P1

1. YN20T01414P1 - CAUTION DECAL 2. PY20T01062P1 - CAUTION DECAL

3. Install the new caution decals inside the cab right side window. Clean glass on left side of existing decals and install YN20T01414P1

Caution Decal (58).

1 2

(53)

and

Caution Decal PY20T01062P1

Figure 78

DC04B353

1. YY20T01039P1 CAUTION DECAL 2. CAB

2. Clean the cab rear right corner surface and install YY20T01039P1

Caution Decal (33).

Caution Decal (60).

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INSTRUCTION SHEET FOR EH160LC 2 WAY - HAND CONTROL (W/BOOM and STD ARM PIPING)

11

13 14

9 10

12 14

14 12

10

14 12 9

14 12

6

5

9

3

4

12 14

9

14 12

7

6

10

10

12 14

2

9

14 12

8

1

8

10

12 14

5

INSTALL THE BOOM HYDRAULIC PIPING

Figure 80

DC04D464

Page 30 of 39

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INSTRUCTION SHEET FOR EH160LC 2 WAY - HAND CONTROL (W/BOOM and STD ARM PIPING) 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

YM42H01105P1 - RH LOWER TUBE YM42H01106P1 - LH LOWER TUBE YM42H01117P1 - RH UPPER TUBE YM42H01118P1 - LH UPPER TUBE ZD12A01800 - O-RING ZD12A02100 - O-RING YM42H01056P1 - O-RING ZE72X16000 - PLUG 2432T6122 - CLAMP 2432T5924 - CLAMP YN42H01366P1 - CLAMP ZS18C12060 - CAPSCREW ZS18C12065 - CAPSCREW ZW26X12000 - WASHER

NOTE 1: Number in parenthesis in the Instructions refer to the reference number in the Parts List.

NOTE 2: Lubricate O-rings with hydraulic oil prior to installation.

NOTE 3: Apply medium strength thread locking adhesive to the clamp mounting capscrews.

NOTE 4: Tightening Torques for M-Threads: Thread Size

Tigthening Torques

M 12

115 ± 12 N.m (85 ± 9 lbf-ft)

NOTE 5: Tightening Torques for PF, PT - Threads: Thread Size

Tightening Torques

1

255 ± 10 N.m (188 ± 7 lbf-ft)

Tightening Torques

1-3/16 - 12UNS

177 ± 18 (130 ± 13 lbf-ft)

1-7/16 - 12UNS

206 ± 21 (152 ± 15 lbf-ft)

1-11/16 - 12UNS

327 ± 33 (241 ± 24 lbf-ft)

1. Position YM42H01106P1 LH Lower Tube (44) and YM42H01105P1 RH Lower Tube (43) on top of the boom base as shown in SECTION F-F. 2. Secure the lower part of the Tubes as shown in SECTION F-F with one YN42H01366P1 Clamp (54) mounted to the bracket with two ZS18C12065 Capscrews (85) and two ZW26X12000 Lock Washers (91). Don’t tighten the clamp at this time.

3. Secure the tubes as shown in SECTION E-E. Use one 2432T6122 Clamp (12) for the LH tube and one 2432T5924 Clamp (11) for the RH tube.

Mount each clamp to their respective bracket with two ZS18C12060 Capscrews (84) and two ZW26X12000 Lock Washers (91). Don’t tighten the clamps at this time.

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Issued 08-04

5. Secure the tubes as shown in SECTION C-C. Use one 2432T6122 Clamp (12) for the LH tube and one 2432T5924 Clamp (11) for the RH tube.

Mount each clamp to their respective bracket with two ZS18C12060 Capscrews (84) and two ZW26X12000 Lock Washers (91). Don’t tighten the clamps at this time.

6. Position YM42H01118P1 LH Upper Tube (46) and YM42H01117P1 RH Upper Tube (45) to the upper part of the boom as shown in SECTION A-A.

NOTE 6: Tightening Torques for ORS - Joint Nut: Thread Size

4. Secure the tubes as shown in SECTION D-D. Use one 2432T6122 Clamp (12) for the LH tube and one 2432T5924 Clamp (11) for the RH tube.

Mount each clamp to their respective bracket with two ZS18C12060 Capscrews (84) and two ZW26X12000 Lock Washers (91). Don’t tighten the clamps at this time.

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7. Secure the tubes as shown in SECTION A-A. Use one 2432T6122 Clamp (12) for the LH tube and 2432T5924 Clamp (11) for RH tube. Mount each clamp to their respective bracket with two ZS18C12060 Capscrews (84) and two ZW26X12000 Lock Washers (91). Don’t tighten the clamps at this time.

8. Secure the tubes as shown in SECTION B-B. Use one 2432T6122 Clamp (12) for the LH tube and one 2432T5924 Clamp (11) for the RH tube.

Mount each clamp to their respective bracket with two ZS18C12060 Capscrews (84) and two ZW26X12000 Lock Washers (91). Don’t tighten the clamps at this time.

9. Adjust the position of the lower tubes with the face end of the connectors approximately 110 mm (4 inches) from the boom base pivot pin center line.

10. Recheck the position of the lower tubes and tighten the cap screws that fastened the clamps securing the tubes to the boom to torque specifications.

Page 31 of 39

INSTRUCTION SHEET FOR EH160LC 2 WAY - HAND CONTROL (W/BOOM and STD ARM PIPING) 11. Install ZE72X16000 Plug (67) to the LH and RH lower tubes.

12. Connect the upper tubes to the lower tubes.

Make sure that ZD12A02100 O-ring (63) for the LH tubes and YM42H01056P1 O-ring (42) for the RH tubes are inserted in between the connectors and are in the O-ring grooves.

13. Check the position of the upper tubes before tightening the tube connector nuts. Tighten the connector nuts to torque specifications.

14. Tighten the cap screws that fastened the clamps securing the upper tubes to the boom to torque specification.

15. The attachment hoses of the upper hydraulic lines are to be connected to the tubes at the boom base. Make sure that when connecting these hoses, the ZD12A01800 O-rings (62) are inserted in between the connectors and are in the O-ring grooves.

Page 32 of 39

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INSTRUCTION SHEET FOR EH160LC 2 WAY - HAND CONTROL (W/BOOM and STD ARM PIPING)

NOTES

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INSTRUCTION SHEET FOR EH160LC 2 WAY - HAND CONTROL (W/BOOM and STD ARM PIPING)

8

15 18 9 11

15 18

15 18

20 19 16 Figure 81

DC04D471

Page 34 of 39

17 14

5

7

22

6

5

21

7

16 19 20

14 17

12

10 8

10 8

18 15

18 15

12 2

13 1 12

9 11

10

3

4

11

9

15 18

INSTALLING THE STANDARD ARM HYDRAULIC PIPING

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IS04-013A-NH NA

INSTRUCTION SHEET FOR EH160LC 2 WAY - HAND CONTROL (W/BOOM and STD ARM PIPING) 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

YM43H01040P1 - RH TUBE YM43H01041P1 - LH TUBE ZX50H12185 - LH HOSE ZX50H16185 - RH HOSE 24100P1006F1 - STOP VALVE HG23H12012G1 - TOP CONNECTOR YW43H01044P1 - STOP VALVE BRACKET LB42H01001P1 - LH CLAMP LS43H01005P1 - RH CLAMP LB42H01004P1 - LH BUSHING LC42H01020P1 - RH BUSHING ZD12A01800 - O-RING ZD12A02100 - O-RING ZS18C08025 - CAPSCREW ZS18C10030 - CAPSCREW ZS18C12045 - CAPSCREW ZW18H08000 - WASHER ZW16H10000 - WASHER 2418T10357 - WASHER ZW26X12000 - LOCK WASHER 2444P1744D2 - BOTTOM CONNECTOR 2420T4404 - CAP

NOTE 1: Number in parenthesis in the Instructions refer to the reference number in the Parts List.

NOTE 2: Lubricate O-rings with hydraulic oil prior to installation.

NOTE 3: Apply medium strength thread locking adhesive to the clamp mounting bolts (cap screws).

NOTE 4: Tightening Torques for M-Threads: Thread Size

Tightening Torques

M8

33 ± 3 N.m (24 ± 2 lbf-ft)

3. Install HG23H12012G1 Top Connector (21) to the top port of the Stop Valve on both sides.

M 10

66 ± 7 N.m (49 ± 5 lbf-ft)

M 12

115 ± 12 N.m (185 ± 9 lbf-ft)

NOTE 5: Tightening Torques for PF, PT - Threads: Thread Size

Tightening Torques

3/4

162 ± 15 N.m (119 ± 11 lbf-ft

Thread Size

Tightening Torques

1-3/16 - 12UNS

177 ± 18 N.m (131 ± 13 lbf-ft)

1-7/16 - 12UNS

206 ± 21 N.m (152 ± 15 lbf-ft)

1. Install YW43H01044P1 Stop Valve Brackets (59) on both sides of the arm tip as shown in SECTION A-A. Mount the bracket with two ZS18C12045 Capscrews (83), two 2418T10357 Washer s (5) and two ZW26X12000 Lock Washers (91) on each side. Use medium strength thread locking adhesive to the capscrews and tighten to torque specification.

Issued 08-04

4. Install 2444P1744D2 Bottom Connector (13) to the bottom port of the stop valve on both sides.

Make sure that O-ring is provided in the connector where it connects to the stop valve. If not install ZD12P02400 O-ring (64) to the connector.

5. Install 2420T4404 Cap Plug (9) to the Bottom Connector on both sides.

NOTE 6: Tightening Torques for ORS - Joint Nut:

IS04-013A-NH NA

2. Install 24100P1006F1 Stop Valves (2) to the brackets as shown in SECTION A-A. Mount the stop valves with four ZS18C08025 Capscrews (78) and four ZW16H08000 Washers (86) on each side. Use medium strength thread locking adhesive to the cap screws and tighten to torque specification.

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LH tube installation 6. Position YM43H01041P1 LH Tube (48) in the arm.

7. Secure the middle part of the tube as shown in SECTION B-B with two LB42H01001P1 Clamps (27) and one LB42H01004P1 Bushing (28) wrap around to the tube for protection. Mount the clamp with two ZS18C10030 Capscrews (81) and two ZW16H10000 Washers (87) to the tapped block. Don’t tighten the clamp at this time.

Page 35 of 39

INSTRUCTION SHEET FOR EH160LC 2 WAY - HAND CONTROL (W/BOOM and STD ARM PIPING) 8. Secure the top part of the tube as shown in SECTION C-C with two LB42H01001P1 Clamps (27) and one LB42H01004P1 Bushing (28) wrap around the tube for protection. Mount the clamps with two ZS18C10030 Capscrews (81) and two ZW16H10000 Washers (87) to the tapped block.

Don’t tighten the clamp at this time.

9. Install ZD12A01800 O-ring (62) to the straight connector of the tube. Make sure that the O-ring is in the O-ring groove.

21. Connect the ZX50H16185 RH Hose (96) to the elbow connector of the tube. Tighten the hose nut to torque specification.

22. Connect the two hoses to the attachment (N & B) tubes in the boom. Make sure that ZD12A01800 O-ring (62) for LH and ZD12A02100 O-ring (63) for RH are in the O-ring grooves of the tube connectors before tightening hose nuts.

10. Connect the tube to the connector in the stop valve. Position the tube as shown and tighten the connector nut to torque specification.

11. Tighten the clamps mounting capscrews that secure the tube to the arm to torque specification.

12. Install ZD12A01800 O-ring (62) to the elbow connector of the tube. Make sure that the O-ring is in the O-ring groove.

13. Connect ZX50H12185 LH Hose (95) to the elbow connector of the tube. Tighten the hose nut to torque specification.

RH tube installation 14. Position YM43H01040P1 RH Tube (47) in the arm.

15. Secure the middle part of the tube as shown in Section B-B with two LS43H01005P1 Clamps (31) and one LC42H01020P1 Bushing (30) wrap around to the tube for protection. Mount the clamps with two ZS18C10030 Capscrews (81) and two ZW16H10000 Washers (87) to the tapped block. Don’t tighten the clamp at this time.

16. Secure the top part of the tube as shown in Section C-C with two LS43H01005P1 Clamps (31) and one LC42H01020P1 Bushing (30) wrap around the tube for protection. Mount the clamps with two ZS18C10030 Capscrews (81) and two ZW16H10000 Washers (87) to the tapped block.

Don’t tighten the clamp at this time.

17. Install an ZD12A01800 O-ring (62) to the straight connector of the tube. Make sure that the O-ring is in the O-ring groove.

18. Connect the tube to the connector in the stop valve. Position the tube as shown and tighten the connector nut to torque specification.

19. Tighten the clamps mounting capscrews that secure the tube to the arm to torque specification.

20. Install ZD12A02100 O-ring (63) to the elbow connector of the tube. Make sure that the O-ring is in the O-ring groove.

Page 36 of 39

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INSTRUCTION SHEET FOR EH160LC 2 WAY - HAND CONTROL (W/BOOM and STD ARM PIPING) REPLACE THE ARM IDLER LINKS USING A CRANE

2

1

NOTE 1: Number in parenthesis in the instructions refer to the reference number in the Part List.

NOTE 2: Tightening Torques for M-Threads.

4

3

Thread Size

Tightening Torques

M 14

181 ± 20 N.m (133 ± 15 lbf-ft)

11

4

3

NOTE 3: Tightening torques for PF, PT - Threads Thread Size

Tightening Torques

1/8

17 ± 2 N.m (13 ± 1.5 lbf-ft)

4

3

NOTE 4: When attaching shims, attach the resin shims first and then fill gap with iron shims. Resin shims must be inserted toward the cylinder side and arm side.

NOTE 5: Weight of the new reinforced arm idler links:

11 4

7

3 14 6

5

8

YM12B01042P1 LH - 19 Kg (42lbs)

12

10

10

9

YM12B01041P1 RH - 20 Kg (44 lbs)

14

5

6

1.

2.

3.

4.

5.

6.

7.

ARM BUCKET CYLINDER SHIMS DUST SEAL BUCKET LINK RH IDLER LINK LH IDLER LINK

13 Figure 83

DC04B002

8.

9.

10.

11.

12.

13.

14.

BUCKET LINK PIN ARM IDLER PIN RETAINING BOLT RETAINING NUT JAM NUT DUST SEAL SHIMS

4. Remove the jam and retaining nuts of the pin retaining bolts and remove the bolts.

1 2

5. Retract the pins and remove the RH idler link.

3

6. Continue retracting the pins and remove the bucket link and the LH idler link.

4 DC04B001

1. ARM 2. WOOD BLOCK 3. ARM IDLER LINK

Figure 82 4. BUCKET LINK 5. BUCKET CYLINDER 6. NYLON ROPE

1. Place a wood block on top of the arm, below the bucket cylinder.

2. Use a 150 Kg (330 lbs) capacity nylon rope and place it around the bucket link.

3. Attach the nylon rope to a crane and lift the crane slightly to remove the link weight.

7. Reassemble the parts as shown installing the new reinforced YM12B01042P1 LH (41) and YM12B01041P1 RH (40) idler links. Make sure that the pins are clean and lubricated with EP grease before installation.

8. Adjust the clearance between the idler links and arm by adding shims per Note 4. The total clearance of both sides to be 0.5 mm (0.02 in) or less after adjusting by shims.

9. Adjust the clearance between the idler links and bucket link by adding shims per Note 4. The total clearance of both sides to be 0.6 ~ 1.0 mm (0.02 ~ 0.04 in) after adjusting by shims.

10. Install both the pin retaining bolts so as the nut faces the inside. Install the bolt retaining nut leaving 1 ~ 2 mm (0.02 ~ 0.08 in) space between the pin boss and nut face. Install the jam nuts.

Hold the retaining nut and tighten the jam nut to torque specification.

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Page 37 of 39

INSTRUCTION SHEET FOR EH160LC 2 WAY - HAND CONTROL (W/BOOM and STD ARM PIPING) REPLACE THE ARM IDLER LINKS USING THE MACHINE. NOTE 1: Number in parenthesis in the instructions refer to the reference number in the Part List NOTE 2: Tightening Torques for M-Threads Thread Size

Tightening Torques

M 14

181 ± 20 N.m (133 ± 15 lbf-ft)

NOTE 3: Tightening torques for PF, PT - Threads Thread Size

Tightening Torques

1/8

17 ± 2 N.m (13 ± 1.5 lbf-ft)

NOTE 4: When attaching shims, attach the resin shims first and then fill gap with iron shims. Resin shims must be inserted toward the cylinder side and arm side.

1

NOTE 5: Weight of the new reinforced arm idler links:

YM12B01042P1 LH - 19 Kg (42lbs) YM12B01041P1 RH - 20 Kg (44 lbs)

Figure 85

DC04B338

1. WOOD BLOCK

1. Place the throttle control in low idle

2. Sound

the

horn

.

before

4. Carefully operate the attachments to remove the weight of the bucket and linkage to facilitate linkage replacement.

5. Place a wood block on top of the arm, below the bucket cylinder.

1

2

starting the engine to alert people around the machine that it is going to be operated.

4

4 11

3 3 3

4

7

12

10

11 4 5

1 8 DC04E122

Figure 84

6

14 13 13 Figure 86

DC04B002

1.

2.

3.

4.

5.

6.

7.

Page 38 of 39

14

10

9

1. FUNCTION CANCELLATION LEVER

3. Lower the function cancellation lever to the down position to unlock the hydraulic system.

3

ARM BUCKET CYLINDER SHIMS DUST SEAL BUCKET LINK RH IDLER LINK LH IDLER LINK

Issued 08-04

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8.

9.

10.

11.

12.

13.

14.

BUCKET LINK PIN ARM IDLER PIN RETAINING BOLT RETAINING NUT JAM NUT DUST SEAL SHIMS IS04-013A-NH NA

INSTRUCTION SHEET FOR EH160LC 2 WAY - HAND CONTROL (W/BOOM and STD ARM PIPING) 6. Remove the jam and retaining nuts of the pin retaining bolts and remove the bolts.

7. Retract the pins and remove the RH idler link.

8. Continue retracting the pins and remove the bucket link and the LH idler link.

9. Assemble the parts as shown installing the new reinforced YM12B01042P1 LH (41) and YM12B01041P1 RH (40) idler links. Make sure that the pins are clean and lubricated with EP grease before installation.

10. Adjust the clearance between the idler links and arm by adding shims per Note 4. The total clearance of both sides to be 0.5 mm (0.02 in) or less after adjusting by shims.

11. Adjust the clearance between the idler links and bucket link by adding shims per Note 4. The total clearance of both sides to be 0.6 ~ 1.0 mm (0.02 ~ 0.04 in) after adjusting by shims.

12. Install both the pin retaining bolts so as the nut faces the inside. Install the bolt retaining nut leaving 1 ~ 2 mm (0.02 ~ 0.08 in) space between the pin boss and nut face. Install the jam nuts.

Hold the retaining nut and tighten the jam nut to torque specification.

CHECK FOR HYDRAULIC LEAKS NOTE: If a vacuum pump was used, make sure that the hydraulic tank breather has been reinstalled before operating the machine.

NOTE: Make sure that the hoses and tubes are tightly connected.

1. Place the throttle control in low idle

2. Sound

the

horn

BLEED THE PILOT SYSTEM Bleed the pilot system before installing back the covers that were removed. Refer to the Operator’s manual for the proper procedure in bleeding the pilot system.

WARNING: Avoid oil spills. Use container, rags, and/or paper towels to contain any oil leakage. Dispose all waste oils and other hazardous waste in accordance with government environmental regulations.

HYDRAULIC OIL LEVEL After bleeding the hydraulic system and test have been done, check the hydraulic oil level. Refer to the Operator’s Manual for proper procedure in checking the hydraulic oil level.

INSTALL COVERS Install back all the covers that were removed in facilitating the installation.

OPERATION AND MAINTENANCE Refer to the Operator’s Manual for the correct operation and maintenance of the system.

NOTE: Adjust the relief pressure of the attachment based on the hydraulic pressure specifications of the attachment manufacturer.

WARNING: Clean all spilled oil to prevent fire. Dispose of hazardous waste according to environmental laws and regulations.

.

before

starting the engine to alert people around the machine that it is going to be operated.

3. Start the engine and let it run in low idle for 5 minutes. Check all new connections for leakage.

4. Repair all leakages.

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Page 39 of 39