New Holland EH160LC Excavator Rotation 2-Way Foot Control with boom & Standard Instructions Manual

INSTRUCTION SHEET INSTRUCTIONS FOR INSTALLING YM32TU1041F3 ROTATION 2-WAY FOOT CONTROL WITH BOOM AND STANDARD ARM PIPING ON EH160LC EXCAVATOR PARTS LIST REF. PART NO.

DESCRIPTION

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SELECTOR VALVE........................................................................................................................ 1 VALVE, STOP ................................................................................................................................ 2 GUARD, HOSE ...............................................................................................................................2 GUARD, HOSE .............................................................................................................................. 4 BLOCK........................................................................................................................................... 1 BLOCK,TAPPED ............................................................................................................................ 2 BLOCK, TAPPED ........................................................................................................................... 2 WASHER ....................................................................................................................................... 4 HOSE ASSEMBLY ......................................................................................................................... 1 HOSE............................................................................................................................................. 2 HOSE............................................................................................................................................. 1 HOSE............................................................................................................................................. 1 PLUG ............................................................................................................................................. 2 PLUG ............................................................................................................................................. 2 CLAMP .......................................................................................................................................... 1 CLAMP .......................................................................................................................................... 5 CLAMP .......................................................................................................................................... 5 CONNECTOR ................................................................................................................................ 2 HOSE............................................................................................................................................. 1 HOSE............................................................................................................................................. 1 ELBOW .......................................................................................................................................... 1 ELBOW .......................................................................................................................................... 1 CONNECTOR ................................................................................................................................ 2 CONNECTOR ................................................................................................................................ 2 CONNECTOR ................................................................................................................................ 1 ELBOW .......................................................................................................................................... 2 HOSE............................................................................................................................................. 1 SWITCH......................................................................................................................................... 1 RELAY ........................................................................................................................................... 2 CONNECTOR ................................................................................................................................ 2 CONNECTOR ................................................................................................................................ 1 CONNECTOR ................................................................................................................................ 1 ELBOW .......................................................................................................................................... 1 ELBOW .......................................................................................................................................... 1 CONNECTOR ................................................................................................................................ 1 ELBOW .......................................................................................................................................... 1 TEE................................................................................................................................................ 2 CLAMP .......................................................................................................................................... 4 BUSHING....................................................................................................................................... 2 SUPPORT...................................................................................................................................... 2 SOLENOID VALVE ........................................................................................................................ 1

24100P1005F1 ..............

24100P1006F1 ..............

2414Z199D050 ..............

2414Z199D100 ..............

2416N6141 ....................

2416T9804 ....................

2416T9804D4 ................

2418T10357...................

2420R349D040 ..............

2420R349D270 ..............

2420R349D280 ..............

2420R349D315 ..............

2420T4404 ....................

2420T4405 ....................

2432T2434 ....................

2432T5924 ....................

2432T6122 ....................

2444P1744D2 ................

2444R1120D030 ............

2444R1120D110 ............

2444R399D6..................

2444R399D7..................

2444T2657D1 ................

2444T2958 ....................

2444Z2760 ....................

2444Z2894 ....................

2444Z3722D4 ................

2479U1190F32 ..............

EN24S00008P1 .............

HG23H12012G1 ............

HG23H12016G1 ............

HG24F10012G3.............

HG33F10016G1.............

HG33H16012G1 ............

HH25R04004G3.............

HH35X04004G3.............

HH55Q06006G1 ............

LB42H01001P1..............

LB42H01004P1..............

LC12B01076P1..............

LC35V00004F2 ..............

IS04-024-NH NA Cst Issued 10-04 Copyright © 2004 CNH America LLC. All Rights Reserved.

QTY.

Printed in U.S.A.

Page 1 of 59

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

DESCRIPTION

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BUSHING....................................................................................................................................... 2 CLAMP .......................................................................................................................................... 1 HARD RUBBER BOOT................................................................................................................... 2 CLAMP .......................................................................................................................................... 4 PLASTIC TIES ................................................................................................................................6 LABEL............................................................................................................................................ 1 LH GRIP ASSEMBLY ..................................................................................................................... 1 RH GRIP ASSEMBLY .................................................................................................................... 1 TUBE ............................................................................................................................................. 1 BRACKET ...................................................................................................................................... 1 TUBE ............................................................................................................................................. 1 SUPPORT...................................................................................................................................... 1 SUPPORT...................................................................................................................................... 1 HOSE............................................................................................................................................. 1 LINK............................................................................................................................................... 1 LINK............................................................................................................................................... 1 TUBE ............................................................................................................................................. 1 O-RING .......................................................................................................................................... 1 TUBE ............................................................................................................................................. 1 TUBE ............................................................................................................................................. 1 TUBE ............................................................................................................................................. 1 TUBE ............................................................................................................................................. 1 TUBE ............................................................................................................................................. 1 TUBE ............................................................................................................................................. 1 TUBE ............................................................................................................................................. 2 TUBE ............................................................................................................................................. 1 TUBE ............................................................................................................................................. 1 TUBE ............................................................................................................................................. 1 TUBE ............................................................................................................................................. 1 BRACKET ...................................................................................................................................... 1 BRACKET ...................................................................................................................................... 1 SPACER ........................................................................................................................................ 1 BLOCK........................................................................................................................................... 1 TUBE ............................................................................................................................................. 1 TUBE ............................................................................................................................................. 1 FLEXIBLE RUBBER BOOT ............................................................................................................ 2 PUMP, GEAR................................................................................................................................. 1 HARNESS...................................................................................................................................... 1 HARNESS...................................................................................................................................... 1 TUBE ............................................................................................................................................. 1 LABEL............................................................................................................................................ 1 HOSE............................................................................................................................................. 1 FLANGE......................................................................................................................................... 1 CLAMP ........................................................................................................................................ 12 CLAMP ........................................................................................................................................ 12 CLAMP .......................................................................................................................................... 1 CLAMP .......................................................................................................................................... 2 LABEL............................................................................................................................................ 1 BRACKET ...................................................................................................................................... 2 LABEL............................................................................................................................................ 1 VALVE, CONTROL ........................................................................................................................ 1 CONNECTOR ................................................................................................................................ 2 CONNECTOR ................................................................................................................................ 1 ELBOW .......................................................................................................................................... 1 ELBOW, 90°................................................................................................................................... 2

LC42H01020P1 .............

LE03H01234P1..............

YN03M01503P1.............

LS43H01005P1..............

PY01P01043D3 .............

PY20T01062P1..............

YB03M01003F2 .............

YB03M01003F3 .............

YM03H01015P1.............

YM03H01041P2.............

YM03H01042P1.............

YM03H01043P1.............

YM03H01064P1.............

YM06H01002D2.............

YM12B01041P1 .............

YM12B01042P1 .............

YM30H01027P1.............

YM42H01056P1.............

YM42H01105P1.............

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

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

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

YM42H01156P1.............

YM42H01157P1.............

YM42H01158P1.............

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

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

YM43H01054P1.............

YM43H01055P1.............

YM64H01019P1.............

YM64H01023P1.............

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

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

YN03H01653P1 .............

YN03H01654P1 .............

YN03M01505P1.............

YN10V00024F1 .............

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

YN11E01113D1 .............

YN20M01046DV ............

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

YN30H01078D3 .............

YN30H01115P1 .............

YN42H01058P1 .............

YN42H01059P1 .............

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

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

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

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

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

YY30V00008F1..............

ZA23B22000 ..................

ZA23H18008..................

ZA33F18008 ..................

ZA33F22008 ..................

Page 2 of 59

QTY.

Issued 10-04

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IS04-024A-NH NA

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

DESCRIPTION

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CLAMP .......................................................................................................................................... 1 CLAMP .......................................................................................................................................... 6 O-RING .......................................................................................................................................... 4 O-RING ........................................................................................................................................ 10 O-RING .......................................................................................................................................... 4 O-RING .......................................................................................................................................... 3 O-RING .......................................................................................................................................... 2 O-RING .......................................................................................................................................... 1 CLAMP, HALF................................................................................................................................ 2 PLUG ............................................................................................................................................. 2 PLUG ............................................................................................................................................. 2 PLUG ............................................................................................................................................. 2 CONNECTOR ................................................................................................................................ 1 ELBOW .......................................................................................................................................... 1 CONNECTOR ................................................................................................................................ 3 CONNECTOR ................................................................................................................................ 2 CONNECTOR ................................................................................................................................ 1 ELBOW, 90°................................................................................................................................... 7 ELBOW, 90°................................................................................................................................... 3 CONNECTOR ................................................................................................................................ 2 SEMS-BOLT .................................................................................................................................. 2 NUT ............................................................................................................................................... 1 NUT ............................................................................................................................................... 1 CAPSCREW .................................................................................................................................. 8 CAPSCREW ................................................................................................................................ 10 CAPSCREW .................................................................................................................................. 3 CAPSCREW .................................................................................................................................. 4 CAPSCREW .................................................................................................................................. 2 CAPSCREW ................................................................................................................................ 10 CAPSCREW .................................................................................................................................. 7 CAPSCREW .................................................................................................................................. 1 CAPSCREW .................................................................................................................................. 9 CAPSCREW ................................................................................................................................ 12 CAPSCREW .................................................................................................................................. 4 CAPSCREW ................................................................................................................................ 20 CAPSCREW .................................................................................................................................. 3 CAPSCREW .................................................................................................................................. 6 CAPSCREW .................................................................................................................................. 4 WASHER ..................................................................................................................................... 19 WASHER ..................................................................................................................................... 13 WASHER ..................................................................................................................................... 11 WASHER ....................................................................................................................................... 7 WASHER ....................................................................................................................................... 8 LOCK WASHER ............................................................................................................................. 8 LOCK WASHER ............................................................................................................................. 8 LOCK WASHER ........................................................................................................................... 38 HOSE............................................................................................................................................. 2 HOSE............................................................................................................................................. 2 HOSE............................................................................................................................................. 1 HOSE............................................................................................................................................. 1 HOSE............................................................................................................................................. 1 HOSE ............................................................................................................................................ 1 HOSE ............................................................................................................................................ 1 HOSE............................................................................................................................................. 2 MAT, FLOOR ................................................................................................................................. 1

ZC26X18011..................

ZC26X22011..................

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

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

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

ZD12P01800..................

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

ZD12P03400..................

ZE12X20000 ..................

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

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

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

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

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

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

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

ZH22X06000..................

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

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

ZH32X08000..................

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

ZN18C10008 .................

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

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

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

ZS18C08030..................

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

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

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

ZS18C10045..................

ZS18C10060..................

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

ZS18C12040..................

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

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

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

ZS28C10035..................

ZS28C10045..................

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

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

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

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

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

ZW26K10000 .................

ZW26X10000 .................

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

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

ZX28N10090..................

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

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

ZX32M08110 .................

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

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

ZX58N10175..................

YN26M00054P1.............

IS04-024A-NH NA

Issued 10-04

QTY.

Cst

Page 3 of 59

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

DESCRIPTION

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CONNECTOR ................................................................................................................................ 1 CAPSCREW .................................................................................................................................. 2 SENSOR, PRESSURE ................................................................................................................... 1 HOSE............................................................................................................................................. 1 NUT ............................................................................................................................................... 1 PIN ................................................................................................................................................ 1 CAPSCREW .................................................................................................................................. 2 LOCK ASSY ................................................................................................................................... 1 PEDAL ........................................................................................................................................... 1 VALVE, PILOT ............................................................................................................................... 1 RUBBER ........................................................................................................................................ 1 VALVE, N&B CONTROL .................................................................................................................1 CAPSCREW ...................................................................................................................................4 PLASTIC TIES ................................................................................................................................6

HH25X04004G2.............

ZS18C10025..................

YX52S00010P1 .............

2420R349D085 ..............

ZN18C08007 .................

PY03M01026P1 .............

ZS28C10020..................

YT30M01002F1 .............

YN03M01319P1.............

YN30V00080F1 .............

YN03M01266P2.............

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

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

PY01P01043D6 .............

Page 4 of 59

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Issued 10-04

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IS04-024A-NH NA

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

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

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

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.

1 Figure 2

DC04E122

1. FUNCTION CANCELLATION LEVER

IS04-024A-NH NA

Issued 10-04

Cst

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

Page 5 of 59

INSTRUCTION SHEET FOR EH160LC ROTATION 2 WAY - FOOT 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.

Page 6 of 59

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INSTRUCTION SHEET FOR EH160LC ROTATION 2 WAY - FOOT 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.

2

Figure 11

DC04C626

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

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.

1

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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Page 7 of 59

INSTRUCTION SHEET FOR EH160LC ROTATION 2 WAY - FOOT 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.

Page 8 of 59

Issued 10-04

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IS04-024A-NH NA

INSTRUCTION SHEET FOR EH160LC ROTATION 2 WAY - FOOT 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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Page 9 of 59

INSTRUCTION SHEET FOR EH160LC ROTATION 2 WAY - FOOT 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.

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

3

2. Position the end cover and YN30V00075F1 N&B Control Valve (163). 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 (164) 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 (164) 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

Figure 20

DC04F040

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

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

2

4

6 5 DC04F041

1.

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

Page 10 of 59

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INSTRUCTION SHEET FOR EH160LC ROTATION 2 WAY - FOOT CONTROL (W/BOOM and STD ARM PIPING) INSTALLATION OF THE N&B HYDRAULIC CONTROL LINES

2

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

3

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

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

1 1 Figure 24

DC04B306

1. YN30V00080F1 - PILOT VALVE 2. ZS18C10025 - CAP SCREW 3. ZW16X10000 - WASHER

Figure 22

DC04A178

1. FLOOR MAT

1. Remove cab floor mat. The floor mat is not bolted to the floor plate. Tag it for storage. It will not be reused.

3. Install the YN30V00080F1 Pilot Valve (161) to the floor plate where the RH foot rest was removed. Make sure that the “T” and “P” ports of the valve faces toward the engine. Fastened the valve with two ZS18C10025 Capscrews (153) and two ZW16X10000 Washers (139). Use medium strength thread locking adhesive on these capscrews and tighten to torque specification.

3

1

4

5

1 2

2

Figure 25

DC04B311

Figure 23

DC04B303

1. RH FOOT REST 2. MOUNTING BOLT

2. Remove the RH foot rest. Tag it for storage. It will not be reused.

1.

2.

3.

4.

5.

YN03M01319P1 - PEDAL YN03M01266P2 - RUBBER PAD ZS28C10020 - CAPS CREW ZW26X10000 - LOCK WASHER ZW16X10000 - WASHER

4. Assemble the YN03M01319P1 Pedal (160) to the pilot valve with two ZS28C10020 Capscrews (158), two ZW26X10000 Lock Washers (141), and two ZW16X10000 Washers (139).

5. Assemble the YN03M01266P2 Rubber Pad (162) to the pedal.

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

6

5

3

2

4

3

1

2 Figure 26

DC04B312

1.

2.

3.

4.

5.

6.

4

1 5

YT30M01002F1 - LOCK ASSEMBLY ZS18C08025 - CAP SCREW ZW16X08000 - WASHER PY03M01026P1 - PIN ZW16X08000 - WASHER ZN18C08007 - NUT

5 Figure 28

DC04B314

6. Install the YT30M01002F1 pedal Lock assembly (159) in front of the pilot valve with two ZS18C08025 Capscrews (121) and two ZW16X08000 Washers (138).

7. Assemble the PY03M01026P1 Pin (157) to the lever of the lock assembly with ZW16X08000 Washer (138) and ZN18C08007 Nut (156). Lock the pedal with the pin.

1.

2.

3.

4.

5.

YX52S00010P1 - PRESSURE SENSOR ZE72X04000 - PLUG ZH22X04000 - CONNECTOR HH25X04004G2 - CONNECTOR ZH32X04000 - ELBOW 90°

9. Assemble YX52S00010P1 pressure Sensor (154) to the left “C2” port of the pilot valve.

10. Assemble ZE72X04000 Plug (106) to the RH “C1” port of the pilot valve. Tighten the plug to 17 ± 2 N.m (13± 1 lbf-ft) torque.

11. Assemble ZH22X04000 Connector (111) to the “T” port of the pilot valve.

12. Assemble HH25X04004G2 Connector (152) to the “P” port of the pilot valve.

13. Assemble the two ZH32X04000 Elbow (114) to the bottom ports of the pilot valve (one on port “A” and one on port “B”). Position the elbows as shown in Figure 28.

1 Figure 27

DC04B313

1. YN26M00054P1 - FLOOR MAT

8. Install the new YN26M00054P1 Floor Mat (151).

2 1 Figure 29

DC04E130

1. HARNESS CONNECTOR MARKED SE11 2. MARKING LOCATION

Page 12 of 59

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Cst

IS04-024A-NH NA

INSTRUCTION SHEET FOR EH160LC ROTATION 2 WAY - FOOT CONTROL (W/BOOM and STD ARM PIPING) 14. Locate electrical harness connector marked SE11 under the cab. Remove the connector plug and connect the connector to the pressure sensor. Untie the harness from the harness loop if pigtail won’t reach the pressure sensor.

6

1

2

1 Figure 31

DC04A214

5

1. RH PILOT HOSE CLAMP

4

3 Figure 30

DC04E134

1.

2.

3.

4.

5.

6.

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

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

4

2444R1120D110 - HOSE (P/V T) 2420R349D085 - HOSE (P/V P) 2420R349D280 - HOSE (P/V A) 2420R349D315 - HOSE (P/V B) HARNESS CONNECTOR SE11 PRESSURE SENSOR

5

6

7

1

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

15. Install 2444R1120D110 Hose (20) to the “T” port of the pilot valve.

16. Install 2420R349D085 Hose (155) to the “P” port of the pilot valve.

17. Install 2420R349D280 Hose (11) to the “A” port of the pilot valve.

18. Install 2420R349D315 Hose (12) to the “B” port of the pilot valve.

19. 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 hoses during routing.

2

8 9

3 Figure 32

DC04C636

1.

2.

3.

4.

5.

6.

7.

8.

9.

YN68H1035P1 - CLAMP ZW16X08000 - WASHER ZS18C08065 - CAPSCREW 2420R349D280 - HOSE (P/V A) 2420R349D315 - HOSE (P/V B) 2444R1120D110 - HOSE (P/V T) 2420R349D085 - HOSE (P/V P) EXISTING CLAMP EXISTING HOSES

21. Insert the new YN68H01035P1 Clamp (88) on top of the existing clamp.

22. Place the pilot hoses through the slots of the new clamp as indicated in Figure 32 (view looking from the front of the cab).

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

IS04-024A-NH NA

Issued 10-04

Cst

Page 13 of 59

INSTRUCTION SHEET FOR EH160LC ROTATION 2 WAY - FOOT CONTROL (W/BOOM and STD ARM PIPING) 23. With the new clamp on top of the existing clamp, fastened the clamps with two ZS18C08065 Capscrews (123) and two ZW16X08000 Washers (138). Use medium strength thread locking adhesive on the capscrews and tighten to 10 ± 1 N.m (7 ± 0.7 lbf-ft) torque.

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

3

2

3

1

4

5

Figure 34

DC04C637

1.

2.

3.

4.

5.

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

28. Remove ZH32X06000 90° elbow fitting from the existing pilot block. This fitting will be reused in the new pilot block.

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

1 Figure 33

DC04B331

1. EXISTING STANDARD PILOT BLOCK

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

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

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

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

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

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.

27. Disconnect all hoses from the existing standard block.

Page 14 of 59

Issued 10-04

Cst

IS04-024A-NH NA

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

5

33. 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 (5) 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

34. Install ZE72X04000 Plug (106) to the front LH “P” port of the new pilot block.

9

35. 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

36. Install ZH22X04000 Straight Fitting (111) to the front RH “P” port of the new pilot block.

VIEW

A

37. 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

38. 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

39. Install ZH32X04006 90° Elbow Fitting (115) to the rear middle “T” port of the new pilot block.

40. Install ZE72X06000 Plug (107) to the rear LH “T” port of the new pilot block.

VIEW

C Figure 35

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

IS04-024A-NH NA

Issued 10-04

41. 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 of Figure 35. Inspect fitting O-ring.

Replace O-ring if damaged before installing fitting.

42. Install ZH22X04000 Straight Fitting (111) to the LH side “P” port of the new pilot block.

Cst

Page 15 of 59

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

4

5

1 1 2

2

6 7 Figure 36

DC04B332

1. 2420R349D085 - HOSE (P/V P) 2. 2444R1120D110 - HOSE (P/V T)

43. Connect 2420R349D085 (P/V P) hose connected from the “P” port of the pilot valve to the front RH “P” port of the new pilot block.

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

45. 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.

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

3 Figure 38

DC04C639

1.

2.

3.

4.

5.

6.

7.

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

49. Insert the new YN68H01035P1 Clamp (88) on top of the existing clamp.

50. Place the pilot hoses through the slots of the new clamp as indicated in Figure 38 (view looking from the front of the cab).

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

51. With the new clamp on top of the existing clamp, fastened the clamps with two ZS18C08065 Capscrews (123) and two ZW16X08000 Washers (138). Use medium strength thread locking adhesive on the capscrews and tighten to 10 ± 1 N.m (7 ± 0.7 lbf-ft) torque.

52. Continue routing the P/V A and P/V B hoses toward the control valve.

1

Figure 37

DC04C638

1. PILOT HOSES CENTER CLAMP

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

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

Page 16 of 59

Issued 10-04

Cst

IS04-024A-NH NA

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

1

56. Continue routing the 2420R349D315 (P/V B) 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: (P/V B) hose connected from the “B” port of the pilot valve will be connected to the top PA02 port of the N&B control valve and the (P/V A) hose connected from “A” port of the pilot valve will be connected to the bottom PB02 port.

2

Figure 39

DC04C638

1. RUBBER WRAPPING 2. PLASTIC TIES

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

1

54. Unwrapped the pilot hoses and route the P/V A and P/V B hoses with the old hoses.

55. Wrap the control hoses with the rubber wrapping.

Secure the rubber wrapping with PY01P01043D6 Plastic Ties (165).

3 Figure 41

DC04B327

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

1

57. Remove the plug on top “PA02” port of the N&B control valve and install ZH32X04006 Elbow fitting (115).

58. Remove the plug on the bottom “PB02” port of the N&B control valve and install ZH22X04006 Straight fitting (112).

2

1

3

Figure 40

DC04B326

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

2 Figure 42

DC04B328

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

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

IS04-024A-NH NA

Issued 10-04

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Page 17 of 59

INSTRUCTION SHEET FOR EH160LC ROTATION 2 WAY - FOOT CONTROL (W/BOOM and STD ARM PIPING) 60. Connect the (P/V A) hose to the straight fitting in the “PB02” port of the N&B control valve.

1

61. Tighten hoses to the fittings.

INSTALLATION OF THE ROTATION HYDRAULIC CONTROL LINES

4

3

Installing the Fittings in the Control Lines Solenoid Valves Manifold

5

6

1 2 1

Figure 45

DC04H035

1.

2.

3.

4.

5.

6.

EXISTING ELBOW - TO BE REUSED EXISTING ELBOW - NOT TO BE REUSED HH55Q06006G1 - TEE ZH22X04006 - CONNECTOR ZH22X06000 - CONNECTOR ZH32X04006 - ELBOW

3. Install HH55Q06006G1 Tee (37) in the A1 solenoid valve port where the elbow was removed. Position the tee as shown in Figure 45.

Figure 43

DC04H034

1. CONTROL LINES SOLENOID VALVES MANIFOLD

1. Locate the control lines solenoid valves manifold in the engine air cleaner compartment.

4. Install ZH22X04006 Connector (112) to the leg end of the tee. Hose from the “P” port of the solenoid control valve will be connected to this connector.

5. Install the elbow that was originally removed from the A1 solenoid valve port to the straight end of the tee. Reconnect the hose to this elbow.

1

3

3

2

4

6

2 1

5

Figure 44

DC04H036

1. A1 SOLENOID VALVE PORT 2. HOSE 3. ELBOW

2. Disconnect the hose that is connected to the elbow in the A1 solenoid valve port and remove the elbow. This elbow will be reused.

Page 18 of 59

Figure 46

DC04H036

1.

2.

3.

4.

5.

6.

Issued 10-04

MANIFOLD “T” PORT CONNECTOR ELBOW TEE HOSE THERMOSTATIC SWITCH

Cst

IS04-024A-NH NA

INSTRUCTION SHEET FOR EH160LC ROTATION 2 WAY - FOOT CONTROL (W/BOOM and STD ARM PIPING) 6. Disconnect the tee with the hose and thermostatic switch from the elbow in the connector at the “T” port of the solenoid valves manifold. Remove the elbow from the connector.

This elbow will not be reused.

7

8

10

6

7. Install HH55Q06006G1 Tee (37) in the connector at the “T” port of the manifold where the elbow was removed. Position the tee as shown in Figure 45.

5

8. Install ZH22X06000 Connector (113) to the leg end of the tee. Reconnect the tee with the hose and thermostatic switch to this connector.

4

9. Install ZH32X04006 Elbow (115) to the straight end of the tee. Hose from the “T” port of the solenoid control valve will be connected to this elbow.

3 6 9

Installing the Rotation Solenoid Control Valve and Fittings.

1

2 Figure 48

DC04H040

1

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

2

ZS18C10030 - CAPSCREW ZW16H10000 - WASHER YM64H01023P1 - BRACKET ZS18C10020 - CAPSCREW ZW16X10000 - WASHER ZH32X04000 - ELBOW 2444Z2894 - ELBOW LC35V00004F2 - SOLENOID VALVE HH25R01004G3 - CONNECTOR SOLENOID VALVE MANIFOLD

11. Position YM64H01023P1 Solenoid Valve Bracket (72) into the two holes in the floor plate.

Figure 47

DC04H039

1. ROTATION VALVE BRACKET MOUNTING HOLES 2. ENGINE AIR CLEANER COMPARTMENT FLOOR PLATE

10. Locate the two holes in the engine air cleaner compartment floor plate where the rotation solenoid valve bracket will be mounted.

12. Mount the bracket into the two holes with two ZS18C10030 Capscrews (125) and two ZW16H10000 Washers (136).

13. Position LC35V00004F2 Rotation Solenoid Control Valve (41) in the bracket with the “P” port of the valve facing upward. Secure the valve to the bracket with two ZS18C10020 Capscrews (124) and two ZW16X10000 Washers (139).

14. Install 2444Z2894 Elbow (26) in the “P” port of the solenoid valve. Position the elbow facing to the right as shown in Figure 48.

15. Install the two ZH32X04000 Elbows (114) in the “A” and “B” ports of the solenoid valve. Position the elbows as shown in Figure 48.

16. Install HH25R04004G3 Connector (35) in the “T” port of the solenoid valve.

17. Connect ZH32X04000 Elbow (114) to the connector at the “T” port of the solenoid valve.

Position the elbow as shown in Figure 48.

IS04-024A-NH NA

Issued 10-04

Cst

Page 19 of 59

INSTRUCTION SHEET FOR EH160LC ROTATION 2 WAY - FOOT CONTROL (W/BOOM and STD ARM PIPING) Installing the Rotation Solenoid Control Valve & Rotation Valve Hoses and Fittings.

6

7

7

5

19. Install 2420R349D040 Hose (9) from the elbow in the “P” port of the solenoid valve to the connector in the A1 port of the solenoid valves manifold.

20. Install 2444R1120D030 Hose (19) from the elbow in the “T” port of the solenoid valve to the elbow in the “T” port of the solenoid valves manifold.

21. If the rotation control valve have already been installed, install 2444Z2894 Elbow (26) in the “Pa1” port of the valve. Install ZH32X04000 Elbow (114) to this elbow. Position the elbow facing the main hydraulic control valve as shown in Figure 49. Install ZH32X04000 Elbow (114) in the “Pb1” port of the rotation valve.

22. Install the two 2420R349D270 Hoses (10) to the “A” and “B” ports of the solenoid valve. Route the hoses from the solenoid valve to the rotation valve as shown in Figure 49.

8 9

2

23. Connect the hose connected from the “A” port of the Solenoid to the elbow in the “Pb1” port of the rotation valve.

24. Connect the hose connected from the “B” port of the solenoid valve to the “Pa1” port of the rotation valve.

NOTE: (S/V A) hose connected from the “A” port of the solenoid valve will be connected to the Pb1 port of the rotation valve and the (S/V B) hose connected from “B” port of the solenoid valve will be connected to the Pa1 port of the rotation valve.

3

25. Tighten all hoses to the fittings per torque specifications.

1

4 Figure 49

DC04H041

1.

2.

3.

4.

5.

6.

7.

8.

9.

SOLENOID CONTROL VALVE HH35X04004G3 - ELBOW 2420R349D040 - HOSE 2444R1120D030 - HOSE ROTATION VALVE 2444Z2894 - ELBOW ZH32X04000 - ELBOW 2420R349D270 - S/V A - C/V Pb1 HOSE 2420R349D270 - S/V B - C/V Pa1 HOSE

18. Install HH35X04004G3 Elbow (36) to the elbow in the “P” port of the solenoid valve. Position the Elbow facing downward.

Page 20 of 59

Issued 10-04

Cst

IS04-024A-NH NA

INSTRUCTION SHEET FOR EH160LC ROTATION 2 WAY - FOOT CONTROL (W/BOOM and STD ARM PIPING) INSTALLATION OF THE HYDRAULIC CONTROL HAND GRIPS AND ELECTRICAL HARNESSES Replacing the LH Hand Grip

3

1 2 Figure 52

DC04G008

1 2

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

Figure 50

DC04G007

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.

4. Raise the boot from the tower.

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.

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

1

2 1

Figure 51

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.

IS04-024A-NH NA

Figure 53

DC04G009

2

Issued 10-04

Cst

1. ELECTRICAL HARNESS 2. HAND GRIP ELECTRICAL WIRE PLUG

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

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.

Page 21 of 59

INSTRUCTION SHEET FOR EH160LC ROTATION 2 WAY - FOOT 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

2 3

4

4

3

Figure 56

DC04G012

Figure 54

DC04G010

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 2 3

4 DC04G011

1.

2.

3.

4.

5.

1.

2.

3.

4.

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 56.

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.

5 Figure 55

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 (77).

10. Assemble the new YN03M01503P1 Hard Rubber Boot (44) 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 (48) to the boot assembly. make sure that the hard rubber boot is properly inserted to the hand grip handle groove.

Page 22 of 59

1 Figure 57

DC04G027

1. LH STANDARD ELECTRICAL HARNESS

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

16. Leave the control box open until the Auxiliary Electrical Wiring Harness has been routed.

Issued 10-04

Cst

IS04-024A-NH NA

INSTRUCTION SHEET FOR EH160LC ROTATION 2 WAY - FOOT CONTROL (W/BOOM and STD ARM PIPING) 22. Remove the inner cover to gain access to the electrical harness that connects to the hand grip electrical wires.

Replacing the RH Hand Grip

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.

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.

1

1 2

Figure 58

DC04G025

1. RH CONSOLE INSTRUMENT PANEL

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

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

3

4 DC04G011

1.

2.

3.

4.

5.

3

4

5 Figure 59 FLEXIBLE BOOT RETAINER LOCK JAM NUT PILOT VALVE NUT SEMS BOLT INNER COVER OUTER COVER

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.

Issued 10-04

27. Assemble the new YB03M01003F3 RH Grip Assembly (49) 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.

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

IS04-024A-NH NA

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

26. Assemble the new YN03M01503P1 Hard Rubber Boot (44) to the new flexible rubber boot. Make sure that the flexible boot is properly inserted to the hard rubber boot groove.

2

1.

2.

3.

4.

5.

6.

Figure 60

25. Disassemble the retaining plate from the old flexible rubber boot and assemble it to the new YN03M01505P1 Flexible Rubber Boot (77).

1

6

DC04G026

5

Cst

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.

Page 23 of 59

INSTRUCTION SHEET FOR EH160LC ROTATION 2 WAY - FOOT CONTROL (W/BOOM and STD ARM PIPING) 31. Connect the Power Boost switch electrical wiring plug (with yellow & green wires) to the standard harness wiring plug (with yellow taping) where the old hand grip wiring was disconnected.

32. Leave the control box open until the Auxiliary Electrical Wiring Harness has been installed.

1

Figure 61

DC04G028

1. RH STANDARD ELECTRICAL HARNESS

Installing the Auxiliary Electrical Wiring Harness inside the Cab

YN11E01111P1 - AUXILIARY HARNESS Figure 62

DC04G029

Page 24 of 59

Issued 10-04

Cst

IS04-024A-NH NA

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

2

1

1

2

2

2

3

3

5

5 6

2

4

6 Figure 64

DC04D556

3 Figure 63

DC04G033

4

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

1.

2.

3.

4.

5.

6.

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

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.

36. Remove the upper cover.

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.

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.

38. Remove the lower cover.

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

IS04-024A-NH NA

Issued 10-04

Cst

Page 25 of 59

INSTRUCTION SHEET FOR EH160LC ROTATION 2 WAY - FOOT CONTROL (W/BOOM and STD ARM PIPING) 42. Locate the harness pigtail with connector tagged “R- ROT” and connect it to this relay.

2 2

1

3 1 Figure 65

DC04H042

Figure 67

DC04G035

1. YN11E01111P1 - AUXILIARY ELECTRICAL HARNESS 2. RH CONTROL BOX 3. LH CONTROL BOX

39. Install YN11E01111P1 Auxiliary Electrical Harness (79) (see Figure 62 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.

1. CONTROLLER 2. MOUNTING SCREWS

43. Remove the Controller mounting screws and flip the controller towards the front to gain access to the standard harness “INST” connector under the controller.

1

40. Continue routing the harness following the standard harness. Position the pigtail with connector tagged “NIBBLER” and connector tagged “ROT” in the right corner where the standard harness is routed down under the floor plate.

Figure 68

DC04J086

3

2 1

Harness Connector Tagged “R - ROT”

Figure 66

DC04H028

1. COMPONENTS PLATE 2. EN24S00008P1 - RELAY 3. ZM61C06016 - SEMS BOLT

1. STANDARD HARNESS INST. CONNECTOR

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

45. Tie the harness to the standard harness with PY01P01043D3 Plastic Ties (46).

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

47. Install back the controller.

41. Locate the components plate on the RH side wall and install one EN24S00008P1 Relay (29) in the plate. Secure The relay to the plate with one ZM61C06016 Sems Bolt (117).

Page 26 of 59

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

3

51. 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.

4

Harness Connector Tagged “L - ROT”

1

5

6

2

FIX TO STANDARD HARNESS

Figure 69

DC04H026

1.

2.

3.

4.

5.

6.

NOTE: Nibbler open and close switches will be connected but will not be powered and used. The nibbler open and close operations will be controlled by the foot control.

CONTROLLER RELAY COVER EN24S00008P1 - CLOCKWISE RELAY ZM61C06016 - SEMS BOLT YN11E01111P1 - AUXILIARY HARNESS PY01P01043D3 - PLASTIC TIE

1

3 2

48. Install one EN24S00008P1 Relay (29) on top of the relays cover. Secure the relay to the plate with one ZM61C06016 Sems Bolt (117).

49. Locate the harness pigtail with connector tagged “L - ROT” and connect it to this relay.

50. Continue threading the harness 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.

1 3

LH CONTROL BOX Figure 71

DC04G042

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

52. 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.

2

RH CONTROL BOX Figure 70

DC04G040

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

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

1

2

DC04J087

Figure 72

NOTE: Figure 72 shows correct location of the grip switches.

Installing the Rotation Solenoid Valve Electrical Harness

Figure 74

DC04H044

1. YN11E01113D1 - ROTATION SOLENOID HARNESS 2. ROTATION SOLENOID VALVE

54. Connect the harness wiring connector tagged “R-ROT” to solenoid “B” (clockwise solenoid).

55. Connect the harness wiring connector tagged “L-ROT” to solenoid “A” (counter clockwise solenoid).

YN11E01113D1 - ROTATION SOLENOID HARNESS DC04H043

Figure 73

53. Install YN11E01113D1 Rotation Solenoid Harness (80) inside the engine air cleaner compartment.

2 1 Figure 75

DC04H045

1. STANDARD ELECTRICAL HARNESS INSIDE ENGINE AIR CLEANER COMPARTMENT 2. HARNESS CLIPS

56. Route the harness following the routing of the standard harness from the solenoid valve to the right rear corner tunnel under the cab where the standard harness is threaded up inside the cab.

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

57. Connect harness connector to the auxiliary harness wiring connector tagged “ROT”.

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INSTRUCTION SHEET FOR EH160LC ROTATION 2 WAY - FOOT CONTROL (W/BOOM and STD ARM PIPING) 58. Clip the solenoid harness with the standard harness.

59. Recheck all electrical wiring connections.

INSTALLATION OF THE N&B UPPER HYDRAULIC LINES

2

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.

3 1 4

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

NOTE 4: Tightening Torques for M-Threads:

Figure 77

DC04C640

Thread Size

Tightening Torques

M8

35 ± 4 N.m (26 ± 3 lbf-ft)

M 12

121 ± 12 N.m (89 ± 9 lbf-ft)

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)

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

2. Install YM03H01043P1 Tube Support (53) to the angle bracket with two ZS18C12030 Capscrews (128) and two ZW16H12000 Washers (137).

Tighten the capscrew to torque specification.

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)

1 1

Figure 78

DC04C642

1. TAPPED BLOCK

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

Figure 76

DC04C641

1. ANGLE BRACKET

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

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Page 29 of 59

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

1

A

3

4

2

VIEW A Figure 79

DC04C643

1.

2.

3.

4.

1.

2.

3.

4.

5.

6.

7.

8.

9.

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

4. Install YM03H01041P2 Selector Valve Bracket (51) to the tapped block with two ZS18C12030 Capscrews (128) and two ZW16H12000 Washers (137). Tighten capscrews to torque specification.

5

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 (120) and four ZW16H08000 Washers (135). Tighten cap screws to torque specification.

6. Install YN03H01489P1 Terminal Block (74) to the valve bracket using four ZS18C08020 Capscrews (120) and four ZW16H08000 Washers (135). Tighten cap screws to torque specification.

7. Install 2444R399D7 Elbow (22) to the outer port of the selector valve.

8. Install the ZG33F10012 Elbow (110) to the top port of the selector valve. Position the elbow as shown.

9. Install HG33H16012G1 Elbow (34) to the inner port of the selector valve.

10. Install HG23H12016G1 Connector (31) to the face port of the terminal block.

6

1

7 A

11. Install HG33F10016G1 Elbow (33) to the top port of the terminal block.

8

3

3 2

2

2

9 4 1

View A Figure 81

DC04A175

1. PLUG 2. HYDRAULIC TANK

12. Remove the Plug from the Hydraulic tank.

DC04A174

Page 30 of 59

Figure 80

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

1

3 1

2

3

A

1

2 3 Figure 82

DC04A177

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

13. Install the 2444Z2760 Connector (25) to the hydraulic tank where the plug was removed.

14. Install 2444Z3722D4 Hose (27) from the selector valve outer elbow to the hydraulic tank connector. Position the hose and tighten to torque specification.

A

1

2

3

VIEW A Figure 84

DC04B355

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

17. Install ZX30H10058 Hose (145) from the selector valve top port to the control valve upper “A02” port. Make sure that ZD12A01600 O-rings (99) 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 (146) from the terminal block top port to the control valve lower “B02” port. Make sure that ZD12A01600 O-rings (99) 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.

3 4

2 VIEW A

Figure 83

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 (109) in this port.

16. Remove the plug from the lower “B02” port of the control valve. Install HG24F10012G3 Connector (32) in this port.

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Page 31 of 59

INSTRUCTION SHEET FOR EH160LC ROTATION 2 WAY - FOOT CONTROL (W/BOOM and STD ARM PIPING) 19. Insert ZD12A02100 O-ring (101) to the selector valve inner elbow and install the YM03H01042P1 Tube (52) 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 (100) to the terminal block face connector and install YM03H01015P1 Tube (50) 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 (15), YN02B01031D2 Spacer ( 7 3 ) , Z S 1 8 C 1 2 0 6 5 C a p s c re w ( 1 3 2 ) , tw o ZW16H12000 Washers (137), and ZN18C12010 Nut (119). 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 85

DC04B356

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

Page 32 of 59

Figure 86

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 (100) to the attachment tubes (one on each tube) and connect ZX20H12105 Hoses (143) 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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IS04-024A-NH NA

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

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.

A1

3

T

P B1

5

6

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 (100) are inserted in between the connectors and are in the O-ring grooves before tightening the connector nuts.

28. Assemble the four 2414Z199D100 Hose Guards (4) 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.

2 4

1

INSTALLATION OF THE ROTATION PUMP AND ROTATION UPPER HYDRAULIC LINES Installing the Rotation Control Valve

DC04H030

1.

2.

3.

4.

5.

6.

1

Figure 87

DC04H029

1. ROTATION VALVE BRACKET SUPPORT

1. Locate the rotation valve bracket support in the upper frame RH beam.

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Issued 10-04

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Figure 88 YM64H01019P1 - ROTATION VALVE BRACKET ZS18C12030 - CAPSCREW ZS18C08030 - CAPSCREW ZW16H12000 - WASHER ZW16H08000 - WASHER YY30V00008F1 - ROTATION CONTROL VALVE

2. Install YM64H01019P1 Rotation Valve Bracket (71) to the support. Secure the bracket to the support with three ZS18C12030 Capscrews (128) and three ZW16H12000 Washers (137).

3. Install YY30V00008F1 Rotation Control Valve (92) to the bracket. Secure the valve to the bracket with three ZS18C08030 Capscrews (122) and three ZW16H08000 Washers (135).

Page 33 of 59

INSTRUCTION SHEET FOR EH160LC ROTATION 2 WAY - FOOT CONTROL (W/BOOM and STD ARM PIPING) Installing the Rotation Control Valve Piping

11 13 10

8

15

1

14

2 13

10

9

16

5 13 2

7 8 4 3

6

12

4

Figure 89

DC04H031

1.

2.

3.

4.

5.

6.

7.

8.

Page 34 of 59

ZS18C12030 - CAPSCREW ZA33F22008 - ELBOW, 90° ZS18C10060 - CAPSCREW ZW16H10000 - WASHER ZW16H12000 - WASHER ZN18C10008 - NUT YM03H01064P1 - SUPPORT ZH32X08000 - ELBOW

9.

10.

11.

12.

13.

14.

15.

16.

ZX32M08110 - HOSE 2444T2958 - CONNECTOR ZA33F18008 - ELBOW LE03H01234P1 - CLAMP ZD12P01800 - O-RING YN03H01654P1 - TUBE YN03H01653P1 - TUBE YN20M01046DV - HOSE GUARD

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IS04-024A-NH NA

INSTRUCTION SHEET FOR EH160LC ROTATION 2 WAY - FOOT CONTROL (W/BOOM and STD ARM PIPING) NOTE: Non-specified tightening torque of capscrews to be of the standard torque specifications.

4. Install YM03H01064P1 Tube Support (54) to the valve bracket as shown in SECTION A-A of Figure 89. Secure the support to the bracket with two ZS18C12030 Capscrews (128) and two ZW16H12000 Washers (137). Tighten the capscrews to standard torque specification.

10. Install ZD12P01800 O-ring (102) to ZA33F18008 Elbow (95) and install the elbow to the “P” port of the rotation valve. Position the elbow facing towards the rear of the machine. This elbow will be connected to the tube coming from the rotation pump.

11. Install ZD12P01800 O-ring (102) to ZA33F22008 Elbow (96) and install the elbow in the “A1” port of the rotation valve. Position the elbow facing towards the cab.

12. Position and install YN03H01653P1 Tube (75) from the elbow in the “A1” port of the rotation valve down to the tube support. Don’t tighten the tube nut at the elbow at this time.

13. Install 2444T2958 Connector (24) in the “B1” port of the rotation valve.

14. Install ZD12P01800 O-ring (102) to ZA33F22008 Elbow (96) and install elbow to the connector at the “B1” port of the rotation valve. Position the elbow facing towards the front.

15. Position and install YN03H01654P1 Tube (76) from the elbow in the “B1” port of the rotation valve down to the tube support. Don’t tighten the tube nut at the elbow at this time.

1 Figure 90

DC04H033

1. PLUG

5. Locate the plug in the bottom of the hydraulic oil return block in the rear of the hydraulic main control valve. Remove the plug.

6. Install ZH32X08000 Elbow (116) where the plug was removed. Position the elbow facing towards the hydraulic tank.

7. Install 2444T2958 Connector (24) in the “T” port of the rotation valve as shown in SECTION B-B of Figure 89.

16. Secure the two tubes on the tube support as shown in SECTION A-A of Figure 89 with LE03H01234P1 Clamp (43). Secure the clamp to the support with one ZS18C10060 Capscrew (127), one ZN18C10008 Nut (118), and two ZW16H10000 Washers (136). Don’t tighten the capscrew at this time.

17. Check the position of the two tubes making sure that there will be no stress applied to the tubes when the tube nuts at the elbows and the tube clamp capscrew are tighten.

18. Tighten the tube nuts at the elbows.

19. Tighten the clamp capscrew to 66 ± 7 N.m (49 ± 5 lbf-ft).

8. Install ZH32X08000 Elbow (116) to the connector installed in the “T” port. Position the elbow facing towards the front of the machine.

9. Position and connect ZX32M08110 Hose (147) from the elbow in the hydraulic oil return block to the elbow in the “T” port of the rotation valve with the straight fitting of the hose connected to the elbow in the return block. Thread the hose as shown in Figure 89. Position the hose away from sharp edges before tightening the hose nuts.

Install YN20M01046DV Hose Guard (81) to the hose.

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Page 35 of 59

INSTRUCTION SHEET FOR EH160LC ROTATION 2 WAY - FOOT CONTROL (W/BOOM and STD ARM PIPING) Installing the Rotation Pump and Hoses 1. SUCTION MANIFOLD 2. PLUG 3. HYDRAULIC MAIN PUMP

3

25. Locate the plug in the hydraulic main pump suction manifold.

2

26. Remove the plug. The O-ring in the plug will be reused.

5

4

1 Figure 91

DC04H046

1. GEAR ASSEMBLY (PTO) 2. PUMP MOUNTING FLANGE 3. COVER

6 8

20. Locate the pump mounting flange in the gear assembly (PTO) on top of the hydraulic main pump.

7

1

21. Remove the cover plate covering the PTO. Be careful in removing the cover for not damaging the O-ring in the flange. This O-ring will be reused in installing the pump.

22. Clean the mounting flange and inspect the O-ring. Replace the O-ring if damaged. Lubricate the O-ring with hydraulic oil before installing it.

3

2

Figure 93

DC04H048

23. Position YN10V00024F1 Gear Pump (78) in the mounting flange with the suction (IN) port facing towards the rear of the machine.

1.

2.

3.

4.

5.

6.

7.

8.

24. Secure the pump to the PTO with two ZS28C10035 Capscrews (133) and two ZW16X10000 Washers (139). Tighten the capscrews to 33 ± 3 N.m (24 ± 2 lbf-ft).

SUCTION MANIFOLD 2444R399D6 - ELBOW YM06H01002D2 - SUCTION HOSE ROTATION - GEAR PUMP ZE12P03800 - O-RING ZE12X20000 - HALF CLAMP ZS28C10035 - CAPSCREW ZW26K10000 - LOCK WASHER

27. Install 2444R399D6 Elbow (21) in the suction manifold where the plug was removed. Position the elbow facing towards the right side of the machine.

28. Position YM06H01002D2 Suction Hose (55) from the elbow in the suction manifold to the suction (IN) port of the rotation gear pump.

29. Connect the hose fitting to the elbow in the suction manifold. Don’t tighten the tube nut at this time.

3 2 1 DC04H047

Page 36 of 59

Figure 92 Issued 10-04

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IS04-024A-NH NA

INSTRUCTION SHEET FOR EH160LC ROTATION 2 WAY - FOOT CONTROL (W/BOOM and STD ARM PIPING) 30. Clean and inspect the O-ring that was removed from the plug removed from the suction manifold.

Replace the O-ring if damaged. Install the O-ring to the hose flange. Mount the hose flange to the pump suction (IN) port with two ZE12X20000 Half Clamps (105). Secure the half clamps to the pump flange with four ZS28C10035 Capscrews (133) and four ZW26K10000 Lock washers (140). Tighten the capscrews to 39 ± 4 N.m (29 ± 3 lbf-ft).

36. Connect YN30H01078D3 Hose (83) to the connector. This hose will be connected to the tube that connects to the elbow in the “P” port of the rotation control valve.

1

31. Tighten the tube nut at the suction manifold elbow.

2

11

3

4

7

5

6

8

1 9

Figure 95

DC04H055

10

1. HOSE AND TUBE BRACKET SUPPORT

37. Locate the hose and tube clamps support on the back side of the hydraulic tank.

Figure 94

DCO4H050

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

7

3

32. Install ZD12P03400 O-ring (104) to YN30H01115P1 Flange (84). Mount the flange to the gear pump discharge (OUT) port with four ZS28C10045 Capscrews (134) and four ZW26K10000 Lock Washers (140). Tighten the capscrews to 39 ± 4 N.m (29 ± 3 lbf-ft).

33. Install ZE72X06000 Plug (107) to the PF3/8 port of the flange.

34. Install ZE72X04000 Plug (106) to the PF1/4 of the flange.

35. Install ZD12A01800 O-ring (100) to ZA23H18008 Connector (94). Connect the connector to the flange at the gear pump discharge port.

IS04-024A-NH NA

2

1

SUCTION HOSE GEAR PUMP YN30H01115P1 - FLANGE ZD12P03400 - O-RING ZS28C10045 - CAPSCREW ZW26K10000 - LOCK WASHER ZA23H18008 - CONNECTOR ZD12A01800 - O-RING YN30H01078D3 - HOSE ZE72X06000 - PLUG ZE72X04000 - PLUG

Issued 10-04

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5

4

6

DC04H056

1.

2.

3.

4.

5.

6.

7.

Figure 96 ROTATION CONTROL VALVE YM30H01027P1 - TUBE ZC26X18011 - CLAMP ZS18C10045 - CAPSCREW ZW16H10000 - WASHER HOSE AND TUBE CLAMPS SUPPORT ROTATION GEAR PUMP DISCHARGE HOSE

Page 37 of 59

INSTRUCTION SHEET FOR EH160LC ROTATION 2 WAY - FOOT CONTROL (W/BOOM and STD ARM PIPING) 38. Position YM30H01027P1 Tube (58) from the elbow at the “P” port of the rotation control valve to the top of the clamp support.

39. Secure the tube at the clamp support with one ZC26X18011 Clamp (97) bolted to the support with one ZS18C10045 Capscrew (126) and one ZW1 6H1 000 0 Was her ( 136 ) as sho wn in SECTION A-A of Figure 96. Don’t tighten the capscrew at this time.

40. Connect the tube to the elbow at “P” port of the rotation control valve. Recheck the position of the tube and tighten the tube nut per torque specification.

41. Tighten the capscrew that mount the clamp to the support to torque specification.

42. Connect the gear pump discharge hose to the tube. Make sure that the hose is properly routed before tightening the tube nut.

Page 38 of 59

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IS04-024A-NH NA

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

REPLACE THE HYDRAULIC RETURN FILTER NOTE: The hydraulic return filter will not have to be replaced on these machines. The return filter on these machines is design to work on both with or without a breaker attachment.

1

INSTALL THE DOUBLE PUMP FLOW SELECTOR SWITCH

1 2

6

7 2 2

5

Figure 98

DC04B352

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

3

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

Caution Decal (89).

4

Figure 97

DC04B351

1.

2.

3.

4.

5.

6.

7.

1 2

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 (28) to this opening. Connect the flow switch wire to the harness connector marked “CONFLUX”.

Figure 99

DC04B353

1. YY20T01039P1 CAUTION DECAL 2. CAB

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

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.

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Issued 10-04

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Caution Decal (91).

Page 39 of 59

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

2 1

Figure 100

DC04B354

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 YN20T01414P

(82)

and

Caution Decal PY20T01062P1

Caution Decal (47).

Page 40 of 59

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

NOTES

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Page 41 of 59

INSTRUCTION SHEET FOR EH160LC ROTATION 2 WAY - FOOT 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

INSTALLING THE BOOM 2 WAY HYDRAULIC PIPING

Figure 101

DC04D464

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

2.

3.

4.

5.

6.

7.

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

8.

9.

10.

11.

12.

13.

14.

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)

Thread Size

Tightening Torques

1

255 ± 10 N.m (188 ± 7 lbf-ft)

NOTE 6: Tightening Torques for ORS - Joint Nut: 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)

5. Secure the tubes as shown in SECTION C-C. Use one 2432T6122 Clamp (17) for the LH tube and one 2432T5924 Clamp (16) for the RH tube.

Mount each clamp to their respective bracket with two ZS18C12060 Capscrews (131) and two ZW26X12000 Lock Washers (142). Don’t tighten the clamps at this time.

6. Position YM42H01118P1 LH Upper Tube (63) and YM42H01117P1 RH Upper Tube (62) to the upper part of the boom as shown in SECTION A-A.

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

Thread Size

ZE72X16000 - PLUG 2432T6122 - CLAMP 2432T5924 - CLAMP YN42H01366P1 - CLAMP ZS18C12060 - CAPSCREW ZS18C12065 - CAPSCREW ZW26X12000 - WASHER

1. Position YM42H01106P1 LH Lower Tube (61) and YM42H01105P1 RH Lower Tube (60) 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 (87) mounted to the bracket with two ZS18C12065 Capscrews (132) and two ZW26X12000 Lock Washers (142). Don’t tighten the clamp at this time.

3. Secure the tubes as shown in SECTION E-E. Use one 2432T6122 Clamp (17) for the LH tube and one 2432T5924 Clamp (16) for the RH tube.

Mount each clamp to their respective bracket with two ZS18C12060 Capscrews (131) and two ZW26X12000 Lock Washers (142). Don’t tighten the clamps at this time.

4. Secure the tubes as shown in SECTION D-D. Use one 2432T6122 Clamp (17) for the LH tube and one 2432T5924 Clamp (16) for the RH tube.

Mount each clamp to their respective bracket with two ZS18C12060 Capscrews (131) and two ZW26X12000 Lock Washers (142). Don’t tighten the clamps at this time.

7. Secure the tubes as shown in SECTION A-A. Use one 2432T6122 Clamp (17) for the LH tube and 2432T5924 Clamp (16) for RH tube. Mount each clamp to their respective bracket with two ZS18C12060 Capscrews (131) and two ZW26X12000 Lock Washers (142). Don’t tighten the clamps at this time.

8. Secure the tubes as shown in SECTION B-B. Use one 2432T6122 Clamp (17) for the LH tube and one 2432T5924 Clamp (16) for the RH tube.

Mount each clamp to their respective bracket with two ZS18C12060 Capscrews (131) and two ZW26X12000 Lock Washers (142). 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.

11. Install ZE72X16000 Plug (108) to the LH and RH lower tubes.

12. Connect the upper tubes to the lower tubes.

Make sure that ZD12A02100 O-ring (101) for the LH tubes and YM42H01056P1 O-ring (59) 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.

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Page 43 of 59

INSTRUCTION SHEET FOR EH160LC ROTATION 2 WAY - FOOT CONTROL (W/BOOM and STD ARM PIPING) 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 (100) are inserted in between the connectors and are in the O-ring grooves.

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

NOTES

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Page 45 of 59

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

8

6 6

5

8

9

3

6

3

6

7

5

8

9

7

5

6

5

9

5

2

6

1

9 8

5

6

4

5

8

9

10

INSTALLING THE BOOM ROTATION HYDRAULIC PIPING

Figure 102

DC04H025

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

2.

3.

4.

5.

YM42H01156P1 - TUBE YM42H01157P1 - TUBE YM42H01158P1 - TUBE ZX28N10090 - HOSE YN42H01058P1 - CLAMP

6.

7.

8.

9.

10.

YN42H01059P1 - CLAMP ZA23B22000 - CONNECTOR ZS18C12040 - CAPSCREW ZW26X12000 - LOCKWASHER 2414Z199D050 - GUARD, HOSE

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

NOTE 2: Apply medium strength thread locking adhesive to the clamp mounting bolts (cap screws).

6. Position the middle and bottom clamps horizontally with the bucket cylinder tube as shown in SECTION B-B and SECTION C-C. Tighten the capscrews to torque specification.

NOTE 3: Tightening Torques for M-Threads:

7. Install ZA23B22000 Connector (93) to the bottom fitting. Tighten to torque specification.

Thread Size

Tightening Torques

M 12

115 ± 12 N.m (85 ± 9 lbf-ft)

8. Position and connect YM42H01156P1 RH Lower tube (64) to the upper tube. Don’t tighten the tube nut at this time.

NOTE 4: Tightening Torques for Nuts and Sleeves: Tube size

Tightening Torques

Ø22 x t 3 mm

216 ± 22 N.m (159 ± 16 lbf-ft)

RH PIPING INSTALLATION 1. Position YM42H01158P1 RH Upper Tube (66) on the RH top side of the boom.

2. Secure the tube top end to the bucket cylinder tube as shown in SECTION A-A with one YN42H01059P1 Clamp (86) and one YN42H01058P1 Clamp (85) bolted together with one ZS18C12040 Capscrew (129) and one ZW26X12000 Lock Washer (142). Position the clamp 220 mm (8.66 in) in front of the bucket cylinder tube vertical bracket. Don’t tighten the clamp at this time.

3. Secure the tube middle area to the bucket cylinder tube as show in SECTIONN B-B with one YN42H01059P1 Clamp (86) and one YN42H01058P1 Clamp (85) bolted together with one ZS18C12040 Capscrew (129) and one ZW26X12000 Lock Washer (142). Position the clamp 680 mm (26.77 in) in front of the bucket/arm cylinder tubes clamp. Don’t tighten the clamp at this time.

4. Secure the tube bottom end to the bucket cylinder tube as shown in SECTION C-C with one YN42H01059P1 Clamp (86) and one YN42H01058P1 Clamp (85) bolted together with one ZS18C12040 Capscrew (129) and one ZW26X12000 Lock Washer (142). Position the clamp 180 mm (7 in) to the rear of the bucket/arm cylinder tubes clamp. Don’t tighten the clamp at this time.

5. Check position of the tube top fitting. It should be approximately 120 mm (4.72 in) from the arm pivot pin center line. Incline the top clamp 30° outward from the vertical position of the bucket cylinder tube as shown in SECTION A-A. Tighten the clamps capscrew to torque specification.

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9. Secure the tube middle area to the bucket cylinder tube as shown in SECTION D-D with one YN42H01059P1 Clamp (86) and one YN42H01058P1 Clamp (85) bolted together with one ZS18C12040 Capscrew (129) and one ZW26X12000 Lock Washer (142). Position the clamp 80 mm (3 in) to the rear of the bucket/arm cylinder tubes clamp. Don’t tighten the clamp at this time.

10. Secure the tube bent area on top of the arm cylinder tube as shown in SECTION E-E with one YN42H01059P1 Clamp (86) and one YN42H01058P1 Clamp (85) bolted together with one ZS18C12040 Capscrew (129) and one ZW26X12000 Lock Washer (142). Position the clamp 375 mm (14.75 in) to the rear of the bucket/arm cylinder tubes clamp. Don’t tighten the clamp at this time.

11. Secure the tube bottom end on top of the bucket cylinder tube as shown in SECTION F-F with one YN42H01059P1 Clamp (86) and one YN42H01058P1 Clamp (85) bolted together with one ZS18C12040 Capscrew (129) and one ZW26X12000 Lock Washer (142). Position the c l a m p 12 0 m m ( 4 . 7 i n ) t o t h e r e a r of t h e bucket/arm cylinder tubes clamp. Don’t tighten the clamp at this time.

12. Recheck position of the tube. Tighten the tube nut at the upper tube connector to torque specification. Tighten the capscrews that hold the clamps together to torque specification.

13. Connect ZX28N10090 Hose (144) to the tube at the boom base.

14. If the Arm Rotation piping is already installed, connect the RH hose at the arm piping to the boom rotation piping RH upper tube. The lower hose is to be connected to the upper hydraulic rotation piping.

Page 47 of 59

INSTRUCTION SHEET FOR EH160LC ROTATION 2 WAY - FOOT CONTROL (W/BOOM and STD ARM PIPING) LH PIPING INSTALLATION 1. Position and install the LH upper tube the same way in installing the RH upper tube only in opposite side.

2. Install ZA23B22000 Connector (93) to the bottom fitting. Tighten to torque specification.

3. Position and connect YM42H01157P1 LH Lower tube (65) to the upper tube. Don’t tighten the tube nut at this time.

4. Secure the tube middle area to the bucket cylinder tube as shown in SECTION D-D with one YN42H01059P1 Clamp (86) and one YN42H01058P1 Clamp (85) bolted together with one ZS18C12040 Capscrew (129) and one ZW26X12000 Lock Washer (142). Position the clamp 80 mm (3 in) to the rear of the bucket/arm cylinder tubes clamp. Don’t tighten the clamp at this time.

5. Secure the tube bent area on top of the bucket cylinder tube as shown in SECTION E-E with one YN42H01059P1 Clamp (86) and one YN42H01058P1 Clamp (85) bolted together with one ZS18C12040 Capscrew (129) and one ZW26X12000 Lock Washer (142). Position the clamp 600 mm (23.6 in) to the rear of the bucket/arm cylinder tubes clamp. Don’t tighten the clamp at this time.

6. Secure the tube bottom end on top of the bucket cylinder tube as shown in SECTION F-F with one YN42H01059P1 Clamp (86) and one YN42H01058P1 Clamp (85) bolted together with one ZS18C12040 Capscrew (129) and one ZW26X12000 Lock Washer (142). Position the c l am p 1 2 0 m m ( 4 . 7 i n) t o t h e r e a r o f t h e bucket/arm cylinder tubes clamp. Don’t tighten the clamp at this time.

7. Recheck position of the tube. Tighten the tube nut at the upper tube connector to torque specification. Tighten the capscrews that hold the clamps together to torque specification.

8. Connect ZX28N10090 Hose (144) to the tube at the boom base.

9. If the Arm Rotation piping is already installed, connect the LH hose at the arm piping to the boom rotation piping LH upper tube. The lower hose is to be connected to the upper hydraulic rotation piping.

10. Assemble the two 2414Z199D050 Hose Guards (3) (one on each hose) to the rotation hoses at the boom base.

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INSTRUCTION SHEET FOR EH160LC ROTATION 2 WAY - FOOT CONTROL (W/BOOM and STD ARM PIPING) INSTALLING THE TUBE SUPPORTS AND TAPPED BLOCKS IN THE ARM FOR THE ROTATION PIPING

3

2

4

3

2

4

2

1

3

4 4

3

Figure 103

DC04H021

1. ARM 2. LC12B01076P1 - SUPPORT

3. 2416T9804 - BLOCK,TAPPED 4. 2416T9804D4 - BLOCK, TAPPED

NOTE 1: Check first the Arm in the machine. If the arm is not provided with the supports and tapped blocks for the rotation hydraulic piping from the factory proceed in the installation.

NOTE 2: Number in parenthesis in the Instructions refer to the reference number in the Parts List.

NOTE 3: Clean the surface where the supports and tapped blocks are to be welded.

NOTE 4: Make fillet bead shape concave not convex.

NOTE 5: For non specified welding rods, use “B” rods.

NOTE 6: Remember to disconnect the negative (-) terminal of the battery as specified in the machine preparation before doing any welding works.

1. Locate the position of the two LC12B01076P1 Tube Supports (40) (one on each side) in the arm as indicated in Figure 103. Position and weld the support on each side of the arm as shown in SECTION A-A.

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2. Locate the position of the two 2416T9804 Tapped Blocks (6) (one on each side) in the arm as indicated in Figure 103. Position and weld the tapped block on each side of the arm as shown in SECTION B-B. 3. Locate the position of the two 2416T9804D4 Tapped Blocks (7) (one on each side) in the arm as indicated in Figure 103. Position and weld the tapped block on each side of the arm as shown in SECTION C-C. 4. Clean and repaint the arm in the areas where the welding was done. The paint materials are not part of the kit.

Page 49 of 59

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

8

15 18 9 11

15 18

15 18

20 19 16 Figure 104

DC04D471

Page 50 of 59

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 2 WAY HYDRAULIC PIPING

Issued 10-04

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IS04-024A-NH NA

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

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

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

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

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:

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

4. Install 2444P1744D2 Bottom Connector (18) 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 (103) to the connector.

5. Install 2420T4404 Cap Plug (13) to the Bottom Connector on both sides.

Thread Size

Tightening Torques

M8

33 ± 3 N.m (24 ± 2 lbf-ft)

M 10

66 ± 7 N.m (49 ± 5 lbf-ft)

M 12

115 ± 12 N.m (185 ± 9 lbf-ft)

LH tube installation

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

Tightening Torques

3/4

162 ± 15 N.m (119 ± 11 lbf-ft

NOTE 6: Tightening Torques for ORS - Joint Nut: 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 (90) on both sides of the arm tip as shown in SECTION A-A. Mount the bracket with two ZS18C12045 Capscrews (130), two 2418T10357 Washers (8) and two ZW26X12000 Lock Washers (142) on each side. Use medium strength thread locking adhesive to the capscrews and tighten to torque specification.

2. Install 24100P1006F1 Stop Valves (2) to the brackets as shown in SECTION A-A. Mount the stop valves with four ZS18C08025 Capscrews (121) and four ZW16H08000 Washers (135) on each side. Use medium strength thread locking adhesive to the cap screws and tighten to torque specification.

3. Install HG23H12012G1 Top Connector (30) to the top port of the Stop Valve on both sides.

6. Position YM43H01041P1 LH Tube (68) in the arm.

7. Secure the middle part of the tube as shown in SECTION B-B with two LB42H01001P1 Clamps (38) and one LB42H01004P1 Bushing (39) wrap around to the tube for protection. Mount the clamp with two ZS18C10030 Capscrews (125) and two ZW16H10000 Washers (136) to the tapped block. Don’t tighten the clamp at this time.

8. Secure the top part of the tube as shown in SECTION C-C with two LB42H01001P1 Clamps (38) and one LB42H01004P1 Bushing (39) wrap around the tube for protection. Mount the clamps with two ZS18C10030 Capscrews (125) and two ZW16H10000 Washers (136) to the tapped block. Don’t tighten the clamp at this time.

9. Install ZD12A01800 O-ring (100) to the straight connector of the tube. Make sure that the O-ring is in the O-ring groove.

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 (100) to the elbow connector of the tube. Make sure that the O-ring is in the O-ring groove.

13. Connect ZX50H12185 LH Hose (148) to the elbow connector of the tube. Tighten the hose nut to torque specification.

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Page 51 of 59

INSTRUCTION SHEET FOR EH160LC ROTATION 2 WAY - FOOT CONTROL (W/BOOM and STD ARM PIPING) RH tube installation 14. Position YM43H01040P1 RH Tube (67) in the arm.

15. Secure the middle part of the tube as shown in Section B-B with two LS43H01005P1 Clamps (45) and one LC42H01020P1 Bushing (42) wrap around to the tube for protection. Mount the clamps with two ZS18C10030 Capscrews (125) and two ZW16H10000 Washers (136) 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 (45) and one LC42H01020P1 Bushing (42) wrap around the tube for protection. Mount the clamps with two ZS18C10030 Capscrews (125) and two ZW16H10000 Washers (136) to the tapped block. Don’t tighten the clamp at this time.

17. Install an ZD12A01800 O-ring (100) 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 (101) to the elbow connector of the tube. Make sure that the O-ring is in the O-ring groove.

21. Connect the ZX50H16185 RH Hose (149) 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 (100) for LH and ZD12A02100 O-ring (101) for RH are in the O-ring grooves of the tube connectors before tightening hose nuts.

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

NOTES

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Page 53 of 59

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

6

8 7

5

6

4

8

7

6

7

8

6

7

8

3 2

8

3 1

6

7

6

7

8

INSTALLING THE ARM ROTATION HYDRAULIC PIPING

Figure 105

DC04H022

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

2.

3.

4.

YM43H01054P1 - TUBE YM43H01055P1 - TUBE ZX58N10175 - HOSE 2444T2657D1 - CONNECTOR

5.

6.

7.

8.

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

NOTE 2: Apply medium strength thread locking adhesive to the clamp mounting bolts (cap screws).

NOTE 3: Tightening Torques for M-Threads: Thread Size

Tightening Torques

M 10

66 ± 7 N.m (49 ± 5 lbf-ft)

2420T4405 - PLUG ZC26X22011 - CLAMP ZS18C10045 - CAPSCREW ZW26X10000 - LOCK WASHER

RH PIPING INSTALLATION 10. Position YM43H01054P1 RH Tube (69) in the arm.

11. Continue installing the RH tube using the same procedures as in installing the LH tube.

12. Install ZX58N10175 Hose (150) to the upper end fitting. Tighten hose to the fitting.

NOTE 4: Tightening Torques for Nuts and Sleeves: Tube size

Tightening Torques

Ø22 x t 3 mm

216 ± 22 N.m (159 ± 16 lbf-ft)

LH PIPING INSTALLATION 1. Position YM43H01055P1 LH Tube (70) in the arm.

2. Secure the middle part of the tube as shown in SECTION B-B with one ZC26X22011 Clamp (98). Mount the clamp to the tapped block with one ZS18C10045 Capscrew (126) and one ZW26X10000 Lock Washer (141). Don’t tighten the clamp at this time.

3. Secure the lower end of the tube as shown in SECTION A-A with one ZC26X22011 Clamp (98).Mount the clamp to the support with one ZS18C10045 Capscrew (126) and one ZW26X10000 Lock Washer (141). Don’t tighten the clamp at this time.

4. Secure the upper end of the tube as shown in SECTION C-C with one ZC26X22011 Clamp (98). Mount the clamp to the tapped block with one ZS18C10045 Capscrew (126) and one ZW26X10000 Lock Washer (141). Don’t tighten the clamp at this time.

5. Adjust the position of the tube with the face of the fitting in the lower end is approximately 820 mm (32 in) from the bucket pivot pin center line.

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

7. Install 2444T2657D1 Connector (23) to the tube lower end fitting. Tighten the connector to the fitting.

8. Install 2420T4405 Plug (14) to the connector.

Tighten the connector.

9. Install ZX58N10175 Hose (150) to the upper end fitting. Tighten hose to the fitting.

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Page 55 of 59

INSTRUCTION SHEET FOR EH160LC ROTATION 2 WAY - FOOT 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)

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.

YM12B01042P1 LH IDLER LINK- 19 Kg (42lbs)

4

3

11 4

7

5

8

6

1

13 Figure 107

DC04B002

ARM BUCKET CYLINDER SHIMS DUST SEAL BUCKET LINK YM12B01041P1 - RH IDLER LINK 7. YM12B01042P1 - LH IDLER LINK

8.

9.

10.

11.

12.

BUCKET LINK PIN ARM IDLER PIN RETAINING BOLT RETAINING NUT JAM NUT

13. DUST SEAL 14. SHIMS

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

3

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

4 Figure 106 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.

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.

Page 56 of 59

10

9

1.

2.

3.

4.

5.

6.

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

14

14

5

DC04B001

3 6

YM12B01041P1 RH IDLER LINK- 20 Kg (44 lbs)

2

12

10

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

7. Reassemble the parts as shown installing the new reinforced YM12B01042P1 LH Idler Link (57)and YM12B01041P1 RH Idler Link (56).

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.

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

Issued 10-04

Cst

IS04-024A-NH NA

INSTRUCTION SHEET FOR EH160LC ROTATION 2 WAY - FOOT 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 and bucket link:

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

1. Place the throttle control in low idle

.

Figure 109

DC04B338

1. WOOD BLOCK

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.

2. Sound

the

horn

before

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

1 DC04E122

Figure 108

1. FUNCTION CANCELLATION LEVER

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

IS04-024A-NH NA

Issued 10-04

Cst

Page 57 of 59

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

1

2 4

4 11

3 3 3

4

7

12

10

11 4 5

8

3 14

10

6

14 13

9 13

Figure 110

DC04B002

1.

2.

3.

4.

5.

6.

ARM BUCKET CYLINDER SHIMS DUST SEAL BUCKET LINK YM12B01041P1 - RH IDLER LINK 7. YM12B01042P1 - LH IDLER LINK

8.

9.

10.

11.

12.

BUCKET LINK PIN ARM IDLER PIN RETAINING BOLT RETAINING NUT JAM NUT

13. DUST SEAL 14. SHIMS

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 Idler Link (57)and YM12B01041P1 RH Idler Link (56). 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.

Page 58 of 59

Issued 10-04

Cst

IS04-024A-NH NA

INSTRUCTION SHEET FOR EH160LC ROTATION 2 WAY - FOOT CONTROL (W/BOOM and STD ARM PIPING) CHECK FOR HYDRAULIC LEAKS

BLEED THE PILOT SYSTEM

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

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.

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

1. Place the throttle control in low idle

.

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

2. Sound

the

horn

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.

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.

IS04-024A-NH NA

Issued 10-04

Cst

Page 59 of 59