New Holland EH215LC Excavator 2-Way Hand Control with boom & Standard arm Piping Instruction Manual

INSTRUCTION SHEET INSTRUCTIONS FOR INSTALLING YN32TU1044F2 2-WAY HAND CONTROL WITH BOOM AND STANDARD ARM PIPING ON EH215LC EXCAVATOR PARTS LIST REF. PART NO.

DESCRIPTION

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VALVE, SELECTOR....................................................................................................................... 1 VALVE, STOP ................................................................................................................................ 2 GUIDE, HOSE................................................................................................................................ 4 BLOCK........................................................................................................................................... 1 HOSE..............................................................................................................................................1 HOSE..............................................................................................................................................1 HOSE..............................................................................................................................................1 CLAMP .......................................................................................................................................... 2 CLAMP .......................................................................................................................................... 3 CONNECTOR ................................................................................................................................ 2 HOSE............................................................................................................................................. 1 PLUG ............................................................................................................................................. 2 ELBOW .......................................................................................................................................... 1 SWITCH......................................................................................................................................... 1 RELAY ........................................................................................................................................... 2 CONNECTOR ................................................................................................................................ 1 ELBOW .......................................................................................................................................... 1 TEE................................................................................................................................................ 1 SOLENOID VALVE ........................................................................................................................ 1 BUSHING....................................................................................................................................... 2 HOSE............................................................................................................................................. 1 CLAMP .......................................................................................................................................... 5 HOSE............................................................................................................................................. 1 BUSHING....................................................................................................................................... 2 CLAMP .......................................................................................................................................... 4 CLAMP .......................................................................................................................................... 4 PLASTIC TIES ............................................................................................................................... 5 LABEL............................................................................................................................................ 1 LH GRIP ASSEMBLY ..................................................................................................................... 1 RH GRIP ASSEMBLY ...........................................................................................................

1 HOSE............................................................................................................................................. 1 SUPPORT...................................................................................................................................... 1 TUBE ............................................................................................................................................. 1 SUPPORT...................................................................................................................................... 1 HOSE............................................................................................................................................. 1 TUBE ............................................................................................................................................. 1 BRACKET ...................................................................................................................................... 1 HARNESS...................................................................................................................................... 1 HARNESS...................................................................................................................................... 1 LINK............................................................................................................................................... 1 LINK............................................................................................................................................... 1 LABEL............................................................................................................................................ 1 CLAMP .......................................................................................................................................... 1

24100P2599F2 ..............

24100P3133F1 ..............

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

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

2420R349D110 ..............

2420R349D305 ..............

2420R349D340 ..............

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

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

2444P1744D3 ................

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

2444T2406 ....................

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

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

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

HH25R04004G5.............

HH35X16016G1.............

HH55X12012G3.............

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

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

LC42H01041D3 .............

LC42H01269P1 .............

LC43H01011D4 .............

LC43H01013P1 .............

LS42H01018P1..............

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

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

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

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

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

YN03H01456D5 .............

YN03H01480P1 .............

YN03H01638P1 .............

YN03H01639P1 .............

YN03H01641D3 .............

YN03H01703P1 .............

YN03H01705P1 .............

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

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

YN12B01321P1 .............

YN12B01322P1 .............

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

YN32H01066P1 .............

IS04-007A-NH NA Cst Issued 07-04 Copyright © 2004 CNH America LLC. All Rights Reserved.

QTY.

Printed in U.S.A.

Page 1 of 39

INSTRUCTION SHEET FOR EH215LC 2 WAY - HAND CONTROL (W/BOOM and STD ARM PIPING) REF. PART NO.

DESCRIPTION

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CLAMP .......................................................................................................................................... 1 TUBE ............................................................................................................................................. 1 TUBE ..............................................................................................................................................1 TUBE ..............................................................................................................................................1 TUBE ..............................................................................................................................................1 CLAMP .......................................................................................................................................... 1 CONNECTOR ................................................................................................................................ 2 WASHER ....................................................................................................................................... 8 WASHER ....................................................................................................................................... 4 HOSE............................................................................................................................................. 1 TUBE ..............................................................................................................................................1 BRACKET ...................................................................................................................................... 2 TUBE ............................................................................................................................................11 CLAMP .......................................................................................................................................... 3 SUPPORT...................................................................................................................................... 1 BRACKET ...................................................................................................................................... 1 LABEL............................................................................................................................................ 1 BUSHING....................................................................................................................................... 1 LABEL............................................................................................................................................ 1 O-RING .......................................................................................................................................... 4 O-RING .......................................................................................................................................... 8 O-RING .......................................................................................................................................... 6 CLAMP, HALF.............................................................................................................................. 14 CLAMP, HALF................................................................................................................................ 8 PLUG ............................................................................................................................................. 1 PLUG ............................................................................................................................................. 1 PLUG ............................................................................................................................................. 2 CONNECTOR ................................................................................................................................ 3 ELBOW, 90°................................................................................................................................... 2 ELBOW, 90°................................................................................................................................... 2 ELBOW, 45°................................................................................................................................... 1 ELBOW .......................................................................................................................................... 1 SEMS-BOLT .................................................................................................................................. 2 NUT ............................................................................................................................................... 1 CAPSCREW .................................................................................................................................. 8 CAPSCREW .................................................................................................................................. 6 CAPSCREW .................................................................................................................................. 4 CAPSCREW ................................................................................................................................ 12 CAPSCREW .................................................................................................................................. 4 CAPSCREW .................................................................................................................................. 2 CAPSCREW .................................................................................................................................. 4 CAPSCREW ................................................................................................................................ 11 CAPSCREW ................................................................................................................................ 12 CAPSCREW .................................................................................................................................. 1 CAPSCREW ................................................................................................................................ 20 CAPSCREW ................................................................................................................................ 12 CAPSCREW ................................................................................................................................ 16 WASHER ..................................................................................................................................... 12 WASHER ....................................................................................................................................... 9 WASHER ....................................................................................................................................... 6 WASHER ....................................................................................................................................... 4 LOCK WASHER ........................................................................................................................... 32 LOCK WASHER ........................................................................................................................... 12 LOCKWASHER ............................................................................................................................ 26 VALVE, N&B CONTROL ................................................................................................................ 1 CAPSCREW .................................................................................................................................. 4

YN42H01078P1 .............

YN42H01348P1 .............

YN42H01970P1 .............

YN42H01971P1 .............

YN42H01972P1 .............

YN42H01990P1 .............

YN43H01005P1 .............

YN43H01151P1 .............

YN43H01163P1 .............

YN43H01211DB.............

YN43H01425P1 .............

YN43H01426P1 .............

YN43H01503P1 .............

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

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

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

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

YX32H01011P1 .............

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

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

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

ZD12P03800..................

ZE13X16000 ..................

ZE13X20001 ..................

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

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

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

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

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

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

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

ZH42X04006..................

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

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

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

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

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

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

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

ZS18C12035..................

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

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

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

ZS18C12075..................

ZS28C12040..................

ZS28C12050..................

ZS28C14050..................

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

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

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

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

ZW26K12000 .................

ZW26K14000 .................

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

YN30V00084F1 .............

ZS23C12100..................

Page 2 of 39

QTY.

Issued 07-04

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IS04-007A-NH NA

INSTRUCTION SHEET FOR EH215LC 2 WAY - HAND CONTROL (W/BOOM and STD ARM PIPING) REF. PART NO.

DESCRIPTION

QTY.

100. YN03M01503P1............. HARD RUBBER BOOT................................................................................................................... 2 101. YN03M01505P1............. FLEXIBLE RUBBER BOOT ............................................................................................................ 2 102. PY01P01043D6 ............. PLASTIC TIES ................................................................................................................................6

IS04-007A-NH NA

Issued 07-04

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Page 3 of 39

INSTRUCTION SHEET FOR EH215LC 2 WAY - HAND CONTROL (W/BOOM and STD ARM PIPING)

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

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

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

Release hydraulic tank pressure before working with any hydraulic components.

Figure 3

DC04E123

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

Figure 1

DC04E121

1. Park the machine on a level surface.

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

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

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

1 2 Figure 4

DC04B339

1. AIR RELEASE BUTTON 2. HYDRAULIC TANK BREATHER

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

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

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

1 Figure 2

DC04E122

1. FUNCTION CANCELLATION LEVER

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

Page 4 of 39

Issued 07-04

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IS04-007A-NH NA

INSTRUCTION SHEET FOR EH215LC 2 WAY - HAND CONTROL (W/BOOM and STD ARM PIPING) VACUUM PUMP USAGE NOTE: To minimize oil loss during installation of the kit, it is highly recommended the use of a vacuum pump on the hydraulic tank capable to vacuum 762 mm Hg (30 in Hg).

1

Figure 5

DC04E124

1. FUNCTION CANCELLATION LEVER

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

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

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

1 Figure 7

DC04B340

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.

IS04-007A-NH NA

Issued 07-04

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Page 5 of 39

INSTRUCTION SHEET FOR EH215LC 2 WAY - HAND CONTROL (W/BOOM and STD ARM PIPING)

1

1

2 Figure 9

DC04B330

1. CONNECTOR 2. VACUUM PUMP

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

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

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

2

1

Figure 11

DC04E127

1. AIR CLEANER COMPARTMENT FLOOR PLATE

2. Remove the air cleaner compartment floor plate to gain access to the control hoses clamps at the rear of the cab and to the pilot hoses behind the operator’s cab

2

1

Figure 10

DC04E126

1. MAIN CONTROL VALVE COVER 2. MOUNTING BOLTS

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

Page 6 of 39

Figure 12

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.

Issued 07-04

Cst

IS04-007A-NH NA

INSTRUCTION SHEET FOR EH215LC 2 WAY - HAND CONTROL (W/BOOM and STD ARM PIPING)

3

2

4 1

2

6 1

5 Figure 13

DC04E129

1. MIDDLE LOWER COVER 2. MOUNTING BOLTS

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

INSTALL THE N&B CONTROL VALVE NOTE: Number in parenthesis in the instruction refer to the reference number in the Parts List.

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

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

3

DC04F041

1.

2.

3.

4.

5.

6.

Figure 15

ZC23C12100 - ALLEN HEAD CAPSCREWS YN30V00084 F1 - 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

2. Position the end cover and YN30V00084F1 N&B Control Valve (98). 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 ZS23C12100 Allen Head Capscrews (99) 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 ZS23C12100 Allen Head Capscrews (99) 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 14

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.

IS04-007A-NH NA

Issued 07-04

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Page 7 of 39

INSTRUCTION SHEET FOR EH215LC 2 WAY - HAND CONTROL (W/BOOM and STD ARM PIPING) INSTALL THE HYDRAULIC CONTROL LINES 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

1

1 Figure 18

DC04G001

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

Figure 16

DC04A178

1. FLOOR MAT

3. Mount YN68H01071P1 Solenoid Valve Support (58) under the RH foot rest and install back the foot rest using the same sems bolt that were removed. Tighten the bolts to 46 ± 5 N.m (34 ± 4 lbf-ft) torque.

4. Install back the floor mat.

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

1

5 1

4

2 2

2 3

3 FRONT VIEW

Figure 17

DC04B303

1. RH FOOT REST 2. MOUNTING BOLT

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

1.

2.

3.

4.

5.

SIDE VIEW

Figure 19

DC04G002

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

5. Install YN68H01073P1 Solenoid Valve Bracket (59) to the valve support. Secure the bracket to the support with two ZS18C10020 Capscrews (80) and two ZW16X10000 Washers (94).

6. Install the LC35V00004F2 Solenoid Valve Assy.

(19) to the solenoid valve bracket. Secure the valve assy. to the bracket with two ZS18C10020 Capscrews (80) and two ZW16X10000 Washers (94). Tighten the capscrews to 22 ± 2 N.m (16 ± 2 lbf-ft).

Page 8 of 39

Issued 07-04

Cst

IS04-007A-NH NA

INSTRUCTION SHEET FOR EH215LC 2 WAY - HAND CONTROL (W/BOOM and STD ARM PIPING)

1

6

2

2 5 4 3

5

5 Figure 20

DC04G003

1.

2.

3.

4.

5.

6.

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

1

8. Install 2444Z2894 Elbow (13) to the connector at “P” port of solenoid valve.

9. Install ZH42X04000 Elbow (74) to the elbow that is connected to the connector in port “P” of the solenoid valve. Position the elbow as shown in Figure 20.

10. Install ZH22X04000 Connector (71) to the “T” port of the solenoid valve. Tighten the connector to 29 ± 2 N.m (21 ± 2 lbf-ft) torque.

11. Assemble the two ZH32X04000 Elbow (72) to the bottom ports of the solenoid valve (one on port “A” and one on port “B”). Position the elbows as shown in Figure 20. Tighten the elbows to 29 ± 2 N.m (21 ± 2 lbf-ft) torque.

Issued 07-04

Cst

3 Figure 21

DC04G005

7. Install HH25R04004G5 Connector (16) to the “P” port of the solenoid valve. Tighten the connector to 29 ± 2 N.m (21 ± 2 lbf-ft) torque.

IS04-007A-NH NA

4 1.

2.

3.

4.

5.

2420R349D110 - HOSE (S/V P) 2444R1120D110 - HOSE (S/V T) 2420R349D305 - HOSE (S/V B) 2420R349D340 - HOSE (S/V A) SOLENOID VALVE

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

12. Install 2420R349D110 Hose (5) to the “P” port of the solenoid valve.

13. Install 2444R1120D110 Hose (11) to the “T” port of the solenoid valve.

14. Install 2420R349D305 Hose (6) to the “B” port of the solenoid valve.

15. Install 2420R349D340 Hose (7) to the “A” port of the solenoid valve.

16. Tighten the hoses to the fittings.

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

Page 9 of 39

INSTRUCTION SHEET FOR EH215LC 2 WAY - HAND CONTROL (W/BOOM and STD ARM PIPING) 20. With the new clamp on top of the existing clamp, fastened the clamps with two ZS18C08065 Capscrews (79) and two ZW16X08000 Washers (93). Use medium strength thread locking adhesive on the capscrews and tighten to 10 ± 1 N.m (7 ± 0.7 lbf-ft) torque.

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

1 Figure 22

DC04A214

1. RH PILOT HOSE CLAMP

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

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

4

5

6

7

1

1 2

8 9

3 Figure 23

DC04C636

1.

2.

3.

4.

5.

6.

7.

8.

9.

YN68H01035P1 - CLAMP ZW16X08000 - WASHER ZS18C08065 - CAPSCREW 2420R349D305 - HOSE (S/V B) 2420R349D340 - HOSE (S/V A) 2444R1120D110 - HOSE (S/V T) 2420R349D110 - HOSE (S/V P) EXISTING CLAMP EXISTING HOSES

18. Insert the new YN68H1035P1 Clamp (57) on top of the existing clamp.

Figure 24

DC04B331

1. EXISTING STANDARD PILOT BLOCK

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

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

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

24. Disconnect all hoses from the existing standard block.

19. Place the pilot hoses through the slots of the new clamp as indicated in Figure 23 (view looking from the front of the cab).

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

Page 10 of 39

Issued 07-04

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IS04-007A-NH NA

INSTRUCTION SHEET FOR EH215LC 2 WAY - HAND CONTROL (W/BOOM and STD ARM PIPING)

2

C

5

3

6

4 3

1

6

B

7

3 4

5

1 10

Figure 25

DC04C637

1.

2.

3.

4.

5.

8

2

9 A

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

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

VIEW

A

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

11

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

VIEW

B

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

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

VIEW

C Figure 26

DC04A210

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

IS04-007A-NH NA

Issued 07-04

Cst

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

Page 11 of 39

INSTRUCTION SHEET FOR EH215LC 2 WAY - HAND CONTROL (W/BOOM and STD ARM PIPING) 30. Clean the capscrews that were removed from the old pilot block. Apply medium strength thread locking adhesive to the capscrews. Install the new 2416N6141 Pilot Block (4) to the block bracket using these capscrews and washers.

Tighten capscrews to torque specification.

1

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.

2

31. Install ZE72X04000 Plug (68) to the front LH “P” port of the new pilot block.

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

Replace O-ring if damaged before installing fitting.

33. Install ZH22X04000 Straight Fitting (71) to the front RH “P” port of the new pilot block.

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

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

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

Figure 27

DC04B332

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

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

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

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

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

43. Continue routing the 2420R349D305 (S/V B) and 2420R349D340 (S/V A) hoses through the structure opening under the cab towards the rear of the cab.

37. Install ZE72X06000 Plug (69) to the rear LH “T” port of the new pilot block.

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

39. Install ZH22X04000 Straight Fitting (71) to the LH side “P” port of the new pilot block.

1 Figure 28

DC04E131

1. PILOT HOSES CENTER CLAMP

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

Page 12 of 39

Issued 07-04

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IS04-007A-NH NA

INSTRUCTION SHEET FOR EH215LC 2 WAY - HAND CONTROL (W/BOOM and STD ARM PIPING) 49. Continue routing the S/V B and S/V A hoses toward the control valve.

1

1 Figure 29

DC04E132

1. CLAMP

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

4

Figure 31

DC04E133

1. CLAMP

50. Locate the hose clamp that holds the pilot hoses toward the control valve.

5

51. Remove the clamp bolts and washers.

5

6

4

3

1

2

2

6 7

1

3

7

Figure 30

DC04C639

1.

2.

3.

4.

5.

6.

7.

YN68H01035P1 - CLAMP ZW16X08000 - WASHER ZS18C08065 - CAPSCREW 2420R349D305 - HOSE (S/V B) 2420R349D340 - HOSE (S/V A) EXISTING CLAMP EXISTING HOSES

46. Insert the new YN68H1035P1 Clamp (57) on top of the existing clamp.

47. Place the pilot hoses through the slots of the new clamp as indicated in Figure 30 (view looking from the front of the cab).

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

48. With the new clamp on top of the existing clamp, fastened the clamps with two ZS18C08065 Capscrews (79) and two ZW16X08000 Washers (93). Use medium strength thread locking adhesive on the capscrews and tighten to 10 ± 1 N.m (7 ± 0.7 lbf-ft) torque.

IS04-007A-NH NA

Figure 32

DC04C649

Issued 07-04

Cst

1.

2.

3.

4.

5.

6.

7.

YN68H01035P1 - CLAMP ZW16X08000 - WASHER ZS18C08065 - CAPSCREW 2420R349D340 - HOSE (S/V A) 2420R349D305 - HOSE (S/V B) EXISTING CLAMP EXISTING HOSES

52. Install YN68H01035P1 Clamp (57) on top of the existing clamp. Place the pilot hoses through the slots of the new clamp as shown.

53. With the new clamp on top of the existing clamp. fastened the clamps with two ZS18C08065 Capscrews (79) and two ZW16X08000 Washers (93). Use medium strength thread locking adhesive on the capscrews and tighten to 10 ± 1 N.m (7 ± 0.7 lbf-ft).

54. Continue routing the (S/V B) and (S/V A) hoses toward the control valve.

Page 13 of 39

INSTRUCTION SHEET FOR EH215LC 2 WAY - HAND CONTROL (W/BOOM and STD ARM PIPING)

1

57. Remove the plug on the bottom “PB02” port of the N&B control valve and install ZH42X04006 Elbow Fitting (75).

1

2 3 2 Figure 35

DC04E090

Figure 33

DC04B326

1. 2420R349D340 - HOSE (S/V A) 2. RUBBER PROTECTOR WRAPPING 3. PLASTIC TIE

55. Continue routing the 2420R349D340 (S/V A) Hose and pass it through the pilot hose rubber protector. You may have to cut the plastic ties that secured the rubber protector to facilitate the routing of the hose toward the top PA02 port of the N&B control valve. Make sure to wrap the hoses with the rubber protector and secure the protector with plastic ties after routing the hoses.

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

1. 242R349D340 - HOSE (S/V A) 2. 2420R349D305 - HOSE (S/V B)

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

59. Connect the (S/V B) hose to the elbow fitting in the “PB02” port of the N&B control valve.

60. Tighten hoses to the fittings.

INSTALLATION OF THE HYDRAULIC CONTROL HAND GRIPS AND ELECTRICAL HARNESSES Replacing the LH Hand Grip

2

1 1 2 3

Figure 36

DC04G007

Figure 34

DC04B327

1. N&B CONTROL VALVE 2. ZH32X04006 - ELBOW FITTING 90° 3. ZH42X04006 - ELBOW FITTING 45°

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

Page 14 of 39

1. LH CONSOLE INSTRUMENT PANEL 2. LH CONTROL BOX

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

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

Issued 07-04

Cst

IS04-007A-NH NA

INSTRUCTION SHEET FOR EH215LC 2 WAY - HAND CONTROL (W/BOOM and STD ARM PIPING)

1

1

2

2 Figure 37

DC04G006

Figure 39

DC04G009

1. FLEXIBLE RUBBER BOOT 2. BOOT RETAINER LOCK

1. ELECTRICAL HARNESS 2. HAND GRIP ELECTRICAL WIRE PLUG

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

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.

1 3 2 1 2 4

3

Figure 38

DC04G008

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

4. Raise the boot from the tower.

Figure 40

DC04G010

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

1.

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.

IS04-007A-NH NA

Issued 07-04

Cst

Page 15 of 39

INSTRUCTION SHEET FOR EH215LC 2 WAY - HAND CONTROL (W/BOOM and STD ARM PIPING) 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 42.

1 2 3

5

4

Figure 41

DC04G011

1.

2.

3.

4.

5.

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.

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 (101).

10. Assemble the new YN03M01503P1 Hard Rubber Boot (100) 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 (29) to the boot assembly. make sure that the hard rubber boot is properly inserted to the hand grip handle groove.

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

1

1 Figure 43

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 (N&B) wiring harness has been routed.

Replacing the RH Hand Grip

2 3

4

Figure 42

DC04G012

1.

2.

3.

4.

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

1

Figure 44

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.

Page 16 of 39

Issued 07-04

Cst

IS04-007A-NH NA

INSTRUCTION SHEET FOR EH215LC 2 WAY - HAND CONTROL (W/BOOM and STD ARM PIPING)

1 2

3

3 4 1

6

4

2

DC04G011

5 Figure 45

DC04G026

1.

2.

3.

4.

5.

6.

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.

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

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.

Issued 07-04

1.

2.

3.

4.

5.

Figure 46 YB03M01003F3 - RH GRIP ASSEMBLY YN03M01503P1 - HARD RUBBER BOOT YN03M01505P1 - FLEXIBLE RUBBER BOOT JAM NUT FROM OLD GRIP ASSEMBLY RETAINER PLATE FROM OLD FLEXIBLE BOOT

25. Disassemble the retaining plate from the old flexible rubber boot and assemble it to the new YN03M01505P1 Flexible Rubber Boot (101).

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

IS04-007A-NH NA

5

Cst

26. Assemble the new YN03M01503P1 Hard Rubber Boot (100) to the new flexible rubber boot. Make sure that the flexible boot is properly inserted to the hard rubber boot groove.

27. Assemble the new YB03M01003F3 RH Grip Assembly (30) to the boot assembly. make sure that the hard rubber boot is properly inserted to the hand grip handle groove.

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

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

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

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

Page 17 of 39

INSTRUCTION SHEET FOR EH215LC 2 WAY - HAND 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 (N&B) wiring harness has been installed.

1

Figure 47

DC04G028

1. RH STANDARD ELECTRICAL HARNESS

INSTALLING THE AUXILIARY (N&B) ELECTRICAL WIRING HARNESS INSIDE THE CAB

YN11E01111P1 - AUXILIARY (N&B) HARNESS Figure 48

DC04G029

Page 18 of 39

Issued 07-04

Cst

IS04-007A-NH NA

INSTRUCTION SHEET FOR EH215LC 2 WAY - HAND CONTROL (W/BOOM and STD ARM PIPING)

2

1

1

2

2

2

3

3

5

5 6

2

4

Figure 50

DC04D556

3 DC04G033

6

4

Figure 49

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.

33. For easy access to the rear panel:

36. Remove the upper cover.

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.

2

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

3

3

1 3 Figure 51

DC04G035

1. CONTROLLER 2. RELAYS COVER 3. MOUNTING SCREWS

IS04-007A-NH NA

Issued 07-04

Cst

Page 19 of 39

INSTRUCTION SHEET FOR EH215LC 2 WAY - HAND CONTROL (W/BOOM and STD ARM PIPING) 39. Remove the Controller and Relays Cover mounting screws and flip both the controller and cover towards the front to gain access to the relays under the controller.

3

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

1

1

2

3

Figure 52

DC04G036

Figure 54

DC04G039

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

40. Install two EN24S00008P1 Relays (15) into the relay plate and secure each with ZM61C06016 Sems Bolt (76) to the plate. Mark the RH relay “Nibbler Open Relay” and the LH relay “Nibbler Close Relay” for identification.

1 2

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

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

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

45. Tie the harness to the standard harness with PY01P01043D3 Plastic Ties (27).

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

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

3

DC04G038

2

Figure 53

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

41. Install YN11E01111P1 Auxiliary (N&B) Electrical Harness (38) (see Figure 48 for harness identification) by threading first the pigtails with white tape (BrW - B wires) and red tape (VW - B wires) to the right console following the standard harness that is already installed in the control box. Clip the wiring with the standard harness.

Page 20 of 39

Issued 07-04

Cst

IS04-007A-NH NA

INSTRUCTION SHEET FOR EH215LC 2 WAY - HAND CONTROL (W/BOOM and STD ARM PIPING) 49. In the LH control box with the LH grip installed and the auxiliary harness wiring in place, connect the Clockwise Switch wiring (white taping) to the auxiliary harness wiring with white taping.

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

1 3

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

They are use only on machine with Rotation Attachment.

2

RH CONTROL BOX Figure 55

DC04G040

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

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

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

DC04G043

Figure 57

NOTE: Figure 57 shows correct location of the grip switches.

Installing the Solenoid Valve Electrical Harness

1

3 2

LH CONTROL BOX Figure 56

DC04G042

YN11E01112P1 - N&B SOLENOID HARNESS DC04G044

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

IS04-007A-NH NA

Figure 58

50. Install YN11E01112P1 N&B Solenoid Valve Harness (39) under the cab floor plate.

Issued 07-04

Cst

Page 21 of 39

INSTRUCTION SHEET FOR EH215LC 2 WAY - HAND CONTROL (W/BOOM and STD ARM PIPING)

1

57. Install back the Controller and covers that were removed in facilitating the grips, auxiliary harness, and solenoid valve harness installation.

2

3 Figure 59

DC04G046

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

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

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

52. Clip the solenoid harness with the standard harness.

1

2 Figure 60

DC04G045

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

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

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

connector

tagged

55. Connect harness single connector to the auxiliary harness wire connector tagged “NIBBLER”.

56. Recheck all electrical wiring connections.

Page 22 of 39

Issued 07-04

Cst

IS04-007A-NH NA

INSTRUCTION SHEET FOR EH215LC 2 WAY - HAND CONTROL (W/BOOM and STD ARM PIPING) INSTALL THE UPPER HYDRAULIC LINES 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.

4. Disconnect the pump return hose from the elbow at the hydraulic tank.

5. Remove the pump hose return hose elbow from the tank.

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

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

Tightening Torques

M8

35 ± 4 N.m (26 ± 3 lbf-ft)

M 12

121 ± 12 N.m (89 ± 9 lbf-ft)

2

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

Tightening Torques

3/4

162 ± 15 N.m (119 ± 11 lbf-ft)

1

255 ± 10 N.m (188 ± 7 lbf-ft)

NOTE 6: Tightening Torques for ORS - Joint Nut:

1

3

Figure 62

DC04D451

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. HH55X12012G3 - TEE 2. SWING MOTOR RETURN HOSE 3. PUMP RETURN HOSE

6. Install HH55X12012G3 Tee (18) to the tank port where the pump return hose elbow was removed.

7. Connect the pump return hose to the tee.

8. Connect the swing motor return hose to the tee.

2

2 1

1

4

Figure 61

DC04D450

1.

2.

3.

4.

3

RETURN HOSE FROM THE SWING MOTOR SWING MOTOR RETURN HOSE ELBOW RETURN HOSE FROM THE PUMP PUMP RETURN HOSE ELBOW

2. Disconnect the swing motor return hose from the elbow at the hydraulic tank.

3. Remove the swing motor return hose elbow from the tank. Plug and/or cover the tank port and hose temporarily to prevent dirt from entering the tank and hose.

Issued 07-04

3

Cst

4 Figure 63

DC04D443

1. Locate the swing motor return hose and the pump return hose at the hydraulic tank.

IS04-007A-NH NA

5

1.

2.

3.

4.

5.

HH35X16016G1 - ELBOW YN03H01480P1 - HOSE SUPPORT ZS18C12030 - CAPSCREW ZW16H12000 - WASHER TAPPED BLOCK

9. Install HH35X16016G1 Elbow (17) to the tank port where the swing motor return hose elbow was removed. Plug and/or cover the elbow temporarily to prevent dirt from entering the tank.

10. Locate the tapped block in the frame to the RH side of the swing motor.

Page 23 of 39

INSTRUCTION SHEET FOR EH215LC 2 WAY - HAND CONTROL (W/BOOM and STD ARM PIPING) 11. Install YN03H01480P1 Hose Support (32) to the tapped block with two ZS18C12030 Capscrews (82) and two ZW16H12000 Washers (92).

Tighten capscrews to torque specification.

1 1 Figure 66

DC04D446

1. TAPPED BLOCK

14. Locate tapped block in the frame to the LH side of the swing motor.

Figure 64

DC04D444

1. ANGLE BRACKET

12. Locate the angle bracket in the frame to the LH side of the control valve.

1 1

2

3

3

Figure 67

DC04D447

Figure 65

DC04D445

2

1. YN03H01639P1 - TUBE SUPPORT 2. ZS18C12035 - CAPSCREW 3. ZW16H12000 - WASHER

1. YN03H01705P1 - BRACKET 2. ZS18C12030 - CAPSCREW 3. ZW16H12000 - WASHER

15. Install YN03H01705P1 Valve Bracket (37) to the tapped block with two ZS18C12030 Capscrews (82) and two ZW16H12000 Washers (92).

13. Install YN03H01639P1 Tube Support (34) to the bracket with two ZS18C12035 Capscrews (83) and two ZW16H12000 Washers (92). Tighten capscrews to torque specification.

Page 24 of 39

Issued 07-04

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IS04-007A-NH NA

INSTRUCTION SHEET FOR EH215LC 2 WAY - HAND CONTROL (W/BOOM and STD ARM PIPING)

4

1

3

215 mm (8.5 in)

5 2 Figure 68

DC04D454

16. Before tightening the capscrews, position the bracket. Measurement from the center of the top mounting bolt to top of the bracket should be 215 mm (8.5 in). Tighten the capscrews to torque specification after positioning the bracket.

1.

2.

3.

4.

5.

1

3

Figure 70

DC04D447

YN03H01641D3 - N&B RETURN HOSE ZE13X16000 - HALF CLAMP ZS28C12040 - CAPSCREW ZW26K12000 - LOCK WASHER ZD12P03400 - O-RING

18. Insert ZD12P03400 O-ring (64) to the flange of YN03H01641D3 N&B Return Hose (35). Make sure that the O-ring is in the O-ring groove.

Install the hose to the RH side “tank” port of the selector valve using two ZE13X16000 Half Clamps (66). Fasten the half clamps to the selector valve with four ZS28C12040 Capscrews (88) and four ZW26K12000 Lock Washers (95).

Don’t tighten the half clamps at this time.

2

3

2

Figure 69

DC04D447

1. 24100P2599F2 - SELECTOR VALVE 2. ZS18C10030 - CAPSCREW 3. ZW16H10000 - WASHER

1

17. Install 24100P2599F2 Selector Valve (1) to the bracket using four ZS18C10030 Capscrews (81) and four ZW16H10000 Washers (91). Tighten capscrews to torque specification.

4

Figure 71

DC04D448

1.

2.

3.

4.

IS04-007A-NH NA

Issued 07-04

Cst

YX32H01011P1 - BUSHING YN32H01066P1 - CLAMP ZS18C12060 - CAPSCREW ZW16H12000 - WASHER

Page 25 of 39

INSTRUCTION SHEET FOR EH215LC 2 WAY - HAND CONTROL (W/BOOM and STD ARM PIPING) 19. Assemble YX32H01011P1 Bushing (61) and YN32H01066P1 Clamp (43) to the hose. Secure the clamp to the hose support with ZS18C12060 Capscrew (85) and ZW16H12000 Washer (92).

Do not tighten the clamp at this time.

1

2

23. Insert ZD12P03400 O-ring (64) to the flange of YN03H01638P1 Attachment Tube (33). Make sure that the O-ring is in the O-ring groove.

Install the tube to the face “ATT” port of the selector valve using two ZE13X16000 Half Clamps (66). Fasten the half clamps to the selector valve with four ZS28C12040 Capscrews (88) and four ZW26K12000 Lock washers (95).

Do not tighten the half flanges at this time.

5

3

Figure 72

DC04D449

1. ELBOW 2. N&B RETURN HOSE

2

3

4

1 Figure 74

DC04D452

20. Connect the N&B return hose to the elbow.

Position the hose and tighten the hose nut to the elbow.

21. Position the N&B return hose at the selector valve. Tighten the capscrews that secure the half clamps to 67 ± 7N.m (49 ± 5 lbf-ft) torque.

22. Position N&B return hose at the hose support.

Tighten the capscrew that secure the hose clamp to torque specification.

6

1.

2.

3.

4.

5.

6.

YN42H01078P1 - TUBE CLAMP ZS18C12075 - CAPSCREW ZW16H12000 - WASHER ZN18C12010 - NUT ATTACHMENT TUBE TUBE SUPPORT

24. Secure the attachment tube to the tube support with YN42H01078P1 Tube Clamp (44). Fasten the tube clamp with one ZS18C12075 Capscrew (87), two ZW16H12000 Washer (92) and one ZN18C12010 Nut (77). Do not tighten the clamp at this time.

25. Position the attachment tube and tighten the capscrews that secure the half clamps to 67 ± 7 N.m (49 ± 5 lbf-ft) torque.

1

26. Tighten the capscrew that secure the tube clamp to the tube support to torque specification.

2 3

5

4

Figure 73

DC04D445

1.

2.

3.

4.

5.

YN03H01638P1 - ATTACHMENT TUBE ZD12P03400 - O-RING ZE13X16000 - HALF CLAMP ZS28C12040 - CAPSCREW ZW26K12000 - LOCK WASHER

Page 26 of 39

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INSTRUCTION SHEET FOR EH215LC 2 WAY - HAND CONTROL (W/BOOM and STD ARM PIPING)

2 4

3

3

2

4 2 5

5

1

1 Figure 75

DC04D453

1.

2.

3.

4.

5.

27. Clean the face surface of the N&B control valve.

Remove the plug at the upper “A0” port of the N&B control valve.

28. Insert ZD12P03400 O-rings (64) on both ends of the YN03H01703P1 valve control Tube (36).

Make sure that the O-rings are in the O-ring grooves.

29. Position the valve control tube from the selector valve to the upper “A0” port of the N&B control valve.

30. Secure the tube at the selector valve with four ZS28C12040 Capscrews (88)and four ZW26K12000 Lock Washers (95). Do not tighten the capscrews at this time.

31. Secure the tube at the N&B control valve with two ZE13X16000 Half Clamps (66). Fasten the half flanges to the control valve with four ZS28C12040 Capscrews (88) and four ZW26K12000 Lock Washers (95). Tighten the capscrews to 67 ± 7 N.m (49 ± 5 lbf-ft) torque.

4 Figure 76

DC04D455

1.

2.

3.

4.

5.

YN03H01703P1 - VALVE CONTROL TUBE ZD12P03400 - O-RING ZS28C12040 - CAPSCREW ZW26K12000 - LOCK WASHER ZE13X16000 - HALF CLAMP

3

YN03H01456D5 - ATTACHMENT HOSE ZD12P03400 - O-RING ZS28C12040 - CAPSCREW ZW26K12000 - LOCK WASHER ZE13X16000 - HALF CLAMP

33. Remove the plug at the lower “B0” port of the N&B control valve.

34. Insert ZD12P03400 O-ring (64) to the elbow flange of the YN03H01456D5 attachment Hose (31). Make sure that the O-ring is in the O-ring groove.

35. Position the hose to the lower “B0” port of the N&B control valve.

36. Secure the hose to the control valve with two ZE13X16000 Half Clamps (66). Fasten the half clamps to the valve with four ZS28C12040 Capscrews (88) and four ZW26K12000 Lock washers (95).

37. Route the hose toward the base of the boom.

Tighten the capscrews to 67 ± 7 N.m (49 ± 5 lbf-ft) torque.

32. Tighten the capscrews that secured the tube to the selector valve to 67 ± 7N.m (49 ± 5 lbf-ft) torque.

1

2 DC04D456

Figure 77

1. LC42H01041D3 - ATTACHMENT HOSE 2. ZD12A02100 - O-RING

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INSTRUCTION SHEET FOR EH215LC 2 WAY - HAND CONTROL (W/BOOM and STD ARM PIPING) 38. Insert ZD12A02100 O-ring (63) to the attachment tube flange. Make sure that the O-ring is in the O-ring groove.

INSTALL THE DOUBLE PUMP FLOW SELECTOR SWITCH

1

39. Position and assemble LC42H01041D3 attachment Hose (21) to the tube.

2

40. Route the hose toward the base of the boom.

Tighten the hose nut to torque specification.

1

5

2

3

6

7 2 5

4 3

6

7

4

8 Figure 78

DC04D457

1.

2.

3.

4.

5.

6.

7.

8.

ZD12P03800 - O-RING ZE13X20001 - HALF CLAMP ZS28C14050 - CAPSCREW ZW26K14000 - LOCK WASHER ZD12A02100 - O-RING 2414Z199D100 - HOSE GUARD ATTACHMENT HOSES ARM HOSES

41. 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.

42. In connecting the hoses to the tube, connect the LH hose to the LH tube. Make sure that ZD12A02100 O-ring (63) is inserted to the tube flange O-ring groove. Tighten the hose nut to torque specification.

43. Connect the RH hose to the RH tube. Insert ZD12P03800 O-ring (65) in the tube flange O-ring groove. Secure the hose to the tube with two ZE13X20001 Half Clamps (67)). Fasten the half clamps to the tube with four ZS28C14050 Capscrews (90) and four ZW26K14000 Lock washer (96). Tighten the capscrews to 103 ± 10 N.m (76 ± 7 lbf-ft).

44. Install the four 2414Z199D100 spiral Hose Guards (3) to the arm hoses and attachment hoses (one to each hose).

Page 28 of 39

Figure 79

DC04B351

1.

2.

3.

4.

5.

6.

7.

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

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

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

3. Remove the cover switch cap and install 2479U1190F32 Double Flow Switch (14) to this opening. Connect the flow switch wire to the harness connector marked “CONFLUX”.

4. Reassemble the panel cover to the console.

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

Issued 07-04

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IS04-007A-NH NA

INSTRUCTION SHEET FOR EH215LC 2 WAY - HAND CONTROL (W/BOOM and STD ARM PIPING) INSTALL THE LABELS

2

1 1

2

Figure 82

DC04B354

Figure 80

DC04B352

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

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

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

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

Caution Decal (60).

1 2

(42)

and

Caution Decal PY20T01062P1

Figure 81

DC04B353

1. YY20T01039P1 CAUTION DECAL 2. CAB

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

Caution Decal (28).

Caution Decal (62).

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INSTRUCTION SHEET FOR EH215LC 2 WAY - HAND CONTROL (W/BOOM and STD ARM PIPING)

14

16 20

13

16

16 20

11

13

13

20 15

13

13

20 15

Figure 83

DC04D459

Page 30 of 39

12

20 15

21 18

19 7 17

9

6

8

11

3

4

16 20

9

16 20

8

12

20 15

7 17 19

6

11

18 21

16 20

20 15

5

1

5

20

2

INSTALL THE BOOM HYDRAULIC PIPING

Issued 07-04

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IS04-007A-NH NA

INSTRUCTION SHEET FOR EH215LC 2 WAY - HAND CONTROL (W/BOOM and STD ARM PIPING) 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

YN42H01972P1 - LH LOWER TUBE YN42H01970P1 - RH LOWER TUBE YN42H01971P1 - RH UPPER TUBE YN42H01348P1 - LH UPPER TUBE ZE72X16000 - PLUG ZE13X16000 - HALF FLANGE ZE13X20001 HALF FLANGE ZD12P03400 0 O-RING ZD12P03800 - O-RING ZD12A02100 - O-RING 2432T6122 - CLAMP

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

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)

M12 (Hex. Socket Head)

83 ± 5 (61 ± 4 lbf-ft)

M14 (Hex. Socket Head)

103 ± 10 N.m (76 ± 7 lbf-ft)

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

Tightening Torques

1

255 ± 10 N.m (188 ± 7 lbf-ft)

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

Tightening Torques

1-3/16 - 12UNS

177 ± 18 (130 ± 13 lbf-ft)

1-7/16 - 12UNS

206 ± 21 (152 ± 15 lbf-ft)

1-11/16 - 12UNS

327 ± 33 (241 ± 24 lbf-ft)

1. Position YN42H01972P1 LH Lower Tube (48) and YN42H01970 RH Lower Tube (46) 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 YN42H01990P1 Clamp (49) mounted to the bracket with two ZS18C12065 Capscrews (86) and two ZW26X12000 Lock Washers (97). Do not tighten the clamp at this time.

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2432T5924 - CLAMP LC42H01269P1 - CLAMP YN42H01990P1 - CLAMP ZS18C12060 - CAPSCREW ZS18C12065 - CAPSCREW ZS28C14050 - CAPSCREW ZS28C12050 - CAPSCREW ZW26K14000 - LOCK WASHER ZW26X12000 - LOCK WASHER ZW26K12000 - LOCK WASHER

3. Secure the tubes as shown in SECTION E-E. Use one 2432T6122 Clamp (9) for the LH tube and one LC42H01269P1 Clamp (22) for the RH tube. Mount the LH clamp to the bracket with two ZS18C12060 Capscrews (85) and two ZW26X12000 Lock Washers (97). Mount the RH clamp to the bracket with two ZS18C12065 Capscrews (86) and two ZW26X12000 Lock Washers (97). Do not tighten the clamps at this time.

4. Secure the tubes as shown in SECTION D-D. Use one 2432T6122 Clamp (9) for the LH tube and one LC42H01269P1 Clamp (22) for the RH tube. Mount the LH clamp to the threaded block with two ZS18C12060 Capscrews (85) and two ZW26X12000 Lock Washers (97). Mount the RH clamp to the threaded block with two ZS18C12065 Capscrew (86) and two ZW26X12000 Lock Washers (97). Do not tighten the clamps at this time.

5. Secure the tubes as shown in SECTION C-C. Use one 2432T6122 Clamp (9) for the LH tube and one LC42H01269P1 Clamp (22) for the RH tube. Mount the LH clamp to the threaded block with two ZS18C12060 Capscrews (85) and two ZW26X12000 Lock Washers (97). Mount the RH clamp to the threaded block with two ZS18C12065 Capscrews (86) and two ZW26X12000 Lock Washers (97)). Do not tighten the clamps at this time.

6. Position YN42H01348P1 LH Upper Tube (45) and YN42H01971P1 RH Upper Tube (47) to the upper part of the boom as shown in SECTION A-A. 7. Secure the tubes as shown in SECTION A-A. Use one 2432T5924 Clamp (8) for the LH tube and LC42H01269P1 Clamp (22) for RH tube.

Mount the LH clamp to the bracket with two ZS18C12060 Capscrews (85) and two ZW26X12000 Lock Washers (97). Mount the RH clamp to the bracket with two ZS18C12065 Capscrews (86) and two ZW26X12000 Lock Washers (97). Do not tighten the clamps at this time.

Page 31 of 39

INSTRUCTION SHEET FOR EH215LC 2 WAY - HAND CONTROL (W/BOOM and STD ARM PIPING) 8. Secure the tubes as shown in SECTION B-B. Use one 2432T5924 Clamp (8) for the LH tube and one LC42H01269P1 Clamp (22) for the RH tube. Mount the LH clamp to the threaded block with two ZS18C12060 Capscrews (85) and two ZW26X12000 Lock Washers (97). Mount the RH clamp to the threaded block with two ZS18C12065 Capscrews (86) and two ZW26X12000 Lock Washers (97). Do not tighten the clamps at this time.

9. Adjust the position of the RH lower tubes with the face of the flange end connector approximately 140 mm (5.5 inches) from the base pivot pin center line.

10. Adjust the position of the LH lower tube with face of the connector approximately 110 mm (4 inches) from the base pivot pin center line.

18. In connecting the RH tube to the arm RH hose, insert ZD12P03800 O-ring (65) between the tube and the hose. Make sure that the O-ring is in the O-ring groove. Connect the hose to the tube with two ZE13X20001 Half Clamp (67). Fasten the half clamps to the tube flange with four ZS28C14050 Capscrews (90) and four ZW26K14000 Lock Washers (96). Tighten the capscrews to torque specification.

19. In connecting the LH tube to the arm LH hose, insert ZD12P03400 O-ring (64) between the tube and the hose. Make sure that the O-ring is in the O-ring groove. Connect the hose to the tube with two ZE13X16000 Half Clamp (66). Fasten the half clamps to the tube flange with four ZS28C12050 Capscrews (89) and four ZW26K12000 Lock Washers (95). Tighten the capscrews to torque specification.

11. Recheck the position of the lower tubes and tighten the capscrews that fastened the clamps securing the lower tubes to the boom per torque specification.

12. Install ZE72X16000 Plug (70) to the LH and RH lower tubes.

13. Insert ZD12P03400 O-ring (64) between the LH lower and upper tubes. Make sure that the O-ring is in the O-ring groove. Connect the two tubes with two ZE13X16000 Half Clamps (66). Fasten the half clamps with four ZS28C12050 Capscrews (89) and four ZW26K12000 Lock Washers (95). Tighten the capscrews to torque specification.

14. Insert ZD12P03800 O-ring (65) between the RH lower and upper tubes. Make sure the O-ring is in the O-ring groove. Connect the two tubes with two ZE13X20001 Half Clamps (67)). Fasten the half clamps with four ZS28C14050 Capscrews (90) and four ZW26K14000 Lock Washers (96).

Tighten the capscrews to torque specification.

15. Tighten the capscrews that fastened the clamps securing the upper tubes to the boom to torque specification.

16. The Tube ends at the boom base will be connected to the attachment hoses of the upper hydraulic lines. See INSTALL THE UPPER HYDRAULIC LINES in connecting the hoses to the tubes.

17. The tube ends at the arm pivot pin end will be connected to the hoses of the arm attachment hydraulic piping.

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INSTRUCTION SHEET FOR EH215LC 2 WAY - HAND CONTROL (W/BOOM and STD ARM PIPING)

NOTES

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INSTRUCTION SHEET FOR EH215LC 2 WAY - HAND CONTROL (W/BOOM and STD ARM PIPING)

13 17

10 24

9

5

6

20

18

Figure 84

DC04D460

Page 34 of 39

12 19

5

14

29

9

28

27

27

14 18 20

12 19

26 2

1

25

7

8

16 21

15 22

11

23

13 17

3

4

17 13

10

24

11

23

13 17

INSTALL THE STANDARD ARM HYDRAULIC PIPING

Issued 07-04

Cst

IS04-007A-NH NA

INSTRUCTION SHEET FOR EH215LC 2 WAY - HAND CONTROL (W/BOOM and STD ARM PIPING) 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

YN43H01503P1 - RH TUBE YN43H01425P1 - LH TUBE YN43H01211DB - LH HOSE LC43H01011D4 - RH HOSE 24100P3133F1 - STOP VALVE YN43H01005P1 - CONNECTOR ZE13X16000 - HALF CLAMP ZE13X20001 - HALF CLAMP YN43H01426P1 BRACKET LS43H01005P1 - CLAMP LS42H01018P1 - CLAMP ZS18C08025 - CAPSCREW ZS18C10030 - CAPSCREW ZS18C12045 - CAPSCREW ZS28C12050 - CAPSCREW

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

28.

29.

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

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

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

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

Tightening Torques

M8

33 ± 3 N.m (24 ± 2 lbf-ft)

M10

66 ± 7 N.m (49 ± 5 lbf-ft)

M12

115 ± 12 N.m (85 ± 9 lbf-ft)

M12 (Hex. Socket Head)

83 ± 5 N.m (61 ± 4 lbf-ft)

M14 (Hex. Socket Head)

103 ± 10 N.m (76 ± 7 lbf-ft)

ZS28C14050 - CAPSCREW ZW16H10000 - WASHER ZW26X12000 - LOCK WASHER YN43H01151P1 - WASHER YN43H01163P1 - WASHER ZW26K14000 - LOCK WASHER ZW26K12000 - LOCK WASHER LC43H01013P1 - BUSHING LC42H01020P1 - BUSHING ZD12P03800 - O-RING ZD12P03400 - O-RING ZD12A02100 - O-RING 2444P1744D3 - C0NNECTOR 2444T2406 - PLUG

2. Install 24100P3133F1 Stop Valves (2) to the brackets as shown in SECTION A-A. Mount the stop valves with four ZS18C08025 Capscrews (78) and four YN43H01151P1 Washers (51) on each side. Use medium strength thread locking adhesive to the cap screws and tighten to torque specification.

3. Install YN43H01005P1 top Connector (50) to the top port of the Stop Valve on both sides.

4. Install 2444P1744D3 Bottom Connector (10) to the bottom port of the stop valve on both sides.

Make sure that the connector is provided with O-ring. If not, install ZD12P03800 O-ring (65) in the connector O-ring groove.

5. Install 2444T2406 cap Plug (12) to the bottom connector on both sides.

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

Tightening Torques

3/4

162 ± 15 N.m (119 ± 11 lbf-ft

LH Tube Installation

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 YN43H01426P1 Stop Valve Brackets (55) on both sides of the arm tip as shown in SECTION A-A. Mount the bracket with two ZS18C12045 Capscrews (84), two YN43H01163P1 Washers (52) and two ZW26X12000 Lock Washers (97) on each side.

Use medium strength thread locking adhesive to the Cap Screws and tighten to torque specification.

6. Position YN43H01425P1 LH Tube (54) in the arm.

7. Secure the middle part of the tube as shown in SECTION B-B with two LS43H01005P1 Clamps (26) and one LC42H01020P1 Bushing (20) wrap around to the tube for protection. Mount the clamp with two ZS18C10030 Capscrews (81) and two ZW16H10000 Washers (91) 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 LS43H01005P1 Clamps (26) and one LC42H01020P1 Bushing (20) wrap around the tube for protection. Mount the clamps with two ZS18C10030 Capscrews (81) and two ZW16H10000 Washers (91) to the tapped block.

Don’t tighten the clamp at this time.

9. Insert ZD12A02100 O-ring (63) to the straight connector of the tube. Make sure that the O-ring is in the O-ring groove.

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INSTRUCTION SHEET FOR EH215LC 2 WAY - HAND CONTROL (W/BOOM and STD ARM PIPING) 10. Connect the tube to the connector in the stop valve. Don’t tighten the connector nut at this time.

11. Insert ZD12P03400 O- ring (64) to the flange end of the tube. Make sure that the O-ring is in the O-ring groove.

12. Position the tube as shown in View I. Insert ZD12P03400 O-ring (64) in between the tube and YN43H01211DB Hose (53) elbow flange.

Make sure that the O-ring is in the O-ring groove.

Connect the hose to the tube with two ZE13X16000 Half Clamps (66). Fasten the half clamps to the tube flange with four ZS28C12050 Capscrews (89) and four ZW26K12000 Lock Washers (95). Tighten the capscrews to torque specification.

13. Tighten the connector nut at the stop valve end.

14. Tighten the capscrews that fastened the clamps securing the tube to the arm to torque specification.

RH Tube Installation 15. Position YN43H01503P1 RH Tube (56) in the arm.

16. Secure the middle part of the tube as shown in Section B-B with two LS42H01018P1 Clamps (25) and one LC43H01031P1 Bushing (24) wrap around to the tube for protection. Mount the clamps with two ZS18C10030 Capscrews (81) and two ZW16H10000 Washers (91) to the tapped block. Don’t tighten the clamp at this time.

17. Secure the top part of the tube as shown in Section C-C with two LS42H01018P1 Clamps (25) and one LC43H01013P1 Bushing (24) wrap around the tube for protection. Mount the clamps with two ZS18C10030 Capscrews (81) and two ZW16H10000 Washers (91) to the tapped block.

Don’t tighten the clamp at this time.

20. Position the tube as shown in View I. Insert ZD12P03800 O-ring (65) between the tube flange and LC43H01011D4 Hose (23) elbow flange. Make sure that the O-ring is in the O-ring groove. Connect the hose to the tube with two ZE13X20001 Half Clamps (67). Fasten the half clamps to the tube flange with four ZS28C14050 Capscrews (90) and four ZW26K14000 Lock Washers (96). Tighten the capscrews to torque specification.

21. Tighten the connector nut at the stop valve end.

22. Tighten the capscrews that fastened the clamps securing the tube to the arm to torque specification.

23. Connect the other ends of the LH and RH hoses to the attachment tubes in the boom at the arm p i v o t p i n e n d . S e e I N S TA L L T H E B O O M HYDRAULIC PIPING. REPLACE THE ARM IDLER LINKS USING A CRANE 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.

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

YN12B01322P1 LH = 23 Kg (50 lbs) YN12B01321P1 RH = 25 Kg (55 lbs).

18. Insert ZD12A02100 O-ring (63) to the straight connector of the tube. Make sure that the O-ring is in the O-ring groove.

19. Connect the tube to the connector in the stop valve. Don’t tighten the connector nut at this time.

Page 36 of 39

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INSTRUCTION SHEET FOR EH215LC 2 WAY - HAND CONTROL (W/BOOM and STD ARM PIPING)

5

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

6

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

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 YN12B01322P1 LH (41) and YN12B01321P1 RH (40) Idler Links. Make sure that the pins are clean and lubricated with EP grease before installation.

1 2

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.

3 4 Figure 85

DC04B001

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

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.

2

1

3 4

3

11 4

7

3 14 6

5

8

10

Tightening Torques

M 14

181 ± 20 N.m (133 ± 15 lbf-ft)

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:

YN12B01322P1 LH = 23 Kg (50 lbs)

9

YN12B01321P1 RH = 25 Kg (55 lbs).

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

IS04-007A-NH NA

13 Figure 86

DC04B002

1.

2.

3.

4.

5.

6.

7.

Thread Size

NOTE 3: Tightening torques for PF, PT - Threads

12

10

REPLACE THE ARM IDLER LINKS USING THE MACHINE.

NOTE 2: Tightening Torques for M-Threads

11

4

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

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

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

4

3

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.

8.

9.

10.

11.

12.

13.

14.

1. Place the throttle control in low idle

.

BUCKET LINK PIN ARM IDLER PIN RETAINING BOLT RETAINING NUT JAM NUT DUST SEAL SHIMS Issued 07-04

Cst

Page 37 of 39

INSTRUCTION SHEET FOR EH215LC 2 WAY - HAND CONTROL (W/BOOM and STD ARM PIPING)

2. Sound

the

horn

1

2

before

4

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

4 11

3 3 3

4

7

12

10

11 4 5

8

1 1. FUNCTION CANCELLATION LEVER

6

14 13 13 Figure 89

DC04B002

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

14

10

9

Figure 87

DC04A001

3

1.

2.

3.

4.

5.

6.

7.

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

8.

9.

10.

11.

12.

13.

14.

BUCKET LINK PIN ARM IDLER PIN RETAINING BOLT RETAINING NUT JAM NUT DUST SEAL 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 YN12B01322P1 LH (41) and YN12B01321P1 RH (40) Idler Links. Make sure that the pins are clean and lubricated with EP grease before installation.

1

Figure 88

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.

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

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.

DC04B338

1. WOOD BLOCK

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

Page 38 of 39

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.

Issued 07-04

Cst

IS04-007A-NH NA

INSTRUCTION SHEET FOR EH215LC 2 WAY - HAND CONTROL (W/BOOM and STD ARM PIPING) CHECK FOR HYDRAULIC LEAKS NOTE: If a vacuum pump was used, make sure that the hydraulic tank breather has been reinstalled before operating the machine.

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

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

1. Place the throttle control in low idle

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.

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

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

HYDRAULIC OIL LEVEL After bleeding the hydraulic system and tests 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.

IS04-007A-NH NA

Issued 07-04

Cst

Page 39 of 39