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160 BOOM ELECTICAL INSTALLATION

160 BOOM ELECTICAL INSTALLATION. 160 BOOM CAB INSTALL. (4) 10-32X3/4 (4) #10 Lock Washers (8) #10 Flat Washers (4) 10-32 Nuts (2) 10” ½ black loom (2) 71/2” ½ black loom. INVERTER HARDWARE KIT. BACK-UP HORN KIT. ¼ -20 Fender Washer (1) ¼ -20 Nut

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160 BOOM ELECTICAL INSTALLATION

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  1. 160 BOOM ELECTICAL INSTALLATION

  2. 160 BOOM CAB INSTALL (4) 10-32X3/4 (4) #10 Lock Washers (8) #10 Flat Washers (4) 10-32 Nuts (2) 10” ½ black loom (2) 71/2” ½ black loom INVERTER HARDWARE KIT BACK-UP HORN KIT • ¼ -20 Fender Washer • (1) ¼ -20 Nut • (1) 800457 back-up horn (PW 0065) K1 RELAY (1) 87541 (FI 0130) 160 CAB ELECTRCAL PARTS • 72369-1 PTO switch (EL 0004) • (1) 800414-1 PTO light (W-101731 24V bulb)-(WH 0469) • 800051 PTO on/off plate (BT CELL 1) • (1) 803220 Inverter 24V on/off plate (WH 0221) • (1) 85355 Green light (12V)-(EL 0003) • (1) 72963 On/off switch (EL 0004) • (1) ????? 5” Terminal strip • (11) 72820 Terminal block (EL 0005) • (2) 75654 Terminal block end (EL 0005)

  3. B A C D 11 12 13 5 7 3 4 4 2 2 6 3 9 8 7 6 6 5 6 1 160 BOOM HARNESS MACK LIGHT HARNESS Find # Qty Part# Description 1 17 ft 86531 Wire 5Cx14 AWG 2 2 800042 Turn/tail connector 3 4 800044 Clearance connector 4 2 800043 Back-Up connector 5 2 800035 Tail light 6 4 800040 Boot 7 2 800036 Back-up light 8 3 800037 Red clearance lights 9 3 800041 Boot 10 1 800348 License plate light 11 30” ¼” Black Loom 12 2 652085 Blue ring lug 13 1 634005 Male conn 14 1 694005 Female conn SIDE VIEW 6.00” L / TURN BRAKE RUNLIGHTS FRONT VIEW MAC PLUG RUNLIGHTS.. GROUND….. BACK-UP… ALARM R / TURN BRAKE BACK -UP R/H TAIL LIGHT HEAT SHRINK L/H TAIL LIGHT 3” BLK-#4 WHT-GND BACK-UP BACK-UP MARKING LIGHTS BLK- #2 RED- #3 WHT-GND BLK- #4 RED-#3 WHT-GND BLK LOOM 30” RED-#1 WHT-GND RED-#1 WHT-GND BLK-#4 WHT-GND #1 HEAT SHRINK #2 3” #3 #4 86531 cut wire 17’ GRN/YELL

  4. NOTE* Drill 7/8” hole into the Bulkhead plate. 160/37M -30FT X3 6” 42M -35FT 2 3 4 1 3” Yell 12-10 AWG Butt splice STRESS RELIEF 3/8 P/N 73783 WH 527 6” 12FT X3 15FT NOTE*Cut flex grey conduit 12 FT 160 BOOM HARNESS MARKER LIGHT HARNESS (TOP) Find # Qty Part# Description 1 ????? Wire 2CX16 AWG BLK 600V 2 3 800037 Red clearance lights 3 3 800041 Boots 4 3 800044 Clearance light conn.

  5. 2 1 3 2 1 3 2 1 3 2 3 1 160 BOOM HARNESS MARKER LIGHT HARNESS (FRAME) Find # Qty Part# Description 1 4 800037 Red lights 2 4 800041 Boot 3 4 800044 Light conn. 4 1 75756 Wire 16 AWG 2C (600V) WHT WIRE GND BLK WIRE +12V NOTE* Connect to Boom wire Harness (TOP) 8 1/2FT 8 1/2FT STRIP 3” 1” black heat shrink cut 10” lengths 2 layers on each side 1FT STRIP 3” 15FT 8FT 18FT 8 1/2FT 16 AWG 2C (600V) P/N 75756

  6. + + - - 2 3 4 3 1 2 1 4 160 BOOM HARNESS BOOM POWER HARNESS Find # Parts qty 1 801359 fuse holder WH 0452 1 2 801360 50A fuse WH0452 1 3 85614 cable 8 AWGX4C 4 256125 ½ Ring lug 4 AWG Del city Instructions: Cut cable as directed for appropriate boom size. 25 FT CUT OFF 12IN WIRE BLK, GRY 6” Shrink 54” Loom 160 37M Boom 1FT Shrink 32” 42” X2 NOTE* Crimp and solder ring lugs BRN, YELL 30 FT CUT OFF 12IN WIRE BLK, GRY 6” Shrink 42M Boom 54” Loom 1FT Shrink 32” 42” X2 NOTE* Crimp and solder ring lugs BRN, YELL

  7. NBB BOOM DECK 160 RADIO REMOTE NBB RADIO INSTALLATION NOTE* Radio bracket is supplied with radio kit Install battery into radio remote. Install battery charger In cab. NBB 160 Bracket Install using (3) 5/16X11/4 Bolt (6) 5/16 Flat washers (3) 5/16 Nylon lock washers Install whip antenna W-104744 PW-0065 WAI108573 NBB radio receiver remote kit Reed P/N 206296 BOOM DECK Plug cable into “D” Junction box

  8. 160 BOOM INVERTER INSTALLATION PART 1 INSTRUCTION: Remove seat and seat Belt bracket using 5/8 socket. Cut out hole using die grinder with cutting wheel. After hole is cut out, Debur and apply Black trim P/N 10196 to edges. SIDE OF CAB INSIDE CAB 9” INVERTER TEMPLATE INVERTER TEMPLATE 1 ¾” REMOVE SEAT BELT BRACKET

  9. 160 BOOM INVERTER INSTALLATION PART 2 INSTRUCTION: Lift cab Up. Use Inverter template and place under cab 5” from the latch, Drill 4 holes .261 drill bit. BOTTOM SIDE LATCH RIGHT SIDE OF CAB INVERTER TEMPLATE 5” BOTTOM SIDE

  10. (4) #10-32X3/4” SCREW (8) #10 LOCK WASHER (8) #10 FLAT WASHER (8) #10-32 NUT INVERTER MOUNT LEG SCREW LOCK WASHER FLAT WASHER NUT FLAT WASHER LOCK WASHER NUT 160 BOOM INVERTER INSTALLATION PART 3 INSTRUCTION: Install hardware as shown below. Wire and install into compartment behind the seat. +24V +12V GND

  11. CUT 4” MAC CLUTCH PETAL BRACKET 4 1/2” 160 BOOM CLUTCH SWITCH INSTALL INSTRUCTION: Install clutch switch onto bracket. Mark and pre drill holes For switch bracket using self taping screws CLUTCH SWITCH BRACKET SELF TAP SCREWS

  12. 1.00” 1.00” OFF ON + 24V DC 1.00” + + PTO 1.50” + 5/8” 15/32” 160 BOOM HARNESS IN CAB PANEL MODIFICATION 160 PART 1 USE HOLE TEMPLATE, CENTER OVER 24V DC PLATE. .877” HOLE LAYOUT PRE DRILL PILOT HOLES IN TEMPLATE. THEN DRILL 7/8 HOLE TO PLACE HYDRALIC PUNCH TOOL.

  13. 160 BOOM HARNESS IN CAB PANEL MODIFICATION 160 PART 2 HYDRALIC PUNCH TOOL

  14. 160 BOOM HARNESS NOTE: install panel into MAC cab NOTE:Install Reed marker light harness and 12V battery harness in MAC frame rail using tie wraps. NOTE: Connect 12V power cable to (+) 12V fused side on Mac battery tray NOTE: Connect (-) 12V to the battery on off selector switch, Off side as shown.

  15. - + IGN CB23 NEUT 8 5 3 7 2 1 6 4 REV 30A 5A 30A 5A 5A 5A IGN CB43 SPARE 3 6 7 8 9 1 2 5 4 G G 160 BOOM HARNESS IN CAB WIRING 160 ON/OFF INVERTER LIGHT CLUTCH SWITCH BLK (+12V) BRN (GND) BLU (+24v) PTO LIGHT - + X1 X2 MAC CAB FUSE BLOCK KEY SWITCH N/C N/O BOTTOM TOP BATT CB38 N/O N/O MAC ECM J2-10 YELL/GRN #3 J1-8 #2 J1-7 J1-6 #1 (BOOM HARNESS) 2 WIRES BLU (+24) 2 BLK (+12) VIBRATOR INVERTER RED 10 AWG CHASSIE GROUND +24V BLU/WHT Y1 BLK/WHT Y2 RED/TELL GRY/RED BRN/BLU WHT -24V GRN (BOOM HARNESS) +12V BLK/GRY +12 BLK/GRY +12 -12V P/N 85614 8AWG-4C GRN/YELL BRN -12V GRN/YELL BRN -12V

  16. - + 8 5 3 7 2 1 6 4 30A 5A 30A 5A 5A 5A PTO LIGHT CONTACT BLOCKS 14 19 10 11 12 17 16 15 13 18 OFF/ON 1 8 6 5 3 9 2 7 4 3 6 7 8 9 1 2 5 4 G G INVERTER LIGHT - + PTO INVERTER +24V -24V +12V -12V 160 BOOM HARNESS IN CAB PARTS 160 Find # Parts Description qty Loc 1 800369-1 Key switch 1 WH514 2 800864-1 N/O contact block 2 WH514 3 800370-1 Key switch base (comes with (1) N/O and (1) N/C block 1 WH514 4 800414-1 PTO Light 1 WH469 5 802408 Clutch bracket 1 WH1158 6 800909 Clutch switch 1 WH829 7 85354 Fuse Block 8 way 1 EL0005 8 90392 Fuse, 5A 4 EL0005 9 ????? Fuse, 30A 2 10 72820 Terminal block 11 EL0005 11 75654 Terminal ends 2 EL0005 12 72824 Jumper 1 EL0005 13 72821 Rail 5 Inches EL0005 14 85355 Inverter light 1 EL0003 15 72963 Inverter switch 1 EL0003 16 87541 Relay 1 FI0130 17 W-108574 Inverter 12V – 24V 1 WH478 18 800051 PTO switch plate 1 ????? 19 803220 24V switch plate 1 WH221 KEYSWITCH KEYSWITCH N/O N/O N/O N/C FUSE BLOCK X4 X2 ON/OFF X2 24VDC

  17. DOUBLE RED FERRULE SINGLE BLK FERRULE 653105 RING YELL 692115 PUSH-ON BLU 652105 #10 RING BLU 692005 PUSH-ON BLU 693005 PUSH-ON YEL 653385 RING LUG 160 BOOM HARNESS IN CAB HARNESS 160 PART 1 85617 Wire Wire 16 AWG-4C 34” Mach ECM..... INVERTER (+) GRN LIGHT Wire 16AWG BLUE 53”………………….. K1 ON/OFF SWITCH K1 TB GROUND Wire16AWG BRN 11”……………………… CB-23 F-7 Wire16AWG BLU 48”…………… F-8 CB-23 Wire16AWG BLU 49”…………… 3” 1 1/2” Heat shrink +24V Inverter F1/F3/F6 Wire 10AWG RED 72”……………… Solder all connections 3” Wire 16 AWG BLU 46”………………….... CB43 F2 Wire 10 AWG RED 12”…………………. TB1 #1 F4

  18. 5” 5” Heat shrink Solder all connections 160 BOOM HARNESS IN CAB HARNESS 160 PART 2 DOUBLE RED FERRULE 692115 PUSH-ON BLU 652105 #10 RING BLU GROUND Inverter Light (-) Wire 16 AWG BRN 13”………………………. GND PTO Light (+) Wire 16 AWG BLU 8”……………………. TB2 PTO Light (+) Wire 16 AWG BRN 11”……………………. Heat shrink PTO Key Switch Wire 16 AWG BLU 16”………………………..... TB3 Solder all connections PTO Key Switch Wire 16 AWG BLU 16”…………………………. TB4 Wire 16 AWG BRN 36”……………….. TB GND CB GND PTO Key Switch Wire 16 AWG BLU 14”……………………….. TB5 PTO Key Switch Wire 16 AWG BLU 14”……………………….. TB6

  19. 160 BOOM HARNESS IN CAB HARNESS 160 PART 3 DOUBLE RED FERRULE 692115 PUSH-ON BLU 400677 DOUBLE LUG 652065 #6 RING LUG BLU ON/OFF SWITCH Wire 16 AWG BLU 9”…………………. F7 PTO KEY SWITCH NO/(GRN) TB5 Wire 16 AWG BLU 12”…………………….…. PTO KEY SWITCH NC/(RED) TB6 Wire 16 AWG BLU 12”………………………. F8 TB9 Wire 16 AWG BLU 12”………………………... F2 TB3 Wire 16 AWG BLU 14”………………………..

  20. ON/OFF - 8 5 3 7 6 4 2 1 + 5A 30A 5A 5A 5A 30A 1 2 3 4 5 6 7 8 9 G G INVERTER +24V -24V +12V -12V 160 BOOM HARNESS IN CAB HARNESS LAYOUT INVERTER PART 4 FUSE BLOCK 652105 #10 RING LUG GROUND MAC PANEL K1 RELAY 1FT 24” 19” 2” 8” 8” CB 23 IGN CB 43 J2-10 J1-7 J1-8 J1-6 26” MAC ECM

  21. - + 160 BOOM HARNESS BATTERY CHARGER INSTALLATION INSTALL HERE AS SHOWN Apply Velcro to back side of battery charger Place on top of cover as shown. 71/2” WIRE HOOK-UP BLK-----------GND BLK/WHT---CB38 Drill 7/16 Install grommet and cable BATTERY CHARGER B9115 Black grommet

  22. 160 BOOM HARNESS HOPPER GRATE SAFTEY SWITCH NOTE: The grate cam may need to be Adjusted . When the grate is closed the switch needs to be closed. BLACK WIRE + BROWN WIRE + + + HOPPER GRATE SAFTY SWITCH W-109027 (WH0511) PROXY BOX S15 S10 Silicone cable in side of box. HEADSIDE SAFETY SWITCH S16 P/N 803105 NOT USED RODSIDE Cable 802700 (WH 0467) Connect to prox switch box S10 (3)

  23. 36M 160 IN CAB WIRING 36M 160 800369 800865 OBSOLETE PTO KEY SWITCH 800864 800369-1 800370-1 REPACEMENT PTO KEY SWITCH 800864-1

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