160 BOOM ELECTICAL INSTALLATION

160 BOOM CAB INSTALL

INVERTERHARDWARE

KIT

(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

BACK-UP HORN KIT

(1) ¼ -20 Fender Washer(1) ¼ -20 Nut(1) 800457 back-up horn (PW 0065)

160 CAB ELECTRCAL PARTS

(1) 72369-1 PTO switch (EL 0004)(1) 800414-1 PTO light (W-101731 24V bulb)-(WH 0469)(1) 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)

K1 RELAY (1) 87541 (FI 0130)

160 BOOM HARNESS MACK LIGHT HARNESSFind # 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

R/HTAIL LIGHT

L/HTAIL LIGHT

BLK- #2RED- #3WHT-GND

BLK- #4RED-#3WHT-GND

BACK-UPBACK-UPMARKING LIGHTS

RED-#1WHT-GND

RED-#1WHT-GND

BLK-#4WHT-GND

BLK-#4WHT-GND

HEAT SHRINK 3”

HEAT SHRINK 3”

BLK LOOM30”

86531 cut wire 17’

12

5

6 5

66

78

9

6

7

6.00”

1

GROUND…..

13

3

2 2

44

3

11

RUNLIGHTS L / TURN BRAKE

R / TURN BRAKE BACK -UP

FRONT VIEWMAC PLUG

A B

D C

SIDE VIEW

BACK-UP…ALARM

RUNLIGHTS..

#1

#2

#3#4

GRN/YELL

160 BOOM HARNESSFind # 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.

MARKER LIGHT HARNESS

(TOP)

2

3

6”

6”

3”

15FT

12FT

STRESS RELIEF 3/8P/N 73783 WH 527

NOTE* Cut flex grey conduit 12 FT

Yell 12-10 AWGButt splice

1

4 X3

X3160/37M -30FT

42M -35FT

NOTE* Drill 7/8” hole into the Bulkhead plate.

160 BOOM HARNESSFind # 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)

MARKER LIGHT HARNESS(FRAME)

18FT

8 1/2FT

8 1/2FT

15FT

1FT 8 1/2FT

8FT

NOTE* Connect to Boom wire Harness

(TOP)

1” black heat shrink cut 10” lengths2 layers on each side

16 AWG 2C (600V)P/N 75756

STRIP 3”STRIP 3”

1

2

3

1

2

3

1

2

3

1

2

3

WHT WIRE GNDBLK WIRE +12V

BOOM POWER HARNESS

Instructions: Cut cable as directed for appropriate boom size.

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

25 FT

16037M

Boom

+

-

BLK, GRY

BRN, YELL

1FTShrink

6”Shrink

54”Loom

30 FT

+

-

1FTShrink

6”Shrink

54”Loom42M

Boom

1 2 3

3

160 BOOM HARNESS

4

4 X2

X2

CUT OFF12INWIRE

BRN, YELL

1 2CUT OFF12INWIRE

NOTE* Crimp and solder ring lugs

NOTE* Crimp and solder ring lugs

32”42”

BLK, GRY

32”

42”

NBB RADIOINSTALLATION

160 RADIO REMOTE

NOTE* Radio bracket is supplied with radio kit

Install battery into radio remote. Install battery charger In cab.

BOOM DECK

NBB 160 Bracket Install using (3) 5/16X11/4 Bolt(6) 5/16 Flat washers(3) 5/16 Nylon lock washers

NBBBOOM DECK

Install whip antennaW-104744 PW-0065

WAI108573NBB radio receiver remote kit

Reed P/N 206296

Plug cable into “D”Junction box

160 BOOM INVERTER INSTALLATION

INSTRUCTION: Remove seat and seatBelt 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

REMOVE SEAT BELT BRACKET

9”

1 ¾”

INVERTERTEMPLATE

INSIDE CAB

INVERTERTEMPLATE

PART 1

160 BOOM INVERTER INSTALLATION

INVERTERTEMPLATE5”

BOTTOMSIDE

LATCH RIGHT SIDE OF

CAB

INSTRUCTION: Lift cab Up. Use Inverter template and place under cab 5” from the latch, Drill 4 holes .261 drill bit.

BOTTOMSIDE

PART 2

160 BOOM

(4) #10-32X3/4” SCREW(8) #10 LOCK WASHER(8) #10 FLAT WASHER(8) #10-32 NUT

INVERTER MOUNT LEG

SCREWLOCK WASHERFLAT WASHER

NUT

FLAT WASHERLOCK WASHERNUT

INVERTER INSTALLATIONINSTRUCTION:

Install hardware as shown below. Wire and install into compartment behind the seat.

+12V

+24V

GND

PART 3

160 BOOM CLUTCH SWITCH INSTALL

4 1/2”

MAC CLUTCH PETAL

BRACKET

CUT 4”

INSTRUCTION:

Install clutch switch onto bracket. Mark and pre drill holes For switch bracket using self taping screws

BRACKET

CLUTCHSWITCH

SELF TAPSCREWS

160 BOOM HARNESS IN CAB PANEL MODIFICATION 160

.877”

HOLE LAYOUT

USE HOLE TEMPLATE, CENTER OVER 24V DC PLATE.

PRE DRILL PILOT HOLES IN TEMPLATE.THEN DRILL 7/8 HOLE TO PLACE HYDRALICPUNCH TOOL.

PART 1

+

+PTO

OFFON

1.50”

1.00”

24V DC

+ +

1.00”

1.00”

5/8” 15/32”

160 BOOM HARNESS IN CAB PANEL MODIFICATION 160

HYDRALIC PUNCH TOOL

PART 2

NOTE: Install Reed marker light harness and12V battery harness in MAC frame rail using tiewraps.

NOTE: Connect (-) 12V to the battery on off selector switch, Off side as shown.

NOTE: Connect 12V power cable to (+) 12V fused side on Mac battery tray

160 BOOM HARNESS

NOTE: install panel into MAC cab

160 BOOM HARNESS IN CAB WIRING 160

75 64321 GG98

+24V

-24V

+12V

-12V

INVERTER

BLK/GRY +12

CHASSIEGROUND

GRN/YELL BRN -12V

BATT CB38

REV

IGN CB43

SPARE

NEUT

IGN CB23

+ -

PTO LIGHT +-

INVERTERLIGHT

ON/OFF

BOTTOM

TOP

KEY SWITCH

CLUTCH SWITCH BLK (+12V)BRN (GND)BLU (+24v)

1

30A

2345678

5A5A5A5A 30A

RED 10 AWG

WH

T

GR

N

MAC ECMJ2-10 YELL/GRNJ1-6 #1

N/CN/O

N/O N/O

#2

J1

-7

#3

J1

-8

BLK

/WH

T Y

2

BLU

/WH

T Y

1

GR

Y/R

ED

BR

N/B

LU

RE

D/T

ELL

(BOOM HARNESS)

(BOOM HARNESS)2 WIRESBLU (+24)

2 BLK (+12)VIBRATOR

FUSE BLOCK

BLK/GRY +12

GRN/YELL BRN -12V

MAC CAB

P/N 85614 8AWG-4C

X1 X2

160 BOOM HARNESS IN CAB PARTS 160

75 64321 GG98

ON/OFF

1

30A

2345678

5A5A5A5A 30A

FUSE BLOCK

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 WH22115

+-

INVERTERLIGHT 14

1913

1011 12X2

7

8

9

+24V

-24V

+12V

-12V

INVERTER

17

16OFF/ON

PTO

+ -

PTO LIGHT4

18

5

6

X4

X2

24VDC

13

KEYSWITCH KEYSWITCH CONTACT BLOCKS

2

N/C

N/O N/O

N/O

160 BOOM HARNESS IN CAB HARNESS 160

85617 Wire

Wire 16 AWG-4C 34” Mach ECM.....

K1 ON/OFF SWITCH

Wire16AWG BRN 11”………………………

Wire 16AWG BLUE 53”…………………..

K1

INVERTER (+) GRN LIGHT

TB GROUND

Wire16AWG BLU 48”…………… CB-23 F-7

Wire16AWG BLU 49”…………… CB-23 F-8

Wire 10AWG RED 72”………………

3”

3”

+24VInverter

F1/F3/F6

1 1/2” Heat shrink

Wire 16 AWG BLU 46”…………………....CB43 F2

TB1 #1 F4Wire 10 AWG RED 12”………………….

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

Solder all connections

PART 1

160 BOOM HARNESS

GNDInverterLight (-)

Wire 16 AWG BRN 13”……………………….

PTOLight (+)

Wire 16 AWG BLU 8”……………………. TB2

PTOLight (+)Wire 16 AWG BRN 11”…………………….

Wire 16 AWG BLU 16”……………………….....

Heat shrink

Solder all connections PTOKey

Switch

TB3

Heat shrink

Solder all connections PTOKey

Switch

TB4Wire 16 AWG BLU 16”………………………….

5”

5”

CB GNDWire 16 AWG BRN 36”……………….. TB GND

TB5Wire 16 AWG BLU 14”………………………..PTOKey

Switch

PTOKey

SwitchTB6Wire 16 AWG BLU 14”………………………..

DOUBLE RED FERRULE

692115 PUSH-ON BLU

652105 #10 RING BLU

GROUND

IN CAB HARNESS 160

PART 2

160 BOOM HARNESS

DOUBLE RED FERRULE

692115 PUSH-ON BLU

400677 DOUBLE LUG

652065 #6 RING LUG BLU

ON/OFFSWITCH

Wire 16 AWG BLU 9”…………………. F7

TB5Wire 16 AWG BLU 12”…………………….….

PTOKEY

SWITCHNO/(GRN)

TB6Wire 16 AWG BLU 12”……………………….

PTOKEY

SWITCHNC/(RED)

TB9Wire 16 AWG BLU 12”………………………...

TB3Wire 16 AWG BLU 14”………………………..

F8

F2

IN CAB HARNESS 160

PART 3

160 BOOM HARNESS IN CAB HARNESS LAYOUT

1 2 3 4 5 6 7 8 9 G G

1FT

+24V

-24V

+12V

-12V

INVERTERJ1-7

J1-8 J1-6J2-10

8”

MAC ECM 26”

CB

43

CB

23

IGN

2”

K1 RELAY

652105 #10 RING LUG

GROUND

8”

19”24”

1

30A

2345678

5A5A5A5A 30A

FUSE BLOCK+-ON/OFF

MAC PANEL

PART 4INVERTER

160 BOOM HARNESS BATTERY CHARGER

INSTALLATION

+ -

71/2”Apply Velcro to back side of battery charger

Place on top of cover as shown.

BATTERY CHARGERB9115 Black grommet

WIRE HOOK-UPBLK-----------GNDBLK/WHT---CB38

Drill 7/16Install grommet and cable

INSTALL HERE AS SHOWN

160 BOOM HARNESS HOPPER GRATE SAFTEY SWITCH

++

+ +

NOTE: The grate cam may need to beAdjusted . When the grate is closedthe switch needs to be closed.

BROWNWIRE

Silicone cable in side of box.

Cable 802700 (WH 0467)Connect to prox switch box S10 (3)

PROXY BOX

NOT USEDRODSIDE

S16

S15

HEADSIDE

S10

BLACKWIRE

HOPPERGRATESAFTY

SWITCHW-109027(WH0511)

P/N 803105

SAFETY SWITCH

36M 160 IN CAB WIRING 36M 160

REPACEMENT PTOKEY SWITCH

800369-1 800370-1

800864-1

OBSOLETE PTOKEY SWITCH 800864

800369 800865