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Machine Assembly
1. Machine must be on a flat level surface.
2. Remove shipping stands (A).

A—Shipping Stand (2 used)

A66508 —UN—12FEB10
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CAUTION: Avoid serious injury or death

caused by dropping frame, use suitable lifting
equipment, in good working order.
To prevent personal injury caused by unexpected
movement of machine, be sure that frame is
stable after positioning. Do not support machine

TS229 —UN—23AUG88
on cinder blocks, hollow tiles, or props that
can crumble under a heavy load.

3. Remove CCS™ tanks (A) from machine.

4. Remove all parts from machine.

A—CCS Tanks
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A66943 —UN—21APR10
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5. Locate wheel hub with sensor ring (A), wheel hub (D),
wheel sensor and bracket (B), and cap screws and
lock nuts (C).
6. Install wheel hub with sensor ring (A) in right­hand
side of center lift section while aligning hole in frame
with hole in hub shaft.

A66951 —UN—21APR10
7. Position sensor and bracket (B) over frame and install
cap screw (C) through bracket, frame, and hub shaft.
Install nut on cap screw and tighten securely.
8. Install wheel hub (D) in left­hand side of center lift
section.
Right­Hand Wheel Hub With Sensor Ring
9. Install cap screw (C) through frame and hub shaft.
Install nut on cap screw and tighten securely.
10. Remove wheel nuts from both hubs (A and D).

A—Wheel Hub with Sensor C—Cap Screw and Lock Nut (2

Ring used)
B—Wheel Sensor and Bracket D—Wheel Hub

A66952 —UN—21APR10
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NOTE: Raise one side of machine at a time when

installing outer main frame tires.

11. Using a suitable lifting device at location (A), raise one

PROOF

side of main lift section and position tire on hub and

install wheel nuts. Tighten wheel nuts to specification.

A66993 —UN—29APR10
Specification
Wheel Nuts—Torque...................................................................176 N∙m
(130 lb.­ft.)

12. Repeat above step on opposite outer main frame tire.

A—Location

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13. Locate CCS rear mounting frame (A).

A—Mounting Frame

A66994 —UN—29APR10
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14. Remove cap screws (A) on rear of main frame. Save

hardware for reuse.
15. Position rear CCS mounting frame (C) on rear of
machine with ladder mount (B) facing to rear.
16. Install previously removed cap screws (A) and tighten
to specification.

A67011 —UN—03MAY10
Specification
Rear CCS Mounting
Frame Attaching Cap
Screws—Torque..........................................................................330 N∙m
PROOF

(245 lb.­ft.)

A—Cap Screw (4 used) C—Rear CCS Mounting Frame

B—Ladder Mount

A67012 —UN—03MAY10

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17. On both sides of CCS tank frame, loosen cap screws
(A) holding legs (B).

A—Cap Screw (6 used) B—Leg

A67014 —UN—05MAY10
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18. Using a suitable lifting device, raise and position CCS

tanks (A) over machine.
NOTE: It can be necessary to start one leg (B) inside of
one end bracket, then strike opposite leg with a
large hammer to force leg inside of end bracket.

A67013 —UN—03MAY10
19. Lower machine until legs (B) slide inside end brackets
(C) while aligning front leg (D) with mounting bracket
(E).

A—CCS Tanks D—Front Leg

B—Legs E—Bracket
C—End Bracket
PROOF

A67040 —UN—05MAY10
A67025 —UN—03MAY10

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20. Align holes and loosely install cap screws and nuts
(C). Do not tighten cap screws and nuts (C) until told
to do so later in this procedure.
21. Ensure bracket (A) is installed and tighten cap screws
and nuts (B).

A67026 —UN—03MAY10
A—Bracket C—Cap Screw and Nut (2 used
B—Cap Screw and Nut (3 used per side)
per side)

FS41334,000039E ­19­12MAY10­9/34

22. Install cap screws as follows:

• Align holes on front leg and bracket.
NOTE: Heads of cap screws (A) must be on
outside of mount.

• Install cap screws (A) through mount and front leg

A67041 —UN—05MAY10
of CCS tanks.
• Position washer over cap screw.
• Install nuts.
• Tighten cap screw and nut securely.
A—M16 x 60 mm Cap Screw (2 B—17 x 30 x 3 mm Washer, and
used) M16 Nut (2 used)

FS41334,000039E ­19­12MAY10­10/34
PROOF

23. Tighten cap screws and nuts (C) to specification.

Specification
Rear Legs of CCS Tank
Support.—Torque........................................................................330 N∙m
(245 lb.­ft.)

A67026 —UN—03MAY10
A—Bracket C—Cap Screw and Nut (2 used
B—Cap Screw and Nut (3 used per side)
per side)

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24. Locate CCS fan (A) and mounting bracket (B).
25. Remove cap screws and nuts (C) from mounting
bracket. Save hardware for reuse,

A—CCS Fan C—Cap Screw and Nut (10

B—Mounting Bracket used)

A67046 —UN—05MAY10
A67048 —UN—05MAY10
FS41334,000039E ­19­12MAY10­12/34

26. Remove cap screws and nuts (A) from front leg of
CCS tank frame. Save hardware for reuse.

A—Cap Screw and Nut (2 used)

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FS41334,000039E ­19­12MAY10­13/34

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27. Position mounting bracket (A) on right­hand side of
front leg (C) on CCS tank frame.
28. Install previously removed cap screws and nuts (B).
Tighten cap screws and nuts.

A—Mounting Bracket C—Front Leg

A67049 —UN—05MAY10
B—Cap Screw and Nut (2 used)

FS41334,000039E ­19­12MAY10­14/34

NOTE: The use of a second technician is required

for this step.

29. Position CCS fan (A) on mounting bracket (D) with

hydraulic motor (B) facing towards front of machine.
30. Install cap screws and nuts (C). Tighten cap screws

A67050 —UN—05MAY10
and nuts securely.

A—CCS Fan C—Cap Screw and Nut (10

B—Hydraulic Motor used)
D—Mounting Bracket

FS41334,000039E ­19­12MAY10­15/34

31. Using a suitable lifting device, raise and position

Refuge Plus tank (A) over center of machine and close
PROOF

to CCS tanks.

A—Refuge Plus Tank

A67031 —UN—04MAY10

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32. Lower Refuge tank and loosely install U bolt (C)
around center tube and in rear hole of front leg (A).
33. Align rear holes in Refuge Plus frame with tabs (D)
on CCS tank frame.
34. Install and tighten cap screws and nuts (B).

A67033 —UN—04MAY10
35. Tighten U bolt lock nuts (C) securely.

A—Front Leg C—U bolt

B—M16 x 40 mm Cap Screw D—Tabs
and M16 Lock Nut (2 used)

A67032 —UN—04MAY10
A67057 —UN—05MAY10
PROOF

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36. Locate air duct (A) and install as follows:
• Install short end of air duct (A) on CCS tank air
plenum (B).
• T fitting on CCS fan (C).
• Long end on Refuge Plus tank plenum (D).
• Tighten all clamps securely.

A67034 —UN—05MAY10
• Secure air duct to side of Refuge Plus tank using
tie bands (E).

A—Air Duct D—Refuge Tank Plenum

B—CCS Tank Air Plenum E—Tie Band (2 used)
C—CCS Fan

A67036 —UN—04MAY10
A67037 —UN—04MAY10
PROOF

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37. Locate hose (A) in bundle of parts and install as
follows:
• Connect end of hose (A) to fitting (C) on gauge (B).
• Route hose out of pinch points to left­hand CCS tank
plenum fitting (D).
• Trim hose length as needed.

A67038 —UN—04MAY10
• Push hose on to fitting (D).
• Secure hose to existing hoses using tie bands (E).
A—250 ID X 0.375 OD (BLACK) D—Fitting
Hose E—Tie Bands
B—Gauge
C—Fitting

A67039 —UN—05MAY10
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PROOF

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PROOF
D
E
C F I
B G
H J

A
E
P
N K

Q O

M L
P

A63657 —UN—05NOV08
A—Arm Extension F— Support K—Sensor P—Ball Joint (2 used)
B—Cap Screw (2 used) G—Snap Ring L— Screw (2 used) Q—Rod
C—Arm H—O­ring (2 used) M—U­bolt
D—O­ring I— Nut (2 used) N—Nut (2 used)
E—Nut (2 used) J— Bracket O—Nut

38. Assemble and install height sensor as follows: a. Assemble height sensor parts (A—N) using
exploded view as guide.
PROOF

FS41334,000039E ­19­12MAY10­20/34

b. Height sensor switch is located (A) on right­hand

side of main lift frame.

A—Switch Location

A63564 —UN—29OCT08

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NOTE: Use exploded view as guide when installing
height sensor on machine.

c. Slide U­bolt (C) up from the bottom of frame (D)

as shown.
d. Position sensor assembly (A) over U­bolt and install

A63658 —UN—05NOV08
nuts (B).
e. Align arm extension (E) with bracket (F). Tighten
nuts (B) securely.

A—Sensor Assembly D—Frame

B—Nut (2 used) E—Arm Extension
C—U­bolt F— Bracket

A63659 —UN—05NOV08
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f. Thread ball joints (B) on rod (C).

g. Set rod length to 292 mm (11.5 in.) (A) center to
center of ball joint studs.
PROOF

A—292 mm (11.5 in.) C—Rod

B—Ball Joint (2 used)

Continued on next page A63661 —UN—06NOV08

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h. Attach rod (A) to arm and bracket using nuts (B).
i. Locate on center frame 3­pin connector (C) labeled
Height Sensor.
j. Connect 3­pin connector (C) to sensor as shown.
k. Retain harness to frame as needed using tie bands.

A63660 —UN—05NOV08
A—Rod C—3­pin Connector
B—Nut (2 used)

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39. Connect hydraulic hoses to CCS fan and flow control
valve:
• In location (A) on center frame hitch, locate one long
hydraulic hose (yellow tape), case drain hose and
return hose.

A67060 —UN—10MAY10
• Connect hydraulic hose marked with yellow tape (D)
to fitting on flow control valve.
• Connect hose (E) on flow control valve to CCS fan
hydraulic motor fitting (A).
• Connect case drain hose (B) to CCS fan hydraulic
motor.
• Connect hose (A) to fitting (B) on oil cooler.
• Connect return hose to fitting (C) on oil cooler. A—Location

A—Hose From Flow Control D—Hydraulic Hose (yellow

Valve tape)
B—Case Drain Hose E—Hose to CCS Fan Motor
C—Hose to Cooler

A—Hose C—Fitting

A67061 —UN—10MAY10
B—Fitting

A67099 —UN—10MAY10
PROOF

A67132 —UN—12MAY10

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40. Locate on left­hand side of center frame, one wiring
harness breakout labeled S8 (A), second breakout
labeled Y3.
41. Route S8 harness breakout along left­hand side of
Refuge Plus tank and over agitator motor housing.

A67128 —UN—12MAY10
42. Connect S8 breakout harness (A) to purge switch
connector (B).
43. Route Y3 harness breakout (D) to left­hand side of
CCS fan.
44. Connect Y3 breakout harness (D) to purge switch
connector (C).

A—S8 Breakout Harness C—CCS Fan Connector

B—Purge Switch Connector D—Y3 Breakout Harness

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45. Secure hoses and harness breakouts to Refuge Plus

tank frame using tie bands (A).

A—Tie Bands
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46. Locate in center of machine, two harness breakouts,
one breakout labeled M2 and P2 (A), second breakout
labeled M4 and P4.
47. Route harness breakout labeled M2 and P2 (A) over
CCS tank air plenum (D) to left side of left­hand CCS
tank.

A67100 —UN—11MAY10
48. Connect connector (A) to agitator motor (C) connector.
49. On agitator motor (C), remove nut from ground stud
(B) and install ground wire. Reinstall and tighten nut.

A—Connector with Ground C—Agitator Motor On CCS

Wire ( labeled M2 and P2) Tank
Agitator Motor on CCS Tank
B—Ground Stud D—CCS Tank Air Plenum

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50. Route harness breakout labeled M4 and P4 (A) to

agitator motor on refuge tank (D).
51. Connect M4 connector (A) to agitator motor (C)
connector.
PROOF

A67103 —UN—12MAY10
52. On agitator motor (C), remove nut from ground stud
(B) and install ground wire. Reinstall and tighten nut.

A—Connector with Ground C—Agitator Motor On Refuge

Wire (labeled M4 and P4) Plus Tank
B—Ground Stud

Agitator Motor on Refuge Tank

A67131 —UN—12MAY10

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53. On Refuge Plus tank:
• Cut tie band (A) and route harness (B) along
right­hand side of center frame.
• Locate on right­hand side of center frame one
harness breakout (C) labeled Y3.
• Connect harness (B) from purge switch to harness

A67101 —UN—10MAY10
(C).
• Use tie bands to secure harness out of pinch points
and fold areas.

A—Tie Band C—Harness

B—Harness

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54. In pallets of parts, locate box containing rear red

amber lights (A) and warning light assemblies for CCS
tank frame.

A—Red Amber Lights

PROOF

A67107 —UN—11MAY10
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55. Position warning light with clamp (A) on bracket (C)
and install cap screws (B).

A—Warning Light with Clamp C—Bracket

B—Cap Screw (2 used per side) D—Nut (2 used per side)

A67108 —UN—10MAY10
Right­Hand Warning Light

A67109 —UN—10MAY10
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56. Install opposite warning light with clamp (A).

A—Warning Lamp with Clamp

A67110 —UN—11MAY10
PROOF

Left­Hand Warning Lamp

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57. Install red amber lamps (B) in locations (A) on rear
of CCS tank frame.
58. Locate in center frame area, lamp wiring harness

A67111 —UN—11MAY10
A—Location B—Red Amber Lamp (2 used)

A67112 —UN—11MAY10
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PROOF

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