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Procedure to Install Water Delivery System (S/N: M4J) on the 785D {5612, 7000} Caterpillar


Procedure to Install Water Delivery System (S/N: M4J) on the 785D {5612, 7000}

Usage:

785D DMC
OEM
CAT WDS (S/N: M4J1-UP)
Off-Highway Truck/Tractor
785D (S/N: DMC1-UP)

Introduction

This Special Instruction will provide the necessary steps to install a CAT® Water Delivery System on a 785D WTR Truck Chassis. This instruction applies to those systems purchased as a factory attachment.

Read the entire Special Instruction before you order any parts or perform the following procedure.

Note: The CAT® Water Delivery System should NOT be installed on 785D WTR model trucks prior to serial number DMC00169. 785D WTR bare chassis trucks built prior to April 1, 2013 are not equipped with adequate power systems to operate the CAT® Water Delivery System.

Note: All descriptions in this document of the "left" and "right" side of the machine are with respect to viewing the machine from the rear.

Note: Put identification marks on all hoses, on all hose assemblies, on all wires, and on all tube assemblies for installation purposes. Plug all hose assemblies and all tube assemblies.

Note: Before starting, block the wheels with wheel chocks.

Note: Many water tanks include a protective lining on the interior of the tank that can be damaged by welding directly onto the tank.

Note: Before starting, move the battery disconnect switch to the OFF position.

Note: Lubricate all O-ring seals with lithium grease prior to installation.

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NOTICE

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publications, NENG2500, "Cat dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar® products. Dispose of all fluids according to local regulations and mandates.

Customer Requirements

Major components included in the WDS Kit are as follows.

  • Spray heads

  • WDS cooling system

  • WDS hydraulic tank

  • WDS pump, charge pump, motor, and water pump

  • Filter group

  • Pump drive (factory installed)

  • Cab controls (factory installed)

  • Cannon

The following attachments are available:

  • Camera and wash kit

  • Cannon nozzles (must choose a nozzle)

The following items are NOT INCLUDED in the WDSKit:

  • Water tank

  • Butterfly valves: cannon, dump bar, and dump valve

  • Cannon and dump bar actuation cylinders, dump valve

  • Cannon piping from the water pump

  • Pump outlet flange Isolation adapter

  • Pump inlet adapter and hardware

  • Remote soap and foam on/off switches

  • Auxiliary wiring harness (for soap and foam switches)

  • Hose reel remote switch and auxiliary wiring harness

  • On/off transmitter and wiring harness for water tank fill operation

  • All hoses to and from the front and rear hydraulic manifold must be cut to length upon installation thus will not be provided. (Hose couplings will be provided.) Recommend minimum of 150 feet Dash 4 standard hose (Cat® 122-6867).

  • Pilot and signal hoses from rear bulkhead to motor (fittings provided)

  • Cannon mounting hardware

  • Dump bar

  • Bosses, hardware, and brackets to mount cameras

  • Bosses, hardware, and brackets to mount washing systems

  • Bosses for hose and wiring harness clips on tank bottom, rear, and front of tank

  • Bosses for brackets, hydraulic and electrical boxes

Service Tooling Requirements

The following items are required for servicing the system:

  • 309-9893 Tool Kit - this kit contains connectors, removal tools, and crimpers for servicing the AMP connectors on the XA2 modules

  • Deutsch connector tools - including 1U-5804 Crimp Tool, 151-6320 Wire Removal Tool, 1U-5805 Wire Removal Tool, and 147-6456 Wedge Removal Tool

  • Flashing software requires 371-3480 Cable for USB "A" to USB "A" connection

Hydraulic and Component Installation (Chassis)

Installation Procedure

Assemble Tube and Hose With Elbow and Clamps

Note: For retrofit kit installation only. Tube, hose, and elbow will come preassembled on S/N:DMC174-UP machines (for reference only). Parts may not be included in the kit.

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Table 1
Required Parts
Group Number 380-4010 Water Lines Gp (Rev. 01) 
Item  Qty  Part Number  Part Description 
1  1  7W-8604  Gasket 
2  1  432-6842  Elbow 
3  1  380-2340  Tube 
4  1  337-1835  Elbow Hose 
5  1  144-0367  Hose Clamp 
6  1  8T-4984  Hose Clamp 
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    Illustration 1g03679543
    (A) Existing elbow
    (B) Existing hose
    (C) Existing tube

  1. Remove elbow (A). Remove hose clamps and hose (B). Remove tube (C).
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    Illustration 2g03679545

  2. Install elbow (2) with gasket (1).

  3. Install tube (3).

  4. Install elbow hose (4). Fasten the elbow hose to elbow (2) with hose clamp (5). Fasten the elbow hose to tube (3) with hose clamp (6).

Pump Group Installation

Charge Pump Installation

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Table 2
Required Parts
Group Number 366-5425 Pump and Mounting Gp (Rev. 05) 
Item  Qty  Part Number  Part Description 
1  1  435-5902  Piston Pump Gp 
2  1  118-3122  O-Ring Seal 
3  1  177-8924  Gear Pump Gp 
4  1  6V-7970  O-Ring Seal 
5  1  8C-4424  Plug 
6  2  8T-4223  Hard Washers 
7  2  8T-4194  Bolts 
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    Illustration 3g03679548

  1. Install seal (2) around the pilot of the charge pump (3). This component will seal the oil between the WDS hydraulic pump (1) and the charge pump. Install charge pump into the coupler on the back of WDS hydraulic pump.

    Note: The charge pump must be oriented with the large suction port to the left.

  2. Fasten charge pump (3) to the WDS hydraulic pump (1) with two bolts (7) and two washers (6). Tighten the bolts to a torque of 100 ± 20 N·m (74 ± 15 lb ft).
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    Illustration 4g03679549

  3. Install plug (5) and O-ring seal (4) in vent port (A). Tighten the plug to a torque of 130 ± 20 N·m (96 ± 15 lb ft).

WDS Hydraulic Pump Installation

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Table 3
Required Parts
Group Number 366-5425 Pump and Mounting Gp (Rev. 05) 
Item  Qty  Part Number  Part Description 
8(1)  2  3D-8439  Studs 
9(1)  2  4K-0367  Nuts 
10(1)  2  5P-8247  Hard Washers 
11  1  4S-5898  O-Ring Seal 
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(1) These components are provided with the drive group.
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    Illustration 5g03679551

  1. Install WDS piston pump group (1) into drive group (B).

    Note: Ensure that the O-ring seal (11) used between the pump and the drive group is lubricated and in place.

    Note: The WDS hydraulic pump must be oriented with pump controls facing downwards.

    Note: Use suitable lifting device to install the WDS hydraulic pump. This pump weighs approximately 76 kg (168 lb).

  2. Fasten WDS piston pump group (1) to drive group (B) with two studs (8), two washers (10) and two nuts (9). Tighten the nuts to a torque of 215 ± 40 N·m (159 ± 30 lb ft).

Cooling Group Installation

Assemble Valve Group With Fittings On The Plate Assembly

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Table 4
Required Parts
Group Number 371-2230 Hydraulic Oil Cooler and Lines Gp (Rev. 03) 
Item  Qty  Part Number  Part Description 
1  1  126-0747  Bypass Valve Gp 
2  1  148-8335  Connector As 
3  1  148-8355  Elbow As 
4  1  142-0038  Elbow 
5  1  148-8357  Elbow As 
6  1  148-8431  Tee 
7  1  4E-1437  Cooler Bypass Valve 
8  1  148-8429  Tee As 
9  1  5K-9090  O-Ring Seal 
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    Illustration 6g03679554

    Note: There are no labels on the ports of the bypass valve. Orient the valve as shown above.

  1. Install connector assembly (2) in the top left outlet port of bypass valve (1). Tighten the connector to a torque of 350 ± 53 N·m (258 ± 39 lb ft).

  2. Connect elbow (4) to connector assembly (2). Tighten the connector to a torque of 220 ± 33 N·m (162 ± 24 lb ft).

  3. Install elbow assembly (3) in the bottom left inlet port of bypass valve (1). Tighten the elbow to a torque of 350 ± 53 N·m (258 ± 39 lb ft).

  4. Install elbow assembly (5) in the top right outlet port of bypass valve (1). Tighten the elbow to a torque of 350 ± 53 N·m (258 ± 39 lb ft).

  5. Install tee (6) in the bottom right inlet port of bypass valve (1). Tighten the tee to a torque of 350 ± 33 N·m (258 ± 24 lb ft).

  6. Connect tee assembly (8) to tee (6). Tighten the tee assembly to a torque of 220 ± 33 N·m (162 ± 24 lb ft).

  7. Connect cooler bypass valve (7) to tee (6). Tighten the valve to a torque of 220 ± 33 N·m (162 ± 24 lb ft).
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    Illustration 7g03679556

  8. Install O-ring seal (9) in elbow (4).

Assemble Valve Group With Fittings On The Plate Assembly

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Table 5
Required Parts
Group Number 371-2230 Hydraulic Oil Cooler and Lines Gp (Rev. 03) 
Item  Qty  Part Number  Part Description 
10  1  374-2439  Plate As 
11  3  8T-4178  Bolts 
12  3  8T-4121  Hard Washers 
13  4  7X-0343  Bolts 
14  4  8T-4123  Washers 
15  3  7X-0507  Hard Washers 
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    Illustration 8g03679558
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    Illustration 9g03679561

  1. Place three washers (15) between bypass valve group (1) and plate assembly (10). Fasten the valve group to the plate assembly with three bolts (11) and three washers (12). Tighten the bolts to a torque of 55 ± 10 N·m (41 ± 7 lb ft).

  2. Install plate assembly (10) on the rear of the air cleaner with four bolts (13) and four washers (14). Tighten the bolts to a torque of 250 ± 40 N·m (184 ± 30 lb ft).

Assemble Hoses to the Cooler Assembly

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Table 6
Required Parts
Group Number 371-2230 Hydraulic Oil Cooler and Lines Gp (Rev. 03) 
Item  Qty  Part Number  Part Description 
16  1  129-1807  Oil Cooler Gp 
17  1  9S-4185  O-Ring Plug 
18  1  7W-6492  Pipe Plug 
19  1  033-6028  O-Ring Seal 
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    Illustration 10g03679563

  1. Install O-ring plug (17) with O-ring seal (19) in oil cooler group (16).

  2. Install pipe plug (18) in oil cooler group (16).

Assemble Hoses to the Cooler Assembly

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Table 7
Required Parts
Group Number 371-2230 Hydraulic Oil Cooler and Lines Gp (Rev. 03) 
Item  Qty  Part Number  Part Description 
20  1  374-2218  Hose As 
21  1  374-2434  Hose As 
22  4  1P-4578  Flange 
23  8  8T-5360  Washers 
24  8  8T-8916  Bolts 
25  2  061-7540  O-Ring Seals 
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    Illustration 11g03679564

  1. Connect hose assembly (20) to the cooler group as shown with O-ring seal (25) and two flanges (22). Fasten the hose to the cooler group with four bolts (24) and four washers (23).

  2. Connect hose assembly (21) to the cooler group as shown with O-ring seal (25) and two flanges (22). Fasten the hose to the cooler group with four bolts (24) and four washers (23).

Assemble Bracket Assembly With Hardware

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Table 8
Required Parts
Group Number 371-2230 Hydraulic Oil Cooler and Lines Gp (Rev. 03) 
Item  Qty  Part Number  Part Description 
14  4  8T-4123  Washers 
26  1  432-4229  Bracket As 
27  1  432-4230  Bracket As 
28  4  8D-8852  Spacers 
29  4  8T-6871  Bolts 
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    Illustration 12g03679565

  1. Install bracket assemblies (26) and (27) on top of the air cooler of the truck. Install spacers (28) on each bracket assembly.

  2. Fasten bracket assemblies (26) and (27) to the truck frame with bolts (29) and washers (14). Tighten the bolts to a torque of 215 ± 40 N·m (159 ± 30 lb ft).

Assemble Bracket Assembly With Hardware

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Table 9
Required Parts
Group Number 371-2230 Hydraulic Oil Cooler and Lines Gp (Rev. 03) 
Item  Qty  Part Number  Part Description 
30  1  425-7801  Radiator Shroud 
31  1  228-7315  Film 
32  1  228-7316  Film 
33  4  9D-7924  Mountings 
34  8  7X-0603  Hard Washers 
35  4  8T-4896  Hard Washers 
36  4  8T-9377  Bolts 
37  4  7X-0521  Hard Washers 
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    Illustration 13g03679567

  1. Install radiator shroud (30) and oil cooler (16) on bracket assemblies (26) and (27).
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    Illustration 14g03679114

  2. Insert mountings (33) through radiator shroud (30) and bracket assemblies (26) and (27). Use four hard washers (37) as shown in Illustration 14.

  3. Insert bolt (36) through washer (35) and washer (34). Push the bolt and washers through each mounting (33) and an additional washer (34).

  4. Insert each bolt (36) into oil cooler (16). Fasten the oil cooler to bracket assemblies (26) and (27). Tighten the bolts to a torque of 47 ± 9 N·m (35 ± 7 lb ft).
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    Illustration 15g03679569

  5. Install warning label films (31) and (32) on the top of radiator shroud (30).
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    Illustration 16g03679570

  6. Connect hose assembly (20) to adapter (A) in the cooler inlet port of the bypass valve (1).

  7. Connect hose assembly (21) to adapter (B) in the cooler outlet port of the bypass valve (1).

WDS Hydraulic Tank Installation

Assemble Adapter Assembly to the Tank Group

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Table 10
Required Parts
Group Number 374-2227 Hydraulic Tank and Mounting Gp (Rev. 06) 
Item  Qty  Part Number  Part Description 
1  1  419-0078  Hydraulic Tank Gp 
2  1  148-8357  Elbow As 
3  1  148-8340  Connector As 
4  1  437-8288  Hose As 
5  1  8J-7844  Reducer Bushing 
6  1  9G-5127  Breather As 
7  1  3K-0360  O-Ring Seal 
8  1  0S-1592  Bolt 
9  1  4L-6454  Bolt 
10  1  5P-8247  Hard Washer 
11  1  137-6722  Clip 
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    Illustration 17g03679146

  1. Install adapter (5) with O-ring seal (7) and breather (6) on top of hydraulic tank group (1).

  2. Install connector assembly (3) on the hydraulic tank group (1). Tighten the connector to a torque of 100 ± 15 N·m (74 ± 11 lb ft).

  3. Connect hose assembly (4) to connector assembly (3). Tighten the hose to a torque of 65 ± 10 N·m (48 ± 7 lb ft).

  4. Install elbow assembly (2) on the hydraulic tank group (1). Tighten the bolts to a torque of 350 ± 53 N·m (258 ± 39 lb ft).

  5. Secure hose assembly (4) with clip (11), bolt (8), and hard washer (10).

  6. Install bolt (9) at location shown in Illustration 17.

Assemble Adapter Assembly to the Tank Group

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Table 11
Required Parts
Group Number 374-2227 Hydraulic Tank and Mounting Gp (Rev. 06) 
Item  Qty  Part Number  Part Description 
12  1  158-7864  Film 
13  1  102-2240  Temperature Sensor Gp 
14  1  285-5105  Liquid Level Sensor Gp 
15  1  3K-0360  O-Ring Seal 
16  1  2M-9780  O-Ring Seal 
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    Illustration 18g03679155

  1. Install sensor group (13) with O-ring seal (15) onto the hydraulic tank group. Tighten the sensor to a torque of 20 ± 3 N·m (15 ± 2 lb ft).

  2. Install sensor group (14) with seal (16) onto the hydraulic tank group. Tighten the sensor to a torque of 25 ± 1 N·m (18 ± 1 lb ft).

  3. Install warning label film (12) onto the hydraulic tank group.

Assemble Plate Assembly to the Tank Group

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Table 12
Required Parts
Group Number 374-2227 Hydraulic Tank and Mounting Gp (Rev. 06) 
Item  Qty  Part Number  Part Description 
17  1  374-2216  Plate As 
18  1  132-5789  Clip 
19  8  6V-5839  Washers 
20  8  6V-1820  Bolts 
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    Illustration 19g03679157
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    Illustration 20g03679159

  1. Mount hydraulic tank group (1) on plate assembly (17). Install clip (18) on the corner of the tank group.

  2. Secure hydraulic tank group (1) to plate assembly (17) with eight bolts (20) and washers (19). Tighten the bolts to a torque of 55 ± 10 N·m (41 ± 7 lb ft).

Assemble Tank Group on the Machine

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Table 13
Required Parts
Group Number 374-2227 Hydraulic Tank and Mounting Gp (Rev. 06) 
Item  Qty  Part Number  Part Description 
21  4  5P-8247  Hard Washers 
22  4  7X-0343  Bolts 
23  1  1S-1409  Clip 
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    Illustration 21g03679160

  1. Mount hydraulic tank group (1) and plate assembly (17) on top of the air cooler of the truck. Fasten the plate assembly to the truck with four bolts (22) and four washers (21). Tighten the bolts to a torque of 215 ± 40 N·m (159 ± 30 lb ft).

  2. Route hose assembly (4) down the rear of the air cooler. Clamp the hose in place with clip (23) and previously installed bolt, refer to Illustration 17. Route the hose under the air cooler to the front of the machine.

Assemble Adapter Assembly to the Tank Group

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Table 14
Required Parts
Group Number 374-2227 Hydraulic Tank and Mounting Gp (Rev. 06) 
Item  Qty  Part Number  Part Description 
24  1  437-8290  Bracket As 
25  2  5P-8247  Hard Washers 
26  2  7X-0343  Bolts 
27  1  6V-9746  O-Ring Seal 
28  1  118-0166  Fitting 
29  1  2S-4078  O-Ring Seal 
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    Illustration 22g03679161

  1. Fasten bracket assembly (24) to the front of the air cooler with two bolts (22) and two hard washers (21). Tighten the bolts to a torque of 215 ± 40 N·m (159 ± 30 lb ft.)

  2. Insert fitting (28) with O-ring seal (29) to the front of bracket assembly (24).

  3. Connect hose assembly (4) with O-ring seal (27) to the back of bracket assembly (24).

Filter Group Installation

Assemble Filter Group

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Table 15
Required Parts
Group Number 366-5413 Hydraulic Filter and Lines Gp (Rev. 06) 
Item  Qty  Part Number  Part Description 
1  1  177-6979  Oil Filter Gp 
2  1  164-5574  Tee 
3  1  7I-1036  Coupling As 
4  1  148-8392  Elbow As 
5  1  148-8357  Elbow As 
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    Illustration 23g03679572

  1. Connect elbow assembly (5) to the outlet of oil filter group (1). Tighten the elbow to a torque of 350 ± 53 N·m (258 ± 39 lb ft).

    Note: There is an arrow on the filter base showing the direction of flow.

  2. Connect tee (2) to the inlet of oil filter group (1). Tighten the tee to a torque of 220 ± 33 N·m (162 ± 24 lb ft)

  3. Connect coupling assembly (3) to tee (2). Tighten the coupling assembly to a torque of 140 ± 21 N·m (103 ± 15 lb ft)

  4. Connect elbow assembly (4) to tee (2). Tighten the elbow assembly to a torque of 140 ± 21 N·m (103 ± 15 lb ft)

Install Filter Group and Mounting Plate

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Table 16
Required Parts
Group Number 366-5413 Hydraulic Filter and Lines Gp (Rev. 06) 
Item  Qty  Part Number  Part Description 
6  1  432-2731  Bracket As 
7  1  8T-4223  Hard Washers 
8  1  5C-6565  Bolts 
9  4  8T-4137  Bolts 
10  5  8T-4121  Hard Washers 
11  1  8T-2502  Bolt 
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    Illustration 24g03679193

  1. Install bracket assembly (6) on the right side of the right frame rail with one bolt (8), one washer (7), one bolt (11), and one hard washer (10). Tighten the bolts to a torque of 105 ± 20 N·m (77 ± 15 lb ft).

  2. Install oil filter group (1) on bracket assembly (6) with four bolts (9) and four hard washers (10). Tighten the bolts to a torque of 55 ± 10 N·m (41 ± 7 lb ft).

Install Clips on the Hose Assembly

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Table 17
Required Parts
Group Number 356-0027 Pump Lines Gp (Rev. 07) 
Item  Qty  Part Number  Part Description 
12  1  192-3668  Reducer As 
13  1  6V-8556  Nut 
14  1  148-8449  Swivel Tee 
15  1  215-3616  Connector As 
16  1  169-1576  Adapter Elbow 
17  1  6V-6560  O-Ring Seal 
18  1  4J-5477  O-Ring Seal 
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    Illustration 25g03679274
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    Illustration 26g03679278

  1. Install connector assembly (15) in the charge inlet port of WDS hydraulic pump (A). Tighten the connector to a torque of 140 ± 21 N·m (103 ± 15 lb ft).

  2. Connect swivel tee (14) to connector assembly (15). Tighten the bolts to a torque of 140 ± 21 N·m (103 ± 15 lb ft).

  3. Connect reducer assembly (12) to swivel tee (14). Tighten the reducer to a torque of 27 ± 4 N·m (20 ± 3 lb ft).

  4. Install nut (13) over reducer assembly (12). Tighten the nut to a torque of 140 ± 21 N·m (103 ± 15 lb ft).
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    Illustration 27g03679279
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    Illustration 28g03679280

  5. Install elbow assembly (16) with O-ring seal (17) in the green port with label "X" of the WDS hydraulic pump.

  6. Install O-ring seal (18) in elbow (16).

Connect Filter Group to WDS Pump

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Table 18
Required Parts
Group Number 366-5413 Hydraulic Filter and Lines Gp (Rev. 06) 
Item  Qty  Part Number  Part Description 
10  4  8T-4121  Hard Washers 
19  1  370-4073  Hose As 
20  1  447-5655  Hose As 
21  1  5D-0718  Clip 
22  2  8C-3206  Flanges 
23  1  4J-0520  O-Ring Seal 
24  4  8T-4196  Bolts 
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    Illustration 29g03679285

  1. Connect hose assembly (19) to elbow assembly (5) at the outlet of filter group (1). Tighten the hose fitting to a torque of 220 ± 33 N·m (162 ± 24 lb ft).

  2. Connect hose assembly (20) to elbow assembly (4) at the inlet of filter group (1). Tighten the hose fitting to a torque of 140 ± 21 N·m (103 ± 15 lb ft).
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    Illustration 30g03679287

  3. Route hose assembly (19) and hose assembly (20) over the frame rail to the charge pump.

  4. Clamp the hoses to the boss on the frame with clip (21).
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    Illustration 31g03679288

  5. Connect hose assembly (20) with O-ring seal (23) to the outlet of the charge pump. Install two flanges (22) around the hose. Tighten the hose to a torque of 140 ± 21 N·m (103 ± 15 lb ft).

  6. Fasten hose assembly (20) and flanges (22) to the charge pump with four bolts (24) and four washers (10). Tighten the bolts to a torque of 55 ± 10 N·m (41 ± 7 lb ft).

  7. Connect hose assembly (19) to tee fitting (14). Tighten the hose to a torque of 140 ± 21 N·m (103 ± 15 lb ft).

Install Fittings on Plate Assembly

Assemble Flanges on Plate Assembly

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Table 19
Required Parts
Group Number 435-5307 Hydraulic Lines Mounting (Rev. 01) 
Item  Qty  Part Number  Part Description 
1  1  438-4415  Plate As 
2  4  1P-5766  Flanges 
3  2  5P-0047  Covers 
4  2  1P-3703  Rectangular Seals 
5  8  8C-6877  Bolts 
6  8  8T-5360  Washers 
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    Illustration 32g03679604
    Front view of bulkhead plate
    (A) Pump high-pressure port
    (B) Pump low-pressure port

  1. Install cover (3) with rectangular seal (4) on pressure ports (A) and (B) of plate assembly (1). Install two flanges (2) over each cover. Fasten each cover to the plate assembly with four bolts (5) and four washers (6). Tighten the bolts to a torque of 70 ± 15 N·m (52 ± 11 lb ft).

Assemble Flanges on Plate Assembly

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Table 20
Required Parts
Group Number 435-5307 Hydraulic Lines Mounting (Rev. 01) 
Item  Qty  Part Number  Part Description 
2  4  1P-5766  Flanges 
3  2  5P-0047  Covers 
4  2  1P-3703  Rectangular Seals 
5  8  8C-6877  Bolts 
6  8  8T-5360  Washers 
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    Illustration 33g03679605
    Rear view of bulkhead plate
    (A) Pump high-pressure port
    (B) Pump low-pressure port

  1. Install cover (3) with rectangular seal (4) on pressure ports (A) and (B) of plate assembly (1). Install two flanges (2) over each cover. Fasten each cover to the plate assembly with four bolts (5) and four washers (6).

Assemble Fittings on Plate Assembly

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Table 21
Required Parts
Group Number 435-5307 Hydraulic Lines Mounting (Rev. 01) 
Item  Qty  Part Number  Part Description 
7  2  6V-9168  Nuts 
8  2  2P-1279  Locknuts 
9  4  6V-9828  Caps 
10  4  6V-9829  Caps 
11  2  6V-8994  Unions 
12  2  6V-8993  Unions 
13  4  4J-5477  O-Ring Seals 
14  4  6V-8397  O-Ring Seals 
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    Illustration 34g03679606
    Rear view of bulkhead plate
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    Illustration 35g03679608
    Front view of bulkhead plate
    (C) Spray head pilot pressure port
    (D) Spray head pilot return port
    (E) Motor signal port
    (F) Motor pilot port

  1. Insert one union (11) through the rear of spray head pilot pressure port (C). Insert the other union through the rear of spray head pilot return port (D). Fasten each adapter to the plate assembly with nut (7). Tighten the locknuts to a torque of 80 ± 12 N·m (59 ± 9 lb ft).

  2. Connect one cap (10) with O-ring seal (14) to the rear end of each union (11). Tighten the caps to a torque of 45 ± 5 N·m (33 ± 4 lb ft).

  3. Connect one cap (10) with O-ring seal (14) to the front end of each union (11). Tighten the caps to a torque of 45 ± 5 N·m (33 ± 4 lb ft).

  4. Insert one union (12) through the rear of motor signal port (E). Insert the other union through the rear of motor pilot port (F). Fasten each adapter to the plate assembly with locknut (8). Tighten the nuts to a torque of 40 ± 6 N·m (30 ± 4 lb ft).

  5. Connect one cap (9) with O-ring seal (13) to the rear end of each union (12). Tighten the caps to a torque of 27 ± 4 N·m (20 ± 3 lb ft).

  6. Connect one cap (9) with O-ring seal (13) to the front end of each union (12). Tighten the caps to a torque of 27 ± 4 N·m (20 ± 3 lb ft).

Assemble Fittings on Plate Assembly

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Table 22
Required Parts
Group Number 435-5307 Hydraulic Lines Mounting (Rev. 01) 
Item  Qty  Part Number  Part Description 
15  1  6V-9172  Nut 
16  1  6V-8998  Union 
17  2  5K-9090  O-Ring Seals 
18  2  6V-9833  Cap Assembly 
    Show/hide table
    Illustration 36g03679609
    Rear view of bulkhead plate
    Show/hide table
    Illustration 37g03679610
    Front view of bulkhead plate
    (G) Motor case drain port

  1. Insert union (16) through the rear side of motor case drain port (G) on plate assembly (1). Fasten the adapter to the plate assembly with nut (15). Tighten the cap assembly and nut to a torque of 350 ± 53 N·m (258 ± 39 lb ft).

  2. Connect one cap (18) with O-ring seal (17) to the rear end of union (16). Tighten the caps to a torque of 220 ± 33 N·m (162 ± 24 lb ft).

  3. Connect one cap (18) with O-ring seal (17) to the front end of union (16). Tighten the caps to a torque of 220 ± 33 N·m (162 ± 24 lb ft).

Pump Group Lines Installation

Install Plate Assembly On Truck Frame

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Table 23
Required Parts
Group Number 356-0027 Pump Lines Gp (Rev. 07) 
Item  Qty  Part Number  Part Description 
1  1  435-5307  Hydraulic Lines Mounting 
2  3  5V-9221  Spacers 
3  3  5P-1075  Hard Washer 
4  3  8T-2501  Bolts 
5  1  8T-4195  Bolt 
6  1  7X-7729  Washer 
    Show/hide table
    Illustration 38g03679724
    Show/hide table
    Illustration 39g03679725

  1. Install plate assembly (A) on the rear frame rail with three spacers (2). Fasten the plate to the tail casting with three bolts (4) and three washers (3). Tighten the bolts to a torque of 55 ± 10 N·m (41 ± 7 lb ft).

  2. Fasten the plate to the tail casting with bolt (5) and washer (6). Tighten the bolt to a torque of 55 ± 10 N·m (41 ± 7 lb ft).

Connect WDS Pressure Hoses to Plate Assembly

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Table 24
Required Parts
Group Number 356-0027 Pump Lines Gp (Rev. 07) 
Item  Qty  Part Number  Part Description 
7  1  366-5423  Hose As 
8  1  366-5424  Hose As 
9  1  366-5420  Hose As 
10  4  6V-0400  Flanges 
11  2  1P-3703  Rectangular Seals 
12  8  5P-8245  Hard Washers 
13  8  6V-5684  Bolts 
    Show/hide table
    Illustration 40g03679727

    Note: Label both ends of all hoses before connecting.

  1. Connect pump high-pressure hose assembly (7) to pump high-pressure port (B) of plate assembly (A) with O-ring seal and two flanges. Fasten the hose to plate with four bolts and four washers. Tighten the bolts to a torque of 70 ± 15 N·m (52 ± 11 lb ft).

    Note: O-ring seal, flanges, bolts and washers were previously installed on plate assembly (A). A cover was installed for temporary purposes. This cover must be removed when a hose is connected to this port.

  2. Connect pump return low-pressure hose assembly (8) to pump low-pressure port (C) of plate assembly (A) with seal and two split flanges . Fasten the hose to plate with four bolts and four washers. Tighten the bolts to a torque of 70 ± 15 N·m (52 ± 11 lb ft).

    Note: O-ring seal, flanges, bolts and washers were previously installed on plate assembly (A). A cover was installed for temporary purposes. This cover must be removed when a hose is connected to this port.

  3. Connect motor case drain hose assembly (9) to adapter (D) in the motor case drain port. Tighten the hose to a torque of 220 ± 33 N·m (162 ± 24 lb ft).

    Note: The adapter and O-ring seal were previously installed on plate assembly (A). A cap was installed for temporary purposes. This cap must be removed when a hose is connected to this port.

    Show/hide table
    Illustration 41g03679728

  4. Route pump high-pressure hose assembly (7) and pump return low-pressure hose assembly (8) along the right frame rail to the front of the machine.
    Show/hide table
    Illustration 42g03679729

  5. Connect pump high-pressure hose assembly (7) to pump high-pressure port (F) on the right side of the WDS hydraulic pump. Secure the hose with two flanges (10) and rectangular seal (11). Fasten the hose to the pump with four bolts (13) and four hard washers (12). Tighten the bolts to a torque of 100 ± 20 N·m (74 ± 15 lb ft).

  6. Connect pump return low-pressure hose assembly (8) to pump low-pressure port (E) on the left side of the WDS hydraulic pump. Secure the hose with two flanges with two flanges (10) and rectangular seal (11). Fasten the hose to pump with four bolts (13) and four hard washers (12). Tighten the bolts to a torque of 100 ± 20 N·m (74 ± 15 lb ft).
    Show/hide table
    Illustration 43g03679730

  7. Route motor case drain hose assembly (9) up through the engine compartment to the bypass valve (G).
    Show/hide table
    Illustration 44g03679731

  8. Connect motor case drain hose assembly (9) to adapter (H) on the bypass valve inlet port. Tighten the hose to a torque of 220 ± 33 N·m (162 ± 24 lb ft).

Connect Motor Signal Pressure Hose and Motor Pilot Pressure Hose to Plate Assembly

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Table 25
Required Parts
Group Number 356-0027 Pump Lines Gp (Rev. 07) 
Item  Qty  Part Number  Part Description 
14  1  447-8081  Hose As 
15  1  447-8082  Hose As 
16  1  326-8241  Bracket 
17  1  242-3633  Boss 
18  1  4D-6466  Clip 
19  1  4S-4456  Clip 
20  1  8T-4186  Bolt 
21  1  344-5675  Nut 
22  2  8T-4121  Hard Washers 

Note: Color codes for hoses are indicated on the WDS pump, the motor, and the bulkhead adapters.

    Show/hide table
    Illustration 45g03679733

  1. Connect green motor signal pressure hose assembly (14) with previously installed O-ring seal to the adapter in motor signal port (J) of the plate assembly. Tighten the hose to a torque of 27 ± 4 N·m (20 ± 3 lb ft).

  2. Connect yellow motor pilot pressure hose assembly (15) with previously installed O-ring seal to the adapter in motor pilot port (K) of the plate assembly. Tighten the hose to a torque of 27 ± 4 N·m (20 ± 3 lb ft).

  3. Secure hoses as shown in Illustration 45 using the following hardware: bracket (16), clip (18), clip (19), boss (17), bolt (20), nut (21) and two hard washers (22).
    Show/hide table
    Illustration 46g03679734

  4. Route green motor signal pressure hose assembly (14) and motor pilot pressure hose assembly (15) along the right frame rail toward the front of the machine.
    Show/hide table
    Illustration 47g03679735

  5. Connect green motor signal pressure hose assembly (14) to left signal port (N) on the bottom of WDS pump (L).

    Note: Connect green motor signal pressure hose to the left port of pump in order to achieve proper water pump operation.

  6. Connect motor pilot pressure hose assembly (15) to tee fitting (M).

Connect Charge Pump Inlet Hose to WDS Hydraulic Tank

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Table 26
Required Parts
Group Number 356-0027 Pump Lines Gp (Rev. 07) 
Item  Qty  Part Number  Part Description 
12  4  5P-8245  Hard Washers 
23  1  393-4658  Hose As 
24  2  1P-4578  Flanges 
25  4  6V-8197  Bolts 
26  1  4J-0522  O-Ring Seal 
27  1  4J-0524  O-Ring Seal 
    Show/hide table
    Illustration 48g03679737

  1. Connect charge pump suction hose assembly (23) to the suction port of the charge pump with O-ring seal (26) and two flanges (24). Fasten the hose to the pump with four bolts (25) and four hard washers (12). Tighten the bolts to a torque of 100 ± 20 N·m (74 ± 15 lb ft)
    Show/hide table
    Illustration 49g03679739

  2. Route charge pump suction hose assembly (23) to the left side of the engine compartment. Route the hose up through the engine compartment to the hydraulic tank.
    Show/hide table
    Illustration 50g03679742

  3. Route charge pump suction hose assembly (23) to suction port (P) on the WDS hydraulic tank.

  4. Remove four bolts, four washers, and two flanges from suction port (P). Remove cover and seal from suction port.

  5. Connect hose assembly (23) with O-ring seal (27) to suction port (P). Fasten the hose to the tank with the two flanges, four bolts, and four washers.

Connect Cold Start Relief Valve to the WDS Hydraulic Tank

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Table 27
Required Parts
Group Number 356-0027 Pump Lines Gp (Rev. 07) 
Item  Qty  Part Number  Part Description 
28  1  370-4064  Hose As 
29  1  198-9219  Relief Valve Gp 
30  1  148-8324  Connector As 
31  1  8T-1685  Tee 
32  1  6V-9853  Elbow 
33  3  6V-9746  O-Ring Seal 
34  1  7M-8485  O-Ring Seal 
    Show/hide table
    Illustration 51g03679743

  1. Install relief valve (29) in the inlet of the filter group. Tighten the relief valve to a torque of 50 ± 3 N·m (37 ± 2 lb ft).

  2. Install connector assembly (30) in relief valve group (29). Tighten the connector to a torque of 140 ± 21 N·m (103 ± 15 lb ft).

  3. Connect charge pump relief hose assembly (28) to connector assembly (30).
    Show/hide table
    Illustration 52g03679748

  4. Route charge pump relief hose assembly (28) from the relief valve to the left side of the machine. Route the hose through the engine compartment and up to the WDS hydraulic tank.
    Show/hide table
    Illustration 53g03679750

  5. Install tee (31) with O-ring seals (33) and (34) in the WDS hydraulic tank.

  6. Connect elbow (32) with O-ring seal (33) to tee (31).

  7. Connect charge pump relief hose assembly (28) with O-ring seal (33) to elbow (32).

Install Clips on the Hose Assembly

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Table 28
Required Parts
Group Number 356-0027 Pump Lines Gp (Rev. 07) 
Item  Qty  Part Number  Part Description 
35  2  154-0273  Clip 
36  3  5P-8247  Hard Washer 
37  3  0S-1592  Bolt 
38  1  259-8974  Clip 
39  1  259-8973  Clip 
40  1  5P-8182  Grommet 
    Show/hide table
    Illustration 54g03679751

  1. Install two clips (35) on charge pump relief hose assembly (28) at the locations shown in Illustration 54. Fasten the clips to the back of the air cooler with bolts (37) and hard washers (36). Tighten the bolts to a torque of 215 ± 40 N·m (159 ± 30 lb ft).

  2. Install grommet (40) on charge pump suction hose assembly (23). Install clip (38) and clip (39) over the grommet. Fasten the clips to the back of the air cooler with bolt (37) and washer (36). Tighten the bolt to a torque of 215 ± 40 N·m (159 ± 30 lb ft).

Install Clips on the Hose Assembly

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Table 29
Required Parts
Group Number 356-0027 Pump Lines Gp (Rev. 07) 
Item  Qty  Part Number  Part Description 
40  1  5P-8182  Grommet 
41  1  5P-7471  Clip 
42  1  5P-7470  Clip 
43  1  3P-2404  Clip 
44  1  323-2501  Two-Piece Clip 
45  1  323-2502  Two-Piece Clip 
46  2  235-2496  Hard Washer 
47  1  0S-1603  Bolt 
48  1  1B-4430  Jam Nut 
    Show/hide table
    Illustration 55g03679752

  1. Install two-piece clips (44) and (45) on existing tube (Q).

  2. Install clip (43) on charge pump relief hose assembly (28).

  3. Install grommet (40) on charge pump suction hose assembly (23). Install clip (41) and clip (42) over the grommet.
    Show/hide table
    Illustration 56g03679753

  4. Insert bolt (47) with hard washer (46) through the clips. Fasten the bolt in place with jam nut (48) and hard washer (46).

Install Clips on the Hose Assembly

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Table 30
Required Parts
Group Number 356-0027 Pump Lines Gp (Rev. 07) 
Item  Qty  Part Number  Part Description 
40  2  5P-8182  Grommet 
41  2  5P-7471  Clip 
42  2  5P-7470  Clip 
43  1  3P-2404  Clip 
44  1  323-2501  Two-Piece Clip 
45  1  323-2502  Two-Piece Clip 
46  4  235-2496  Hard Washer 
47  2  0S-1603  Bolt 
48  2  1B-4430  Jam Nut 
    Show/hide table
    Illustration 57g03679754
    Show/hide table
    Illustration 58g03679755

  1. Install grommet (40) on charge pump suction hose assembly (23). Install clip (41) and clip (42) over the grommet.

  2. Install two-piece clips (44) and (45) on existing tube (Q).

  3. Fasten charge pump suction hose assembly (23) to existing tube (Q). Insert bolt (47) with hard washer (46) through the clips. Fasten the bolt in place with jam nut (48) and hard washer (46).

  4. Install grommet (40) on charge pump suction hose assembly (23). Install clip (41) and clip (42) over the grommet.

  5. Install clip (43) on charge pump relief hose assembly (28).

  6. Fasten charge pump relief hose assembly (28) to charge pump suction hose assembly (23). Insert bolt (47) with hard washer (46) through the clips. Fasten the bolt in place with jam nut (48) and hard washer (46).

Install Clips on the Hose Assembly

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Table 31
Required Parts
Group Number 356-0027 Pump Lines Gp (Rev. 07) 
Item  Qty  Part Number  Part Description 
35  1  154-0273  Clip 
36  2  5P-8247  Hard Washers 
37  2  0S-1592  Bolts 
49  1  374-2222  Hose As 
50  1  431-4196  Hose As 
51  1  9X-8402  Clip 
    Show/hide table
    Illustration 59g03679757
    Show/hide table
    Illustration 60g03679759

  1. Connect check valve return hose assembly (49) to tee (R) on the tank group.

  2. Route check valve return hose assembly (49) across the back of the air cooler to the bypass valve group.

  3. Connect check valve return hose assembly (49) to the check valve on the bypass valve inlet port. Tighten the hose to a torque of 140 ± 21 N·m (103 ± 15 lb ft).

  4. Connect tank return hose assembly (50) to adapter assembly (S) on the tank group.

  5. Route tank return hose assembly (50) across the back of the air cooler to the bypass valve group.

  6. Connect tank return hose assembly (50) to the bypass valve outlet port.

  7. Install clip (35) on check valve return hose assembly (49). Fasten the clip to the back of the air cooler with bolt (37) and hard washer (36). Tighten the bolt to a torque of 215 ± 40 N·m (159 ± 30 lb ft).

  8. Install clip (51) on tank return hose assembly (50). Fasten the clip to the back of the air cooler with bolt (37) and hard washer (36). Tighten the bolt to a torque of 215 ± 40 N·m (159 ± 30 lb ft).

Install Clips on the Hose Assembly

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Table 32
Required Parts
Group Number 356-0027 Pump Lines Gp (Rev. 07) 
Item  Qty  Part Number  Part Description 
5  2  8T-4195  Bolts 
21  2  344-5675  Nuts 
22  4  8T-4121  Hard Washers 
43  4  3P-2404  Clips 
52  2  6V-1573  Clips 
53  2  6V-1572  Clips 
54  2  6V-1875  Grommets 
    Show/hide table
    Illustration 61g03679764

  1. Install grommets (54) on the machine tube behind the engine compartment. Install clips (52) and (53) over each grommet.

  2. Install four clips (43) on charge pump relief hose assembly (28).

  3. Clamp charge pump relief hose assembly (28) to the back of the engine compartment. Fasten two clips (43) to clips (52) and (53) with bolts (5), hard washers (22), and nuts (21).

  4. Fasten the remaining two clips (43) to the machine frame behind the engine compartment.

Install Clips on the Hose Assembly

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Table 33
Required Parts
Group Number 356-0027 Pump Lines Gp (Rev. 07) 
Item  Qty  Part Number  Part Description 
55  1  513-1592  Hose As 
56  1  421-6194  Connector As 
57  1  142-0038  Elbow 
58  1  5K-9090  O-Ring Seal 
    Show/hide table
    Illustration 62g06145086
    Show/hide table
    Illustration 63g03679766

  1. Install elbow (57) in the tee of the bypass valve inlet port. Tighten the elbow to a torque of 220 ± 33 N·m (162 ± 24 lb ft).

  2. Connect pump case drain return hose assembly (55) with O-ring seal (58) to the elbow. Tighten the hose to a torque of 220 ± 33 N·m (162 ± 24 lb ft).

  3. Route hose assembly (55) down through the engine compartment to the WDS hydraulic pump.
    Show/hide table
    Illustration 64g06145087

  4. Install connector assembly (56) in the case drain port of the WDS hydraulic pump. Tighten the connector to a torque of 140 ± 21 N·m (103 ± 15 lb ft).

  5. Connect hose assembly (55) to the connector assembly. Tighten the hose to a torque of 220 ± 33 N·m (162 ± 24 lb ft).

Install Clips on the Hose Assembly

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Table 34
Required Parts
Group Number 356-0027 Pump Lines Gp (Rev. 07) 
Item  Qty  Part Number  Part Description 
5  2  8T-4195  Bolts 
21  2  344-5675  Nuts 
22  4  8T-4121  Washers 
46  3  235-2496  Hard Washers 
47  2  0S-1603  Bolt 
48  2  1B-4430  Jam Nut 
59  2  6V-1867  Clips 
60  2  6V-1868  Clips 
61  2  6V-1869  Grommets 
62  3  8C-7534  Clips 
63  3  4D-7388  Clips 
    Show/hide table
    Illustration 65g03679773
    Show/hide table
    Illustration 66g03679776

  1. Install clip (63) on motor case drain hose assembly (9). Fasten the clip to the hose with bolt (5), washer (22) and nut (21).

  2. Install clip (62) on motor case drain hose assembly (9). Install second clip (62) on pump case drain return hose assembly (55).

  3. Install grommet (61) on the suction line going to the steering oil hydraulic tank. Install clips (59) and (60) over the grommet.

  4. Insert bolt (47) with hard washer (46) through clips (59) and (60). Fasten the bolt in place with nut (48) and hard washer (46).
    Show/hide table
    Illustration 67g03679777
    Show/hide table
    Illustration 68g03679780

  5. Install clip (63) on motor case drain hose assembly (9). Install second clip (63) on pump case drain return hose assembly (55).

  6. Insert bolt (5) with washer (22) through both clips (63). Fasten the bolt in place with nut (21).
    Show/hide table
    Illustration 69g03679781
    Show/hide table
    Illustration 70g03679783

  7. Install grommet (61) on the suction line going to the steering oil hydraulic tank. Install clips (59) and (60) over the grommet.

  8. Install clip (62) on pump case drain return hose assembly (55).

  9. Insert bolt (47) with washer (46) through clips (59), (60), and (62). Fasten the bolt in place with nut (48).

Install Clips on the Hose Assembly

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Table 35
Required Parts
Group Number 356-0027 Pump Lines Gp (Rev. 07) 
Item  Qty  Part Number  Part Description 
5  3  8T-4195  Bolt 
6  12  7X-7729  Washer 
18  3  4D-6466  Clip 
20  1  8T-4186  Bolt 
21  9  344-5675  Nut 
22  6  8T-4121  Hard Washer 
52  3  6V-1573  Clip 
53  3  6V-1572  Clip 
63  3  4D-7388  Clips 
64  3  6V-1574  Grommet 
65  3  8T-4196  Bolt 
66  3  302-4612  Plate 
67  3  7G-5985  Clips 
68  3  7G-5984  Clips 
69  3  7G-5986  Grommets 
    Show/hide table
    Illustration 71g03679785
    Show/hide table
    Illustration 72g03679789
    Show/hide table
    Illustration 73g03679787

  1. Install grommet (69) on hose assemblies (7) and (8) at locations (W), (X), and (Y). Install clips (67) and (68) over each grommet.

  2. Install grommet (64) at locations (W), (X) and (Y) on the tube to the engine cooler. This tube runs along the inside of the right frame rail. Install clips (52) and (53) over each grommet.

  3. Install clips (63) on hose assembly (9) at locations (W), (X), and (Y).

  4. Install clips (18) on hose assemblies (14) and (15) at locations (W), (X), and (Y).

  5. Add plate (66), insert bolt (5) with hard washer (22) through each set of clips. Fasten the bolt in place with nut (21) and hard washer (22) at locations (W), (X), and (Y).

  6. Insert bolt (65) with washer (6) through each plate (66) and each set of clips (67) and (68). Fasten the bolt in place with washer (6) and nut (21) at locations (W), (X), and (Y).

  7. Insert bolt (20) with washer (6) through each set of clips (52) and (53). Fasten the bolt in place with washer (6) and nut (21) at locations (W), (X), and (Y).

Install Spray Head Pilot Pressure and Pilot Return Hoses

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Table 36
Required Parts
Group Number 356-0028 Pilot Lines Gp (Rev. 02) 
Item  Qty  Part Number  Part Description 
1  1  366-5414  Hose As 
2  1  366-5415  Hose As 
3  1  6V-9873  Connector 
4  2  3J-1907  O-Ring Seals 
5  1  6V-8398  O-Ring Seal 
6  1  6V-8781  Tee 
7  1  6V-9829  Cap As 
8  2  6V-8397  O-Ring Seals 
    Show/hide table
    Illustration 74g03681843

  1. Connect spray head pilot drain hose assembly (2) to the adapter in spray head pilot drain port (A). Tighten the hose to a torque of 45 ± 5 N·m (33 ± 4 lb ft).

  2. Connect spray head pilot pressure hose assembly (1) to the adapter in spray head pilot pressure port (B). Tighten the hose to a torque of 45 ± 5 N·m (33 ± 4 lb ft).
    Show/hide table
    Illustration 75g03681833

  3. Route hose assembly (1) and hose assembly (2) along the right frame rail to the front of the machine.
    Show/hide table
    Illustration 76g03681845

  4. Install connector (3) with O-ring seal (4) in hoist valve (C). Tighten the connector to a torque of 55 ± 8 N·m (41 ± 6 lb ft).

  5. Connect spray head pilot pressure hose assembly (1) with O-ring seal (5) to connector (3). Tighten the hose to a torque of 65 ± 5 N·m (48 ± 4 lb ft).
    Show/hide table
    Illustration 77g03681937

  6. Install tee (6) with O-ring seal (4) in the hydraulic tank (D). Tighten the tee to a torque of 55 ± 8 N·m (41 ± 6 lb ft).

  7. Install cap assembly (7) with O-ring seal (8) on tee (6). Tighten the cap to a torque of 45 ± 5 N·m (33 ± 4 lb ft).

  8. Connect spray head pilot drain hose assembly (2) with O-ring seal (8) to tee (6).

Clip Hoses to the Truck Frame

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Table 37
Required Parts
Group Number 356-0028 Pump Lines Gp (Rev. 02) 
Item  Qty  Part Number  Part Description 
9  1  8T-4133  Nut 
10  2  5K-5338  Clip 
11  2  8T-4121  Hard Washer 
12  1  8T-4195  Bolt 
13  1  356-6693  Plate 
    Show/hide table
    Illustration 78g03682089
    Show/hide table
    Illustration 79g03682092
    Location (E)

  1. Install one clip (10) around spray head pilot pressure hose assembly (1) and spray head pilot drain hose assembly (2) at location (E). Fasten the clip to the machine frame.
    Show/hide table
    Illustration 80g03682093
    Location (F)

  2. Install plate (13) at location (F) on the hose clamps that were previously installed.

  3. Install one clip (10) around spray head pilot pressure hose assembly (1) and spray head pilot drain hose assembly (2) at location (F). Fasten the clip to plate (13) with bolt (12), hard washer (11) and nut (9). Tighten the nut to a torque of 55 ± 10 N·m (41 ± 7 lb ft).

Hydraulic and Component Installation (Tank)

Water Pump Installation

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Table 38
Required Parts (1)
Group Number 428-7861 Pump and Drive Gp (Rev. 04) 
Item  Qty  Part Number  Part Description 
1  1  428-7857  Water Pump Gp 
2  1  452-2338  Coupling As 
3  1  284-2728  Pressure Sensor Gp 
4  1  437-3854  Gasket Kit 
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(1) If stainless steel water pump is ordered, refer to Table 39.

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Table 39
Required Parts
Group Number 448-5559 Pump and Drive Gp (Rev. 03) - Stainless Steel Kit 
Item  Qty  Part Number  Part Description 
1  1  436-2443  Water Pump Gp 
2  1  452-2338  Coupling As 
3  1  448-3671  Pressure Sensor Gp 
4  1  436-2444  Gasket Kit 
    Show/hide table
    Illustration 81g03682130

  1. Install water pump adapter (A) on the water tank outlet.

    Note: Water pump adapter must be fabricated and installed by the customer. The dimensions of the adapter and mounting method must be determined with regards to the specific water tank.

    Note: Gaskets are provided with each water pump. Refer to the service repair kit for gasket part numbers if replacements are required.

  2. Bolt water pump and drive group (1) onto water pump adapter (A) on the water tank.

    Note: Use the provided inlet gasket from gasket kit (4) when bolting the water pump to the adapter.

    Note: Mounting hardware must be provided by the customer.

  3. Bolt water pump and drive group (1) onto mounting adapter (B) on the water tank.

  4. Connect outlet of water pump and drive group (1) to adapter (C) on the spray bar.

    Note: Spray bar adapter must be fabricated and installed by the customer. Connecting hardware must be provided by the customer.

    Note: Use the provided outlet gasket from gasket kit (4) when connecting the water pump to the spray bar.

    Note: Make sure that the water pump bearings have been properly lubricated before starting the WDS system.

    Show/hide table
    Illustration 82g03697323

  5. Use coupling assembly (2) for attaching water pump shaft with shaft on motor.

    Note: This is a wet coupling pump. Coupling compartment must be filled with oil.

    Show/hide table
    Illustration 83g03697384

  6. Install pressure sensor (3) onto spray bar at location shown in Illustration 83.

WDS Motor Installation

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Table 40
Required Parts
Group Number 371-2721 Piston Motor and Mounting Gp (Rev. 04) 
Item  Qty  Part Number  Part Description 
1  1  358-0163  Piston Motor Gp 
2  2  8T-4122  Hard Washers 
3  2  7X-0347  Bolts 
    Show/hide table
    Illustration 84g03682131
    Show/hide table
    Illustration 85g03682135

  1. Install coupler (B) on spline of water pump (A).

    Note: Coupler (B) is included with water pump (A). The coupler does not come assembled to the water pump.

    Show/hide table
    Illustration 86g03682136
    Show/hide table
    Illustration 87g03682137

    Note: The water pump group includes an O-ring seal that must be installed on the WDS motor. Install this O-ring seal prior to mounting the WDS motor.

  2. Mount WDS piston motor group (1) onto water pump (A). Ensure that the spline of motor engages coupler (B).

    Note: Use suitable lifting device to install the WDS motor. This pump weighs approximately 55 kg (121 lb).

    Note: Orient the WDS motor as shown in the above Illustration. The motor pressure ports should be facing downwards.

  3. Fasten WDS piston motor group (1) to water pump (A) with two bolts (3) and two hard washers (2). Tighten the bolts to a torque of 215 ± 40 N·m (159 ± 30 lb ft).

Install Pump Breather Group

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Table 41
Required Parts
Group Number 420-4443 Breather Gp (Rev. 00) 
Tool  Qty  Part Number  Part Description 
1  1  6V-8641  Connector 
2  1  8T-4191  Bolt 
3  1  9G-5127  Breather 
4  1  4K-8864  Clip 
5  1  8T-1031  Connector 
6  1  422-9448  Hose As 
7  1  152-8181  Fitting As 
8  5  9S-4191  O-Ring Plugs 
9  9  3J-1907  O-Ring Seals 
10  1  4J-5477  O-Ring Seal 
11  2  8T-4121  Hard Washers 
    Show/hide table
    Illustration 88g03367416
    Vertically Mounted Water Pump
    Show/hide table
    Illustration 89g03368841
    Horizontally Mounted Water Pump

  1. Install five plugs (8) with seal (9) in the water pump.

  2. Install connector (5) with seal (9).

  3. Install quick disconnect nipple (7) in connector (5) with seal (9).

  4. Install adapter (1) with seal (9).

  5. Connect hose assembly (6) to adapter (1) with seal (10).

  6. Install breather (3) in the end of hose assembly (6).

  7. Install clip (4) on hose assembly (6). Fasten the clip to the rear of the water tank with bolt (2) and two washers (11).

  8. Remove the plug from oil level check port (A).

  9. Use the quick disconnect fitting to fill the pump couple cavity with SAE 60W oil. Monitor the oil level at port (A) and replace the plug when the cavity is full of oil.

    Note: For horizontally mounted water pumps, add oil until the pump cavity is half full.

Water Pump Motor to Bulkhead Lines Routing

Connect WDS Motor Pressure Hoses

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Table 42
Required Parts
Group Number 372-1177 Motor Lines Gp (Rev. 01) 
Item  Qty  Part Number  Part Description 
1  1  418-4215  Hose As 
2  1  418-4216  Hose As 
3  1  369-6506  Hose As 
4  1  421-6193  Connector 
5  1  6V-7970  O-Ring Seal 
6  1  6V-9746  O-Ring Seal 
7  1  246-2951  Adapter 
8  4  6V-0400  Flanges 
9  2  1P-3703  Rectangular Seals 
10  1  4J-0522  O-Ring Seal 
11  1  9S-4191  O-Ring Plug 
12  1  3J-1907  O-Ring Seal 
13  8  8T-4223  Hard Washers 
14  4  8T-4184  Bolts 
15  4  6V-8336  Bolts 
16  1  5K-9090  O-Ring Seal 
17  1  6V-8946  Reducer 
    Show/hide table
    Illustration 90g03747973
    Water pump motor
    (A) Motor high-pressure port
    (B) Motor low-pressure port
    (C) Case drain port
    Show/hide table
    Illustration 91g03682162

  1. Install adapter (7) with O-ring seal (10) in motor high-pressure port (B).

  2. Install O-ring plug (11) with O-ring seal (12) in adapter (7).

  3. Connect motor high-pressure hose assembly (2) with rectangular seal (9) to motor high-pressure port (B). Install two flanges (8) around the hose assembly.

  4. Fasten the motor high-pressure hose assembly (2) and flanges (8) to the motor with four bolts (15) and four hard washers (13).

  5. Connect motor low-pressure hose assembly (1) with rectangular seal (9) to motor low-pressure port (C). Install two flanges (8) around the hose assembly.

  6. Fasten the motor low-pressure hose assembly (1) and flanges (8) to the motor with four bolts (15) and four hard washers (13).

  7. Install connector (4) and O-ring seal (5) in case drain port (A). Add reducer (17) and O-ring seal (16) to connector (4).

  8. Connect case drain hose assembly (3) with O-ring seal (6) to reducer (17).
    Show/hide table
    Illustration 92g03682163

  9. Route motor low-pressure hose assembly (1), motor high-pressure hose assembly (2) and case drain hose assembly (3) to the plate assembly on the rear frame rail of the truck.
    Show/hide table
    Illustration 93g03682164

  10. Connect motor low-pressure hose assembly (1) to the pump low-pressure port (D) of the plate assembly with seal and two split flanges. Fasten the hose to the plate with four bolts and four washers. Tighten the bolts to a torque of 70 ± 15 N·m (52 ± 11 lb ft).

    Note: Seal, split flanges, bolts and washers were previously installed on the plate assembly. A cover was installed for temporary purposes. This cover must be removed when a hose is connected to this port.

  11. Connect motor high-pressure hose assembly (2) to the pump low-pressure port (E) of the plate assembly with seal and two split flanges. Fasten the hose to the plate with four bolts and four washers. Tighten the bolts to a torque of 70 ± 15 N·m (52 ± 11 lb ft).

    Note: Seal, split flanges, bolts and washers were previously installed on the plate assembly. A cover was installed for temporary purposes. This cover must be removed when a hose is connected to this port.

  12. Connect case drain hose assembly (3) to the case drain port (F) of the plate assembly.

    Note: A cap was previously installed on the plate assembly for temporary purposes. This cap must be removed when a hose is connected to this port.

Connect Motor Signal Pressure Hose and Motor Pilot Pressure Hose to Plate Assembly

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Table 43
Required Parts
Group Number 372-1177 Motor Lines Gp (Rev. 04) 
Item  Qty  Part Number  Part Description 
18  2  124-2159  Couplings 
19  1  6V-9850  Elbow 
20  2  8T-7489  Connectors 
21  3  6V-8397  O-Ring Seals 
22  2  6V-6560  O-Ring Seals 
23  2  124-2111  Couplings 
(24)(1)  1  122-6877  Hose 
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(1) This component must be provided by the customer.
    Show/hide table
    Illustration 94g03682186

  1. Measure two lengths of bulk hose (24) from the WDS motor (H) to the plate assembly (G) on the rear of the truck. Cut the hoses to length.

    Note: Ensure that each hose has adequate length in order to accommodate lifting and lowering of the water tank.

  2. Create two hose assemblies as follows:

    • Motor pilot pressure hose - install one coupling (18) on one end and install one coupling (23) on the other end

    • Motor signal pressure hose - install one coupling (18) on one end and install one coupling (23) on the other end

    Note: Label both ends of both hoses before connecting.

    Show/hide table
    Illustration 95g03748112
    WDS Motor
    (E) Motor pilot port
    (X) Motor signal port

  3. Install adapter (20) with O-ring seal (22) in motor pilot port (J) of the WDS motor.

  4. Connect elbow (19) with O-ring seal (21) to adapter (20).

  5. Install adapter (20) with O-ring seal (22) in motor signal port (K) of the WDS motor.

  6. Connect the end of the motor pilot pressure hose with elbow coupling (18) to elbow (19) in motor pilot port (J) with O-ring seal (21).

  7. Connect the end of the motor signal pressure hose with elbow coupling (18) to adapter (20) in motor signal port (K) with O-ring seal (21).

  8. Route both hoses under the water tank to the plate assembly (G) on the back of the truck.
    Show/hide table
    Illustration 96g03682189
    Rear view of bulkhead plate
    (L) Motor signal line fitting
    (M) Motor pilot pressure fitting

  9. Connect the motor signal line to bulkhead adapter (L) with previously installed seal.

    Note: A cap was previously installed on the plate assembly for temporary purposes. This cap must be removed when a hose is connected to this port.

    Note: The seal was previously installed in this adapter. Verify that the seal is in place prior to connecting the hose.

  10. Connect the motor pilot pressure hose to bulkhead adapter (M) with previously installed seal.

    Note: The seal was previously installed in this adapter. Verify that the seal is in place prior to connecting the hose.

Install Clips on Hose Assemblies

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Table 44
Required Parts
Group Number 372-1177 Motor Lines Gp (Rev. 02) 
Item  Qty  Part Number  Part Description 
25  3  7G-5985  Clips 
26  3  7G-5984  Clips 
27  3  143-4299  Grommets 
28  3  6V-1889  Clips 
29  5  6V-5839  Washers 
30  3  0S-1594  Bolts 
31  2  6V-8801  Nuts 
    Show/hide table
    Illustration 97g03682216
    Show/hide table
    Illustration 98g03682217

  1. Install three grommets (27) on motor low-pressure hose assembly (1) and motor high-pressure hose assembly (2).

  2. Install clips (25) and clips (26) over each grommet.

  3. Install three clips (28) on motor case drain hose assembly (3).

  4. Insert bolt (30) and washer (29) through each set of clips in order to clamp the three hoses together. Fasten each bolt in place with nut (31) and washer (29).

Spray Head Installation

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Table 45
Required Parts
Spray Head Installation 
Item  Qty  Part Number  Part Description 
1(1)  5 (2)  431-9716  Water Control Valve Gp 
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(1) These parts are fabricated with aluminum. Stainless steel components 416-9877 are available
(2) Kits are available with 3, 5, or 7 water control valve groups.
    Show/hide table
    Illustration 99g03682220

  1. Locate water control valve group (1). Loosen bolts (B) on one split flange (A). Remove the other split flange (not shown).

    Note: Make sure that valve group O-ring seal (C) is in place.

    Show/hide table
    Illustration 100g03682222
    Show/hide table
    Illustration 101g03682224

  2. Install water control valve group (1) on spray bar (D). Reinstall split flanges (A). Do not tighten the mounting bolts.
    Show/hide table
    Illustration 102g03697517
    (E) 152 mm (6 inch)
    Show/hide table
    Illustration 103g03682226

  3. Rotate water control valve group (1) on spray bar (D) in order to obtain the desired direction for water spray. Tighten the mounting bolts on both flanges to a torque of 55 ± 10 N·m (41 ± 7 lb ft).

    Note: Orient the spray heads as shown with each spray head angled 20 degrees away from the center line. Refer to the reference marks on the bottom of the stainless steel spray heads.

    Show/hide table
    Illustration 104g03682227

  4. Repeat the previous steps for the remaining spray heads on the rear spray bar.
    Show/hide table
    Illustration 105g03682228

  5. Install water control valve group (1) on front spray bar (F). Reinstall split flanges (A). Do not tighten the mounting bolts.

    Note: Two spray heads can be installed on the front of the truck. The spray head on the left side of the truck is shown above.

  6. Rotate water control valve group (1) on spray bar (F) in order to obtain the desired direction for water spray. Tighten the mounting bolts.

  7. Repeat the previous steps for the remaining spray head on the opposite side of the water tank.

Chassis Harness Installation

Chassis Harness Assembly Routing

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Table 46
Required Parts
Group Number 431-9358 Chassis Wiring Gp (Rev. 01) 
Item  Qty  Part Number  Part Description 
1  1  435-9656  Chassis Harness As 
    Show/hide table
    Illustration 106g03682258

  1. Connect the fan power wire "H-C4" from chassis harness assembly (1) to contact (A) on the fan motor. Connect the fan ground wire "H-C3" to contact (B).
    Show/hide table
    Illustration 107g03682259

  2. Locate the portion of chassis harness assembly (1) that connects to the WDS hydraulic tank. Route this wiring to the front of the hydraulic tank.

  3. Connect the temperature sensor wire to the temperature sensor connector (C).

  4. Connect the tank level sensor wire to tank level sensor connector (D).

    Note: Proper connections of the temperature sensor and level sensor wiring is of critical importance.

    Show/hide table
    Illustration 108g03682260
    Show/hide table
    Illustration 109g03682261

  5. Route chassis harness assembly (1) along the rear of the air cooler to the right side of the operator cab.

  6. Plug the "H-C1" connector of chassis harness assembly (1) into the receptacle (E) on the bulkhead plate of the operator cab.
    Show/hide table
    Illustration 110g03682262

  7. Route chassis harness assembly (1) under the operator cab and through the engine compartment. Route the harness assembly along the truck chassis and down to the right frame rail.
    Show/hide table
    Illustration 111g03682264

  8. Plug the "H-C2" connector of chassis harness assembly (1) into the solenoid connector (F) on the WDS pump.
    Show/hide table
    Illustration 112g03682265

  9. Route the "H-C5" connector of chassis harness assembly (1) over the right frame rail to the oil filter. Plug the connector into the bypass switch connector (G) on the oil filter.

  10. Route the remainder of chassis harness assembly (1) along the right frame rail to the rear of the machine.
    Show/hide table
    Illustration 113g03682266

  11. Locate the portion of chassis harness assembly (1) that connects to the machine hoist valve. Route this cable down the right frame rail. Plug the "H-C7" connector into the hoist raise solenoid (H). Plug the "H-C8" connector into the hoist lower solenoid (J).
    Show/hide table
    Illustration 114g03682268

  12. Route the remainder of chassis harness assembly (1) along the right frame rail to the rear frame rail (K).

Install Clips on Harness Assembly

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Table 47
Required Parts
Group Number 431-9358 Chassis Wiring Gp 
Item  Qty  Part Number  Part Description 
2  7  4P-8134  Clips 
3  7  8T-4121  Hard Washers 
4  7  8T-4136  Bolts 
    Show/hide table
    Illustration 115g03682292
    Show/hide table
    Illustration 116g03682293

  1. Install clips (2) on the right frame rail. Fasten the clips to the machine frame with bolts (4) and hard washers (3).

Install Clips on Harness Assembly

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Table 48
Required Parts
Group Number 431-9358 Chassis Wiring Gp 
Item  Qty  Part Number  Part Description 
2  1  4P-8134  Clip 
3  1  8T-4121  Hard Washer 
4  1  8T-4136  Bolt 
    Show/hide table
    Illustration 117g03682295
    Show/hide table
    Illustration 118g03682296

  1. Install clip (2) on the rear frame rail. Fasten the clip to the machine frame with bolt (4) and hard washer (3).

Install Clips on Harness Assembly

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Table 49
Required Parts
Group Number 431-9358 Chassis Wiring Gp 
Item  Qty  Part Number  Part Description 
3  7  8T-4121  Hard Washers 
4  7  8T-4136  Bolts 
5  4  148-3495  Bracket As 
6  7  132-5789  Clips 
7  4  7X-0343  Bolts 
8  4  8T-4122  Hard Washers 
    Show/hide table
    Illustration 119g03682301
    Show/hide table
    Illustration 120g03682303
    Show/hide table
    Illustration 121g03682305

  1. Install bracket assemblies (5) on the rear of the air cooler. Fasten the bracket assemblies to the machine with bolts (7) and hard washers (8).

  2. Install clips (6) on each bracket assembly (5). Fasten the clips to the bracket assemblies with bolts (4) and hard washers (3).

  3. Install clips (6) on the rear of the air cooler. Fasten the clips to the machine with bolts (4) and hard washers (3).

Install Clips on Harness Assembly

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Table 50
Required Parts
Group Number 431-9358 Chassis Wiring Gp 
Item  Qty  Part Number  Part Description 
3  1  8T-4121  Hard Washer 
4  1  8T-4136  Bolt 
9  1  4P-7581  Clip 
10  1  130-5300  Clip 
    Show/hide table
    Illustration 122g03682324

  1. Install clip (9) on the right side of the engine compartment. Fasten the clip to the machine with bolt (4) and hard washer (3).

  2. Install clip (10) at shown in Illustration 122.

Install Clips on Harness Assembly

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Table 51
Required Parts
Group Number 431-9358 Chassis Wiring Gp 
Item  Qty  Part Number  Part Description 
11  14  200-6345  Mounts 
12  28  204-2281  Cable Straps 
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    Illustration 123g03682326
    Show/hide table
    Illustration 124g03682327

  1. Install mounts (11) on pump high-pressure hose (L). Fasten the mounts to the hose with cable straps (12).

  2. Fasten chassis harness assembly (1) to mounts (11) with cable straps (12).

Install Clips on Harness Assembly

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Table 52
Required Parts
Group Number 431-9358 Chassis Wiring Gp 
Item  Qty  Part Number  Part Description 
13  37  7K-1181  Cable Straps 
    Show/hide table
    Illustration 125g03682495

  1. Fasten chassis harness assembly (1) to clips (6) on the rear of the air cooler with cable straps (13).
    Show/hide table
    Illustration 126g03682498

  2. Fasten chassis harness assembly (1) to the right frame rail with cable straps (13).

Install Bracket

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Table 53
Required Parts
Group Number 431-9363 Electrical Installation Gp (Rev. 01) 
Item  Qty  Part Number  Part Description 
1  1  201-1024  Bracket 
2  1  8T-4121  Hard Washer 
3  1  8T-4137  Bolt 
4  1  4P-8134  Clip 
5  1  7K-1181  Cable Strap 
    Show/hide table
    Illustration 127g03682505
    Show/hide table
    Illustration 128g03682506

  1. Install bracket (1) and clip (4) on the rear frame rail with bolt (3) and hard washer (2).
    Show/hide table
    Illustration 129g03682510

  2. Connect the "H-C6" connector (B) of harness assembly (C) to bracket (1).

  3. Fasten the "H-C11" connector (A) of harness assembly (C) to clip (4) with cable strap (5).

Install Bracket

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Table 54
Required Parts
Group Number 431-9363 Electrical Installation Gp (Rev. 01) 
Item  Qty  Part Number  Part Description 
6  1  335-5321  Pressure Sensor Gp 
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    Illustration 130g03682519

  1. Remove plug and install pressure sensor group (6) on the motor inlet pressure tap.

Rear Hydraulic Manifold Installation

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Table 55
Required Parts
Group Number 382-7808 Control Manifold and Lines Gp (Rev. 02) 
Item  Qty  Part Number  Part Description 
(1)(1)  1  354-0304  Control Manifold Gp 
(2)(1)  5  354-2266  Control Manifold Gp 
(3)(1)  3  7U-4417  Rod 
(4)(1)  3  8T-4205  Hard Washer 
(5)(1)  3  6V-8185  Nut 
(6)(2)  10  6V-8647  Connector 
(7)(2)  10  3J-7354  O-Ring Seal 
(8)(2)  20  4J-5477  O-Ring Seal 
(9)(3)  1  122-6867  Hose 
(10)(2)  10  124-2111  Permanent Coupling 
(11)(2)  10  124-2140  Permanent Coupling 
(12)(2)  10  6V-1889  Clip 
(13)(2)  10  3J-1907  O-Ring Seal 
(14)(2)  10  6V-8627  Elbow 
(15)(4)  2  6V-8636  Connector 
(16)(4)  2  3J-1907  O-Ring Seal 
(17)(4)  2  6V-9836  Swivel Tee 
(18)(4)  6  6V-8397  O-Ring Seal 
(19)(4)  2  6V-9829  Cap As 
(20)(3)  1  122-6869  Hydraulic Hose 
(21)(4)  4  124-2114  Coupling 
(22)(4)  4  5K-5338  Clip 
(23)(4)  4  8T-4191  Bolt 
(24)(4)  4  8T-4121  Hard Washer 
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(1) These components come pre-assembled.
(2) These components are included with 354-7577 Hydraulic Oil Lines Gp. Each lines group contains components to connect one spray head.
(3) This component must be provided by the customer.
(4) These components are included with 372-1178 Pilot Lines Gp

Note: Parts listed above are for the installation of five spray heads. Depending on the configuration of the water delivery system, a different number of spray heads may be connected to the rear hydraulic manifold.

    Show/hide table
    Illustration 131g03682523
    Rear Hydraulic Manifold (C)
    Show/hide table
    Illustration 132g03682527

  1. Mount rear hydraulic manifold (C) on the rear of the water tank.

    Note: Mounting bosses must be provided with the tank. Refer to Tank Requirements Guide, REHS7098.

    Note: Many water tanks include a protective lining on the interior of the tank that can be damaged by welding directly onto the tank.

    Show/hide table
    Illustration 133g03682531
    (A) Spray head open port
    (B) Spray head close port

  2. Locate connector (6) for the spray head pressure lines. Install O-ring seal (7) on each adapter.

  3. Install connector (6) in rod pressure port (A) and head pressure port (B) of each spray valve on the rear spray bar. Install O-ring seal (8) in each adapter.

    Note: "A" and "B" labels are on the cylinder.

    Note: Port (A) of each spray valve opens the spray valve. Port (B) of each spray valve closes the spray valve.

    Note: The spray heads on the rear spray bar are numbered #2 through #5 from left to right. An optional center-mounted rear spray head will be numbered #6 when installed.

    Show/hide table
    Illustration 134g03682532

  4. Measure length of bulk hose (9) from each spray head to the rear hydraulic manifold. Cut the hose to length and create hose assembly with permanent coupling (10) on one end and permanent coupling (11) on the other end.

    Note: Label hoses with the spray head number, and "A" or "B" for open/close head.

    Note: Ensure that each hose has adequate length in order to accommodate routing the hose across the water tank and strapping the hose in place.

    Note: Connect the end of each hose assembly with permanent coupling (10) to the spray head. Route the end of each hose assembly with permanent coupling (11) to the rear hydraulic manifold.

  5. Install one end of each line in the rod pressure fitting and the head pressure fitting of each spray valve with permanent coupling (10).

  6. Clamp the spray head hoses to water tank with clips (12).
    Show/hide table
    Illustration 135g03682536

  7. Install elbow (14) with O-ring seal (13) in each side of control manifold group (2). Repeat this step for both sides of all the manifolds.
    Show/hide table
    Illustration 136g03682537
    (A) Spray head - open "A"port
    (B) Spray head - close "B"port
    Show/hide table
    Illustration 137g03682538
    Reference Labels On Hydraulic Manifold
    (D) Spray valve "5A"
    (E) Spray valve "4A"
    (F) Spray valve "6A"
    (G) Spray valve "3A"
    (H) Spray valve "2A"
    (J) Spray valve "5B"
    (K) Spray valve "4B"
    (L) Spray valve "6"B
    (M) Spray valve "3B"
    (N) Spray valve "2B"
    Show/hide table
    Illustration 138g03682539
    (P) Spray head "2"
    (Q) Spray head "3"
    (R) Spray head "6"
    (S) Spray head "4"
    (T) Spray head "5"

  8. Connect the hose from each spray valve to the corresponding fitting on the rear hydraulic manifold with O-ring seal (8). Configure the connections as shown:

    • Spray valve "5A" (D) - open (B) line of #5 spray head (T)

    • Spray valve "4A" (E) - open (B) line of #4 spray head (S)

    • Spray valve "6A" (F) - open (B) line of #6 spray head (R)

    • Spray valve "3A" (G) - open (B) line of #3 spray head (Q)

    • Spray valve "2A" (H) - open (B) line of #2 spray head (P)

    • Spray valve "5B" (J) - close (C) line of #5 spray head (T)

    • Spray valve "4B" (K) - close (C) line of #4 spray head (S)

    • Spray valve "6B" (L) - close (C) line of #6 spray head (R)

    • Spray valve "3B" (M) - close (C) line of #3 spray head (Q)

    • Spray valve "2B" (N) - close (C) line of #2 spray head (P)
    Show/hide table
    Illustration 139g03682541
    ( U) Spray head pilot return port (black)
    (V) Spray head pilot supply port (brown)

  9. Install connector (15) with O-ring seal (16) in spray head pilot return port (U) of rear hydraulic manifold (A).

  10. Install connector (15) with O-ring seal (16) in spray head pilot supply port (V) of rear hydraulic manifold (A).

  11. Connect one swivel tee (17) with O-ring seal (18) to each adapter (16).

  12. Connect one cap assembly (19) with O-ring seal (18) to each tee adapter (17).

  13. Measure two lengths of bulk hose (20) from rear manifold group (1) to the plate assembly on the rear of the truck. Cut the hoses to length and create two hose assemblies with coupling (21) on each end.

    Note: Ensure that each hose has adequate length in order to accommodate routing the hose and strapping the hose in place.

    Note: Ensure that each hose has adequate length in order to accommodate lifting and lowering of the water tank.

    Note: Clearly mark each end of both hoses for identification purposes, using color codes provided for mating components.

  14. Connect one end of each hose assembly to the tee adapter at the bottom of the rear hydraulic manifold.
    Show/hide table
    Illustration 140g03682545
    (W) Spray head pilot return fitting (black)
    (X) Spray head pilot supply fitting (brown)

  15. Route the black hose from spray head pilot return port (U) to spray head pilot return fitting (W) in the plate assembly. Connect the hose assembly to port with O-ring seal (18).

  16. Route the brown hose from spray head pilot supply port (V) to spray head pilot return fitting (X) in the plate assembly. Connect the hose assembly to port with O-ring seal (18).
    Show/hide table
    Illustration 141g03682546

  17. Clamp the spray head pilot hoses to water tank with clips (22). Secure the clips in place with bolts (23) and hard washers (24).

Rear Harness Assembly Installation

Install Rear Hydraulics Control Group Mounting Plate

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Table 56
Required Parts
Group Number 431-9360 Control Wiring Gp (Rev. 01) 
Item  Qty  Part Number  Part Description 
1  1  357-7152  Plate As 
2  4  7X-7729  Washers 
3  4  8T-4195  Bolts 
    Show/hide table
    Illustration 142g03682647

  1. Mount plate assembly (1) to the rear of the water tank.

    Note: Mounting bosses must be provided with the tank. Reference the Special Instruction, REHS7098, "Tank Requirements Guide".

  2. Fasten plate assembly (1) in place with four bolts (3) and four washers (2).

Install Rear Electrical Control Group

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Table 57
Required Parts
Group Number 431-9360 Control Wiring Gp (Rev. 01) 
Item  Qty  Part Number  Part Description 
4  1  423-1574  Control Box Gp 
5  4  242-2961  Spacers 
6  4  8T-8908  Bolts 
7  4  5P-0537  Hard Washers 
    Show/hide table
    Illustration 143g03682650
    Show/hide table
    Illustration 144g03682652
    Show/hide table
    Illustration 145g03682654

  1. Mount control group (4) to plate assembly (1), with the connectors pointing down.

  2. Insert spacers (5) between control group (4) and plate assembly (1).

  3. Fasten control group (4) to plate assembly (1) with four bolts (6) and four hard washers (7).

Connect Rear Control Harness Assembly

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Table 58
Required Parts
Group Number 431-9360 Control Wiring Gp (Rev. 01) 
Item  Qty  Part Number  Part Description 
8  1  435-9653  Chassis Harness As 
    Show/hide table
    Illustration 146g03682664

  1. Connect the "R-C1" connector of chassis harness assembly (8) to control group (4).
    Show/hide table
    Illustration 147g03682667
    Reference Labels on Hydraulic Manifold
    (A) Spray valve "5A"
    (B) Spray valve "4A"
    (C) Spray valve "6A"
    (D) Spray valve "3A"
    (E) Spray valve "2A"
    (F) Spray valve "5B"
    (G) Spray valve "4B"
    (H) Spray valve "6B"
    (J) Spray valve "3B"
    (K) Spray valve "2B"

  2. Locate the hydraulic manifold portion of chassis harness assembly (8). This portion of the harness assembly can be identified by eight connectors at the end. Route this portion of the harness to the rear hydraulic manifold.

  3. Connect chassis harness assembly (8) to the rear hydraulic manifold as shown:

    • Spray valve "5A" (A) - J750-OR(Orange)wire "R-C10"

    • Spray valve "4A" (B) - L944-GY(Grey)wire "R-C8"

    • Spray valve "6A" (C) - L937-OR(Orange)wire "R-C14"

    • Spray valve "3A" (D) - J747-BU(Blue)wire "R-C5"

    • Spray valve "2A" (E) - L949-BU(Blue)wire "R-C7"

    • Spray valve "5B" (F) - J751-GN(Green)wire "R-C11"

    • Spray valve "4B" (G) - L947-BR(Brown)wire "R-C9"

    • Spray valve "6B" (H) - L942-GN(Green)wire "R-C13"

    • Spray valve "3B" (J) - J748-PK(Pink)wire "R-C4"

    • Spray valve "2B" (K) - L951-GN(Green)wire "R-C6"
    Show/hide table
    Illustration 148g03682682

  4. Connect the "R-C12" connector of chassis harness assembly (8) to pressure sensor group (L) on the motor inlet pressure tap.
    Show/hide table
    Illustration 149g03682684

  5. Connect the "R-C2" connector of chassis harness assembly (8) to pressure sensor group (M) on the rear spray bar.
    Show/hide table
    Illustration 150g03682687
    Show/hide table
    Illustration 151g03682690

  6. Route the tank level sensor wires of chassis harness assembly (8) along the bottom of the water tank.

    Note: This portion of the harness assembly will be connected after the tank level sensor is installed.

Install Tank Level Sensor

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Table 59
Required Parts
Group Number 431-9360 Control Wiring Gp (Rev. 01) 
Item  Qty  Part Number  Part Description 
9  1  7J-8611  Pipe Elbow 
10  1  355-9448  Pressure Sensor 
11  2  4P-8134  Clips 
12  2  8T-4136  Bolts 
13  2  8T-4121  Hard Washers 
    Show/hide table
    Illustration 152g03682708

  1. Install pipe elbow (9) in the front of the water tank. Connect pressure sensor (10) to the elbow in the front of the water tank.

    Note: The location of the water tank level sensor may vary based on tank manufacturing design.

  2. Connect chassis harness assembly (8) to pressure sensor (10).

  3. Install two clips (11) on the front of the water tank. Fasten the clips to the tank with bolts (12) and hard washers (13).

Install Straps Along Harness Assembly

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Table 60
Required Parts
Group Number 431-9360 Control Wiring Gp (Rev. 01) 
Item  Qty  Part Number  Part Description 
12  5  8T-4136  Bolts 
13  5  8T-4121  Hard Washers 
14  1  310-1898  Clip 
15  4  4P-7581  Clips 
    Show/hide table
    Illustration 153g03682719

  1. Attach clips (15) to the rear of water tank with bolts (12) and hard washers (13).
    Show/hide table
    Illustration 154g03682721

  2. Attach clip (14) to the rear of water tank with bolt (12) and hard washer (13).

Install Straps Along Harness Assembly

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Table 61
Required Parts
Group Number 431-9360 Control Wiring Gp (Rev. 01) 
Item  Qty  Part Number  Part Description 
11  8  4P-8134  Clips 
12  8  8T-4136  Bolts 
13  8  8T-4121  Hard Washers 
    Show/hide table
    Illustration 155g03682766

  1. Attach clips (11) to the rear spray bar with bolts (12) and hard washers (13).

Install Straps Along Harness Assembly

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Table 62
Required Parts
Group Number 431-9360 Control Wiring Gp (Rev. 01) 
Item  Qty  Part Number  Part Description 
16  15  7K-1181  Cable Straps 
    Show/hide table
    Illustration 156g03682771

  1. Tie chassis harness assembly (8) to the rear of the water tank with cable straps (16).

  2. Tie chassis harness assembly (8) to the rear spray bar with cable straps (16).
    Show/hide table
    Illustration 157g03682773

  3. Tie chassis harness assembly (8) to the front of the water tank with cable straps (16).

Front Hydraulic Manifold Installation

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Table 63
Required Parts
Group Number 382-7797 Control Manifold and Lines Gp (Rev. 01) 
Item  Qty  Part Number  Part Description 
(1)(1)  3  7X-0268  Bolt 
(2)(1)  3  8T-4205  Hard Washer 
(3)(2)  4  6V-8627  Elbow 
(4)(2)  4  6V-8647  Connector 
(5)(2)  8  8T-4136  Bolt 
(6)(2)  2  6V-9828  Cap 
(7)(2)  8  4D-6466  Clip 
(8)(2)  4  124-2111  Permanent Coupling 
(9)(2)  4  124-2140  Permanent Coupling 
(10)(2)  4  3J-1907  O-Ring Seal 
(11)(2)  4  3J-7354  O-Ring Seal 
(12)(2)  8  4J-5477  O-Ring Seal 
(13)(2)  8  8T-4121  Hard Washer 
(14)(1)  2  354-2266  Control Manifold Gp 
(15)(1)  1  354-7580  Control Manifold and Lines Gp 
(16)(1)  4  2H-3755  Bolt 
(17)(1)  4  5M-3062  Bolt 
(18)  4  8T-4191  Bolt 
(19)  4  8T-4121  Hard Washer 
(20)(3)  1  6V-9850  Elbow 
(21)(3)  1  6V-8724  Elbow 
(22)(3)  1  8T-9041  Connector 
(23)(3)  13  7E-7606  Bolt 
(24)(3)  13  5K-5338  Clip 
(25)(3)  4  124-2114  Coupling 
(26)(3)  2  3J-1907  O-Ring Seal 
(27)(3)  3  6V-8397  O-Ring Seal 
(28)(3)  13  8T-4121  Hard Washer 
(29)(4)  1  122-6869  Hydraulic Hose 
(30)(4)  1  122-6867  Hydraulic Hose 
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(1) These components come pre-assembled.
(2) These components are included with 354-7577 Hydraulic Oil Lines Gp
(3) These components are included with 354-6906 Pilot Lines Gp
(4) This component must be provided by the customer.
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    Illustration 158g03682778
    Front hydraulic manifold (A)
    Show/hide table
    Illustration 159g03682781

  1. Mount front hydraulic manifold (A) on the front of the water tank with bolts (18) and hard washers (19).

    Note: Mounting bosses must be provided with the tank. Reference the Special Instruction, REHS7098, "Tank Requirements Guide".

    Note: Many water tanks include a protective lining on the interior of the tank that can be damaged by welding directly onto the tank.

    Show/hide table
    Illustration 160g03682782
    (B) Spray head pilot supply port (brown)
    (C) Spray head pilot return port (black)

  2. Connect connector (22) with O-ring seal (26) to spray head pilot supply port (B).

  3. Connect elbow (20) with O-ring seal (27) to connector (22).

  4. Connect elbow (21) with O-ring seal (26) to spray head pilot return port (C).

  5. Measure two lengths of hydraulic hose (29) from the front hydraulic manifold down to the bottom of the water tank. Continue measuring bulk hose across the bottom of the water tank to the plate assembly on the back of the truck. Cut each hose to length and create two hose assemblies with couplings (25) on each end.

    Note: Clearly mark each end of both hoses for identification purposes using color codes provided for mating components.

  6. Connect the brown hose assembly to elbow (20) in spray head pilot supply port (B) with O-ring seal (27).

  7. Connect the black hose assembly to elbow (21) in spray head pilot return port (C) with O-ring seal (27).
    Show/hide table
    Illustration 161g03682783

  8. Route the hose assemblies down the front of the water tank. Clamp the hoses to the water tank with the following: Clips (24), bolts (23) and hard washers (28).
    Show/hide table
    Illustration 162g03682784

  9. Route the hose assemblies under the water tank to the back of the truck. Clamp the hoses to the water tank with the following: Clips (24), bolts (23) and hard washers (28).
    Show/hide table
    Illustration 163g03682787
    (D) Spray head pilot return port (black)
    (E) Spray head pilot supply port (brown)
    Show/hide table
    Illustration 164g03682788
    Alternate connection locations on plate assembly
    (D) Spray head pilot return fitting
    (E) Spray head pilot supply fitting

    Note: Pilot supply and pilot return hose assemblies can be connected to the plate assembly or the rear hydraulic manifold.

  10. Connect the brown hose assembly from spray head pilot supply coupling (B) to spray head pilot supply fitting (E) with O-ring seal (11).

  11. Connect the black hose assembly from spray head pilot return coupling (C) to spray head pilot return fitting (D) with O-ring seal (11).
    Show/hide table
    Illustration 165g03682789
    (F) Spray head "7"
    Show/hide table
    Illustration 166g03682790
    (G) Spray head "1"

  12. Measure two lengths of hydraulic hose (30) from each spray head to front hydraulic manifold (A). Cut each hose to length and create four hose assemblies with permanent coupling (8) on one end and permanent coupling (9) on the other end.

    Note: Ensure that each hose has adequate length in order to accommodate routing the hose across the water tank and strapping the hose in place.

    Note: Connect the end of each hose assembly with the straight coupling to the spray head. Route the end of each hose assembly with the elbow coupling to the front hydraulic manifold.

    Note: Label hose ends "1A", "1B", "7A", and "7B" per labels on the hydraulic manifold and the spray heads.

    Show/hide table
    Illustration 167g03682791
    Spray head "7" (F)
    ( H) Spray head - close "B" port
    (J) Spray head - open "A" port

    Note: "A" and "B" labels are on the cylinder.

  13. Install connector (4) with O-ring seal (12) in spray head close port (H) and spray head open port (J) of spray valve "7" (F).
    Show/hide table
    Illustration 168g03682794
    Spray head "1" (G)
    ( K) Spray head - open "A" port
    (L) Spray head - close "B" port

  14. Install connector (4) with O-ring seal (12) in spray head close port (L) and spray head open port (K) of spray valve "1" (G).

  15. Connect the four hose assemblies to the spray heads. Connect the end of each hose assembly with straight permanent coupling (8) to connector (4) with O-ring seal (11).
    Show/hide table
    Illustration 169g03682795

  16. Install elbow (3) with O-ring seal (10) in each side of control manifold group (14). Repeat this step for both sides of both the manifolds.
    Show/hide table
    Illustration 170g03682797
    Reference labels on hydraulic manifold
    (M) Spray valve "7B" - close port
    (N) Spray valve "1B" - close port
    (P) Spray valve "7A" - open port
    (Q) Spray valve "1A" - open port

  17. Connect the hose from each spray valve to the corresponding fitting on the front hydraulic manifold with O-ring seal (12). Configure the connections as shown:

    • Spray valve "7B" (M) - close (H) line of #7 spray head (F)

    • Spray valve "1B" (N) - close (L) line of #1 spray head (G)

    • Spray valve "7A" (P) - open (J) line of #7 spray head (F)

    • Spray valve "1A" (Q) - open (K) line of #1 spray head (G)

  18. Secure the hoses to the water tank with the following: Clips (7), bolts (5) and hard washers (13).

Cannon Group Installation

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Table 64
Required Parts
Group Number 422-5872 Water Cannon Gp (Rev. 02) 
Item  Qty  Part Number  Part Description 
1  1  355-8625  Water Cannon Gp 
2  1  421-7217  Film 
    Show/hide table
    Illustration 171g03682840
    Show/hide table
    Illustration 172g03682841
    Show/hide table
    Illustration 173g03682842
    Show/hide table
    Illustration 174g03682843

    Note: This safety message is located on the cannon.

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    ------ WARNING! ------

    The spray of high-pressure water can break the operator station windows and could result in injury or death. Install the water cannon rotation stop to prevent the spray of high-pressure water at the operator station.

  1. Verify safety label (A) is properly installed on water cannon (1).

    Note: There are several specific safety messages on this machine. The exact location of the hazards and the description of the hazards are reviewed in this section. Become familiarized with all safety messages.

    Note: Make sure that all of the safety messages are legible. Clean the safety messages or replace the safety messages if the words or the images become unreadable. When you clean the safety messages, use a cloth, water, and soap. Do not use solvent, gasoline, or other harsh chemicals to clean the safety messages. Solvents, gasoline, or harsh chemicals could loosen the adhesive that secures the safety message. Loose adhesive will allow the safety message to separate from the machine.

    Note: Replace any safety message that is damaged, or missing. If a safety message is attached to a part that is replaced, install a safety message on the replacement part. Any Cat® dealer can provide new safety messages.

    Show/hide table
    Illustration 175g03682845

  2. Verify the position of rotation and elevation stops (B) for the water cannon turret.

    Note: The rotation and elevation stops set the boundaries for the area in which the cannon is allowed to travel.

    Note: The cannon is shipped with rotation stops at 90° right and at 90° left. All other positions are achieved by switching the factory set stop and the plug in the desired stop location. Both stops (B) and plugs (C) and (D). have a one and a half inch hex head.

    Note: Plug (D) in the illustration is in the front of the cannon.

  3. Install butterfly valve (H) on the tank connection.

    Note: Butterfly valve must be provided by the customer. This component is not included with the WDS kit.

  4. Assemble water cannon (1) to the flange mount on the butterfly valve. The front of the cannon should be 45° to right of center line (E). The cannon is shipped with the first stop assembled at 90°. The cannon cannot rotate past the 90° stop and will not point at the cab.

    Note: Mounting hardware must be provided by the customer.

    Note: If the cannon is mounted in a different location, evaluate the safety of the cannon stops. Ensure that the stops will not allow the cannon to point at the cab.

Water Cannon Hydraulic Lines Routing

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Table 65
Required Parts
Group Number 355-8914 Hydraulic Oil Lines Gp (Rev. 01) 
Item  Qty  Part Number  Part Description 
1  4  3J-1907  O-Ring Seals 
2  4  6V-8641  Connector 
3  2  124-2140  Permanent Coupling 
4  10  124-2111  Permanent Coupling 
5  12  4J-5477  O-Ring Seals 
6  2  7X-5331  Elbows 
7  6  3J-7354  O-Ring Seals 
8  2  6V-8628  Elbows 
9  4  6V-8647  Connectors 
10  2  5P-4325  Clips 
11(1)  1  122-6867  Hydraulic Hose 
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(1) This component must be provided by the customer.
    Show/hide table
    Illustration 176g03682868

  1. Measure four lengths of bulk hose (11) from water cannon (B) to front manifold group (D). Cut the hoses to length.

    Note: Ensure that each hose has adequate length in order to accommodate routing the hose across the water tank and strapping the hose in place.

    Note: Ensure that each hose has adequate length in order to accommodate movement of the water cannon.

  2. Create four hose assemblies for the water cannon as follows:

    • "DOWN" hose - install one coupling (4) on one end and install one coupling (3) on the other end

    • "UP" hose - install one coupling (4) on one end and install one coupling (3) on the other end

    • "LT" hose - install one coupling (4) on one end and install one coupling (3) on the other end

    • "RT" hose - install one coupling (4) on one end and install one coupling (3) on the other end.

    Note: Label both ends of all hoses per reference labels on the manifold before connecting.

  3. Measure two lengths of bulk hose from cannon shut off valve (C) to front manifold group (D). Cut the hoses to length.

  4. Create two hose assemblies for the cannon shut-off valve as follows:

    • "ON" hose - install one coupling (4) on each end of this hose

    • "OFF" hose - install one coupling (4) on each end of this hose.

    Note: Label both ends of all hoses before connecting.

    Show/hide table
    Illustration 177g03682869

  5. Locate cannon operation fittings on the water cannon. The fittings are identified as follows:

    • "DOWN" fitting (F)

    • " UP" fitting (E)

    • " LT" fitting (G)

    • " RT" fitting (H)

  6. Install adapter (2) with O-ring seal (1) in each fitting.

  7. Connect the end of the "DOWN" hose with elbow coupling (3) to "DOWN" fitting (F) with O-ring seal (5).

  8. Connect the end of the "UP" hose with elbow coupling (3) to "UP" fitting (E) with seal (5).

  9. Connect the end of the "LT" hose with straight coupling (7) to "LT" fitting (G) with seal (5).

  10. Connect the end of the "RT" hose with straight coupling (7) to "RT" fitting (H) with seal (5).

  11. Route the four hoses from water cannon (B) to front manifold group (D).

  12. Locate cannon operation fittings on the front hydraulic manifold. The hydraulic ports are labeled as follows:

    • "DOWN" (J)

    • " UP" (K)

    • " LT" (L)

    • " RT" (M).

    Note: Reference the markings stamped on the manifold.

  13. Install adapter (9) and O-ring seal (7) in each of the four ports.

  14. Connect the end of the "DOWN" hose with straight coupling (4) to "DOWN" fitting (J) with seal (5).

  15. Connect the end of the "UP" hose with straight coupling (4) to "UP" fitting (K) with seal (5).

  16. Connect the end of the "LT" hose with straight coupling (4) to "LT" fitting (L) with seal (5).

  17. Connect the end of the "RT" hose with straight coupling (4) to "RT" fitting (M) with seal (5).
    Show/hide table
    Illustration 178g03682904

  18. Locate the hydraulic fittings on the butterfly valve. The fittings are identified as follows:

    • "OFF" (N) - rod end of the hydraulic cylinder

    • "ON" (P) - head end of the hydraulic cylinder.

  19. Install elbow (6) in each of the fittings on the butterfly valve.

    Note: Customer supplied valve may contain pre-installed fittings. Replace pre-installed fittings with elbows (6) provided

  20. Connect the "OFF" hose to the "OFF" fitting (N) O-ring seal (5).

  21. Connect the "ON" hose to the "ON" fitting (P) with O-ring seal (5).

  22. Route the two hoses from shut-off valve (C) to front manifold group (D).
    Show/hide table
    Illustration 179g03682906

  23. Locate shut-off valve fittings on the front hydraulic manifold. The hydraulic ports are labeled as follows:

    • "OFF" (R)

    • " ON" (Q).

  24. Install adapter (8) with O-ring seal (7) in both of these ports.

  25. Connect the "OFF" hose to the "OFF" fitting (R) O-ring seal (5).

  26. Connect the "ON" hose to the "ON" fitting (Q) with O-ring seal (5).
    Show/hide table
    Illustration 180g03682907

  27. Fasten the shut-off valve hoses and the cannon operation hoses to water tank with clips (10).

Front Harness Assembly Installation

Install Front Electrical Control Group Mounting Plate

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Table 66
Required Parts
Group Number 431-9359 Control Wiring Gp (Rev. 01) 
Item  Qty  Part Number  Part Description 
1  1  357-7152  Plate As 
2  4  7X-7729  Washers 
3  4  8T-4195  Bolts 
    Show/hide table
    Illustration 181g03682925

    Note: Mounting bosses must be provided with the tank. Reference the Special Instruction, REHS7098, "Tank Requirements Guide".

  1. Mount plate assembly (1) to the front of the water tank.

  2. Fasten plate assembly (1) in place with four bolts (3) and four washers (2).

Install Front Hydraulics Control Group

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Table 67
Required Parts
Group Number 431-9359 Control Wiring Gp (Rev. 01) 
Item  Qty  Part Number  Part Description 
4  1  423-1575  Control Box Gp 
5  4  5P-0537  Hard Washers 
6  4  7X-2501  Bolts 
7  1  310-1898  Clip 
8  4  242-2961  Spacers 
    Show/hide table
    Illustration 182g03682927
    Show/hide table
    Illustration 183g03682928
    Show/hide table
    Illustration 184g03682930

  1. Mount control group (4) to plate assembly (1), with the connectors pointing down.

  2. Insert spacers (8) between control group (4) and plate assembly (1).

  3. Install clip (7) on the bottom right corner of the control group (4).

  4. Fasten control group (4) to plate assembly (1) with four bolts (6) and four washers (5).

Install Straps Along Harness Assembly

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Table 68
Required Parts
Group Number 431-9359 Control Wiring Gp (Rev. 01) 
Item  Qty  Part Number  Part Description 
7  1  310-1898  Clip 
9  1  8T-4121  Hard Washer 
10  1  8T-4136  Bolt 
    Show/hide table
    Illustration 185g03682931

  1. Install clip (7) on the bottom of the front hydraulic manifold with bolts (10) and washers (9).

Connect Front Control Harness Assembly

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Table 69
Required Parts
Group Number 431-9359 Control Wiring Gp (Rev. 01) 
Item  Qty  Part Number  Part Description 
11  1  426-1523  Sensor Harness As 
12  1  7K-1181  Cable Straps 
    Show/hide table
    Illustration 186g03682934
    Show/hide table
    Illustration 187g03682935
    Reference labels on hydraulic manifold
    (A) Spray valve "7B" - close port
    (B) Spray valve "1B" - close port
    (C) Cannon "RIGHT"
    (D) Cannon "UP"
    (E) Cannon "DOWN"
    (F) Spray valve "7A" - open port
    (G) Spray valve "1A" - open port
    (H) Cannon "LEFT"
    (J) Cannon shutoff valve

  1. Connect sensor harness assembly (11) to control group (4).

  2. Locate the hydraulic manifold portion of sensor harness assembly (11). This portion of the harness assembly can be identified by nine connectors at the end. Route this portion of the harness to the front hydraulic manifold.

  3. Connect sensor harness assembly (11) to the front hydraulic manifold as shown:

    • Spray valve "7B" (A) - J741-GY(Grey)wire "F-C11"

    • Spray valve "1B" (B) - J739-GN(Green)wire "F-C9"

    • Cannon "RIGHT" (C) - J736-OR(Orange)wire "F-C6"

    • Cannon "UP" (D) - J729-GN(Green)wire "F-C4"

    • Cannon "DOWN" (E) - J730-BU(Blue)wire "F-C3"

    • Spray valve "7A" (F) - J742-BR(Brown)wire "F-C10"

    • Spray valve "1A" (G) - J738-BU(Blue)wire "F-C5"

    • Cannon "LEFT" (H) - J735-PU(Purple)wire "F-C7"

    • Cannon Shutoff Valve (J) - T805-GY(Grey)wire "F-C8"

  4. Attach sensor harness assembly (11) to clip (7) with cable strap (12).
    Show/hide table
    Illustration 188g03682940

  5. Connect sensor harness assembly (11) to the cannon nozzle motor.

    Note: This step is only required for electrical pattern control nozzle. For fixed pattern and manual pattern control nozzles, the cannon nozzle motor (volute wires) of the front harness should be terminated.

  6. Connect communication cable (K) to control group (5).

    Note: This harness was installed and routed with the rear control harness assembly.

Install Communication Harness

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Table 70
Required Parts
Group Number 431-9359 Control Wiring Gp (Rev. 01) 
Item  Qty  Part Number  Part Description 
12  1  7K-1181  Cable Straps 
13  1  435-9660  Control Harness As 
    Show/hide table
    Illustration 189g03682941

  1. Connect control harness assembly (13) to connector (K) on bottom of control group (4).

  2. Fasten control harness assembly (13) to the clip below control group (4) with cable strap (12).
    Show/hide table
    Illustration 190g03682944

  3. Route control harness assembly (13) along the bottom of the water tank to the rear of the truck.

    Note: This cable should be installed along the same route as the tank level sensor wire of the rear control harness assembly.

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    Illustration 191g03682945

  4. Connect the "RM-C4" portion of control harness assembly (13) to the "H-C11" connector (L) of the chassis harness.

  5. Connect the "RM-C1" portion of control harness assembly (13) to the "H-C6" connector (M) of the chassis harness.
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    Illustration 192g03682946

  6. Route the remainder of control harness assembly (13) to the control group (N) on the rear of the water tank. Connect the cable to control group (4).

Install Communication Harness

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Table 71
Required Parts
Group Number 431-9359 Control Wiring Gp (Rev. 01) 
Item  Qty  Part Number  Part Description 
14  1  435-9831  Window Wiper Harness As 
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    Illustration 193g03682963

  1. Connect window wiper harness assembly (14) to control harness assembly (13).

  2. Connect window wiper harness assembly (14) to washer bottle. Refer to Special Instruction, REHS3673, "Generic Installation of the WAVS Cleaning System" for more details.

Install Communication Harness

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Table 72
Required Parts
Group Number 431-9359 Control Wiring Gp (Rev. 01) 
Item  Qty  Part Number  Part Description 
9  63  8T-4121  Hard Washers 
10  63  8T-4136  Bolts 
12  63  7K-1181  Cable Straps 
15  63  4P-8134  Clips 
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    Illustration 194g03682964
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    Illustration 195g03682965
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    Illustration 196g03682966
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    Illustration 197g03682968

  1. Install clips (15) on the front, bottom, and rear of the water tank. Fasten the clips in place with bolts (10) and hard washers (9).

  2. Tie the tank level sensor wire and the communication cable to the clips with cable straps (12).

Cab and Chassis Electrical Installation

Note: For retrofit kit installation only. Cab is pre-assembled with WDS components when WDS is ordered from Factory with machine as an attachment. Parts may not be included in the kit.

Cab Controls Installation

Assemble Bracket and Hardware in the Cab

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Table 73
Required Parts
Group Number 437-5096 Control Wiring Gp (Rev. 02) 
Item  Qty  Part Number  Part Description 
1  1  437-5073  Bracket As 
2  1  8T-4121  Hard Washer 
3  1  6V-6317  Bolt 
4  4  8T-4138  Bolts 
5  4  8T-4896  Hard Washers 
6  4  5M-3062  Bolts 
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    Illustration 198g03682971
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    Illustration 199g03682972

  1. Assemble the parts of bracket assembly (1) as shown with four bolts (4). Fasten the parts together with bolt (3) and hard washer (2).

  2. Install bracket assembly (1) on the right side of the operator console. Fasten the bracket assembly to the instrument panel with four bolts (6) and four hard washers (5).

    Note: Use two mounting holes shown by (A) for trucks S/N:DMC1-171. Only two bolts (6) and washers (5) will be used in this mounting pattern.

Assemble Control Group in the Cab

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Table 74
Required Parts
Group Number 437-5096 Control Wiring Gp (Rev. 02) 
Item  Qty  Part Number  Part Description 
7  1  355-9440  Joystick Control Gp 
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    Illustration 200g03682975

  1. Install joystick control group (7) in bracket assembly (1).

Assemble Control Group in the Cab

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Table 75
Required Parts
Group Number 437-5096 Control Wiring Gp (Rev. 02) 
Item  Qty  Part Number  Part Description 
4  4  8T-4138  Bolts 
8  1  437-5070  Cover Plate 
9  4  9X-8256  Washers 
10  1  6V-3987  Seal (Bulk) 
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    Illustration 201g03682979
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    Illustration 202g03682980

  1. Install cover plate (8) on the bottom of bracket assembly (1). Fasten the cover plate to the bracket with four bolts (4) and four washers (9).

  2. Install seal (10) to guard the three edges shown on Illustration 202.

Assemble Control Group in the Cab

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Table 76
Required Parts
Group Number 437-5096 Control Wiring Gp (Rev. 02) 
Item  Qty  Part Number  Part Description 
2  2  8T-4121  Hard Washers 
3  2  6V-6317  Bolts 
11  1  377-4675  Keypad Module Gp 
12  1  096-3872  Grommet 
13  1  143-0089  Grommet 
14  1  441-7013  Bracket 
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    Illustration 203g03682982
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    Illustration 204g03682984

  1. Fasten the keypad bracket and bracket (13) to bracket assembly (1) with two bolts (3) and two hard washers (2).

  2. Install grommet (13) in the keypad bracket.

  3. Install grommet (12) in the top of bracket assembly (1).

  4. Install keypad module group (11) in the top of the keypad bracket.

Assemble Mounting Group in the Cab

Assemble Mounting Group in the Cab

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Table 77
Required Parts
Group Number 437-5065 Control Wiring Gp (Rev. 02) 
Item  Qty  Part Number  Part Description 
1  1  261-3222  Display Mounting Gp 
2  4  8T-4138  Bolts 
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    Illustration 205g03683225
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    Illustration 206g03683227

  1. Install display mounting group (1) on the ceiling of the cab. Fasten the display mount to the ceiling with four bolts (2).

Assemble Mounting Group in the Cab

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Table 78
Required Parts
Group Number 437-5065 Control Wiring Gp (Rev. 02) 
Item  Qty  Part Number  Part Description 
3  1  451-2056  Plate As 
4  4  9X-8256  Washers 
2  4  8T-4138  Bolts 
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    Illustration 207g03683229

  1. Install plate assembly (3) on the display mounting group (1).

  2. Fasten the plate assembly to the display mounting group with four bolts (2) and four washers (4).

Assemble Cover Plate in the Cab

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Table 79
Required Parts
Group Number 437-5065 Control Wiring Gp (Rev. 02) 
Item  Qty  Part Number  Part Description 
5  1  451-2057  Plate 
6  4  366-0242  Control Group 
7  4  103-2006  Screws 
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    Illustration 208g03683231

  1. Install control group (6) in plate (5).

  2. Fasten the control group to the plate with four screws (7).

Assemble Cover Plate in the Cab

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Table 80
Required Parts
Group Number 437-5065 Control Wiring Gp (Rev. 02) 
Item  Qty  Part Number  Part Description 
2  4  8T-4138  Bolts 
8  4  2R-2376  Washers 
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    Illustration 209g03683233

  1. Install control group (6) and plate (5) in plate assembly (3).

  2. Fasten the plate to the plate assembly with four bolts (2) and four washers (8).

Assemble Plate Assembly to the Cab

Assemble Plate Assembly to the Cab

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Table 81
Required Parts
Group Number 431-9357 Cab Wiring Gp (Rev. 01) 
Item  Qty  Part Number  Part Description 
1  1  374-9696  Plate 
2  2  067-7897  Bolts 
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    Illustration 210g03683238

  1. Remove the mounting bolts from access panel (A) located on the rear of the cab. Remove the panel.
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    Illustration 211g03683239
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    Illustration 212g03683240

  2. Mount plate assembly (1) on the vertical plate inside the cab compartment. Fasten the plate assembly in place with two bolts (2).

Assemble Control Group to the Plate Assembly

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Table 82
Required Parts
Group Number 431-9357 Cab Wiring Gp (Rev. 01) 
Item  Qty  Part Number  Part Description 
3  1  379-4010  Plate As 
4  4  9S-8413  Retaining Washers 
5  8  8T-9655  Mounts 
6  1  304-5687  Electronic Control Module 
7  1  288-1401  Bracket 
8  1  324-8176  Bracket 
9  5  9N-0869  Hard Washers 
10  3  8T-4224  Hard Washers 
11  3  8T-6869  Bolts 
12  1  8T-6912  Bolt 
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    Illustration 213g03683242
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    Illustration 214g03683244

  1. Mount control group (6) on plate assembly (3).

  2. Insert two mounts (5) in each mounting hole of the control group (6).

  3. Install washers (4) between the control group (6) and the plate assembly (3) at each mounting hole.

  4. Install hard washers (9) on the control group (6) at each mounting hole.
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    Illustration 215g03683245
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    Illustration 216g03683247

  5. Fasten control group (6) to the plate assembly (3) with bolt (12).

  6. Install bracket (7) along the side of control group (6).

  7. Install bracket (8) over bracket (7) along the bottom of control group (6).

  8. Fasten the brackets to control group (6) and plate assembly (3) with three bolts (11) and three hard washers (10).

Assemble Insulators to the Plate Assembly

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Table 83
Required Parts
Group Number 431-9357 Cab Wiring Gp (Rev. 01) 
Item  Qty  Part Number  Part Description 
10  4  8T-4224  Hard Washers 
13  4  112-8242  Insulators 
14  4  8T-4908  Bolts 
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    Illustration 217g03683251

  1. Install four insulators (13) on the back of plate assembly (3).

  2. Fasten the insulators to the plate assembly with four bolts (14) and four hard washers (10).

Assemble Plate Assembly to the Cab

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Table 84
Required Parts
Group Number 431-9357 Cab Wiring Gp (Rev. 01) 
Item  Qty  Part Number  Part Description 
15  1  8T-4137  Bolt 
16  1  8T-4121  Hard Washer 
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    Illustration 218g03683252

  1. Install control group (6) and plate assembly (3) inside the cab compartment. Insert the insulators on the back of the control group into the slots on plate assembly (1).
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    Illustration 219g03683253

  2. Fasten plate assembly (3) to plate assembly (1) with bolt (15) and hard washer (16).

Assemble Clip and Hardware in the Cab

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Table 85
Required Parts
Group Number 431-9357 Cab Wiring Gp (Rev. 01) 
Item  Qty  Part Number  Part Description 
15  1  8T-4137  Bolt 
16  1  8T-4121  Hard Washer 
17  1  132-5789  Clip 
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    Illustration 220g03683268

  1. Install clip (17) on plate assembly (3).

  2. Fasten clip (17) and plate assembly (3) to plate assembly (1) with bolt (15) and hard washer (16).

Assemble Clip and Hardware in the Cab

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Table 86
Required Parts
Group Number 431-9357 Cab Wiring Gp (Rev. 01) 
Item  Qty  Part Number  Part Description 
1  1  374-9696  Plate 
2  2  067-7897  Bolts 
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    Illustration 221g03683269
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    Illustration 222g03683270

  1. Mount plate assembly (1) on the vertical plate on the right side of the cab compartment. Fasten the plate assembly in place with two bolts (2).

Assemble Control to the Plate with Hardware

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Table 87
Required Parts
Group Number 431-9357 Cab Wiring Gp (Rev. 01) 
Item  Qty  Part Number  Part Description 
18  1  435-6042  Plate As 
19  1  274-7921  Machine Electronic Control Module 
20  2  8T-4138  Bolts 
21  2  9X-8256  Washers 
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    Illustration 223g03683273

  1. Fasten control group (19) to plate assembly (18) with two bolts (20) and two washers (21).

Assemble Relay Assembly to the Plate with Hardware

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Table 88
Required Parts
Group Number 431-9357 Cab Wiring Gp (Rev. 01) 
Item  Qty  Part Number  Part Description 
21  3  9X-8256  Washers 
22  3  231-3930  Relay As 
23  3  8T-4970  Bolts 
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    Illustration 224g03683275

  1. Fasten three relay assemblies (22) to plate assembly (18) with three bolts (23) and three washers (21).

Assemble Plates with Hardware

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Table 89
Required Parts
Group Number 431-9357 Cab Wiring Gp (Rev. 01) 
Item  Qty  Part Number  Part Description 
21  4  9X-8256  Washers 
24  4  7C-9900  Spacers 
25  4  8T-6974  Bolts 
26  1  365-4532  Plate 
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    Illustration 225g03683276

  1. Install plate (26) with four spacers (24) on plate assembly (18).

  2. Fasten plate (26) to plate assembly (18) with four bolts (25) and four washers (21). Insert the bolts through the spacers (24).

Assemble Insulators to the Plate Assembly

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Table 90
Required Parts
Group Number 431-9357 Cab Wiring Gp (Rev. 01) 
Item  Qty  Part Number  Part Description 
10  8  8T-4224  Hard Washers 
13  4  112-8242  Insulators 
14  4  8T-4908  Bolts 
27  4  5C-7261  Nuts 
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    Illustration 226g03683285
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    Illustration 227g03683286

  1. Install four insulators (13) on the front of plate (26).

  2. Fasten the insulators to the plate with four bolts (14), four hard washers (10) and four nuts (27).

Assemble Plate Assembly with Hardware

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Table 91
Required Parts
Group Number 431-9357 Cab Wiring Gp (Rev. 01) 
Item  Qty  Part Number  Part Description 
15  2  8T-4137  Bolts 
16  2  8T-4121  Hard Washers 
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    Illustration 228g03683288

  1. Install plate (26) and plate assembly (18) on the right side of the cab compartment. Insert the insulators on the back of the plate into the slots on plate assembly (1).
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    Illustration 229g03683290

  2. Fasten plate (26) to plate assembly (1) with two bolts (15) and two hard washers (16).

Route Harness Assembly and Connect to Cab

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Table 92
Required Parts
Group Number 431-9357 Cab Wiring Gp (Rev. 03) 
Item  Qty  Part Number  Part Description 
28  1  445-1525  Cab Harness As 

Note: For the retrofit kit installation, the cab may not have required holes on the side manifold plate for the WDS harness and the communication cable. If needed, one hole has a diameter of 28.6 mm (1.13 inch). The second hole has a diameter of 43 mm (1.7 inch).

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    Illustration 230g03683319
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    Illustration 231g03683320

  1. Connect the "CC-C19" connector of cab harness assembly (28) to the "J2" connector (D) of control module (6).

  2. Connect the "CC-C4" connector of cab harness assembly (28) to the "J1" connector (E) of control module (6).

  3. Connect the "CC-C21" connector of cab harness assembly (28) to location (B) by removing com adapter port of the main cab harness.

  4. Connect "CC-C20" of cab harness assembly (28) to the com adapter port of the main cab harness at location (F).

  5. Connect the "CC-T8" connector of cab harness assembly (28) to connector (C). This connector mates to a switched side of the main power relay in the cab.

  6. Connect the "CC-C2" connector of cab harness assembly (28) to the "H-C1" connector (G) of the chassis harness assembly.
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    Illustration 232g03683334

  7. Connect the "CC-T9" connector, "CC-T10" connector, "CC-T11"connector and "CC-M12" connector of cab harness assembly (28) to the ground boss (G) at the lower left corner in the back of the cab.

  8. Route the "CC-C3" connector of cab harness assembly (28) to the right side of the compartment.

    Note: This portion of the harness will be connected to the joystick harness.

    Show/hide table
    Illustration 233g03683336

  9. Connect the "CC-C1" connector (L) of cab harness assembly (28) to the control group (19).

  10. Connect the "CC-C8" connector of cab harness assembly (28) to the "K4" fill relay (M).

  11. Connect the "CC-C9" connector of cab harness assembly (28) to the "K5" fan relay (N).

  12. Connect the "CC-C11" connector of cab harness assembly (28) to the "K6" fill relay (P).

  13. Route the "CC-C14" connector of cab harness assembly (28) to the position (Q) as shown.
    Show/hide table
    Illustration 234g03683339

  14. Route the long portion of cab harness assembly (28) up the rear of the cab to the ceiling. Route the cable along the ceiling of the cab to the display module (R) in the front.
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    Illustration 235g03683340

  15. Connect the "CC-C12" connector of cab harness assembly (28) to the MD3 display (S).

  16. Connect the "CC-C6" connector of cab harness assembly (28) to the MD3 display (T).

  17. Connect the "CC-C15" connector of cab harness assembly (28) to the port on the display mounting box (U).

Install Fuse Resistor and Assemble Harness End with Hardware

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Table 93
Required Parts
Group Number 431-9357 Cab Wiring Gp (Rev. 03) 
Item  Qty  Part Number  Part Description 
21  2  9X-8256  Washers 
23  2  8T-4970  Bolts 
29  2  113-8491  Fuses 
30  1  352-1143  Resistor 
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    Illustration 236g03683360
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    Illustration 237g03683362
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    Illustration 238g03683364

  1. Fasten the "CC-C14" connector of cab harness assembly (28) to plate assembly (18) with two bolts (23) and two washers (21).

  2. Remove the protective cap from the "CC-C14" connector of cab harness assembly (28). Install two fuses (29) and resistor (30) in the connector. Replace the protective cap.

Route Harness Assembly and Connect Ends

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Table 94
Required Parts
Group Number 431-9357 Cab Wiring Gp (Rev. 03) 
Item  Qty  Part Number  Part Description 
31  1  435-9655  Monitor Harness As 
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    Illustration 239g03683378

  1. Connect the "JK-C1" connector of joystick harness (31) to the "CC-C13" connector of cab harness assembly (28).

  2. Connect the "JK-C9" connector of joystick harness (31) to the "CC-C10" connector of cab harness assembly (28).

  3. Route the joystick harness (31) through the access penetration (V) into the operator compartment.
    Show/hide table
    Illustration 240g03683382

  4. Route the joystick harness (31) through the armrest to the joystick module (W).

  5. Connect the "JK-C2" connector of joystick harness (31) to the joystick module.

  6. Connect the "JK-C3" connector of joystick harness (31) to the keypad module.

  7. Connect the "JK-C4" connector of joystick harness (31) to the oncoming traffic switch.

    Note: If the oncoming traffic switch is not installed, tie back the connector.

  8. Connect the "JK-C5" connector of joystick harness (31) to the alarm module.

  9. Connect the "JK-C6" connector of joystick harness (31) to the WAVS display module.

    Note: If "WAVS" display is mounted on the headliner, connect the "JK-C7" and "JK-C8" to the MD3 Display mounted on the joystick bracket. Either of the displays can be mounted on joystick bracket and headliner.

Route Cable Assembly and Connect Ends

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Table 95
Required Parts
Group Number 431-9357 Cab Wiring Gp (Rev. 03) 
Item  Qty  Part Number  Part Description 
32  1  251-8248  Communication Cable As 
33  1  9G-2673  Grommet 
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    Illustration 241g03683425
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    Illustration 242g03683427

  1. Install communication cable (32) in bulkhead plate (X) of the operator cab. Install grommet (33) in order to fasten the cable in place.
    Show/hide table
    Illustration 243g03683429

  2. Route communication cable (32) through the access penetration (V) into the operator compartment.
    Show/hide table
    Illustration 244g03683430

  3. Route the joystick harness (32) through the armrest to the camera display (Y).

    Note: If the visibility arrangement is not ordered, tie this portion of the harness back inside the joystick mounting bracket.

Assemble Straps Along the Harness in the Cab

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Table 96
Required Parts
Group Number 431-9357 Cab Wiring Gp (Rev. 03) 
Item  Qty  Part Number  Part Description 
34  36  7K-1181  Cable Straps 
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    Illustration 245g03683435
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    Illustration 246g03683436

  1. Fasten cab harness assembly (28) and joystick harness (31) to the cab with cable straps (34).

Assemble VLPM to the Harness Assembly

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Table 97
Required Parts
Group Number 431-9357 Cab Wiring Gp (Rev. 03) 
Item  Qty  Part Number  Part Description 
35  1  396-6500  Voltage Control Gp 
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    Illustration 247g03683437

  1. Connect voltage control group (35) to the "CC-C16" connector of cab harness assembly (28).

Optional Display Mounting Location

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Table 98
Required Parts
Group Number 431-9357 Cab Wiring Gp (Rev. 03) 
Item  Qty  Part Number  Part Description 
36  1  445-1527  Control Harness As 
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    Illustration 248g03697748

  1. Attach "JK-C8" of joystick harness (31) to MD3 display (A).

  2. Attach "JW-C2" of harness assembly (36) to "JK-C7" of joystick harness (31).

  3. Plug "JW-C1" of harness assembly (36) in to MD3 display (A).

  4. Mount com adapter connector "JW-C3" of harness assembly (36) through hole (B) on the box.

WAVS Camera System Installation

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Table 99
Required Parts 
Item  Qty  Part Number  Part Description 
1  1  251-4168  Switch 
2  3  347-1668  Camera Gp 
3  3  276-2638  Bracket As 
4  3  274-4479  Cable As 

  1. Install WAVS monitor and cable. Reference Special Instruction, REHS7242.
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    Illustration 249g03358188

  2. Mount switch assembly (1) on the inside of the right frame rail. Connect cable assembly (A) to the "MON" connector on the switch assembly.
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    Illustration 250g03358189
    Rear View of Water Tank

  3. Mount camera (2) in location (B) shown.
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    Illustration 251g03358190
    Top of Water Tank

  4. Mount two additional cameras (2) on the top of the water tank. Mount one camera on the rear of water tank at location (E). Point this camera forward at tank fill hole (D). Mount second camera at location (C) oriented 90° to camera at location (E). Point this camera at tank fill hole (D).

    Note: Bracket assemblies (3) are recommended to provide protection for cameras.

  5. Connect one cable assembly (4) to each camera group (2). Route these cable assemblies down the rear of the water tank. Strap the cables to existing bosses on the water tank. Route cable assemblies (4) under the water tank to switch assembly (1).

    Note: Ensure that the cables have adequate length in order to accommodate lifting and lowering of the water tank.

  6. Connect cable assemblies (4) to switch assembly (1) in the following configuration:

    • Camera "1" (B) - connect to terminal "C1"

    • Camera "2" (C) - connect to terminal "C2"

    • Camera "3" (E) - connect to terminal "C3".

  7. On the WAVS monitor, press and hold the camera selection button (button #1) and the contrast button (button #4) for 40 seconds. The green power LED will flash once to indicate that the WAVS system has been configured for multiple cameras.

    Note: The factory default setting is for a single camera configuration.

  8. Any camera can be configured for a reverse (mirror) image. Select the camera with the WAVS monitor. Press and hold buttons #1 and #3 until the green LED flashes. The camera image will be reversed.

  9. Any camera can be configured for an inverted image. Select the camera with the WAVS monitor. Press and hold buttons #1 and #2 until the green LED flashes. The camera image will be inverted.

Electronic Technician Setup

  1. Connect a laptop computer with Cat® ET software to the diagnostic connector on the truck.

  2. Launch the Cat® ET program on the computer.

  3. Select the "Hoist System Enable" option. Change this option to "Not Installed."

  4. Disconnect the laptop computer.

MD3 Setup

  1. Move the battery disconnect switch to the ON position.

  2. Move the engine start switch to the ON position. Do not start the engine.
    Show/hide table
    Illustration 252g03358191

  3. Press menu button (C) on the MD3 display module.

  4. Press "F3" button (B) to select the "Preferences" menu.

  5. Use up button (F) and down button (D) to select the preferred language.

    Note: The default language is English.

  6. Press "OK" button (E) to confirm the selection.

  7. Press menu button (C) to return to the "Main" page.

  8. In the "Main" display screen, press "F1" button (A) to select the "Adjust" menu.
    Show/hide table
    Illustration 253g03358192

  9. In the "Adjust" screen, press "OK" button (E) to select the "SetUp" menu.
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    Illustration 254g03358193

  10. Enter the PIN code. Use up button (F) and down button (D) to select a digit. Use back button (G) to delete a digit. Use "OK" button (E) to enter the digit.
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    Illustration 255g03697620

  11. Select the "Truck Model" option in the "SetUp" menu. Press "OK" button (E).
    Show/hide table
    Illustration 256g03358195

  12. Select the truck model and press "OK" button (E).
    Show/hide table
    Illustration 257g03697624

  13. Select the "Spray Configuration Set Up" option in the "SetUp" menu. Press "OK" button (E).
    Show/hide table
    Illustration 258g03697629

  14. Scroll down and select the spray configuration for the truck. Press OK button (E).
    Show/hide table
    Illustration 259g03697664
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    Illustration 260g03697699
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    Illustration 261g03697665
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    Illustration 262g03697667
    Show/hide table
    Illustration 263g03697668
    Show/hide table
    Illustration 264g03697669
    Show/hide table
    Illustration 265g03697708

  15. Select "Water Pump Selection" then choose type of pump.
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    Illustration 266g03697710
    Show/hide table
    Illustration 267g03697715

  16. Select "Spray Head Type" then choose type of spray head.
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    Illustration 268g03697720
    Show/hide table
    Illustration 269g03697727

  17. Select the "Tank Lift Option" option in the "SetUp" menu. Press "OK" button (E).
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    Illustration 270g03358201

  18. Scroll down and select the "Enable" option. Press "OK" button (E).

    Note: It is recommended that the tank lift function to be selected as "Disabled" during normal operation. "Enable" Tank Lift for servicing purposes only.

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    Illustration 271g03697729

  19. If the water cannon is installed as part of the system, select "Cannon Install Option" in the "SetUp" menu. Press "OK" button (E).
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    Illustration 272g03358203

  20. Scroll down and select the "Installed" option. Press "OK" button (E).
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    Illustration 273g03697730
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    Illustration 274g03697731

    Note: The "Auxilary" button operates an auxiliary valve. Currently this is used for hose reel water on applications or spray bar applications, where in the valve shuts off water flow to these features.

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    Illustration 275g03697732
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    Illustration 276g03358204

  21. Scroll down and select the "Momentary Single" option. Press "OK" button (E).
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    Illustration 277g03697733

  22. Select the "Manual Mode Enable" option in the "SetUp" menu. Press "OK" button (E).
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    Illustration 278g03358206

  23. Scroll down and select the "Enabled" option. Press "OK" button (E).
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    Illustration 279g03358207

  24. Select the "Manual Speed Deactivation" option in the "SetUp" menu. Press "OK" button (E).
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    Illustration 280g03358209

  25. Select the manual speed deactivation value. This feature disables manual operation of the system when machine speed is greater than the deactivation value.

    Note: This feature can be used at work sites that desire system operation to be disabled while operating at road speeds.

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    Illustration 281g03358212

  26. Select the "Intermittent Mode Enable" option in the "SetUp" menu. Press "OK" button (E).
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    Illustration 282g03358213

  27. Scroll down and select the "Enabled" option. Press "OK" button (E).
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    Illustration 283g03358214

  28. If the PIN code needs to be changed, select the "Config Change PIN code" option in the "SetUp" menu. Press "OK" button (E).

WDS Initial System Startup

Circuit Fill and Prime Procedure

Note: This pump priming procedure applies to the Linde Variable 105cc pump, motor, and charge pump.

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Table 100
Needed Parts 
Item  Qty  Part Number  Description 
1  1  7X-0873  Tee 
2  1  3J-1907  O-Ring Seal 
3  1  6V-3965  Fitting (Test) 
4  1  8F-0024  Hose As 
5  1  6V-4144  Quick Connect Coupler 
6  1  231-6284  Filter Cart Gp 
7  1  6V-0852  Dust Cap 
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    Illustration 284g03860179
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    Illustration 285g03860180
    View (A-A)
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    Illustration 286g03358215
    View (B-B)

    Note: Refer to Illustration 286. Port (A) is the S·O·S sample port. Port (B) is a gauge port for checking charge pump pressure.

  1. Refer to Illustration 285. Check the oil filter group to ensure tee (1) and test fitting (3) are installed. If installed, proceed to Step 4. If not installed, proceed to Step 2.

  2. Remove the hose assembly from filter inlet (C). Install tee (1) to the inlet as shown.

  3. Install one O-Ring seal (2) onto test fitting (3). Install the test fitting into tee (1). Install the hose assembly removed in Step 2.

  4. Use quick disconnect coupler (5), and hose assembly (4) to connect filter cart group (6) to test fitting (3).

  5. Fill the Water Delivery System (WDS) with Cat® HYDO Advanced 10 hydraulic oil.

  6. Allow pressure in the hydraulic circuit to build. Hold the pressure until the WDS hydraulic tank is full. The approximate capacity of the tank is 33 L (8.7 US gal).

  7. Remove quick connect coupler (5) from test fitting (3). Install one dust cap (7) onto test fitting (3).

Bleeding Air From Spray Head Cylinders

Note: This operation must be done prior to putting water in the tank.

  1. Start the truck and let the engine idle.

    Note: Ensure that the truck pumps and motors have been primed and are showing adequate system pressure before starting the truck for WDS operation. Refer to "Pump Priming Procedure."

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    Illustration 287g03358216

  2. Place a drip pan under the spray head being bled. Loosen upper fitting (C) approximately one turn. Ensure that lower fitting (D) is tight. DO NOT OPEN the bottom fitting.

    Note: When the spray heads are opened, the upper fitting is under low pressure and the bottom fitting is pressurized up to 3400 kPa (500 psi). Opening the bottom fitting may result in a dangerous release of pressure.

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    Illustration 288g03358218

  3. Press head clean button (E) on the keypad. in order to activate the head clean mode.

  4. Press number key (F) corresponding to the spray head being bled.

  5. Let the air purge out of the line to upper fitting (C) until a steady flow of hydraulic oil is present. Tighten the fitting.

  6. Press head clean button (E) in order to deactivate the head clean mode.

  7. Repeat this procedure for each spray head.

  8. Stop the engine.

  9. If the wrong spray head is activated during the head clean operation, the system is connected improperly. Troubleshoot the hydraulic lines in order to determine if the hydraulic lines have been switched between spray heads. Check the hydraulic line connections at the spray head and at the hydraulic manifold. If the hydraulic lines are connected correctly, troubleshoot the electrical connections on the solenoids. Determine if the electrical connections have been switched between spray heads.

  10. If any spray head opens when the spray head should be closed, the system is connected improperly. If any spray head remains closed when the spray head should open, the system is connected improperly. Troubleshoot the hydraulic lines in order to determine if the lines are reversed. Check the hydraulic line connections at the spray head and at the hydraulic manifold. If the hydraulic lines are connected correctly, troubleshoot the electrical connections on the solenoids in order to determine if the electrical connections are reversed.

Water Pump Fill Procedure

  1. Fill the water tank.

  2. Start the truck and let the engine idle.

  3. Press head clean button (E) on the keypad.

  4. Press the "#2" number key (F) in order to open the spray head to the maximum opening position. This action will cause water to gravity feed out the spray head. This process will prime the pump with water.

  5. Press head clean button (E) in order to deactivate the head clean mode.

  6. Stop the engine.

Water Pump Rotation

Note: On first startup, check the direction of water pump rotation in order to ensure proper connections. Improper pump rotation will result in water pump failure.

Note: Prime the water pump prior to starting the water pump. Refer to "Water Pump Fill Procedure".

Note: Make sure that the water pump bearings have been properly lubricated before starting the WDS system.

Note: The water pump will not operate if the low water warning is on the screen. Ensure that there is adequate water in the water tank.

  1. Start the truck and let the engine idle.
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    Illustration 289g03358219

  2. Press cannon mode button (G).
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    Illustration 290g03699910

  3. Pull trigger (H) on the joystick to open the butterfly valve.
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    Illustration 291g03358223
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    Illustration 292g03358224
    Rotation Direction Indicator
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    Illustration 293g03358225
    Clockwise Pump Shaft Rotation

  4. Press water pump "on/off" button (J) quickly while another person observes the water pump shaft rotation to make sure that the rotation is correct. The proper direction of pump rotation is shown by arrow (K) on the side of the pump.

    Note: Running the water pump backwards may loosen the impeller bolt.

  5. If water pump rotation is observed to be in the wrong direction, do not run the pump. Troubleshoot the electrical connections and hydraulic connections to determine the cause of pump reversal.

Spray Head Calibration

Note: The machine should be at an operating temperature of 65 °C (149 °F) before performing this calibration procedure.

Note: The main display can be used to monitor hydraulic temperatures. Press the"F2" button to open the "Measure" menu. Scroll down and select the "WDS Hyd Tank & Fan" option in order to monitor hydraulic temperatures.

Note: This calibration procedure will require spraying up to a half tank of water. Perform this procedure in a location that can accommodate spraying. Ensure that adequate water supplies are in the water tank before commencing the calibration.

Note: If the spray is uneven after calibration, small adjustments can be made to even out the spray pattern.

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    Illustration 294g03358226

  1. In the "Main" display screen, press "F1" button (A) to select the "Adjust" menu.
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    Illustration 295g03358227

  2. In the "Adjust" screen, scroll down and press "OK" button (E) to select the "Spray Head Calibration" menu.
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    Illustration 296g03358228

  3. Enter the PIN code. Use "up" button (C) and "down" button (D) to select a digit. Use "back" button (E) to delete a digit. Use "OK" button (B) to enter the digit.
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    Illustration 297g03358229

  4. Scroll down and select the "2-5 Spray Head Calibration" option. Press "OK" button (B).

    Note: The "167 Spray Head Calibration" option is performed for the auxiliary spray head options. This calibration does not affect water coverage but can be used to obtain a more consistent spray.

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    Illustration 298g03358230

  5. Scroll down and select the "Enable" option. Press "OK" button (B). Press "back" button (E) to exit the screen.
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    Illustration 299g03358231

  6. The calibration screen allows the operator to activate one spray head at a time and calibrate individual spray heads. Activate the WDS pump. Once the water is activated, push the accelerator to the floor to achieve the target speed of 2000 rpm. Once the target speed is met, the light will turn green. Water pressure should automatically settle to a pressure of 551 kPa (80 psi) if the system is working correctly. The light will turn green. Select an individual spray head by pressing corresponding function key (F) below the head being calibrated.

  7. When calibrating an individual spray head, adjust the head intensity until hydraulic pressure target light is solid green. If hydraulic pressure is low, increase the head intensity by pressing up arrow. If hydraulic pressure is high, decrease the head intensity value by pressing the down arrow. After adjusting the value for head intensity, press the "OK" button to accept the change. Check hydraulic pressure. If pressure is within 50 psi of the target pressure, the light will turn green. Continue adjusting head intensity until the light maintains green status a majority of the time.
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    Illustration 300g03358233

  8. After the individual spray head has been adjusted to maintain consistent green light status, adjust the next spray head. Repeat this procedure until all the spray heads have been calibrated.

Water Tank Sensor Calibration

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    Illustration 301g03697740

  1. Press "Tank Fill" button on the keypad to display the tank level screen.

  2. Fill the water tank to a minimum level of approximately 1100 to 1900 L (300 to 500 US gal).
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    Illustration 302g03358235

  3. Press Menu button (B) to open the main display page.

  4. Press "F1" button (A) to select the "Adjust" menu.
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    Illustration 303g03697742

  5. Use up button (E) and down button (C) to scroll down and select the "Tank Properties" menu. Press "OK" button (D).

  6. Enter the PIN code. Use up button (E) and down button (C) to select a digit. Use "OK" button (D) to enter the digit.
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    Illustration 304g03358238

  7. Scroll down to the "Tank Empty Value" option. Press "OK" button (D).

  8. Use up button (E) and down button (C) to adjust value (F) displayed on the screen to 0.10.

  9. Adjust the value until 0% is displayed on the tank level screen.

  10. Press Menu button (B) to return to the tank level screen.

  11. Fill the water tank to the desired full level.

  12. Press Menu button (B) to open the main display page.

  13. Press "F1" button (A) to select the "Adjust" menu.

  14. Use up button (E) and down button (C) to scroll down and select the "Tank Properties" menu. Press "OK" button (D).

  15. Scroll down to the "Tank Full Value" option. Press "OK" button (D).

  16. Use up button (E) and down button (C) to adjust value (F).

  17. Press Menu button (B) to return to the tank level screen.

  18. Adjust value (F) until the tank level screen shows 100%.

    Note: The low water warning value is set at 10%. The low water warning value is adjustable and can be changed by selecting the option, then increasing or decreasing the value.

  19. Press Menu button (B) to open the main display page.

  20. Press "F1" button (A) to select the "Adjust" menu.

  21. Use up button (E) and down button (C) to scroll down and select the "Tank Properties" menu. Press "OK" button (D).

  22. Scroll down to the "Low water shut off value" option. Press "OK" button (D).

  23. Use up button (E) and down button (C) to adjust value (F) displayed on the screen. Enter a value greater than the "Tank Empty Value" so the system shuts off before the water tank is empty.

    Note: If "Tank Empty Value" is 0.1, set the "Low Water Shutoff" to 0.2.

  24. Press Menu button (B) to open the main display page.

  25. Press "F1" button (A) to select the "Adjust" menu.

  26. Use up button (E) and down button (C) to scroll down and select the "Tank Properties" menu. Press "OK" button (D).

  27. Scroll down to the "Tank full shut off" option. Press "OK" button (D).

  28. Use up button (E) and down button (C) to adjust value (F) displayed on the screen. Enter a value less than the "Tank Full Value" so the system shuts off before the water tank is full.

    Note: This value depends how fast the fill station operates and the time required to shut the fill valve. The WDS system can transmit a signal to the fill valve automatically when this percentage is achieved. A value of 95% is normal.

Cannon Adjustments

  1. Press Menu button (B) to open the main display page.

  2. Press F1 button (A) to select the "Adjust" menu.

  3. Use up button (E) and down button (C) to scroll down and select the "Cannon Adjustments" menu. Press "OK" button (D).

  4. The cannon adjustments menu allows the operator to adjust the speed and sensitivity of the joystick.

Operating Pressures

Note: The following information is for reference only. If the system does not meet requirements, refer to Troubleshooting Guide, UENR3533.

  1. Charge pump pressure is 1930 kPa (280 psi) at normal operating temperatures. The charge relief valve will limit pressure to 3100 kPa (450 psi). Charge pump pressure will normally reach relief pressure when starting with cold oil.

  2. Pilot pressure to the spray heads and cannon manifolds is 3447 kPa (500 psi).

  3. Hydraulic pressure to open and close the spray heads will vary depending on the requested spray head opening.

  4. Pump relief pressure is 28000 kPa (4100 psi). Software limits system pressure to 24000 kPa (3500 psi). Pump and motor inlet and outlet pressure should be approximately 1930 kPa (280 psi) when the engine is at low idle and the WDS system is not activated.

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