Procedure to Install Water Delivery System (Retrofit) (S/N: M6J) on the 777G WTR {5612, 7000} Caterpillar

Procedure to Install Water Delivery System (Retrofit) (S/N: M6J) on the 777G WTR {5612, 7000}

Usage:

777G M6J

OEM: CAT WDS (S/N: M6J1-UP)
Off-Highway Truck/Tractor: 777G (S/N: T5A1-UP; T4Y1-UP)

Introduction

This Special Instruction will provide the necessary steps to install a CAT^® Water Delivery System (S/N: M6J) on a 777G WTR Truck Chassis.

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

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 machine. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide", for tools and supplies suitable to collect and contain fluids in Caterpillar machines. 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
Cab controls
Cannon

The following attachments are available:

Camera and wash kit
Cannon nozzles (must choose a nozzle)

The following items are NOT INCLUDED in the Kit:

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 Hose).
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)

Lines Group Removal

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Illustration 1	g03349083

Disconnect hose (A) from outlet port (B) of the torque converter charge pump.
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Illustration 2 g03349108
Disconnect hose (A) from inlet port (C) of the torque converter charge filter. Remove the hose.
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Illustration 3 g03349113
Disconnect hose (D) from outlet port (E) of the transmission charge pump.
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Illustration 4 g03349133
Remove clamp (H) from hose (D).
Disconnect hose (D) from tube (F). Remove hose (D).
Remove clamp (G) from tube (F).
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Illustration 5 g03349137
Remove clamp (J) from tube (F).
Disconnect tube (F) from inlet port (K) of the transmission filter. Remove tube (F).
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Illustration 6 g03349140
Remove clamp (N) from tube (M).
Disconnect tube (M) from return port (L) of the hoist valve cylinder.
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Illustration 7 g03349148
Disconnect tube (M) from hose (P). Remove tube (M).
Remove clamp (Q) from hose (P).
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Illustration 8 g03349161
Disconnect hose (P) from port (R) of the hoist/brake hydraulic tank. Remove hose (P).

Pump Group Installation

Drive Group Installation

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Table 1
Required Parts Group Number 390-4264 Pump and Mounting Gp (Rev 06)
Item	Qty	Part Number	Part Description
(1)	2	1F-1006	Dowel
(2)	1	261-3062	Gasket
(3)	1	389-2123	Pump Drive Gp
(4)	8	8T-4896	Hard Washer
(5)	8	085-8091	Bolt

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Illustration 9	g03375657

Remove eight bolts (C) and eight washers (D). Remove cover plate (A) and gasket (B).
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Illustration 10 g03349180

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Illustration 11 g03349184
Install pump drive group (3) with gasket (2). Fasten the drive group to the machine frame with eight bolts (5) and eight hard washers (4). Tighten the bolts to a torque of 55 ± 10 N·m (41 ± 7 lb ft).

WDS Hydraulic Pump Installation

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Table 2
Required Parts Group Number 390-4264 Pump and Mounting Gp (Rev 06)
Item	Qty	Part Number	Part Description
(6)	1	460-0078	Piston Pump Gp (WDS Hydraulic Pump)
(7)	2	8T-4122	Hard Washer
(8)	2	7X-0346	Bolt
(9)	1	6V-7970	O-Ring Seal
(10)	2	8C-4424	Plug

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Illustration 12	g03349200

Remove drive shaft cover (F).
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Illustration 13 g03369828

Note: Use suitable lifting device to install the WDS hydraulic pump (6). This pump weighs approximately 76 kg (168 lb).
Note: The WDS hydraulic pump (6) must be oriented with pump controls (J) facing downwards.
Note: Ensure that the O-ring seal used between the pump and the drive group is lubricated and in place.
Install WDS hydraulic pump (6) to pump drive group (3).
Fasten WDS hydraulic pump (6) to pump drive group (3) with two bolts (8) and two hard washers (7). Tighten the bolts to a torque of 215 ± 40 N·m (159 ± 30 lb ft).
Install plug (10) and O-ring seal (9) in vent port (G). Tighten the plug to a torque of 105 ± 10 N·m (77 ± 7 lb ft).
Install plug (10) in drain port (H). Tighten the plug to a torque of 105 ± 10 N·m (77 ± 7 lb ft).

Charge Pump Installation

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Table 3
Required Parts Group Number 390-4264 Pump and Mounting Gp (Rev 06)
Item	Qty	Part Number	Part Description
(11)	1	118-3122	O-Ring Seal
(12)	1	177-8924	Gear Pump Gp (Charge Pump)
(13)	2	8T-4223	Hard Washer
(14)	2	8T-4194	Bolt

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Illustration 14	g03349226

Remove temporary cover and seal from WDS hydraulic pump (6).
Note: Charge pump (12) must be oriented with the large suction port to the left of the machine.
Install O-ring seal (11) around the pilot of charge pump (12) in order to seal the oil between the WDS hydraulic pump (6) and charge pump (12). Install charge pump (12) into the coupler on the back of WDS hydraulic pump (6).
Fasten charge pump (12) to the WDS hydraulic pump with two bolts (14) and two hard washers (13). Tighten the bolts to a torque of 100 ± 20 N·m (74 ± 15 lb ft).

Lines Group Installation

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Table 4
Required Parts Group Number 417-9304 Pump Lines Gp (Rev 03)
Item	Qty	Part Number	Part Description
(1)	2	7k-1181	Cable Strap
(2)	1	200-6345	Mount
(3)	1	423-7786	Hose As
(4)	1	423-7788	Hose As
(5)	1	423-7791	Tube As
(6)	1	430-8896	Hose As
(7)	2	198-4777	Hard Washer
(8)	2	139-1398	Clip
(9)	6	1P-4578	Half Flange
(10)	4	4J-0522	O-Ring Seal
(11)	2	4J-0524	O-Ring Seal
(12)	2	5P-2369	Clip
(13)	2	5P-7470	Clip
(14)	2	5P-7471	Clip
(15)	2	5P-8182	Grommet
(16)	1	7D-1553	Clip
(17)	1	7X-7729	Washer
(18)	1	8T-0315	O-Ring Seal
(19)	18	8T-4121	Hard Washer
(20)	2	8T-4133	Nut
(21)	2	8T-4136	Bolt
(23)	14	8T-4196	Bolt
(24)	1	8T-5005	Bolt
(25)	1	9D-6196	Clip
(26)	1	9D-6197	Clip
(27)	1	9V-5382	Grommet

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Illustration 15	g03370478

Connect hose assembly (4) with two half flanges (9), O-ring seal (10), four hard washers (19), and four bolts (23) to the torque converter charge pump.
Connect hose assembly (4) with two half flanges (9), O-ring seal (10), four hard washers (19), and four bolts (23) to the torque converter charge filter.
Connect hose assembly (6) with two half flanges (9), O-ring seal (10), four hard washers (19), and four bolts (23) to the transmission charge pump.
Install cable strap (1) and mount (2) around hose assembly (6).
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Illustration 16 g06207980
Route hose assembly (6) up the side of the right frame rail.
Route hose assembly (6) over the cross tube. On top of the cross tube, clamp hose assembly (6) in place with clip (13), clip (14), grommet (15), hard washer (19), and bolt (23).
Install grommet around hose assembly (6) with clip (13), clip (14), grommet (15), hard washer (17).
Install clip onto hose assembly (6) with clip (8), clip (12), hard washer (19), nut (20), and bolt (21).
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Illustration 17 g03373848
Connect hose assembly (6) with O-ring seal (10) to the transmission filter.
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Illustration 18 g03369702
Connect tube assembly (5) with O-ring seal (11) to the hoist valve cylinder.
Clamp tube assembly (5) in place with clip (25), clip (26), and grommet (27).
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Illustration 19 g06207394
Connect hose assembly (3) to tube assembly (5) with O-ring seal (18).
Install clip on hose assembly (3) with spacer (7), clip (16), hard washer (19), and bolt (24).
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Illustration 20 g03373836

View A-A
Connect hose assembly (3) with O-ring seal (11) to the hoist/brake hydraulic tank.

Cooling Group Installation

Weld Cooler Gussets

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Table 5
Required Parts Group Number 438-3411 Mounting
Item	Qty	Part Number	Part Description
(1)	1	435-5884	Plate As
(2)	1	438-3405	Gusset
(3)	1	438-8268	Gusset
(4)	1	438-8270	Gusset

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Illustration 21	g03384582
Cooler gusset weld location

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Illustration 22	g03381004
Bottom view View A-A

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Illustration 23	g03381535
View B-B (A) 194 mm (7.64 inch) (B) 49 mm (1.93 inch)

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Illustration 24	g03381577
View C-C (A) 194 mm (7.64 inch)

Note: Remove paint on surfaces as required before welding.

Tack weld gusset (3) in position using dimension (B).
Position gusset (2) against gusset (3) as shown in Illustration 23.

Tack Weld gusset (2) and (4) in position using dimension (A).

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Illustration 25	g03381058
View B-B (W1) AWS A5.18 ER70S-2 or equivalent (C) 50 mm (1.97 inch) (D) 25 mm (0.98 inch) (E) Alternate skip weld (F) 3 mm (0.12 inch) fillet weld (G) Continuous fillet weld (H) Continuous fillet weld (J) Continuous fillet weld (K) Alternate skip weld (L) Continuous fillet weld

Weld gusset (3) using an alternate skip weld (K) that is 3 mm (0.12 inch) fillet weld (F). Place alternate skip weld (K) onto both sides of gusset (3) that is 25 mm (0.98 inch) (D) long. The weld must be every 50 mm (1.97 inch) (C) from center to center.
Weld the ends of gusset (3) using continuous fillet welds (H) and (J) that are 3 mm (0.12 inch) fillet welds (F). Place continuous fillet welds (H) and (J) onto both sides of gusset (3).
Weld gusset (2) using an alternate skip weld (E) that is 3 mm (0.12 inch) fillet weld (F). Place an alternate skip weld (E) onto both sides of gusset (2) that is 25 mm (0.98 inch) (D) long. The weld must be every 50 mm (1.97 inch) (C) from center to center.
Weld the ends of gusset (2) using continuous fillet welds (G) and (L) that are 3 mm (0.12 inch) fillet welds (F). Place continuous fillet welds (G) and (L) onto both sides of gusset (2).
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Illustration 26 g03381956

View C-C
(W1) AWS A5.18 ER70S-2 or equivalent
(M) Alternate skip weld
(N) Continuous fillet weld
(P) Continuous fillet weld
Weld gusset (4) using an alternate skip weld (M) that is 3 mm (0.12 inch) fillet weld (F). Place alternate skip weld (M) onto both sides of gusset (4) that is 25 mm (0.98 inch) (D) long. The weld must be every 50 mm (1.97 inch) (C) from center to center.

Weld the ends of gusset (3) using continuous fillet welds (P) and (N) that are 3 mm (0.12 inch) fillet welds (F). Place continuous fillet welds (P) and (N) onto both sides of gusset (4).

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Illustration 27	g03381076
Top view (W1) AWS A5.18 ER70S-2 or equivalent (Q) 3000 mm (118.11 inch) (R) 100 mm (3.93700 inch) (S) 50 mm (1.96850 inch) (T) Skip Weld (U) Fillet weld (V) 25 mm (0.98425 inch)

Tack weld plate assembly (1) in position using dimensions (Q) and (V).
Weld the four corners of plate assembly (1) using fillet weld (U) that is 3 mm (0.12 inch) fillet weld (F).
Weld plate assembly (1) using a skip weld (T) that is 3 mm (0.12 inch) fillet weld (F). Place skip weld (T) around plate assembly (1) that is 50 mm (1.96850 inch) (S) long. Skip weld (T) must be every 100 mm (3.93700 inch) (R) from center to center.

Cooler Mounting Group

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Table 6
Required Parts Group Number 428-9380 Supplemental Cooling Gp (Rev. 05) Sub Group Number 433-7385 Wear Plate (Rev. 00)
Item	Qty	Part Number	Part Description
(1)⁽¹⁾	1	432-4229	Bracket As
(2)⁽¹⁾	1	432-4230	Bracket As
(3)⁽¹⁾	1	129-1807	Oil Cooler Gp
(4)⁽¹⁾⁽²⁾	1	228-7315	Film
(5)⁽¹⁾	1	228-7316	Film
(6)⁽¹⁾	1	425-7801	Radiator Shroud
(7)⁽¹⁾	4	8T-9377	Bolt
(8)⁽¹⁾	4	8T-4896	Hard Washer
(9)⁽¹⁾	8	7X-0603	Hard Washer
(10)⁽¹⁾	4	9D-7924	Mounting
(11)⁽¹⁾	4	7X-0521	Hard Washer
(12)⁽¹⁾	1	033-6028	O-Ring Seal
(13)⁽¹⁾	1	9S-4185	O-Ring Plug
(14)⁽¹⁾	1	7W-6492	Pipe Plug
(15)	8	8T-6871	Bolt
(16)	4	8D-8852	Spacer
(17)	8	8T-4122	Hard Washer
(18)	4	110-6923	Spacer

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⁽¹⁾	These components are pre-assembled.
⁽²⁾	Use if required.

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Illustration 28	g03382456

Mount cooling group (A) on the cooler mounting plate (B).
Note: Cooling group (A) includes items (1) through (14)
Note: Attach film (5) over film (4) on top of the cooler if the water truck will be in service in North America.
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Illustration 29 g06207408
Fasten cooling group (A) to mounting plate (B) with four spacers (16), eight bolts (15) and eight hard washers (17) and four washers (18).

WDS Hydraulic Tank Installation

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Table 7
Required Parts Group Number 428-9380 Supplemental Cooling Gp (Rev. 05) Sub Group Number 443-6968 Hydraulic Tank and Mounting Gp (Rev. 01)
Item	Qty	Part Number	Part Description
(1)⁽¹⁾	1	419-0078	Hydraulic Tank Gp
(2)⁽¹⁾	1	390-4578	Plate
(3)⁽¹⁾	1	435-3384	Plate As
(4)⁽¹⁾	1	9G-5127	Breather
(5)⁽¹⁾	1	158-7864	Film
(6)⁽¹⁾	1	126-0747	Bypass Valve Gp
(7)⁽¹⁾	1	285-5105	Liquid Level Sensor Gp
(8)⁽¹⁾	1	102-7532	Temperature Sensor Gp
(9)⁽¹⁾	1	8J-7844	Reducing Bushing
(10)⁽¹⁾	1	3K-0360	O-Ring Seal
(11)⁽¹⁾	1	6V-8785	Tee
(12)⁽¹⁾	1	2S-4663	O-Ring Seal
(13)⁽¹⁾	2	329-5468	Connector As
(14)⁽¹⁾	1	418-9806	Hose As
(15)⁽¹⁾	1	148-8357	Elbow As
(16)⁽¹⁾	3	6V-7730	Bolt
(17)⁽¹⁾	3	8T-4121	Hard Washer
(18)⁽¹⁾	3	7X-0507	Hard Washer
(19)⁽¹⁾	3	2Y-5829	Nut
(20)⁽¹⁾	1	8C-3443	Connector
(21)⁽¹⁾	2	7M-8485	O-Ring Seal
(22)⁽¹⁾	1	9S-4181	O-Ring Plug
(23)⁽¹⁾	1	5K-9090	O-Ring Seal
(24)⁽¹⁾	1	3K-0360	O-Ring Seal
(25)⁽¹⁾	1	2M-9780	O-Ring Seal
(26)⁽¹⁾	7	8T-4195	Bolt
(27)⁽¹⁾	7	8T-4121	Hard Washer
(28)⁽¹⁾	1	132-5789	Clip
(29)	4	8T-4192	Bolt
(30)	2	8T-4139	Bolt
(31)	6	8T-4223	Hard Washer
(32)⁽²⁾	1	8T-0077	Connector
(33)⁽²⁾	1	416-2632	Hose As
(34)⁽²⁾	1	319-6218	Elbow As
(35)⁽²⁾	2	1S-0994	Clip
(36)⁽²⁾	1	433-7852	Guard As
(37)⁽²⁾	1	6V-9746	O-Ring Seal
(38)⁽²⁾	1	2S-4078	O-Ring Seal
(39)	6	8T-4121	Hard Washer
(40)	6	8T-4137	Bolt
(41)	1	7D-7233	Clip
(42)	1	8T-4133	Nut
(43)⁽²⁾	1	118-0166	Fitting

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⁽¹⁾	These components are pre-assembled.
⁽²⁾	These components are pre-assembled.

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Illustration 30	g03356972

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Illustration 31	g03359146

Mount the hydraulic tank assembly (A) on the truck hydraulic tank (B) with bolts (29) and (30) and hard washers (31).
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Illustration 32 g03359317
Position quick fill assembly (C) on the bottom of the hydraulic tank (B).
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Illustration 33 g06207299
Fasten guard assembly (36) to the bottom of the truck hydraulic tank with four bolts (40) and four hard washers (39). Tighten the bolts to a torque of 55 ± 10 N·m (41 ± 7 lb ft).
Install elbow assembly (34) onto tank. Connect one end of hose (33) to elbow assembly (34). Clamp hose assembly (33) to the bottom of hydraulic tank (B) with clips (35). Fasten the clip to tank with bolt (40) and hard washer (39).

Cooling Group Lines Installation

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Table 8
Required Parts Group Number 428-9380 Supplemental Cooling Gp (Rev. 05)
Item	Qty	Part Number	Part Description
(1)	4	1P-4578	Half Flange
(2)	8	8T-8916	Bolt
(3)	8	8T-5360	Washer
(4)	2	061-7540	O-Ring Seal
(5)	3	5P-2369	Clip
(6)	14	5P-7470	Clips
(7)	14	5P-7471	Clip
(8)	14	5P-8182	Grommet
(9)	2	200-6345	Mount
(10)	4	7K-1181	Cable Strap
(11)	4	8T-4185	Bolt
(12)	1	8T-4186	Bolt
(13)	1	4L-6459	Bolt
(14)	1	8T-4196	Bolt
(15)	1	8T-5005	Bolt
(16)	1	435-4091	Bracket As
(17)	1	206-5593	Bar
(18)	1	426-2165	Hose As
(19)	1	426-2166	Hose As
(20)	2	5K-9090	O-Ring Seal
(21)	1	282-3811	Plate
(22)	1	7D-7233	Clip
(23)	1	7X-2552	Bolt
(24)	1	122-4026	Spacer
(25)	1	091-9035	Spacer
(26)	1	302-9799	Spacer
(27)	8	7X-7729	Washer
(28)	6	8T-4133	Nut
(29)	3	8T-4121	Hard Washer
(30)	4	8T-4195	Bolt
(31)	1	3E-4353	Hard Washer
(32)	1	5P-1075	Hard Washer
(33)	1	9X-8257	Washer
(34)	1	228-7094	O-Ring Seal
(35)⁽¹⁾	1	319-6218	Elbow As
(36)	1	4D-7388	Clip

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⁽¹⁾	Preassembled with tank

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Illustration 34	g03363414

Connect hose assembly (19) with O-ring seal (4) to the cooler group. Install two half flanges (1) around the hose.
Fasten hose assembly (19) and half flanges (1) to the cooler group with four bolts (2) and four washers (3).
Connect hose assembly (18) with O-ring seal (4) to the cooler group. Install two half flanges (1) around the hose.
Fasten hose assembly (18) and half flanges (1) to the cooler group with four bolts (2) and four washers (3).
Install clips (5) on hose assembly (18) and hose assembly (19). Thread bolt (30) with hard washer (29) through the clips. Install nut (28) with hard washer (31) on the bolt and tighten.
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Illustration 35 g03363418
Install three grommets (8) on hose assembly (18) and three grommets on hose assembly (19) at the locations shown.
Install clips (6) and clips (7) over each grommet.
Fasten hose assembly (18) and hose assembly (19) to the machine with bolt (11) and washer (27) through each set of clips.
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Illustration 36 g06207310
Route hose assembly (18) and hose assembly (19) across the rear of the cab. Tie the hoses together with mount (9) and cable straps (10).
Install two grommets (8) on hose assembly (18) and two grommets on hose assembly (19) at the locations shown.
Install clips (6) and clips (7) over each grommet.
Insert bolt (12) with washer (27) through the first set of clips. Install plate (21) on the back of the clips and fasten plate (21) to the clips with nut (28).
Fasten plate (21) to the back of the cab with bolt (30) and hard washer (29).
Install bracket assembly (16) onto the machine frame with bolt (23) and washer (33).
Fasten the second set of clips to bracket assembly (16) with spacer (24), bolt (13) and hard washer (32).
Route hose assembly (18) and hose assembly (19) down to the left frame rail. Install clips (5) on the hoses. Insert bolt (12) through the clips and spacer (25). Fasten the hoses to the machine frame in the location shown.
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Illustration 37 g06207317
Install grommet (8) on hose assembly (18) and on hose assembly (19) at the location shown.
Install clips (6) and clips (7) over each grommet.
Secure hose assembly (19) using clip (5), bolt (28), hard washer (29), bolt (30) and clip (36).
Insert bolt (14) with washer (27) through the clips on hose assembly (18) and through bar (17). Fasten the clips to the bar with nut (28).
Insert bolt (15) with washer (27) through the clips on hose assembly (19) and through spacer (26). Insert the bolt through bar (17) and fasten the two hoses to the truck frame.
Connect hose assembly (18) to bypass valve (A) with O-ring seal (34).
Connect hose assembly (19) to hydraulic tank (B) with O-ring seal (34).

Pump Group Lines Installation

Relocate Position Sensor Assembly

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Illustration 38	g03381209

Remove position sensor assembly (AA).
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Illustration 39 g03381210
Cut mounting block (BB) from the rear frame rail.
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Illustration 40 g03381212
Weld mounting block (BB) to the frame rail at the location shown.
Note: Place the block as shown in Illustration 40. The block should be 181 mm (7.1 inch) from the left edge of the frame. The block should be 65 mm (2.6 inch) from the rear edge of the machine frame.
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Illustration 41 g03381215
Reinstall position sensor assembly (AA) on mounting block (BB).

Install Plate Assembly On Truck Frame

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Table 9
Required Parts Group Number 390-4262 Pump Lines Gp (Rev 06)
Item	Qty	Part Number	Part Description
(1)	4	105-7781	Spacer
(2)	1	435-5307	Hydraulic Lines Mounting
(3)	4	8T-4121	Hard Washer
(4)	4	8T-5005	Bolt

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Illustration 42	g03374309
Rear View Of Bulkhead Plate (A) Pump low-pressure port (Blue) (B) Pump high-pressure port (Red)

Install hydraulic lines mounting (2) on the rear left tail light mounting bosses with fours spacers (1). Fasten the plate to the tail casting with four bolts (4) and four hard washers (3). Tighten the bolts to a torque of 55 ± 10 N·m (41 ± 7 lb ft).
Note: Do not scratch high-pressure port faces (A) and (B) on the plate assembly. Damage to either side of these port faces can cause hydraulic leaks.
Note: Remove tail light assembly and relocate to the water tank as per tank manufacturer location.

Connect Pressure Hoses to WDS Hydraulic Pump

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Table 10
Required Parts Group Number 390-4262 Pump Lines Gp (Rev 06)
Item	Qty	Part Number	Part Description
(5)	2	1P-3703	Rectangular Seal
(6)	1	390-4562	Hose As
(7)	1	390-4563	Hose As
(8)	4	6V-0400	Half Flange
(9)	8	8T-4223	Hard Washer
(10)	8	8T-4184	Bolt

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Illustration 43	g03349445
Top of WDS Hydraulic Pump (C) Pump low-pressure port (blue) (D) Pump high-pressure port (red)

Note: Ends of all pump-related hoses are color coded.

Connect red pump high-pressure hose assembly (6) to pump high-pressure port (D) on the right side of the WDS hydraulic pump with two half flanges (8) and rectangular seal (5). Fasten the hose to pump with four bolts (10) and four hard washers (9). Tighten the bolts to a torque of 100 ± 20 N·m (74 ± 15 lb ft).
Connect blue pump return low-pressure hose assembly (7) to pump low-pressure port (C) on the left side of the WDS hydraulic pump. Secure the blue pump low-pressure hose with two flanges with two flanges (8) and rectangular seal (5). Fasten the hose to pump with four bolts (10) and four hard washers (9). Tighten the bolts to a torque of 100 ± 20 N·m (74 ± 15 lb ft).
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Illustration 44 g03349459
Route pump high-pressure hose assembly (6) and pump return low-pressure hose assembly (7) over to the left side of the machine.

Connect WDS Pressure Hoses to Plate Assembly

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Illustration 45	g03368080
Front View Of Bulkhead Plate (A) Pump low-pressure port (blue) (B) Pump high-pressure port (red)

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Illustration 46	g03349472
Rear View Of Bulkhead Plate (A) Pump low-pressure port (blue) (B) Pump high-pressure port (red)

Note: Label both ends of all hoses before connecting.

Connect red pump high-pressure hose assembly (6) to location (B) of hydraulic lines mounting (2) 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: Seal, split flanges, bolts and washers are included with hydraulic lines mounting (2). A cover is installed for temporary purposes. This cover must be removed when a hose is connected to this port.
Connect blue pump return low-pressure hose assembly (7) to location (A) of hydraulic lines mounting (2) 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: Seal, split flanges, bolts and washers are included with hydraulic lines mounting (2). A cover is installed for temporary purposes. This cover must be removed when a hose is connected to this port.

Clip WDS Pressure Hoses to the Truck Frame

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Table 11
Required Parts Group Number 390-4262 Pump Lines Gp (Rev 06)
Item	Qty	Part Number	Part Description
(3)	3	8T-4121	Hard Washer
(11)	3	9U-0810	Block
(12)	6	8T-2525	Grommet
(13)	6	5P-7468	Clip
(14)	6	5P-7469	Clip
(15)	3	6V-5842	Bolt

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Illustration 47	g03349485

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Illustration 48	g03356981

Route pump high-pressure hose assembly (6) and pump return low-pressure hose assembly (7) along the left side of the machine frame. Remove existing nuts and install blocks (11) at location (E), location (F) and location (G) on the machine frame. Install grommet (12) and clips (13) and (14) on each hose. Fasten each hose to block with bolt (15) and hard washer (3).

Connect Charge Pump Inlet Hose to WDS Hydraulic Tank

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Table 12
Required Parts Group Number 390-4262 Pump Lines Gp (Rev 06)
Item	Qty	Part Number	Part Description
(9)	4	8T-4223	Hard Washer
(16)	1	4J-0522	O-Ring Seal
(17)	1	435-2930	Hose As (Charge Pump Suction Hose)
(18)	2	173-1437	Half Flange
(19)	4	8T-4183	Bolt

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Illustration 49	g03356982

Connect charge pump suction hose assembly (17) to the suction port of charge pump with O-ring seal (16) and two half flanges (18). Fasten the hose to pump with four bolts (19) and four hard washers (9). Tighten the bolts to a torque of 100 ± 20 N·m (74 ± 15 lb ft)
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Illustration 50 g03356983
Route charge pump suction hose (17) under the left frame rail and up the side of the hydraulic tank.
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Illustration 51 g03375046
Route charge pump suction hose (17) to suction port (H) on the WDS hydraulic tank.
Remove four bolts, four washers, and two flanges from suction port (H). Remove cover and seal from suction port. Install the seal from the cover in the end of hose assembly (17).
Connect hose assembly (17) to suction port (H) with the seal. Fasten the hose to the tank with the two flanges, four bolts, and four washers.

Assemble Fittings on the Cooling Bypass Valve

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Table 13
Required Parts Group Number 390-4262 Pump Lines Gp (Rev 06)
Item	Qty	Part Number	Part Description
(20)	3	5K-9090	O-Ring Seal
(21)	1	6V-9854	Elbow
(22)	1	6V-8785	Tee
(23)	1	7M-8485	O-Ring Seal

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Illustration 52	g03375054

Install tee (22) and O-ring seal (23) in the inlet port of bypass valve (J). Tighten the adapter to a torque of 350 ± 53 N·m (258 ± 39 lb ft).
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Illustration 53 g03356986
Install elbow (21) with O-ring seal (20) in tee (22). Tighten the adapter to torque of 220 ± 33 N·m (162 ± 24 lb ft).
Install O-ring seal (20) in inlet of elbow (21).
Install O-ring seal (20) in tee (22).

Connect Motor Case Drain Hose to the Plate Assembly

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Table 14
Required Parts Group Number 390-4262 Pump Lines Gp (Rev 06)
Item	Qty	Part Number	Part Description
(20)	2	5K-9090	O-Ring Seal
(24)	1	390-4566	Hose As
(25)	1	142-0038	Elbow

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Illustration 54	g03349523
Rear View Of Bulkhead Plate (K) Motor case drain port (2) 435-5307 Hydraulic Lines Mounting

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Illustration 55	g06207415

Connect elbow (25) to rear end of motor case drain port (K). Tighten the elbow to a torque of 220 ± 33 N·m (162 ± 24 lb ft).
Connect reducer with O-ring seal (20) to elbow (25). Tighten the adapter to a torque of 220 ± 33 N·m (162 ± 24 lb ft).
Connect motor case drain hose assembly (24) with O-ring seal (20) to front end of motor case drain port (K). Tighten the hose to a torque of 220 ± 33 N·m (162 ± 24 lb ft).
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Illustration 56 g03356989
Route motor case drain hose assembly (24) along the left frame rail to the front of the machine.
Note: motor case drain hose assembly hose (24) will be clamped in place later in the installation. Reference Illustration 103 for placement of the hose in preparation for clamping.
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Illustration 57 g03356990
Route motor case drain hose assembly (24) under the left frame rail and up the right side of the hydraulic tank.
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Illustration 58 g03375065
Route motor case drain hose assembly (24) around the WDS hydraulic tank to bypass valve (J).
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Illustration 59 g03356992
Connect motor case drain hose assembly (24) to tee (22).
Note: O-ring seal (20) was previously installed in this adapter. Verify that the seal is in place before connecting hose.

Connect WDS Pump Case Drain to Thermal Bypass Valve

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Table 15
Required Parts Group Number 390-4262 Pump Lines Gp (Rev 06)
Item	Qty	Part Number	Part Description
(20)	1	5K-9090	O-Ring Seal
(27)	1	6V-7970	O-Ring Seal
(28)	1	421-6194	Connector As
(29)	1	390-4569	Hose As
(65)	3	4D-7388	Clip

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Illustration 60	g03349553

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Illustration 61	g03356994

Install connector assembly (28) with O-ring seal (27) in WDS pump case drain fitting (L). Tighten the connector to a torque of 140 ± 21 N·m (103 ± 15 lb ft).
Note: Fill the case drain with SAE 10W oil before connecting hose assembly.
Connect WDS pump case drain hose assembly (29) with O-ring seal (20) to connector assembly (28). Tighten the hose to a torque of 220 ± 33 N·m (162 ± 24 lb ft).
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Illustration 62 g06207434
Route WDS pump case drain hose assembly (29) over to the left side of the machine. Clamp the hose to machine frame at location (M) and secure the hose assembly using clip (65).
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Illustration 63 g03356996
Connect WDS pump case drain hose assembly (29) to elbow (21) on the bypass valve.

Install Charge Pump Outlet Flange

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Table 16
Required Parts Group Number 390-4262 Pump Lines Gp (Rev 06)
Item	Qty	Part Number	Part Description
(3)	4	8T-4121	Hard Washer
(5)	1	1P-3703	Rectangular Seal
(30)	1	7Y-3731	Flange
(31)	4	6V-1820	Bolt

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Illustration 64	g03356997

Install flange (30) with rectangular seal (5) on the outlet port of the charge pump. Fasten the flange to pump with four bolts (31) and four hard washers (3). Tighten the bolts to a torque of 55 ± 10 N·m (41 ± 7 lb ft).

Install Cold Start Relief Valve

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Table 17
Required Parts Group Number 390-4262 Pump Lines Gp (Rev 06)
Item	Qty	Part Number	Part Description
(20)	1	5K-9090	O-Ring Seal
(26)	1	6V-8946	Reducer
(32)	2	6V-9746	O-Ring Seal
(33)	1	6V-9839	Swivel Tee
(34)	1	7I-1036	Coupling As
(35)	1	3K-0360	O-Ring Seal
(36)	1	198-9219	Relief Valve Gp

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Illustration 65	g03356998

Assemble the cold start relief valve. Connect reducer (26) with O-ring seal (20) to flange (30) in the outlet port of the charge pump. Tighten the adapter to a torque of 220 ± 33 N·m (162 ± 24 lb ft).
Connect swivel tee (33) with O-ring seal (32) to reducer (26). Tighten the adapter to a torque of 140 ± 21 N·m (103 ± 15 lb ft).
Connect coupling assembly (34) with O-ring seal (32) to swivel tee (33). Tighten the adapter to a torque of 140 ± 21 N·m (103 ± 15 lb ft).
Connect relief valve group (36) with O-ring seal (35) to coupling assembly (34). Tighten the valve group to a torque of 50 ± 3 N·m (37 ± 2 lb ft).

Connect Cold Start Relief Valve to the WDS Hydraulic Tank

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Table 18
Required Parts Group Number 390-4262 Pump Lines Gp (Rev 06)
Item	Qty	Part Number	Part Description
(23)	1	7M-8485	O-Ring Seal
(32)	2	6V-9746	O-Ring Seal
(35)	1	3K-0360	O-Ring Seal
(37)	1	6V-9874	Connector
(38)	1	390-4568	Hose As
(39)	1	6V-9182	Elbow

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Illustration 66	g03356999

Connect connector (37) with O-ring seal (35) to relief valve group (36). Tighten the adapter to a torque of 100 ± 15 N·m (74 ± 11 lb ft).
Connect charge pump relief hose assembly (38) with O-ring seal (32) to connector (37). Tighten the hose to a torque of 140 ± 21 N·m (103 ± 15 lb ft).
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Illustration 67 g03357000
Route charge pump relief hose assembly (38) from the cold start relief valve to the left side of the machine. Route the hose under the left frame rail and up to the WDS hydraulic tank.
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Illustration 68 g03357001
Install elbow (39) with O-ring seal (23) in the inlet port of the WDS hydraulic tank. Tighten the adapter to a torque of 220 ± 33 N·m (162 ± 24 lb ft).
Connect charge pump relief hose assembly (38) with O-ring seal (32) to elbow (39). Tighten the hose to a torque of 140 ± 21 N·m (103 ± 15 lb ft).

Hose Assembly to the Filter Group and Pump Group

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Table 19
Required Parts Group Number 390-4262 Pump Lines Gp (Rev 06)
Item	Qty	Part Number	Part Description
(40)	1	1P-3704	Rectangular Seal
(41)	1	132-6194	Adapter
(42)	4	8T-6466	Bolt
(43)	2	3J-1907	O-Ring Seal
(44)	1	6V-8724	Elbow
(45)	1	6V-8397	O-Ring Seal
(46)	1	390-4570	Hose As
(47)	1	6V-8397	O-Ring Seal
(48)	1	8T-9041	Connector

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Illustration 69	g03368640

Attach adapter (41) with rectangular seal (40) to the charge filter outlet port on the torque converter. Fasten the adapter to the outlet port with four bolts (42). Tighten the bolts to a torque of 55 ± 10 N·m (41 ± 7 lb ft).
Attach elbow (44) with O-ring seal (43) to adapter (41). Tighten the adapter to a torque of 55 ± 8 N·m (41 ± 6 lb ft).
Attach pump drive lube hose assembly (46) with O-ring seal (45) to elbow (44). Tighten the hose to a torque of 45 ± 5 N·m (33 ± 4 lb ft).
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Illustration 70 g03368643

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Illustration 71 g03368648
Route pump drive lube hose assembly (46) to the pump adapter lube port of the pump drive.
Note: Do not start the engine without pump adapter lube hose assembly (46) in place.
Install connector (48) with O-ring seal (43) in the pump adapter lube port of the pump drive. Tighten the adapter to a torque of 27 ± 4 N·m (20 ± 3 lb ft).
Connect pump drive lube hose assembly (46) to adapter with O-ring seal (47). Tighten the hose to a torque of 45 ± 5 N·m (33 ± 4 lb ft).

Install Clips on the Hose Assembly

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Table 20
Required Parts Group Number 390-4262 Pump Lines Gp (Rev 06)
Item	Qty	Part Number	Part Description
(49)	1	5P-2369	Clip
(50)	1	6V-1889	Clip
(51)	1	2V-2793	Clip
(52)	1	097-4896	Spacer
(53)	2	3E-4353	Hard Washer
(54)	1	6V-5230	Bolt
(55)	1	2Y-5829	Nut

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Illustration 72	g03368671
Right Side of Truck Hydraulic Tank

Install clip (51) on tube (N). Install clip (49) on charge pump suction hose (17). Install clip (50) on charge pump relief hose assembly (38).
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Illustration 73 g03368672
Insert spacer (52) between clip (51) and clips (49) and (50). Insert bolt (54) with hard washer (53) through the clips and the spacer. Fasten the bolt in place with nut (55) and hard washer (53).

Install Clips on the Hose Assembly

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Table 21
Required Parts Group Number 390-4262 Pump Lines Gp (Rev 06)
Item	Qty	Part Number	Part Description
(15)	1	6V-5842	Bolt
(49)	1	5P-2369	Clip
(53)	2	3E-4353	Hard Washer
(55)	1	2Y-5829	Nut
(56)	1	7D-7233	Clip
(57)	1	6V-5386	Clip

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Illustration 74	g03368702

Install clip (57) on hoist pump suction tube (P). Install clip (49) on charge pump suction hose assembly (17). Install clip (56) on charge pump relief hose assembly (38).
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Illustration 75 g03368704
Insert bolt (15) with hard washer (53) through the clips. Fasten the bolt in place with nut (55) and hard washer (53).

Install Fittings on the Plate Assembly

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Table 22
Required Parts Group Number 390-4262 Pump Lines Gp (Rev 06)
Item	Qty	Part Number	Part Description
(58)	4	4J-5477	O-Ring Seal
(59)	2	8C-8408	Elbow
(60)	2	6V-9828	Cap As
(61)	10	6V-8397	O-Ring Seal
(62)	2	8C-8988	Elbow
(63)	2	6V-9829	Cap As
(64)	2	6V-9836	Swivel Tee

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Illustration 76	g03368783

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Illustration 77	g03368785
Rear View Of Bulkhead Plate (Q) Motor signal port (green) (R) Motor pilot port (yellow)

Connect one elbow (59) with O-ring seal (58) to the adapter in motor signal port (Q). Tighten the elbow to a torque of 27 ± 4 N·m (20 ± 3 lb ft).
Connect one elbow (59) with O-ring seal (58) to the adapter in motor pilot port (R). Tighten the elbow to a torque of 27 ± 4 N·m (20 ± 3 lb ft).
Connect one temporary cap assembly (60) with seal (58) to each elbow (59). Tighten the caps to a torque of 27 ± 4 N·m (20 ± 3 lb ft).

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Illustration 78	g03368787
Rear View off Bulkhead Plate (S) Spray head pilot return port (black) (T) Spray head pilot pressure port (brown)

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Illustration 79	g03368789

Connect one elbow (62) with O-ring seal (61) to the rear end of the adapter in spray head pilot return port (S). Connect one elbow (62) with O-ring seal (61) to the rear end of the adapter in spray head pilot pressure port (T).Tighten the adapters to a torque of 45 ± 5 N·m (33 ± 4 lb ft).
Connect one cap assembly (63) with O-ring seal (61) to each elbow (62). Tighten the caps to a torque of 45 ± 5 N·m (33 ± 4 lb ft).
Connect one tee swivel (64) with O-ring seal (61) to the front end of the adapter in spray head pilot return port (S). Connect one tee swivel (64) with O-ring seal (61) to the front end of the adapter in spray head pilot pressure port (T).Tighten each tee swivel to a torque of 45 ± 5 N·m (33 ± 4 lb ft).
Install O-ring seal (61) in each tee swivel.

Filter Group Installation

Install Filter Group

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Table 23
Required Parts Group Number 390-4265 Hydraulic Filter and Lines Gp (Rev 04)
Item	Qty	Part Number	Part Description
(1)	1	437-1909	Plate As
(2)	1	177-6979	Oil Filter Gp
(3)	4	8T-4121	Hard Washer
(4)	4	8T-4137	Bolt

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Illustration 80	g03361215

Mount oil filter group (2) to plate assembly (1) with bolts (4) and hard washers (3). Tighten the bolts to a torque of 55 ± 10 N·m (41 ± 7 lb ft).
Note: There is an arrow on the filter base showing the direction of flow. The filter group must be mounted with the arrow pointing away from the plate assembly.

Install Filter Mounting Plate

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Table 24
Required Parts Group Number 390-4265 Hydraulic Filter and Lines Gp (Rev 04)
Item	Qty	Part Number	Part Description
(3)	4	8T-4121	Hard Washer
(5)	4	8T-4136	Bolt

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Illustration 81	g03375706

Install plate assembly (1) on the fuel tank with four bolts (5) and four hard washers (3). Tighten the bolts to a torque of 55 ± 10 N·m (41 ± 7 lb ft).

Connect Filter Group to Charge Pump Outlet

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Table 25
Required Parts Group Number 390-4265 Hydraulic Filter and Lines Gp (Rev 04)
Item	Qty	Part Number	Part Description
(6)	1	3D-2824	O-Ring Seal
(7)	1	6V-9007	Elbow
(8)	3	6V-9746	O-Ring Seal
(9)	1	8T-8899	Elbow
(10)	1	390-4574	Hose As
(25)	2	3J-1907	O-Ring Seal
(26)	1	6V-3965	Fitting (TEST)
(27)	1	7X-0873	Tee

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Illustration 82	g03374159

Install elbow (7) with O-ring seal (6) on the inlet fitting of oil filter group (2). Tighten the adapter to a torque of 220 ± 33 N·m (162 ± 24 lb ft).
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Illustration 83 g06207330
Attach elbow (9) with O-ring seal (8) to elbow (7). Tighten the adapter to a torque of 140 ± 21 N·m (103 ± 15 lb ft).
Connect filter inlet hose assembly (10) to elbow (9) with O-ring seal (8). Tighten the hose to a torque of 140 ± 21 N·m (103 ± 15 lb ft).
Connect elbow (9) to Tee (27) with Fitting (26) and O-ring seal (25).
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Illustration 84 g03349698
Route filter inlet hose assembly (10) to the charge pump discharge port. Connect this hose to the tee fitting on the charge pump discharge port with O-ring seal (8). Tighten the hose to a torque of 140 ± 21 N·m (103 ± 15 lb ft).

Connect Filter Group to WDS Pump

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Table 26
Required Parts Group Number 390-4265 Hydraulic Filter and Lines Gp (Rev 04)
Item	Qty	Part Number	Part Description
(6)	1	3D-2824	O-Ring Seal
(8)	1	6V-9746	O-Ring Seal
(11)	1	8T-2883	Tee
(12)	1	390-4575	Hose As
(13)	1	7J-9108	O-Ring Seal
(14)	1	232-4869	Elbow
(15)	1	6V-7970	O-Ring Seal
(16)	1	6V-8397	O-Ring Seal

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Illustration 85	g03374154

Attach tee fitting (11) with O-ring seal (6) to outlet of oil filter group (2). Tighten the tee fitting to a torque of 220 ± 33 N·m (162 ± 24 lb ft).
Install O-ring seal (16) in tee fitting (11).
Connect WDS pump charge inlet hose (12) to tee fitting (11) with seal (8). Tighten the hose to a torque of 140 ± 21 N·m (103 ± 15 lb ft).
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Illustration 86 g03349713
Route WDS pump charge inlet hose assembly (12) to the charge inlet port of the WDS hydraulic pump.
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Illustration 87 g03349716
Install elbow (14) with O-ring seal (15) in the inlet port of the WDS hydraulic pump. Tighten the elbow to a torque of 140 ± 21 N·m (103 ± 15 lb ft).
Connect WDS pump charge inlet hose assembly (12) to elbow (14) with O-ring seal (13). Tighten the hose to a torque of 110 ± 17 N·m (81 ± 13 lb ft).

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

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Table 27
Required Parts Group Number 390-4262 Pump Lines Gp (Rev 06)
Item	Qty	Part Number	Part Description
(17)	3	4J-5477	O-Ring Seal
(18)	1	418-4213	Hose As
(19)	1	418-4214	Hose As

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

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Illustration 88	g03357345

Connect green motor signal pressure hose assembly (18) with O-ring seal (17) to the adapter in the motor signal port of the plate assembly. Tighten the hose to a torque of 27 ± 4 N·m (20 ± 3 lb ft).
Connect yellow motor pilot pressure hose assembly (19) with O-ring seal (17) to the adapter in the motor pilot port of the plate assembly. Tighten the hose to a torque of 27 ± 4 N·m (20 ± 3 lb ft).
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Illustration 89 g03357346
Route green motor signal pressure hose assembly (18) and motor pilot pressure hose assembly (19) along the left frame rail toward the front of the machine.
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Illustration 90 g03357349
Route green motor signal pressure hose assembly (18) to the bottom of WDS pump (A).
Note: Connect green motor signal pressure hose to the left port of pump in order to achieve proper water pump operation.
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Illustration 91 g03357352
Connect green motor signal pressure hose assembly (18) with O-ring seal (17) to elbow (B).
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Illustration 92 g03375710
Connect motor pilot pressure hose assembly (19) to tee fitting (11).
Note: O-ring seal (16) was previously installed in this fitting. Verify that seal is in place prior to connecting hose.

Install Clips on the Hose Assembly

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Table 28
Required Parts Group Number 390-4262 Pump Lines Gp (Rev 06)
Item	Qty	Part Number	Part Description
(20)	1	6V-1889	Clip
(21)	1	8M-2770	Clip
(22)	2	3E-4352	Hard Washer
(23)	1	6V-3940	Bolt
(24)	1	5C-7261	Nut

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Illustration 93	g03357354

Install clip (20) on filter inlet hose (10). Install clip (21) on motor signal pressure hose assembly (18).
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Illustration 94 g03357356
Insert bolt (23) with hard washer (22) through the clips. Fasten the bolt in place with nut (24) and hard washer (22).

Install spray head Pilot Pressure and Pilot Return Hoses

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Table 29
Required Parts Group Number 390-4263 Pilot Lines Gp (Rev 03)
Item	Qty	Part Number	Part Description
(1)	1	390-4577	Hose As
(2)	1	390-4576	Hose As
(3)	5	6V-8397	O-Ring Seal
(4)	1	7X-3406	Cross Union
(5)	2	6V-9829	Cap As
(6)	1	4I-6287	Coupling
(7)	3	3J-1907	O-Ring Seal
(8)	1	126-6872	Tee
(9)	1	9S-4191	O-Ring Plug

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Illustration 95	g03349743

Disconnect hose (B) from adapter (C) on hoist valve (A).
Disconnect hose (D) from adapter (C) on hoist valve (A).
Remove adapter (C) from hoist valve (A).
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Illustration 96 g03349749
Install coupling (6) in hoist valve (A) with O-ring seal (7).
Install cross union (4) into coupling (6) with O-ring seal (3). Tighten the adapter to a torque of 45 ± 5 N·m (33 ± 4 lb ft).
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Illustration 97 g03349751
Connect hose (B) to cross union (4) with O-ring seal (3).
Connect hose (D) to cross union (4) with O-ring seal (3).
Connect brown spray head pilot pressure hose assembly (2) to cross union (4) with O-ring seal (3). Tighten this hose to a torque of 45 ± 5 N·m (33 ± 4 lb ft).
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Illustration 98 g03357362
Route brown spray head pilot pressure hose assembly (2) along the left frame rail to spray head pilot pressure port (E).
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Illustration 99 g03357365
Connect brown spray head pilot pressure hose assembly (2) to the adapter in spray head pilot pressure port (E).
Note: Seal was previously installed in this fitting. Verify that the seal is in place prior to connecting hose.
Connect black spray head pilot return hose assembly (1) to the adapter in spray head pilot return port (F).
Note: Seal was previously installed in this fitting. Verify that the seal is in place prior to connecting hose.
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Illustration 100 g03357367

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Illustration 101 g03349769
Route black spray head pilot return hose assembly (1) along the right frame rail to the machine hydraulic tank.
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Illustration 102 g03349770
Install tee (8) with O-ring seal (7) in the port of the machine hydraulic tank. Tighten the adapter to a torque of 55 ± 8 N·m (41 ± 6 lb ft).
Install O-ring plug (9) with O-ring seal (7) in tee (8). Tighten the plug to a torque of 60 ± 1 N·m (44 ± 1 lb ft).
Connect black spray head pilot return hose assembly (1) with O-ring seal (3) to tee (8). Tighten the hose to a torque of 45 ± 5 N·m (33 ± 4 lb ft).

Clip Hoses to the Truck Frame

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Table 30
Required Parts Group Number 390-4262 Pump Lines Gp (Rev 06)
Item	Qty	Part Number	Part Description
(10)	3	9U-0810	Block
(11)	3	4D-7733	Clip
(12)	3	4K-6177	Clip
(13)	3	8T-4121	Hard Washer
(14)	3	6V-5842	Bolt

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Illustration 103	g03357371
Left Frame Rail (1) Spray head pilot return hose (black) (2) Spray head pilot pressure hose (brown) (K) Motor signal pressure hose (green) (L) Motor pilot pressure hose (yellow) (M) Motor case drain hose

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Illustration 104	g03357372

Install blocks (10) at location (G), location (H) and location (J) on the machine frame.
For each location, install clip (11) on spray head pilot return hose assembly (1) and spray head pilot pressure hose assembly (2). Install clip (12) on motor signal pressure hose (K) and motor pilot pressure hose (L).
For each location, fasten clip (11) and clip (12) to each block (10) with bolt (14) and washer (13).

Install Clips on the Hose Assembly

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Table 31
Required Parts Group Number 390-4262 Pump Lines Gp (Rev 06)
Item	Qty	Part Number	Part Description
(12)	4	4K-6177	Clip
(13)	14	8T-4121	Hard Washer
(15)	3	8M-2773	Clip
(16)	7	7D-7233	Clip
(17)	7	6V-1820	Bolt
(18)	7	2Y-5829	Nut

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Illustration 105	g03357375

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Illustration 106	g03349784

Install three clips (15) on spray head pilot pressure hose assembly (2). Install three clips (16) on pump high-pressure hose (N).
Insert bolt (17) and hard washer (13) through each pair of clips (15) and (16). Fasten each bolt in place with nut (18) and hard washer (13).
Install three clips (12) on motor signal pressure hose (K) and motor pilot pressure hose (L). Install three clips (16) on pump low-pressure hose (P).
Insert bolt (17) and hard washer (13) through each pair of clips (12) and (16). Fasten each bolt in place with nut (18) and hard washer (13).

Install Clips on the Hose Assembly

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Table 32
Required Parts Group Number 390-4262 Pump Lines Gp (Rev 06)
Item	Qty	Part Number	Part Description
(13)	5	8T-4121	Hard Washer
(18)	2	2Y-5829	Nut
(19)	6	8T-2525	Grommet
(20)	6	5P-7469	Clip
(21)	6	5P-7468	Clip
(22)	2	6V-1869	Grommet
(23)	2	6V-1868	Clip
(24)	2	6V-1867	Clip
(25)	2	6V-4249	Bolt
(26)	1	105-7781	Spacer
(27)	1	6V-7730	Bolt

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Illustration 107	g03357379

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Illustration 108	g03357381

Install six grommets (19) on pump high-pressure hose (N) and pump low-pressure hose (P). Install clips (20) and clips (21) over each grommet.
Install grommet (22) on tube (Q). Install clip (23) and clip (24) over the grommet.
Insert bolt (25) and hard washer (13) through these clips in order to clamp the pair of hoses to tube (Q). Fasten the bolt in place with nut (18) and hard washer (13).
Install grommet (22) on tube (R). Install clip (23) and clip (24) over the grommet.
Insert bolt (25) and hard washer (13) through these clips in order to clamp the pair of hoses to tube (R). Fasten the bolt in place with nut (18) and hard washer (13).
Install spacer (26) on the machine cross tube at location (S). Insert bolt (25) and hard washer (13) through clips (20) and (21) and the spacer to clamp the pair of hoses to the machine frame.

Install Clips on the Hose Assembly

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Table 33
Required Parts Group Number 390-4262 Pump Lines Gp (Rev 06)
Item	Qty	Part Number	Part Description
(12)	1	4K-6177	Clip
(15)	1	8M-2773	Clip
(28)	1	8T-4224	Hard Washer
(29)	1	6V-3940	Bolt
(30)	1	3E-4352	Hard Washer
(31)	1	5C-7261	Nut

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Illustration 109	g03357424

Install clip (15) on motor signal pressure hose (K) and motor pilot pressure hose (L).
Install clip (12) on spray head pilot pressure hose assembly (2).
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Illustration 110 g03349798
Insert bolt (29) and hard washer (28) through these clips in order to clamp the three hoses together. Fasten the bolt in place with nut (31) and hard washer (30).

Install Clips on the Hose Assembly

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Table 34
Required Parts Group Number 390-4262 Pump Lines Gp (Rev 06)
Item	Qty	Part Number	Part Description
(13)	2	8T-4121	Hard Washer
(15)	1	8M-2773	Clip
(17)	1	6V-1820	Bolt
(18)	1	2Y-5829	Nut
(32)	1	6V-1889	Clip

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Illustration 111	g03357427

Install clip (32) on motor case drain hose (M).
Install clip (15) on spray head pilot return hose assembly (1).
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Illustration 112 g03350014
Insert bolt (17) and hard washer (13) through these clips in order to clamp the two hoses together. Fasten the bolt in place with nut (18) and hard washer (13).

Install Drive Shaft Guard Assembly

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Table 35
Required Parts Group Number 390-4262 Pump Lines Gp (Rev. 06)
Item	Qty	Part Number	Part Description
(33)	1	435-5395	Guard As

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Illustration 113	g03368981

Install guard assembly (33) over the drive shaft.

Hydraulic and Component Installation (Tank)

Water Pump Installation

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Table 36
Required Parts ⁽¹⁾ Group Number 477-8411 Pump and Mounting Gp (Rev. 01)
Item	Qty	Part Number	Part Description
1	1	477-8412	Water Pump Gp
2	1	452-2338	Coupling As
3	1	284-2728	Pressure Sensor Gp
4	1	436-2444	Gasket Kit

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⁽¹⁾	If stainless steel water pump is ordered, refer to Table 37.

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Table 37
Required Parts Group Number 448-5559 Pump and Drive Gp (Rev. 04) - 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
5⁽¹⁾	1	5P-4675	Adapter

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⁽¹⁾	Preassembled to pump

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Illustration 114	g03350017

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Illustration 115	g03350020

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.
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.
Bolt water pump and drive group (1) onto mounting adapter (B) on the water tank.
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.
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Illustration 116 g03697323
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.
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Illustration 117 g03697384
Install pressure sensor (3) onto spray bar at location shown in Illustration 117.

WDS Motor Installation

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Table 38
Required Parts Group Number 371-2721 Piston Motor and Mounting Gp (Rev 05)
Item	Qty	Part Number	Part Description
(1)	1	358-0163	Piston Motor Gp
(2)	2	8T-4122	Hard Washer
(3)	2	7X-0347	Bolt

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Illustration 118	g03714786

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.
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Illustration 119 g03350024

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.
Note: Use suitable lifting device to install the WDS motor. This pump weighs approximately 55 kg (121 lb).
Mount WDS piston motor group (1) onto water pump (A). Ensure that the spline of motor engages coupler (B).
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Illustration 120 g03375720

Note: Orient the WDS motor as shown in the above Illustration with motor signal port (C) and motor pilot port (D) on the left side of the truck.
FastenWDS 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).

Water Pump Motor to Bulkhead Lines Routing

Connect WDS Motor Pressure Hoses

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Table 39
Required Parts Group Number 372-1177 Motor Lines Gp (Rev 04)
Item	Qty	Part Number	Part Description
(1)	1	4J-0522	O-Ring Seal
(2)	1	246-2951	Adapter
(3)	2	1P-3703	Rectangular Seal
(4)	1	418-4216	Hose As (High-Pressure - red)
(5)	1	418-4215	Hose As (Low-Pressure - blue)
(6)	4	6V-0400	Half Flange
(7)	8	8T-4223	Hard Washer
(8)	4	6V-8336	Bolt
(9)	4	8T-4184	Bolt
(10)	3	3J-1907	O-Ring Seal
(11)	1	9S-4191	O-Ring Plug
(34)	1	6V-8076	Elbow

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Illustration 121	g06207335
Water Pump Motor (A) Motor high-pressure port (red) (B) Motor low-pressure port (blue)

Install adapter (2) with seal (1) to elbow (34) with O-Ring Seal (10) in motor high pressure port (A).
Connect red motor high-pressure hose assembly (4) with rectangular seal (3) to motor high-pressure port (A). Install two half flanges (6) around the hose.
Connect blue motor low-pressure hose assembly (5) with rectangular seal (3) to motor low-pressure port (B). Install two half flanges (6) around the hose.
Note: The motor high-pressure hose and the motor low-pressure hose are provided with reusable couplings. Cut hoses to length based upon requirements.
Note: Ensure that each hose has adequate length in order to accommodate lifting and lowering of the water tank.
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Illustration 122 g03375730
Fasten the red motor high-pressure hose assembly (4) and half flanges (6) to the WDS motor with four bolts (8) and four hard washers (7). Tighten the bolts to a torque of 100 ± 20 N·m (74 ± 15 lb ft).
Fasten the blue motor low-pressure hose (5) and half flanges (6) to the WDS motor with four bolts (9) and four hard washers (7). Tighten the bolts to a torque of 100 ± 20 N·m (74 ± 15 lb ft).
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Illustration 123 g03350066
Install O-ring plug (11) with O-ring seal (10) in bottom of adapter (2). Tighten the plug to a torque of 60 ± 9 N·m (44 ± 7 lb ft).
Note: The plug is a temporary component. This plug must be removed when the sensor is installed or item (34) is installed.

Connect WDS Motor Pressure Hoses to Plate Assembly

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Table 40
Required Parts Group Number 372-1177 Motor Lines Gp (Rev 04)
Item	Qty	Part Number	Part Description
(3)	2	1P-3703	Rectangular Seals

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Illustration 124	g03357439
Rear View Of Bulkhead Plate (C) Pump low-pressure port (blue) (D) Pump high-pressure port (red)

Route blue motor low-pressure hose assembly (5) from the WDS motor to pump low-pressure port (C) on the bulkhead plate.
Route red motor high-pressure hose assembly (4) from the WDS motor to pump high-pressure port (D) on the bulkhead plate.
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Illustration 125 g03357440

Rear View Of Bulkhead Plate
(C) Pump low-pressure port (blue)
(D) Pump high-pressure port (red)
Connect blue motor low-pressure hose assembly (5) with rectangular seal (3) to pump low-pressure port (C) with two flanges (E). Fasten the flanges to the plate assembly with four bolts (G) and four washers (F). Tighten the bolts to a torque of 70 ± 15 N·m (52 ± 11 lb ft).
Connect red motor high-pressure hose assembly (4) with rectangular seal (3) to pump high-pressure port (D) with two flanges (E). Fasten the flanges to the plate assembly with four bolts (G) and four washers (F). Tighten the bolts to a torque of 70 ± 15 N·m (52 ± 11 lb ft).

Install WDS Motor Case Drain Fitting

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Table 41
Required Parts Group Number 372-1177 Motor Lines Gp (Rev 04)
Item	Qty	Part Number	Part Description
(12)	1	6V-7970	O-Ring Seal
(13)	1	421-6193	Connector
(14)	1	6V-9746	O-Ring Seal
(33)	1	5K-9090	O-Ring Seal

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Illustration 126	g03357441

Install connector (13) with O-ring seal (12) in the case drain line fitting of the WDS motor. Tighten the adapter to a torque of 140 ± 21 N·m (103 ± 15 lb ft).
Install O-ring seal (14) in connector (13).

Connect WDS Motor Case Drain Hose to the Plate Assembly

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Table 42
Required Parts Group Number 372-1177 Motor Lines Gp (Rev 04)
Item	Qty	Part Number	Part Description
(15)	1	469-1914	Hose As
(16)	3	143-4299	Grommet
(17)	3	7G-5984	Clip
(18)	3	7G-5985	Clip
(19)	3	7D-7233	Clip
(20)	5	6V-5839	Washer
(21)	3	0S-1594	Bolt
(22)	2	6V-8801	Nut

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Illustration 127	g06207339
Vertical Mounting of WDS Motor

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Illustration 128	g03357443
Case Drain Port for Inverted Horizontal Mounting

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Illustration 129	g03357444
Case Drain Port for Horizontal Mounting

Connect motor case drain hose assembly (15) with O-ring seal (14) to connector (13) in the case drain line fitting of the WDS motor. Tighten the hose to a torque of 140 ± 21 N·m (103 ± 15 lb ft).
Note: Water pump drive motor mounting orientation varies, depending on your tank supplier.
Note: Water pump drive motor has two case drain ports. The case drain hose must be installed in the higher of the two ports on the motor.
Note: Ensure that proper case drain port is selected for your water pump drive motor orientation.
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Illustration 130 g03357445
Route motor case drain hose assembly (15) to motor case drain port (H) of the plate assembly.
Note: The motor case drain hose is provided with reusable couplings. Cut this hose to length based upon requirements.
Note: Ensure that the hose has adequate length in order to accommodate lifting and lowering of the water tank.
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Illustration 131 g03357446

Rear View Of Bulkhead Plate
Connect motor case drain hose assembly (15) to the adapter in motor case drain port (H) on the bulkhead plate. Tighten the hose to a torque of 140 ± 21 N·m (103 ± 15 lb ft).
Note: The seal was previously installed in this adapter. Verify that the seal is in place prior to connecting the hose.
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Illustration 132 g03357447
Install three grommets (16) on motor low-pressure hose assembly (5) and motor high-pressure hose assembly (4).
Install clips (17) and clips (18) over each grommet.
Install three clips (19) on motor case drain hose assembly (15).
Insert bolt (21) and washer (20) through each set of clips in order to clamp the three hoses together. Fasten each bolt in place with nut (22) and washer (20).

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
(23)	2	6V-6560	O-Ring Seal
(24)	2	8T-7489	Connector
(25)	3	6V-8397	O-Ring Seal
(26)	1	6V-9850	Elbow
(27)	2	124-2159	Permanent Coupling
(28)	2	124-2111	Permanent Coupling
(29)	5	100-4336	Clip
(30)	5	8T-4121	Hard Washer
(31)	5	7E-7606	Bolt
(32)⁽¹⁾	1	122-6867	Hose

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⁽¹⁾	This component must be provided by the customer.

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Illustration 133	g03357448
WDS Motor (J) Motor signal port (green) (K) Motor pilot port (yellow)

Install connector (24) with O-ring seal (23) in motor pilot port (K) of the WDS motor. Tighten the adapter to a torque of 50 ± 8 N·m (37 ± 6 lb ft).
Connect elbow (26) with O-ring seal (25) to connector (24). Tighten the adapter to a torque of 45 ± 5 N·m (33 ± 4 lb ft).
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Illustration 134 g03357450

WDS Motor
(J) Motor signal port (green) - straight fitting
(K) Motor pilot port (yellow) - 90 degree adapter
Install connector (24) with O-ring seal (23) into motor signal port (J) of the WDS motor. Tighten the adapter to a torque of 50 ± 8 N·m (37 ± 6 lb ft).
Measure two lengths of bulk hose (32) from the WDS motor to the plate assembly 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.
Create two hose assemblies as follows:
- Yellow motor pilot pressure hose - install one permanent coupling (27) on one end and install one permanent coupling (28) on the other end
- Green motor signal pressure hose - install one permanent coupling (27) on one end and install one permanent coupling (28) on the other end
Note: Label both ends of both hoses before connecting.
Connect the end of the yellow motor pilot pressure hose with permanent coupling (27) to elbow (26) in motor pilot port (K) with O-ring seal (25).
Connect the end of the green motor signal pressure hose with permanent coupling (27) to connector (24) in motor signal port (J) with O-ring seal (25).
Route both hoses under the water tank to the plate assembly on the back of the truck.
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Illustration 135 g03357452

Rear View Of Bulkhead Plate
(L) Motor signal line fitting (green)
(M) Motor pilot pressure hose fitting (yellow)
Connect the green motor signal line to bulkhead adapter (L) with seal (4).
Note: The seal was previously installed in this adapter. Verify that the seal is in place prior to connecting the hose.
Connect the yellow motor pilot pressure hose to bulkhead adapter (M) with seal (4).
Note: The seal was previously installed in this adapter. Verify that the seal is in place prior to connecting the hose.
Clip the yellow motor pilot pressure hose and the green motor signal pressure hose together with five clips (29). Fasten the clips in place with bolts (31) and hard washers (30).

Install Pump Breather Group

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Table 44
Required Parts Group Number 420-4443 Breather Gp (Rev. 00)
Item	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 Plug
(9)	9	3J-1907	O-Ring Seal
(10)	1	4J-5477	O-Ring Seal
(11)	2	8T-4121	Hard Washer

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Illustration 136	g03367416
Vertically Mounted Water Pump

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Illustration 137	g03368841
Horizontally Mounted Water Pump

Install five O-ring plugs (8) with O-ring seals (9) in the water pump.
Install connector (5) with O-ring seal (9).
Install fitting assembly (7) in connector (5) with O-ring seal (9).
Install connector (1) with O-ring seal (9).
Connect hose assembly (6) to connector (1) with O-ring seal (10).
Install breather (3) in the end of hose assembly (6).
Install clip (4) on hose assembly (6). Fasten clip (4) to the rear of the water tank with bolt (2) and two hard washers (11).
Remove the plug from oil level check port (A).
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.

Spray Head Installation

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Table 45
Required Parts Spray Head Installation
Item	Qty	Part Number	Part Description
1	5	416-9877	Water Control Valve Gp (STAINLESS STEEL)

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Illustration 138	g03714795

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.
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Illustration 139 g03714799

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Illustration 140 g03714801
Install water control valve group (1) on spray bar (D). Reinstall split flanges (A). Do not tighten the mounting bolts.
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Illustration 141 g03697517

(E) 152 mm (6 inch)

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Illustration 142 g03714803
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.
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Illustration 143 g03682227
Repeat the previous steps for the remaining spray heads on the rear spray bar.
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Illustration 144 g03714804
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.
Rotate water control valve group (1) on spray bar (F) in order to obtain the desired direction for water spray. Tighten the mounting bolts.
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 423-1568 Sensor Wiring Gp (Rev. 02)
Item	Qty	Part Number	Part Description
(1)	4	4P-7581	Clip
(2)	3	4P-8134	Clip
(3)	3	132-5789	Clip
(4)	1	294-3313	Clip
(5)	2	310-1898	Clip
(6)	1	455-3054	Sensor Harness As
(7)	7	200-6345	Mount
(8)	58	7K-1181	Cable Strap
(9)	14	204-2281	Cable Strap

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Illustration 145	g03375209

Plug chassis sensor harness assembly (6) into the receptacle on the rear bulkhead of the operator cab. Route sensor harness assembly (6) along truck chassis harness (A). Strap sensor harness assembly (6) in place with cable straps (8).
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Illustration 146 g03367784
Route chassis sensor harness assembly (6) under the operator cab. Route sensor harness assembly (6) along truck chassis harness (A). Strap sensor harness assembly (6) in place with cable straps (8).
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Illustration 147 g03362967
Locate portion (B) of sensor harness assembly (6) that connects to the fan. Route this portion of the harness assembly up and over the deck plates to cooler group (C).
Fasten mounts (7) to the installed hoses with cable straps (9). Strap the sensor harness assembly (6) to the mounts with cable straps.
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Illustration 148 g03362966
Fasten clip (4) to the mounting plate of cooling group (C). Tie sensor harness assembly (6) to clip (4) with cable straps (8).
Connect the fan power wire from sensor harness assembly (6) to contact (D). Connect the fan ground wire to contact (E).
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Illustration 149 g03358051
Route the remainder of chassis sensor harness assembly (6) along the truck chassis harness (A). Tie the cable in place with cable straps (8).
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Illustration 150 g03358053
Locate portion (F) of sensor harness assembly (6) that connects to the WDS pump. Route this portion of the harness assembly over the drive shaft cover and down to the pump.
Fasten clips (1) and (3) to the cross tube and the drive shaft cover. Tie sensor harness assembly (6) to the clips with cable straps (8).
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Illustration 151 g03362969
Plug sensor harness assembly (6) into the solenoid connector (G) on the WDS pump.
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Illustration 152 g03362972
Route the remainder of chassis sensor harness assembly (6) along truck chassis harness (A). Tie the cable in place with cable straps (8).
Locate portion (H) of harness assembly (6) that connects to the hoist valve and the oil filter. Route this portion of the harness assembly over the drive shaft cover and down to the oil filter.
Tie the sensor harness assembly (6) to the truck chassis harness with cable straps (8).
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Illustration 153 g03358058
Locate the portion of sensor harness assembly (6) that connects to the oil filter. Route this portion down the right frame rail to the oil filter.
Install clips (3) and (5). Tie sensor harness assembly (6) to clips (3) and (5) with cable straps (8).
Locate bypass switch connector (J) on the oil filter. Connect the wiring to the bypass switch.
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Illustration 154 g03358056
Locate the portion of sensor harness assembly (6) that connects to the hoist valve. Route this portion along the right frame rail to the hoist valve. Tie sensor harness assembly (6) to the frame with cable straps (8).
Connect the hoist lower connector of sensor harness assembly (6) to the hoist lower solenoid (K).
Connect the hoist raise connector of sensor harness assembly (6) to the hoist raise solenoid (L).
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Illustration 155 g03362980
Locate the portion (M) of sensor harness assembly (6) that connects to the WDS hydraulic tank. Route this portion down the inside of the left frame rail. Tie the harness assembly to the frame with cable straps (8).
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Illustration 156 g03362968
Route sensor harness assembly (6) under the left frame rail and up the side of the truck hydraulic tank. Tie the harness assembly to the frame with mount (7) and cable straps (9).
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Illustration 157 g03358055
Route sensor harness assembly (6) up and over the WDS hydraulic tank. Tie the cable in place with clips (2) and cable straps (8).
Connect the temperature sensor wire to the temperature sensor connector (P).
Connect the tank level sensor wire to tank level sensor connector (N).
Note: Proper connections of the temperature sensor and level sensor wiring is of critical importance.
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Illustration 158 g03358180
Route the remainder of chassis sensor harness assembly (6) along the left frame rail to the rear of the machine. Tie the cable in place with cable straps (8).

Install Bracket

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Table 47
Required Parts Group Number 423-1578 Electrical Installation Gp (Rev. 02)
Item	Qty	Part Number	Part Description
(10)	1	8T-4137	Bolt
(11)	1	418-9739	Bracket
(12)	1	8T-4121	Hard Washer
(13)	1	9R-2613	Weld Boss

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Illustration 159	g06207341

Fasten bracket (11) onto weld boss (13) to the right side of the rear truck frame with bolt (10) and hard washer (12).
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Illustration 160 g03362997
Route the remainder of the sensor harness assembly (6) to the rear of the truck. Plug the harness assembly into bracket (11) on the rear of the truck.

Rear Hydraulic Manifold Installation

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Table 48
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	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.

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Illustration 161	g03357466
Rear Hydraulic Manifold (C)

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Illustration 162	g03357467

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.
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Illustration 163 g03357469

(A) Spray head open port
(B) Spray head close port
Locate connector (6) for the spray head pressure lines. Install O-ring seal (7) on each adapter.
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.
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Illustration 164 g03357470
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.
Install one end of each line in the rod pressure fitting and the head pressure fitting of each spray valve with permanent coupling (10).
Clamp the spray head hoses to water tank with clips (12).
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Illustration 165 g03357471

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.

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Illustration 166	g03357473
(A) Spray head - open "A"port (B) Spray head - close "B"port

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Illustration 167	g03357475
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"

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Illustration 168	g03357478
(P) Spray head "2" (Q) Spray head "3" (R) Spray head "6" (S) Spray head "4" (T) Spray head "5"

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)
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Illustration 169 g03357480

( U) Spray head pilot return port (black)
(V) Spray head pilot supply port (brown)
Install connector (15) with O-ring seal (16) in spray head pilot return port (U) of rear hydraulic manifold (A).
Install connector (15) with O-ring seal (16) in spray head pilot supply port (V) of rear hydraulic manifold (A).
Connect one swivel tee (17) with O-ring seal (18) to each adapter (16).
Connect one cap assembly (19) with O-ring seal (18) to each tee adapter (17).
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.
Connect one end of each hose assembly to the tee adapter at the bottom of the rear hydraulic manifold.
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Illustration 170 g03357481

(W) Spray head pilot return fitting (black)
(X) Spray head pilot supply fitting (brown)
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).
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).
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Illustration 171 g03357482
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 49
Required Parts Group Number 423-1578 Electrical Installation Gp (Rev. 02) Refer 423-1577 Control Wiring Gp (REAR) (Rev. 00)
Item	Qty	Part Number	Part Description
(1)	1	357-7152	Plate As
(2)	4	7X-7729	Washer
(3)	4	8T-4195	Bolt

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Illustration 172	g03357483

Mount plate assembly (1) to the rear of the water tank.
Note: Mounting bosses must be provided with the tank. Reference the Tank Requirements Guide, REHS7098.
Fasten plate assembly (1) in place with four bolts (3) and four washers (2).

Install Rear Electrical Control Group

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Table 50
Required Parts Group Number 423-1578 Electrical Installation Gp (Rev. 02) Refer 423-1577 Control Wiring Gp (REAR) (Rev. 00)
Item	Qty	Part Number	Part Description
(4)	4	242-2961	Spacer
(5)	1	423-1574	Control Box Gp
(6)	4	5P-0537	Hard Washer
(7)	4	8T-9808	Grommet

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Illustration 173	g03357484

Mount control box group (5) to plate assembly (1), with the connectors pointing down.
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Illustration 174 g03375906
Insert spacers (4) between control box group (5) and plate assembly (1).
Fasten control box group (5) to plate assembly (1) with four bolts (7) and four hard washers (6).

Connect Rear Control Harness Assembly

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Table 51
Required Parts Group Number 423-1578 Control Wiring Gp (Rev. 02) Refer 423-1577 Control Wiring Gp (REAR) (Rev. 00)
Tool	Qty	Part Number	Part Description
(8)	1	335-5321	Pressure Sensor Gp
(9)	1	423-1571	Sensor Harness As
(10)⁽¹⁾	1	284-2728	Pressure Sensor Gp

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⁽¹⁾	For pressure sensor rust proof, use 448-3671 Pressure Sensor Gp supplied with stainless steel water pump

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Illustration 175	g03375267

Connect sensor harness assembly (9) to control group (5).
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Illustration 176 g03357487
Remove plug and install pressure sensor group (8) on the motor inlet pressure tap.
Route sensor harness assembly (9) to pressure sensor group (8). Connect the harness assembly to the pressure sensor.
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Illustration 177 g03362982
Install pressure sensor group (10) on the rear spray bar.

Route sensor harness assembly (9) to pressure sensor group (10). Connect the harness assembly to the pressure sensor.

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Illustration 178	g03357489
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"

Locate the hydraulic manifold portion of sensor harness assembly (9). 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.
Connect sensor harness assembly (9) to the rear hydraulic manifold as shown:
- Spray valve "5A" (A) - J750-OR(Orange)wire
- Spray valve "4A" (B) - L944-GY(Grey)wire
- Spray valve "6A" (C) - L937-OR(Orange)wire
- Spray valve "3A" (D) - J747-BU(Blue)wire
- Spray valve "2A" (E) - L949-BU(Blue)wire
- Spray valve "5B" (F) - J751-GN(Green)wire.
- Spray valve "4B" (G) - L947-BR(Brown)wire
- Spray valve "6B" (H) - L942-GN(Green)wire
- Spray valve "3B" (J) - J748-PK(Pink)wire
- Spray valve "2B" (K) - L951-GN(Green)wire
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Illustration 179 g03361304
Route the tank level sensor wires of sensor harness assembly (9) 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 Straps Along Harness Assembly

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Table 52
Required Parts Group Number 423-1578 Control Wiring Gp (Rev. 02) Refer 423-1577 Control Wiring Gp (REAR) (Rev. 00)
Tool	Qty	Part Number	Part Description
(12)	9	8T-4136	Bolt
(13)	5	4P-7581	Clip
(14)	1	303-4649	Clip
(15)	4	310-1898	Clip
(16)	11	7K-1181	Cable Strap
(17)	9	8T-4121	Hard Washer

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Illustration 180	g03375264
Rear of Water Tank

Attach clips (13) to the rear of the water tank with bolts (12) and hard washers (17).
Attach clip (14) and clips (15) to the rear of the water tank with bolts (12) and hard washers (17).
Tie sensor harness assembly (9) to the rear of the water tank with cable straps (16).

Install Communication Harness

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Table 53
Required Parts Group Number 423-1576 Control Wiring Gp (Rev. 00)
Tool	Qty	Part Number	Part Description
(18)	1	423-1572	Control Harness As
(19)	19	4P-7581	Clip
(20)	19	8T-4121	Hard Washer
(21)	19	8T-4136	Bolt
(22)	1	310-1898	Clip
(23)	20	7K-1181	Cable Strap

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Illustration 181	g03375257

Connect control harness assembly (18) to connector (L) on bottom of control box group (5).
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Illustration 182 g03357497
Route control harness assembly (18) with sensor harness assembly (9) along the rear of the water tank.
Install clips (22) and (19) on the rear and bottom of the water tank with bolts (21) and hard washers (20).
Tie control harness assembly (18) and sensor harness assembly (9) to the clips with cable straps (23).
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Illustration 183 g03357498
Locate the portion of control harness assembly (18) that connects to the chassis harness. Plug this portion into the connector on bracket (M).
Install clips (19) on the bottom of the water tank with bolts (21) and hard washers (20).
Route control harness assembly (18) along sensor harness assembly (9) across and under the water tank.
Tie control harness assembly (18) and sensor harness assembly (9) to clips (19) with cable straps (23).
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Illustration 184 g03362632
Install clips (19) on the front of the water tank with bolts (21) and hard washers (20).
Route control harness assembly (18) up the front of the water tank. Tie the cable to the clips with cable straps (23).
Note: This cable will be connected after the front control group is installed.

Install Tank Level Sensor

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Table 54
Required Parts Group Number 423-1578 Control Wiring Gp (Rev. 00)
Tool	Qty	Part Number	Part Description
(24)	1	7J-8611	Pipe Elbow
(25)	1	355-9448	Pressure Sensor

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Illustration 185	g03357490

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Illustration 186	g03357491

Install pipe elbow (24) in the front of the water tank. Connect pressure sensor (25) 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.
Connect sensor harness assembly (9) to the pressure sensor (25).

Front Hydraulic Manifold Installation

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Table 55
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 187	g03357500
Front Hydraulic Manifold (A)

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Illustration 188	g03357501

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 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.
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Illustration 189 g03357502

(B) Spray head pilot supply port (brown)
(C) Spray head pilot return port (black)
Connect connector (22) with O-ring seal (26) to spray head pilot supply port (B).
Connect elbow (20) with O-ring seal (27) to connector (22).
Connect elbow (21) with O-ring seal (26) to spray head pilot return port (C).
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 coupling (25) on each end.
Note: Clearly mark each end of both hoses for identification purposes using color codes provided for mating components.
Connect the brown hose assembly to elbow (20) in spray head pilot supply port (B) with O-ring seal (27).
Connect the black hose assembly to elbow (21) in spray head pilot return port (C) with O-ring seal (27).
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Illustration 190 g03375932
Route the hose assemblies down the front of the water tank. Clamp the hoses to the water tank with clips (24), bolts (23) and hard washers (28).
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Illustration 191 g03357505
Route the hose assemblies under the water tank to the plate assembly on the back of the truck. Clamp the hoses to the water tank with clips (24), bolts (23) and hard washers (28).
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Illustration 192 g03357506

(D) Spray head pilot return fitting
(E) Spray head pilot supply fitting

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Illustration 193 g03367810

Alternate Connection Locations On Rear Hydraulic Manifold
(D) Spray head pilot return port (black)
(E) Spray head pilot supply port (brown)

Note: Pilot supply and pilot return hose assemblies can be connected to the plate assembly or the rear hydraulic manifold.
Connect the brown hose assembly from spray head pilot supply coupling (B) to spray head pilot supply fitting (E) with O-ring seal (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).
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Illustration 194 g03357507

(F) Spray head "7"

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Illustration 195 g03357508

(G) Spray head "1"
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.
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Illustration 196 g03357509

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.
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).
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Illustration 197 g03357510

Spray head "1" (G)
( K) Spray head - open "A" port
(L) Spray head - close "B" port
Install adapter (4) with seal (12) in spray head close port (L) and spray head open port (K) of spray valve "1" (G).
Connect the four hose assemblies to the spray heads. Connect the end of each hose assembly with straight permanent coupling (8) to adapter (4) with O-ring seal (11).
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Illustration 198 g03357511

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.

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Illustration 199	g03357512
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

Connect the hose from each spray valve to the corresponding fitting on the front hydraulic manifold with O-ring seal (19). 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)
Clamp the hoses to the water tank with clips (7), bolts (5) and hard washers (13).

Cannon Group Installation

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Table 56
Required Parts Group Number 421-8349 Water Cannon Ar (Rev. 03)
Item	Qty	Part Number	Part Description
(1)	1	422-5872	Water Cannon Gp

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Illustration 200	g03357513

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Illustration 201	g03357514

Note: This safety message is located on the cannon.

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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.

Verify safety label (A) is properly installed on water cannon group (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.
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Illustration 202 g03357515
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 Illustration 202 is in the front of the cannon.
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Illustration 203 g03357516

Water Cannon Position on the Machine

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Illustration 204 g03357517
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.
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 57
Required Parts Group Number 355-8914 Hydraulic Oil Lines Gp (Rev. 01)
Item	Qty	Part Number	Part Description
(1)	4	3J-1907	O-Ring Seal
(2)	4	6V-8641	Connector
(3)⁽¹⁾	4	164-0193	Adapter
(4)	4	4J-5477	O-Ring Seal
(5)	2	124-2140	Permanent Coupling
(7)	10	124-2111	Permanent Coupling
(8)	8	4J-5477	O-Ring Seal
(9)	2	7X-5331	Elbow
(10)	6	3J-7354	O-Ring Seal
(11)	2	6V-8628	Elbow
(12)	4	6V-8647	Connector
(13)	2	5P-4325	Clip
(14)⁽²⁾	1	122-6867	Hydraulic Hose

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⁽¹⁾	Not required and not supplied with kit, listed for reference only.
⁽²⁾	This component must be provided by the customer.

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Illustration 205	g03357525

Measure four lengths of hydraulic hose (14) 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.
Create four hose assemblies for the water cannon as follows:
- "DOWN" hose - install one permanent coupling (7) on one end and install one permanent coupling (5) on the other end
- "UP" hose - install one permanent coupling (7) on one end and install one permanent coupling (5) on the other end
- "LT" hose - install one permanent coupling (7) on one end and install one permanent coupling (5) on the other end
- "RT" hose - install one permanent coupling (7) on one end and install one permanent coupling (5) on the other end.
Note: Label both ends of all hoses per reference labels on the manifold before connecting.
Measure two lengths of bulk hose from cannon shut off valve (C) to front manifold group (D). Cut the hoses to length.
Create two hose assemblies for the cannon shut-off valve as follows:
- "ON" hose - install one permanent coupling (7) on each end of this hose
- "OFF" hose - install one permanent coupling (7) on each end of this hose.
Note: Label both ends of all hoses before connecting.
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Illustration 206 g06207344
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)
Install connector (2) with O-ring seal (1) in each fitting.
Install adapter (3) in each connector (2).
Connect the end of the "DOWN" hose with elbow permanent coupling (5) to "DOWN" fitting (F) with O-ring seal (4).
Connect the end of the "UP" hose with elbow permanent coupling (5) to "UP" fitting (E) with O-ring seal (4).
Connect the end of the "LT" hose with straight permanent coupling (6) to "LT" fitting (G) with O-ring seal (4).
Connect the end of the "RT" hose with straight permanent coupling (6) to "RT" fitting (H) with O-ring seal (4).
Route the four hoses from water cannon (B) to front manifold group (D).
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Illustration 207 g03357527
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.
Install connector (12) and O-ring seal (10) in each of the four ports.
Connect the end of the "DOWN" hose with straight permanent coupling (7) to "DOWN" fitting (J) with O-ring seal (8).
Connect the end of the "UP" hose with straight permanent coupling (7) to "UP" fitting (K) with O-ring seal (8).
Connect the end of the "LT" hose with straight permanent coupling (7) to "LT" fitting (L) with O-ring seal (8).
Connect the end of the "RT" hose with straight permanent coupling (7) to "RT" fitting (M) with O-ring seal (8).
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Illustration 208 g06207452
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.
Install elbow (9) in each of the fittings on the butterfly valve.
Note: Customer supplied valve may contain pre-installed fittings. Replace pre-installed fittings with elbows (9) provided
Connect the "OFF" hose to the "OFF" fitting (N) O-ring seal (8).
Connect the "ON" hose to the "ON" fitting (P) with O-ring seal (8).
Route the two hoses from shut-off valve (C) to front manifold group (D).
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Illustration 209 g06207348
Locate shut-off valve fittings on the front hydraulic manifold. The hydraulic ports are labeled as follows:
- "OFF" (R)
- " ON" (Q).
Install elbow (11) with O-ring seal (10) in both of these ports.
Connect the "OFF" hose to the "OFF" fitting (R) O-ring seal (8).
Connect the "ON" hose to the "ON" fitting (Q) with O-ring seal (8).
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Illustration 210 g06207350
Fasten the shut-off valve hoses and the cannon operation hoses to the water tank with clips (13).

Front Harness Assembly Installation

Install Front Electrical Control Group Mounting Plate

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Table 58
Required Parts Group Number 423-1576 Control Wiring Gp (Rev. 00)
Item	Qty	Part Number	Part Description
(1)	1	357-7152	Plate As
(2)	4	7X-7729	Washer
(3)	4	8T-4195	Bolt

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Illustration 211	g03357518

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

Mount plate assembly (1) to the front of the water tank.
Fasten plate assembly (1) in place with four bolts (3) and four washers (2).

Install Front Hydraulics Control Group

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Table 59
Required Parts Group Number 423-1576 Control Wiring Gp (Rev. 00)
Item	Qty	Part Number	Part Description
(4)	4	242-2961	Spacer
(5)	1	423-1575	Control Box Gp
(6)	4	5P-0537	Hard Washer
(7)	4	8T-8908	Bolt
(8)	1	423-1572	Control Harness As

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Illustration 212	g03357519

Mount control box group (5) to plate assembly (1), with the connectors pointing down.
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Illustration 213 g03357520
Insert spacers (4) between control box group (5) and plate assembly (1).
Fasten control box group (5) to plate assembly (1) with four bolts (7) and four hard washers (6).

Connect Front Control Harness Assembly

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Table 60
Required Parts Group Number 423-1576 Control Wiring Gp (Rev. 00)
Item	Qty	Part Number	Part Description
(9)	10	8T-4136	Bolt
(10)	10	4P-7581	Clip
(11)	1	423-1573	Sensor Harness As (Front Harness As)
(12)	10	7K-1181	Cable Strap
(13)	10	8T-4121	Hard Washer

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Illustration 214	g03357522

Connect sensor harness assembly (11) to control box group (5).

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Illustration 215	g03357523
Reference Labels on Manifold and Solenoids (A) Spray valve "7B" (B) Spray valve "1B" (C) Cannon "RIGHT" (D) Cannon "UP" (E) Cannon "DOWN" (F) Spray valve "7A" (G) Spray valve "1A" (H) Cannon "LEFT" (J) Cannon shutoff valve

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.
Connect sensor harness assembly (11) to the front hydraulic manifold as shown:
- Spray valve "7B" (A) - J741-GY(Grey)wire
- Spray valve "1B" (B) - J739-GN(Green)wire
- Cannon "RIGHT" (C) - J736-OR(Orange)wire
- Cannon "UP" (D) - J729-GN(Green)wire
- Cannon "DOWN" (E) - J730-BU(Blue)wire
- Spray valve "7A" (F) - J742-BR(Brown)wire
- Spray valve "1A" (G) - J738-BU(Blue)wire
- Cannon "LEFT" (H) - J735-PU(Purple)wire.
- Cannon Shutoff Valve (J) - T805-GY(Grey)wire.
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Illustration 216 g03357524
Attach sensor harness assembly (11) to the front of water tank with clips (10) and cable straps (12). Attach each clip to the water tank with a bolt (9) and hard washer (13).
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Illustration 217 g03367814
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.
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Illustration 218 g03362998
Connect communication cable (K) to control box group (5).
Note: This harness was installed and routed with the rear control harness assembly.

Cab and Chassis Electrical Installation

Side Console Preparation

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Illustration 219	g03350856

Lift two vents (B) in the right upper portion of gearshift trim panel (A). Cut the plastic ties that hold the vents in place.
Remove the mounting screws from trim panel (A). Lift the trim panel slightly to unplug the wires to the rocker switches and cigarette lighter.
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Illustration 220 g03350866
Move gearshift lever (C) to the "N" position in order to provide additional clearance.
Remove trim panel (A).
Note: Maybe necessary to remove instrument panel in order to provide clearance to remove the trim panel.
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Illustration 221 g03350867
Remove the mounting screws from rear trim panel (D). Remove the rear trim panel.

Cab Electrical Systems Installation

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Table 61
Required Parts Group Number 423-1570 Cab Wiring Gp (Rev 05)
Item	Qty	Part Number	Part Description
(1)	1	382-7848	Plate As
(2)	3	231-3930	Relay As
(3)	9	114-6658	Washer
(4)	9	9X-2043	Screw
(5)	1	3E-6328	Alarm Gp
(6)	1	274-7921	Machine Electronic Control Module
(7)	2	9X-8256	Washer
(8)	2	8T-4138	Bolt

Install Relay Assemblies

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Illustration 222	g03387814

Fasten three relay assemblies (2) to plate assembly (1) with screws (4) and washers (3).
Fasten connector of alarm group (5) to plate assembly (1) with screws (4) and washers (3).

Install Control Module

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Illustration 223	g03375966

Install machine electronic control module (6) on bottom of plate assembly (1). Fasten the control group to the plate assembly with two bolts (8) and two washers (7). Refer to Table 61 for part identification.

Plate Assembly Installation

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Illustration 224	g03391982
Right side view of cab - behind operator seat

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Illustration 225	g03388722
Right rear view of cab - behind operator seat

Fasten plate assembly (1) of the control group assembly (B) to the bottom of the cab mounting plate (A) with four screws (4) and four washers (3). Refer to Table 61 for part identification.

Install Gear Shift

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Table 62
Required Parts Group Number 423-1570 Cab Wiring Gp (Rev 05)
Item	Qty	Part Number	Part Description
(9)	1	477-3857	Transmission Control Gp
(10)	4	8C-8585	Screw

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Illustration 226	g03389637

Disconnect connectors (D) and (E) from control lever assembly (C).
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Illustration 227 g03389776
Remove the mounting screws from control lever assembly (C). Remove the assembly.
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Illustration 228 g03390445
Install transmission control group (9) in the side console. Fasten the control group in place with four screws (10).
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Illustration 229 g03389257
Reconnect the harness connector (E) to transmission control group (9).

Install Display Module

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Table 63
Required Parts Group Number 423-1570 Cab Wiring Gp (Rev 05)
Item	Qty	Part Number	Part Description
(3)	9	114-6658	Washer
(4)	9	9X-2045	Screw
(11)	1	455-7689	Plate As
(12)	4	4B-4274	Washer
(13)	4	161-6984	Screw
(14)	1	366-0242	Display Module Gp
(15)	4	131-3987	Screw
(16)	1	455-7690	Plate

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Illustration 230	g03391998

Fasten display module group (14) to plate assembly (11) with four screws (15).
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Illustration 231 g06207457
Install display module group (14) and plate assembly (11) onto plate (16) in the front right ROPS post.
Note: Before installing display module group (14) to the front right ROPS post, must assemble display module group (14) to plate assembly (11).
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Illustration 232 g03390459
Fasten plate assembly (11) to ROPS post with four screws (13) and four washers (12).
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Illustration 233 g03375967
Fasten plate assembly (11) to ROPS post with screw (4) and washer (3).

Joystick Installation

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Table 64
Required Parts Group Number 423-1570 Cab Wiring Gp (Rev 05)
Item	Qty	Part Number	Part Description
(1)	1	355-9440	Joystick Control Gp

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Illustration 234	g03381259

Install the joystick (1) to the plate assembly (A) using the bolts provided with the joystick.

Cab Harness Installation

Install Cab Electrical Harness

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Table 65
Required Parts Group Number 423-1570 Cab Wiring Gp (Rev 05)
Item	Qty	Part Number	Part Description
(2)	1	396-6500	Voltage Control Gp
(3)	1	445-1526	Cab Harness As
(4)	2	9X-2043	Screw
(5)	2	114-6658	Washer
(6)	1	352-1143	Resistor
(7)	2	113-8491	Fuse
(8)	1	8D-1470	Grommet
(14)	1	113-8490	Fuse (10-AMPERE)

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Illustration 235	g03392529

Locate the portion of cab harness assembly (3) with the "CC-C6" connector, the "CC-C12" connector, and the "CC-C5" connector. Route this portion of the cab harness assembly up plate assembly (C) on the front right ROPS post. Connect the harness assembly to monitor control group (B).
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Illustration 236 g03387829
Locate portion of cab harness assembly (3) with the "CC-C10" connector. Connect the "CC-C10" connector into the connector "MC-C16" (D) on the main cab harness assembly.
Route remainder of cab harness assembly (3) to the rear of the cab.
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Illustration 237 g03381761

Right side view of cab

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Illustration 238 g03389671

Right side view of cab - under joystick
Locate the portion of cab harness assembly (3) with the "CC-T10" connector. Fasten this portion of the harness assembly to cab ground on frame (E).
Connect the "CC-C15" connector of cab harness assembly (3) to receptacle on the bottom of joystick control group (1).
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Illustration 239 g03389801

Right side view of cab

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Illustration 240 g03389804

Right rear corner view of cab

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Illustration 241 g03389028

Left side view of cab
Route cab harness assembly (3) to control group (F) as shown in Illustration 239 to Illustration 241.
Connect the "CC-C4" connector of cab harness assembly (3) to control group (F).
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Illustration 242 g03388336
Connect the "CC-C7" connector of cab harness assembly (3) to connector (G) of the alarm group.
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Illustration 243 g03388353

(H) Fill Relay "K4"
(J) Fill Relay "K6"
(K) Fan Relay "K5"
Connect the "CC-C8" connector of cab harness assembly (3) to the connector of fill relay "K4" (H).
Connect the "CC-C11" connector of cab harness assembly (3) to the connector of fill relay "K6" (J).
Connect the "CC-C9" connector of cab harness assembly (3) to the connector of fan relay "K5" (K).
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Illustration 244 g03389807

Top view of cab

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Illustration 245 g03389011

Top rear view of cab

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Illustration 246 g03389808

Left side view of cab
Route cab harness assembly (3) behind cab seat as shown in Illustration 244 to Illustration 246.
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Illustration 247 g03388989

Left rear view of cab
Connect the "CC-T8" terminal of cab harness assembly (3) to a stud on magnetic switch assembly (L).
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Illustration 248 g03388999
Connect the "CC-C19" connector of the cab harness assembly (3) to voltage control group (2). Use a tie strap to secure voltage control group (2) to the harness bundle.
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Illustration 249 g03388455

Left rear of cab
Locate holder assembly (M) on the "CC-C14" connector of cab harness assembly (3). Fasten holder assembly (M) to the relay plate assembly with two screws (4) and two washers (5).
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Illustration 250 g06207458
Install two fuses (7), one resistor (6) and fuse (14) in holder assembly (M).
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Illustration 251 g03381755

Right side view of cab
Install grommet (8) on the "CC-C2" connector of cab harness assembly (3). Route this portion of the harness assembly through the penetration in the back of the cab. Install the grommet in the penetration.
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Illustration 252 g03388361

Right side view of cab
Route remainder of cab harness assembly (3) across the back of the cab to the cab bulkhead plate. Connect the "CC-C2" connector of harness assembly to terminal (N) of the cab bulkhead plate.

Install Cable Straps on Cab Electrical Harness

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Table 66
Required Parts Group Number 423-1570 Cab Wiring Gp (Rev 05)
Item	Qty	Part Number	Part Description
(9)	38	7K-1181	Cable Strap
(10)	4	3S-2093	Cable Strap

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Illustration 253	g03381751

Fasten cab harness assembly (3) in place with cable straps (9).
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Illustration 254 g03381750
Fasten cab harness assembly (3) in place with cable straps (9).
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Illustration 255 g03381749
Fasten cab harness assembly (3) in place with cable straps (9).
Fasten cable assembly to the front right ROPS post with cable straps (10).

Install Trim Panel and Keypad

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Table 67
Required Parts Group Number 423-1570 Cab Wiring Gp (Rev 05)
Item	Qty	Part Number	Part Description
(11)⁽¹⁾	1	376-3871	Cover (trim panel)
(12)	1	377-4675	Keypad Module Gp

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⁽¹⁾	Trim panel is a part of 423-1578 Electrical Installation Gp

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Illustration 256	g03392080

Install keypad module group (12) into trim panel (11).
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Illustration 257 g03392238
Install trim panel (11) and rear trim panel (P).
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Illustration 258 g03381745
Before installing trim panel (11) on the right side of cab. Connect the "CC-C16" connector of cab harness assembly (3) to the connector on the bottom of the keypad module group (12).
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Table 68
Required Parts
Group Number 423-1570 Cab Wiring Gp (Rev 05)

Item Qty Part Number Part Description

(13) 1 386-1518 Film

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Illustration 259 g03392245
Install film (13) to trim panel (11) as shown in Illustration 259.

WAVS Camera System Installation (Optional)

Note: WAVS camera system installation is an optional attachment

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Table 69
Required Parts Group Number 436-2188 Visibility Ar (Rev 01)
Qty	Part Number	Part Description
1	309-5339	Cab Wiring Gp
1	435-8004⁽¹⁾	Cab Wiring Gp
1	436-2187	Camera Wiring Gp
1	435-4013	Installation Field Gp

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⁽¹⁾	May not be supplied and for reference only. Removed in Revision 01.

309-5339 Cab Wiring Group Installation

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Table 70
Required Parts Group Number 309-5339 Cab Wiring Gp (Rev 07)
Item	Qty	Part Number	Part Description
(1)	2	259-4399	Base
(2)	1	270-3311	Clamp Gp
(3)	1	333-8153	Connection Assembly
(4)	1	464-6047	Display Electronic Control Gp
(5)	1	367-4855	Cable As
(6)	1	372-6064	Wiring Harness
(7)	4	161-6984	Screw
(8)	1	162-9112	Split Grommet
(9)	8	4B-4274	Washer
(10)	4	7Y-7388	Screw

Note: Reference Special Instruction, REHS7242

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Illustration 260	g03381934
Right rear view of cab

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Illustration 261	g03381925
Inside cab view

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Illustration 262	g03389216
Right side of cab

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Illustration 263	g03384064
Monitor mount location - right front of cab

Install display module group (4) on mounting location as shown in Illustration 261 to Illustration 263.
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Illustration 264 g03389489

Right side view of cab

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Illustration 265 g03391418

Right font view of cab
Connect male end of cable assembly (5) to connector (A) of display module group (4). Route cable assembly (5) along the main wiring harness on the right side of cab as shown in Illustration 264 and Illustration 265.
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Illustration 266 g03384062

Right side view of cab

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Illustration 267 g03389447

Right rear corner view of cab
Route cable assembly (5) through split grommet (8). Route cable assembly (5) along the main wiring harness around the back right corner of the cab as shown in Illustration 266 and Illustration 267.
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Illustration 268 g03389443

Rear view of cab

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Illustration 269 g03391398

Left rear view of cab
Route cable assembly (5) along the back of the cab. Connect female end of cable assembly (5) to electronic connector group (3) as shown in Illustration 268 and Illustration 269.
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Illustration 270 g03389468

Right side view of cab

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Illustration 271 g03391725
Connect the male end of wiring harness (6) receptacle "MM-C1" (C) to receptacle (B) of display module group (4). Route wiring harness (6) along cable assembly (5) towards the rear of the cab. Connect the female end of wiring harness (6) receptacle "MM-C2" (D) to main wiring harness receptacle "MC-C7" (E).

Cable Straps Installation

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Table 71
Required Parts Group Number 309-5339 Cab Wiring Gp (Rev 07)
Item	Qty	Part Number	Part Description
(11)	19	7K-1181	Cable Strap

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Illustration 272	g03390145

Fasten cable assembly (5) in place with cable straps (11).
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Illustration 273 g03390526

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Illustration 274 g03390538
Fasten cab harness assembly (5) in place with cable straps (11).

435-8004 Cab Wiring Group Installation

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Table 72
Required Parts Group Number 435-8004 Cab Wiring Gp (Rev 01)
Item	Qty	Part Number	Part Description
(1)	1⁽¹⁾	113-8490	Fuse
(2)	1⁽¹⁾	284-3659	Rocker Switch
(3)	1	435-6161	Switch Harness As

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⁽¹⁾	These parts are also included in 423-1570 Cab Wiring Gp (WORK AREA VISUAL SYSTEM). Table 65 use this section for routing reference only.

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Illustration 275	g03381936
Right rear view of cab

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Illustration 276	g03384726
Location of Washer Rocker Switch

Install washer rocker switch (2) in bezel as shown in Illustration 276.
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Illustration 277 g03384115

Right front view of cab

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Illustration 278 g03384111

Right side view of cab

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Illustration 279 g03384113

Rear view of cab
Route switch harness assembly (3) along the side of the main wiring harness as shown in Illustration 277 to Illustration 279. Switch harness assembly (3) splits and connects to ground (A) and fuse (1).
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Illustration 280 g03390716

Fuse box location in cab

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Illustration 281 g03390698
Terminate "A-T1" pink wire to G5 of connector "MC-C90" (B).
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Illustration 282 g03383834

Right rear view of cab
Route switch harness assembly (3) along the side of the main wiring harness as shown in Illustration 282.
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Illustration 283 g03390820

Left rear view of cab
Route switch harness assembly (3) to connector "CC-C2" (C) as shown in Illustration 283.
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Illustration 284 g03390733
Terminate "A-T3" black wire to pin 1 of connector "CC-C2" (C).
Terminate "A-T4" yellow wire to pin 2 of connector "CC-C2" (C).
Install 10 amp fuse (1) inside fuse box (B) using fuse location "F25".

Cable Straps Installation

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Table 73
Required Parts Group Number 435-8004 Cab Wiring Gp (Rev 01)
Item	Qty	Part Number	Part Description
(4)	40	7K-1181	Cable Strap

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Illustration 285	g03390061

Fasten cab harness assembly (3) in place with cable straps (4).
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Illustration 286 g03390079

Right front view of cab

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Illustration 287 g03390121

Right side view of cab
Fasten cab harness assembly (3) in place with cable straps (4).
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Illustration 288 g03390102

Rear view of cab
Fasten cab harness assembly (3) in place with cable straps (4).

436-2187 Camera Wiring Group Installation

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Table 74
Required Parts Group Number 436-2187 Camera Wiring Gp (Rev 01)
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

Install WAVS monitor and cable. Reference Special Instruction, REHS7242.
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Illustration 289 g03384035
Mount switch (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 290 g03384037

Rear View of Water Tank
Mount camera group (2) in location (B) as shown in Illustration 290.
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Illustration 291 g03384039

Top of Water Tank
Mount two additional camera groups (2) onto 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) position 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.
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 (1).
Note: Ensure that the cables have adequate length in order to accommodate the lifting and lowering of the water tank.
Connect cable assemblies (4) to switch (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".
Note: The factory default setting for the WAVS monitor is for a single camera configuration.
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.
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.
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.

WAVS Washer Group Installation (Optional)

Note: WAVS washer group installation is an optional attachment

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Table 75
Required Parts Group Number 436-2188 Visibility Ar (Rev 01)
Qty	Part Number	Part Description
1	435-4013	Installation Field Gp

435-4013 Installation Field Gp for WAVS Camera Cleaning System

Procedure for installation of the camera wash system for the WAVS Camera.

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The safety information in this document and the safety information on the machine are not all inclusive. You must determine that the tools, procedures, work methods, and operating techniques are safe. You must determine that the operation, lubrication, maintenance, and repair procedures will not damage the machine. Also, you must determine that the operation, lubrication, maintenance, and repair procedures will not make the machine unsafe.

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Structural damage, an overturn, modification, alteration, or improper repair can impair this structure's protection capability thereby voiding this certification. Do not weld on or drill holes in the structure. Consult a Caterpillar dealer to determine this structure's limitations without voiding its certification.

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Protect yourself and others; read and understand this warning. Fumes and gases can be dangerous to your health. Ultraviolet rays from the weld arc can injure eyes and burn skin. Electric shock can kill.
Read and understand the manufacturer's instruction and your employer's safety practices. Keep your head out of the fumes. Use ventilation, exhaust at the arc, or both, to keep fumes and gases from your breathing zone and the general area. Wear correct eye, ear and body protection. Do not touch live electric parts.

Refer to the American National Standard Z49.1, "Safety in Welding and Cutting" published by the American Welding Society, 2501 N.W. 7th Street, Miami, Florida 33125: OSHA Safety and Health Standards, 29 CFR 1910, available from U.S. Dept. of Labor, Washington D.C. 20210.

Note: Personal breathing protection should be worn by the personnel that are welding. Personal breathing protection will prevent fumes from entering the lungs of the person that is welding. Use a 1U-8088 Type H Respirator for breathing protection.

Proper Welding Procedure on Machines and Engines with Electronic Controls

Proper precautions are necessary to prevent damage to electronic controls. When you weld on a machine with electronic controls, use the steps that follow:

Turn off the engine. Put the key start switch in the OFF position.
If the machine has a battery disconnect switch, open the switch. If the machine does not have a battery disconnect switch, disconnect the negative battery cable at the battery.
Connect the ground cable for the welder directly to the actual machine component that will be welded. Attach the clamp for the ground cable as close as possible to the area that is being welded in order to reduce the chance of damage from welding current to the components that follow: bearings, hydraulic components and electrical components.
Note: Do Not use ground points for electronic components as a ground point for the welder.
Protect the wiring harnesses from the weld splatter.

Required Parts

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Table 76
Required Parts Group Number 435-4013 Installation Field Gp (Rev 01)
Item	Qty	Part Number	Part Description
(1)	1	2L-8071	Terminal
(2)	1	3K-8782	Fuse
(3)	4	4E-8266	Boss
(4)	60ft	5P-0651	Electrical Wire
(5)	10ft	5P-0653	Wire
(6)	5	5P-4115	Hard Washer
(7)	15ft	6A-3361	Electrical Wire
(8)	5	6V-7357	Bolt (M6x1x25)
(9)	1	8D-8719	Holder and Wire Assembly
(10)	40	8L-8413	Cable Strap
(11)	4	8T-4138	Bolt (M6x1x20)
(12)	6	8T-8730	Connector Socket
(13)	5	9X-8267	Washer
(14)	3	129-3178	Locknut (M6x1)
(15)	4	136-4877	Wire Splice
(16)	10ft	144-0195	Hose
(17)	3	155-2270	Connecting Plug Kit
(18)	3	469-5745	Check Valve
(19)	21	228-5009	Clip
(20)	1	236-4631	Bezel
(21)	1	245-7434	Connecting Plug Kit
(22)	1	284-3659	Rocker Switch
(23)	3	307-3001	Bracket
(24)	3	307-3003	Extension Plate
(25)	3	307-4415	Clip
(26)	3	307-6218	Nozzle
(27)	3	307-6221	Fitting
(28)	1	368-5695	Washer Bottle Gp
(29)	1	5P-9085	Clip

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Illustration 292	g03385004
Parts Identification

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Illustration 293	g03385002
Parts Identification

Installation Procedure

Identify a location for installation of washer bottle group (28). Ensure that the location for installation is protected. Ensure that the location of washer bottle group (28) is lower than nozzle (26).
Follow the steps that are listed below in order to install washer bottle group (28).
1. Position nozzle (26) in a horizontal position that is less than 3.0m (10 ft) away from washer bottle group (28).
2. Position washer bottle group (28) no lower than 1.5 m (5 ft) from nozzle (26).
Inspect the location for the installation and ensure that welding in the location will not damage any of the nearby components.
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Illustration 294 g03383209

Location of Washer Bottle

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Illustration 295 g03384722

Location of Bosses for Washer Bottle
(A) 306 ± 1.5 mm (12 ± 0.1 inch)
(B) 150 ± 1 mm (5.9 ± 0.04 inch)
Weld bosses (3) onto the frame in order to mount washer bottle group (28).
Install washer bottle group (28) for the cleaning system.
Mount nozzle (26).
The following requirements need to be followed for the installation of nozzle (26).
1. For optimal performance install nozzle (26) within 25 mm (1 inch) of the camera lens.
  Note: When installing nozzle (26) ensure that nozzle (26) is not viewable in the camera image.
2. Nozzle (26) will need to be angled at 45 degrees from the surface of the lens.
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  Illustration 297 g01338194
  
  Nozzle
3. Mount spray nozzle (26) so that the projection of the spray cuts at the base of the glass.
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Illustration 298 g01341873

Typical Installation of the Sensor Harness Assembly
Install sensor harness assembly (C) along the WDS chassis harness on the side of the frame rail.
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Illustration 299 g03396487

(C) 419-5591 Sensor harness assembly
(D) Connector plug
The power and ground for the washer bottle pump connects to connector plug (D) on sensor harness assembly (C) at the cab-chassis interface bulkhead behind the cab.
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Illustration 300 g03395944
Install ground wire in pin 1 of connector plug (D). Connector plug (D) is located on 419-4491 sensor harness assembly (C) that was installed in section "Chassis Harness Installation" within this document.
Install power wire in pin 2 of connector plug (D). Connector plug (D) is located on 419-4491 sensor harness assembly (C) that was installed in section "Chassis Harness Installation" within this document.
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Illustration 301 g03384984

Check Valve

Note: You must prime the pump before installing check valve assembly (18). In order to prime the pump allow the water to flow out of the line in order to purge the air out of the line.
Route the fluid line from the pump to nozzle (26). Cut the fluid line and install check valve assembly (18) no more than 304 mm (12 inch) away from water bottle group (28). Ensure that the arrow on check valve assembly (18) is pointed away from the pump.
Check the operation of the system.

Monitor Setup

Electronic Technician Setup

Connect a laptop computer with Cat^® ET software to the diagnostic connector on the truck.
Launch the Cat^® ET program on the computer.
Select the "Hoist System Enable" option. Change this option to "Not Installed."
Disconnect the laptop computer.

MD3 Setup

Move the battery disconnect switch to the ON position.
Move the engine start switch to the ON position. Do not start the engine.
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Illustration 302 g03358191
Press menu button (C) on the MD3 display module.
Press "F3" button (B) to select the "Preferences" menu.
Use up button (F) and down button (D) to select the preferred language.
Note: The default language is English.
Press "OK" button (E) to confirm the selection.
Press menu button (C) to return to the "Main" page.
In the "Main" display screen, press "F1" button (A) to select the "Adjust" menu.
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Illustration 303 g03358192
In the "Adjust" screen, press "OK" button (E) to select the "SetUp" menu.
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Illustration 304 g03358193
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 305 g03697620
Select the "Truck Model" option in the "SetUp" menu. Press "OK" button (E).
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Illustration 306 g03358195
Select the truck model and press "OK" button (E).
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Illustration 307 g03697624
Select the "Spray Configuration Set Up" option in the "SetUp" menu. Press "OK" button (E).
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Illustration 308 g03697629
Scroll down and select the spray configuration for the truck. Press OK button (E).
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Illustration 309 g03697664

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Illustration 310 g03697699

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Illustration 312 g03697667

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Illustration 313 g03697668

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Illustration 314 g03697669

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Illustration 315 g03697708
Select "Water Pump Selection" then choose type of pump.
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Illustration 316 g03697710

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Illustration 317 g03697715
Select "Spray Head Type" then choose type of spray head.
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Illustration 318 g03697720

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Illustration 319 g03697727
Select the "Tank Lift Option" option in the "SetUp" menu. Press "OK" button (E).
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Illustration 320 g03358201
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 321 g03697729
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 322 g03358203
Scroll down and select the "Installed" option. Press "OK" button (E).
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Illustration 323 g03697730

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Illustration 324 g03697731

Note: The "Auxiliary" 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 325 g03697732

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Illustration 326 g03358204
Scroll down and select the "Momentary Single" option. Press "OK" button (E).
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Illustration 327 g03697733
Select the "Manual Mode Enable" option in the "SetUp" menu. Press "OK" button (E).
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Illustration 328 g03358206
Scroll down and select the "Enabled" option. Press "OK" button (E).
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Illustration 329 g03358207
Select the "Manual Speed Deactivation" option in the "SetUp" menu. Press "OK" button (E).
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Illustration 330 g03358209
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 331 g03358212
Select the "Intermittent Mode Enable" option in the "SetUp" menu. Press "OK" button (E).
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Illustration 332 g03358213
Scroll down and select the "Enabled" option. Press "OK" button (E).
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Illustration 333 g03358214
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 77
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 334	g03860567

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Illustration 335	g03860570
View (A-A)

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Illustration 336	g03358215
View (B-B)

Note: Refer to Illustration 336. Port (A) is the S·O·S sample port. Port (B) is a gauge port for checking charge pump pressure.

Refer to Illustration 335. 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.
Remove the hose assembly from filter inlet (C). Install tee (1) to the inlet as shown.
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.
Use quick disconnect coupler (5), and hose assembly (4) to connect filter cart group (6) to test fitting (3).
Fill the Water Delivery System (WDS) with Cat® HYDO Advanced 10 hydraulic oil.
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).
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.

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 337 g03358216
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 338 g03358218
Press head clean button (E) on the keypad. in order to activate the head clean mode.
Press number key (F) corresponding to the spray head being bled.
Let the air purge out of the line to upper fitting (C) until a steady flow of hydraulic oil is present. Tighten the fitting.
Press head clean button (E) in order to deactivate the head clean mode.
Repeat this procedure for each spray head.
Stop the engine.
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.
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

Fill the water tank.
Start the truck and let the engine idle.
Press head clean button (E) on the keypad.
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.
Press head clean button (E) in order to deactivate the head clean mode.
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.

Start the truck and let the engine idle.
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Illustration 339 g03358219
Press cannon mode button (G).
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Illustration 340 g03358222
Pull trigger (H) on the joystick to open the butterfly valve.
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Illustration 341 g03358223

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Illustration 342 g03375251

Rotation Direction Indicator

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Illustration 343 g03375247

Clockwise Pump Shaft Rotation
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.
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.

Calibrations

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 344	g03358226

In the "Main" display screen, press "F1" button (A) to select the "Adjust" menu.
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Illustration 345 g03358227
In the "Adjust" screen, scroll down and press "OK" button (E) to select the "Spray Head Calibration" menu.
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Illustration 346 g03358228
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 347 g03358229
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 348 g03358230
Scroll down and select the "Enable" option. Press "OK" button (B). Press "back" button (E) to exit the screen.
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Illustration 349 g03358231
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.
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 350 g03358233
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 351	g03358234

Press "F1" button (A) to display the tank level screen.
Fill the water tank to a minimum level of approximately 1100 to 1900 L (300 to 500 US gal).
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Illustration 352 g03358235
Press Menu button (B) to open the main display page.
Press "F1" button (A) to select the "Adjust" menu.
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Illustration 353 g03358237
Use up button (E) and down button (C) to scroll down and select the "Tank Properties" menu. Press "OK" button (D).
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 354 g03358238
Scroll down to the "Tank Empty Value" option. Press "OK" button (D).
Use up button (E) and down button (C) to adjust value (F) displayed on the screen to 0.10.
Adjust the value until 0% is displayed on the tank level screen.
Press Menu button (B) to return to the tank level screen.
Fill the water tank to the desired full level.
Press Menu button (B) to open the main display page.
Press "F1" button (A) to select the "Adjust" menu.
Use up button (E) and down button (C) to scroll down and select the "Tank Properties" menu. Press "OK" button (D).
Scroll down to the "Tank Full Value" option. Press "OK" button (D).
Use up button (E) and down button (C) to adjust value (F).
Press Menu button (B) to return to the tank level screen.
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.
Press Menu button (B) to open the main display page.
Press "F1" button (A) to select the "Adjust" menu.
Use up button (E) and down button (C) to scroll down and select the "Tank Properties" menu. Press "OK" button (D).
Scroll down to the "Low water shut off value" option. Press "OK" button (D).
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 completely empty.
Note: If "Tank Empty Value" is 0.1, set the "Low Water Shutoff" to 0.2.
Press Menu button (B) to open the main display page.
Press "F1" button (A) to select the "Adjust" menu.
Use up button (E) and down button (C) to scroll down and select the "Tank Properties" menu. Press "OK" button (D).
Scroll down to the "Tank full shut off" option. Press "OK" button (D).
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 completely 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

Press Menu button (B) to open the main display page.
Press F1 button (A) to select the "Adjust" menu.
Use up button (E) and down button (C) to scroll down and select the "Cannon Adjustments" menu. Press "OK" button (D).
The cannon adjustments menu allows the operator to adjust the speed and sensitivity of the joystick.

Operating Pressures

Note: The following section is for troubleshooting the WDS system and is included for reference purposes.

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.
Pilot pressure to the spray heads and cannon manifolds is 3447 kPa (500 psi).
Hydraulic pressure to open and close the spray heads will vary depending on the requested spray head opening.
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. Pump relief pressure is 28000 kPa (4100 psi). Software limits system pressure to 24000 kPa (3500 psi).

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Illustration 26	g03381956
View C-C (W1) AWS A5.18 ER70S-2 or equivalent (M) Alternate skip weld (N) Continuous fillet weld (P) Continuous fillet weld




Illustration 125	g03357440
Rear View Of Bulkhead Plate (C) Pump low-pressure port (blue) (D) Pump high-pressure port (red)




Illustration 134	g03357450
WDS Motor (J) Motor signal port (green) - straight fitting (K) Motor pilot port (yellow) - 90 degree adapter




Illustration 135	g03357452
Rear View Of Bulkhead Plate (L) Motor signal line fitting (green) (M) Motor pilot pressure hose fitting (yellow)




Illustration 163	g03357469
(A) Spray head open port (B) Spray head close port




Illustration 169	g03357480
( U) Spray head pilot return port (black) (V) Spray head pilot supply port (brown)




Illustration 170	g03357481
(W) Spray head pilot return fitting (black) (X) Spray head pilot supply fitting (brown)




Illustration 189	g03357502
(B) Spray head pilot supply port (brown) (C) Spray head pilot return port (black)




Illustration 192	g03357506
(D) Spray head pilot return fitting (E) Spray head pilot supply fitting




Illustration 193	g03367810
Alternate Connection Locations On Rear Hydraulic Manifold (D) Spray head pilot return port (black) (E) Spray head pilot supply port (brown)




Illustration 2	g03349108




Illustration 3	g03349113




Illustration 4	g03349133




Illustration 5	g03349137




Illustration 196	g03357509
Spray head "7" (F) ( H) Spray head - close "B" port (J) Spray head - open "A" port




Illustration 197	g03357510
Spray head "1" (G) ( K) Spray head - open "A" port (L) Spray head - close "B" port




Illustration 203	g03357516
Water Cannon Position on the Machine




Illustration 238	g03389671
Right side view of cab - under joystick




Illustration 243	g03388353
(H) Fill Relay "K4" (J) Fill Relay "K6" (K) Fan Relay "K5"




Illustration 295	g03384722
Location of Bosses for Washer Bottle (A) 306 ± 1.5 mm (12 ± 0.1 inch) (B) 150 ± 1 mm (5.9 ± 0.04 inch)




Illustration 298	g01341873
Typical Installation of the Sensor Harness Assembly




Illustration 299	g03396487
(C) 419-5591 Sensor harness assembly (D) Connector plug