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


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

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 on a 777G WTR Truck Chassis. This instruction applies to those systems purchased as a factory attachment. For retrofit installations, refer to Special Instruction, REHS7109.

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 product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publications, NENG2500, "Cat dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar® products. Dispose of all fluids according to local regulations and mandates.

Customer Requirements

Major components included in the WDS Kit are as follows.

  • Spray heads

  • WDS cooling system

  • WDS hydraulic tank

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

  • Filter group

  • Pump drive (factory installed)

  • Cab controls (factory installed)

  • Cannon

The following attachments are available:

  • Camera and wash kit

  • Cannon nozzles (must choose a nozzle)

The following items are NOT INCLUDED in the WDSKit:

  • Water tank

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

  • Cannon and dump bar actuation cylinders, dump valve

  • Cannon piping from the water pump

  • Pump outlet flange Isolation adapter

  • Pump inlet adapter and hardware

  • Remote soap and foam on/off switches

  • Auxiliary wiring harness (for soap and foam switches)

  • Hose reel remote switch and auxiliary wiring harness

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

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

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

  • Cannon mounting hardware

  • Dump bar

  • Bosses, hardware, and brackets to mount cameras

  • Bosses, hardware, and brackets to mount washing systems

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

  • Bosses for brackets, hydraulic and electrical boxes

Service Tooling Requirements

The following items are required for servicing the system:

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

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

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

Hydraulic and Component Installation (Chassis)

Pump Group Installation

WDS Hydraulic Pump Installation

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Table 1
Required Parts
Group Number 418-9813 Pump and Mounting Gp (Rev. 01) 
Tool  Qty  Part Number  Part Description 
1  1  460-0078  Piston Pump Gp 
2  2  8T-4122  Hard Washers 
3  2  7X-0346  Bolts 
4  1  6V-7970  O-Ring Seal 
5  2  8C-4424  Plugs 
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    Illustration 1g03356851

  1. Remove drive shaft cover (A).
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    Illustration 2g03356966

  2. Install WDS hydraulic pump (1) into drive group (B).

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

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

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

  3. Fasten WDS hydraulic pump (1) to drive group (B) with two bolts (3) and two washers (2). Tighten the bolts to a torque of 215 ± 40 N·m (159 ± 30 lb ft).

  4. Install plug (5) and seal (4) in vent port (D). Tighten the plug to a torque of 105 ± 10 N·m (77 ± 7 lb ft).

  5. Install plug (4) in drain port (C). Tighten the plug to a torque of 105 ± 10 N·m (77 ± 7 lb ft).

Charge Pump Installation

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Table 2
Required Parts
Group Number 418-9813 Pump and Mounting Gp (Rev. 01) 
Tool  Qty  Part Number  Part Description 
6  1  118-3122  O-Ring Seal 
7  1  177-8924  Gear Pump Gp 
8  2  8T-4223  Hard Washers 
9  2  8T-4194  Bolts 
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    Illustration 3g03356969

  1. Remove temporary cover and seal from WDS hydraulic pump (1).

  2. Install seal (6) around the pilot of the charge pump in order to seal the oil between the WDS hydraulic pump and the charge pump. Install charge pump (7) into the coupler on the back of WDS hydraulic pump (1).

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

  3. Fasten charge pump (7) to the WDS hydraulic pump with two bolts (9) and two washers (8). Tighten the bolts to a torque of 100 ± 20 N·m (74 ± 15 lb ft).

Cooling Group Installation

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Table 3
Required Parts
Group Number 428-9380 Supplemental Cooling Gp (Rev. 05)
Sub Group Number 433-7385 Wear Plate (Rev. 00) 
Tool  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  Bolts 
8(1)  4  8T-4896  Hard Washers 
9(1)  8  7X-0603  Hard Washers 
10(1)  4  9D-7924  Mountings 
11(1)  4  7X-0521  Hard Washers 
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  Bolts 
16  4  8D-8852  Spacers 
17  8  8T-4122  Hard Washers 
18  4  110-6923  Spacer 
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(1) These components are pre-assembled.
(2) Use if required.
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    Illustration 4g03356970

  1. Mount cooling group (A) on the cooler mounting plate (B).

    Note: Cooling group (A) includes components (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 5g06207408

  2. Fasten cooling group (A) to mounting plate (B) with four spacers (16), eight bolts (15) and eight washers (17) and four spacers (18).

WDS Hydraulic Tank Installation

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Table 4
Required Parts
Group Number 428-9380 Supplemental Cooling Gp (Rev. 05)
Sub Group Number 443-6968 Hydraulic Tank and Mounting Gp (Rev. 01) 
Tool  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  Bolts 
17(1)  3  8T-4121  Hard Washers 
18(1)  3  7X-0507  Hard Washers 
19(1)  3  2Y-5829  Nuts 
20(1)  1  8C-3443  Connector 
21(1)  2  7M-8485  O-Ring Seals 
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  Bolts 
27(1)  7  8T-4121  Hard Washers 
28(1)  1  132-5789  Clip 
29  4  8T-4192  Bolts 
30  2  8T-4139  Bolts 
31  6  8T-4223  Hard Washers 
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  Clips 
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 Washers 
40  6  8T-4137  Bolts 
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 6g03356972
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    Illustration 7g03359146

  1. Mount the hydraulic tank assembly (A) on the truck hydraulic tank (B) with bolts (29) and (30) and washers (31).
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    Illustration 8g03359317

  2. Position quick fill assembly (C) on the bottom of the hydraulic tank (B).
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    Illustration 9g06207299

  3. Fasten guard assembly (36) to the bottom of the truck hydraulic tank with four bolts (40) and four washers (39). Tighten the bolts to a torque of 55 ± 10 N·m (41 ± 7 lb ft).

  4. Clamp hose assembly (33) to the bottom of hydraulic tank (B) with clips (35). Fasten the clip to tank with bolt (40) and washer (39).

Cooling Group Lines Installation

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Table 5
Required Parts
Group Number 428-9380 Supplemental Cooling Gp (Rev. 05) 
Tool  Qty  Part Number  Part Description 
1  4  1P-4578  Half Flanges 
2  8  8T-8916  Bolts 
3  8  8T-5360  Washers 
4  2  061-7540  O-Ring Seals 
5  3  5P-2369  Clips 
6  14  5P-7470  Clips 
7  14  5P-7471  Clips 
8  14  5P-8182  Grommets 
9  2  200-6345  Mounts 
10  4  7K-1181  Cable Straps 
11  4  8T-4185  Bolts 
12  1  8T-4186  Bolts 
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 Seals 
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  Washers 
28  6  8T-4133  Nuts 
29  3  8T-4121  Hard Washers 
30  4  8T-4195  Bolts 
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 10g03363414

  1. Connect hose (19) with seal (4) to the cooler group. Install two flanges (1) around the hose.

  2. Fasten hose (19) and flanges (1) to the cooler group with four bolts (2) and four washers (3).

  3. Connect hose (18) with seal (4) to the cooler group. Install two flanges (1) around the hose.

  4. Fasten hose (18) and flanges (1) to the cooler group with four bolts (2) and four washers (3).

  5. Install clips (5) on hose (18) and hose (19). Thread bolt (30) with washer (29) through the clips. Install nut (28) with washer (31) on the bolt and tighten.
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    Illustration 11g03363418

  6. Install three grommets (8) on hose (18) and three grommets on hose (19) at the locations shown.

  7. Install clips (6) and clips (7) over each grommet.

  8. Fasten hose (18) and hose (19) to the machine with bolt (11) and washer (27) through each set of clips.
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    Illustration 12g06207310

  9. Route hose (18) and hose (19) across the rear of the cab. Tie the hoses together with mount (10) and cable straps (9).

  10. Install two grommets (8) on hose (18) and two grommets on hose (19) at the locations shown.

  11. Install clips (6) and clips (7) over each grommet.

  12. Insert bolt (12) with washer (27) through the first set of clips. Install plate (21) on the back of the clips and fasten the plate to the clips with nut (28).

  13. Fasten plate (21) to the back of the cab with bolt (30) and washer (29).

  14. Install bracket assembly (16) on the machine frame with bolt (23) and washer (33).

  15. Fasten the second set of clips to bracket assembly (16) with spacer (24), bolt (13) and washer (32).

  16. Route hose (18) and hose (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 13g06207317

  17. Install grommet (8) on hose (18) and on hose (19) at the location shown.

  18. Install clips (6) and clips (7) over each grommet.

  19. Secure hose assembly (19) using clip (5), bolt (28), hard washer (29), bolt (30) and clip (36).

  20. Insert bolt (14) with washer (27) through the clips on hose (18) and through bar (17). Fasten the clips to the bar with nut (28).

  21. Insert bolt (15) with washer (27) through the clips on hose (19) and through spacer (26). Insert the bolt through bar (28) and fasten the two hoses to the truck frame.

  22. Connect hose (19) to the bypass valve (A) with seal (34).

  23. Connect hose (18) to the hydraulic tank (B) with seal (34).

Pump Group Lines Installation

Relocate Position Sensor Assembly

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    Illustration 14g03371413

  1. Remove position sensor assembly (A).
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    Illustration 15g03371414

  2. Cut mounting block (B) from the rear frame rail.
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    Illustration 16g03371416

  3. Weld mounting block (B) to the frame rail at the location shown.

    Note: Place the block as shown in the above illustration. 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 17g03371417

  4. Reinstall position sensor assembly (A) on mounting block (B).

Install Plate Assembly On Truck Frame

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Table 6
Required Parts
Group Number 418-9812 Pump Lines Gp (Rev. 01) 
Tool  Qty  Part Number  Part Description 
1  4  105-7781  Spacers 
2  1  435-5307  Hydraulic Lines Mounting 
3  4  8T-4121  Hard Washers 
4  4  8T-5005  Bolts 
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    Illustration 18g03356974
    Rear View Of Bulkhead Plate
    (C) Pump low-pressure port (blue)
    (D) Pump high-pressure port (red)

  1. Install plate assembly (2) on the rear left tail light mounting bosses with fours spacers (1). Fasten the plate to the tail casting with four bolts (3) and four washers (4). Tighten the bolts to a torque of 55 ± 10 N·m (41 ± 7 lb ft).

    Note: Remove tail light assembly prior to installing plate assembly. Relocate tail light assembly to the water tank in accordance with tank manufacturing location.

Connect Pressure Hoses to WDS Hydraulic Pump

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Table 7
Required Parts
Group Number 418-9812 Pump Lines Gp (Rev. 01) 
Tool  Qty  Part Number  Part Description 
5  2  1P-3703  Rectangular Seals 
6  1  390-4562  Hose As 
7  1  390-4563  Hose As 
8  4  6V-0400  Half Flange 
9  8  8T-4223  Hard Washers 
10  8  8T-4184  Bolts 
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    Illustration 19g03356975
    Top of WDS Hydraulic Pump
    (E) Pump low-pressure port (blue)
    (F) Pump high-pressure port (red)

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

  1. Connect red pump high-pressure hose (6) to pump high-pressure port (F) on the right side of theWDS hydraulic pump. Secure the hose with two flanges (8) and seal (5). Fasten the hose to pump with four bolts (10) and four washers (9). Tighten the bolts to a torque of 100 ± 20 N·m (74 ± 15 lb ft).

  2. Connect blue pump return low-pressure hose (7) to pump low-pressure port (E) on the left side of the WDS hydraulic pump. Secure the hose with two flanges with two flanges (8) and seal (5). Fasten the hose to pump with four bolts (10) and four washers (9). Tighten the bolts to a torque of 100 ± 20 N·m (74 ± 15 lb ft).
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    Illustration 20g03356976

  3. Route pump high-pressure hose (6) and pump return low-pressure hose (7) over to the left side of the machine.

Connect WDS Pressure Hoses to Plate Assembly

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    Illustration 21g03356977
    Front View Of Bulkhead Plate
    (C) Pump low-pressure port (blue)
    (D) Pump high-pressure port (red)

    Note: Label both ends of all hoses before connecting.

  1. Connect red pump high-pressure hose (6) to location (D) of plate assembly (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 plate assembly (2). A cover is installed for temporary purposes. This cover must be removed when a hose is connected to this port.

  2. Connect blue pump return low-pressure hose (7) to location (C) of plate assembly (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 plate assembly (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 8
Required Parts
Group Number 418-9812 Pump Lines Gp (Rev. 01) 
Tool  Qty  Part Number  Part Description 
3  3  8T-4121  Hard Washers 
11  3  9U-0810  Blocks 
12  6  8T-2525  Grommets 
13  6  5P-7468  Clips 
14  6  5P-7469  Clips 
15  3  6V-5842  Bolts 
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    Illustration 22g03356980
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    Illustration 23g03356981

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

Connect Charge Pump Inlet Hose to WDS Hydraulic Tank

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Table 9
Required Parts
Group Number 418-9812 Pump Lines Gp (Rev. 01) 
Tool  Qty  Part Number  Part Description 
9  4  8T-4223  Hard Washers 
16  1  4J-0522  O-Ring Seal 
17  1  435-2930  Hose As 
18  2  173-1437  Half Flange 
19  4  8T-4183  Bolts 
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    Illustration 24g03356982

  1. Connect charge pump suction hose (17) to the suction port of charge pump with seal (16) and two split flanges (18). Fasten the hose to pump with four bolts (19) and four washers (9). Tighten the bolts to a torque of 100 ± 20 N·m (74 ± 15 lb ft)
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    Illustration 25g03356983

  2. Route charge pump suction hose (17) under the left frame rail and up the side of the hydraulic tank.
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    Illustration 26g03356984

  3. Route charge pump suction hose (17) to suction port (K) on the WDS hydraulic tank.

  4. Remove four bolts, four washers, and two flanges from suction port (K). Remove cover and seal from suction port. Install the seal in end of hose (17).

  5. Connect hose (17) to suction port (K) 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 10
Required Parts
Group Number 418-9812 Pump Lines Gp (Rev. 01) 
Tool  Qty  Part Number  Part Description 
20  3  5K-9090  O-Ring Seals 
21  1  6V-9854  Elbow 
22  1  6V-8785  Tee 
23  1  7M-8485  O-Ring Seal 
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    Illustration 27g03356985

  1. Install adapter (22) and seal (23) in the inlet port of bypass valve (L). Tighten the adapter to a torque of 350 ± 53 N·m (258 ± 39 lb ft).
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    Illustration 28g03356986

  2. Install adapter (21) with seal (20) in adapter (22). Tighten the adapter to torque of 220 ± 33 N·m (162 ± 24 lb ft).

  3. Install seal (20) in inlet of adapter (21).

  4. Install seal (20) in adapter (22).

Connect Motor Case Drain Hose to the Plate Assembly

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Table 11
Required Parts
Group Number 418-9812 Pump Lines Gp (Rev. 01) 
Tool  Qty  Part Number  Part Description 
20  2  5K-9090  O-Ring Seals 
24  1  390-4566  Hose As 
25  1  142-0038  Elbow 
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    Illustration 29g03356987
    Rear View Of Bulkhead Plate
    (M) Motor case drain port
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    Illustration 30g06207463

  1. Connect elbow (25) to rear end of adapter (M). Tighten the elbow to a torque of 220 ± 33 N·m (162 ± 24 lb ft).

  2. Connect adapter (26) with seal (20) to elbow (25). Tighten the adapter to a torque of 220 ± 33 N·m (162 ± 24 lb ft).

  3. Connect motor case drain hose (24) with seal (20) to front end of adapter (M). Tighten the hose to a torque of 220 ± 33 N·m (162 ± 24 lb ft).
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    Illustration 31g03356989

  4. Route motor case drain hose (24) along the left frame rail to the front of the machine.

    Note: This hose will be clamped in place later in the installation.

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    Illustration 32g03356990

  5. Route motor case drain hose (24) under the left frame rail and up the right side of the hydraulic tank.
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    Illustration 33g03356991

  6. Route motor case drain hose (24) around the WDS hydraulic tank to bypass valve (L).
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    Illustration 34g03356992

  7. Connect motor case drain hose (24) to adapter (22).

    Note: 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 12
Required Parts
Group Number 418-9812 Pump Lines Gp (Rev. 01) 
Tool  Qty  Part Number  Part Description 
27  1  6V-7970  O-Ring Seal 
28  1  421-6194  Connector As 
20  1  5K-9090  O-Ring Seal 
29  1  390-4569  Hose As 
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    Illustration 35g03356993
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    Illustration 36g03356994

  1. Install connector (28) with seal (27) in WDS pump case drain fitting (N). 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.

  2. Connect WDS pump case drain hose (29) with seal (20) to connector (28). Tighten the hose to a torque of 220 ± 33 N·m (162 ± 24 lb ft).
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    Illustration 37g03356995

  3. Route WDS pump case drain hose (29) over to the left side of the machine. Clamp the hose to machine frame at location (P).
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    Illustration 38g03356996

  4. Connect WDS pump case drain hose (29) to adapter (21) on the bypass valve.

Install Charge Pump Outlet Flange

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Table 13
Required Parts
Group Number 418-9812 Pump Lines Gp (Rev. 01) 
Tool  Qty  Part Number  Part Description 
5  1  1P-3703  Rectangular Seal 
30  1  7Y-3731  Flange 
3  4  8T-4121  Hard Washers 
31  4  6V-1820  Bolts 
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    Illustration 39g03356997

  1. Install flange (30) with seal (5) on the outlet port of the charge pump. Fasten the flange to pump with four bolts (318) and four 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 14
Required Parts
Group Number 418-9812 Pump Lines Gp (Rev. 01) 
Tool  Qty  Part Number  Part Description 
20  1  5K-9090  O-Ring Seal 
26  1  6V-8946  Reducer 
32  2  6V-9746  O-Ring Seals 
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 
    Show/hide table
    Illustration 40g03356998

  1. Assemble the cold start relief valve. Connect adapter (26) with 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).

  2. Connect adapter (33) with seal (32) to adapter (26). Tighten the adapter to a torque of 140 ± 21 N·m (103 ± 15 lb ft).

  3. Connect adapter (34) with seal (32) to adapter (33). Tighten the adapter to a torque of 140 ± 21 N·m (103 ± 15 lb ft).

  4. Connect valve group (36) with seal (35) to adapter (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 15
Required Parts
Group Number 390-4262 Pump Lines Gp (Rev. 06) 
Tool  Qty  Part Number  Part Description 
23  1  7M-8485  O-Ring Seal 
32  2  6V-9746  O-Ring Seals 
35  1  3K-0360  O-Ring Seal 
37  1  6V-9874  Connector 
38  1  390-4568  Hose As 
39  1  6V-9182  Elbow 
    Show/hide table
    Illustration 41g03356999

  1. Connect adapter (37) with seal (35) to valve group (36). Tighten the adapter to a torque of 100 ± 15 N·m (74 ± 11 lb ft).

  2. Connect charge pump relief hose (38) with seal (32) to adapter (37). Tighten the hose to a torque of 140 ± 21 N·m (103 ± 15 lb ft).
    Show/hide table
    Illustration 42g03357000

  3. Route charge pump relief hose (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.
    Show/hide table
    Illustration 43g03357001

  4. Install adapter (39) with 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).

  5. Connect charge pump relief hose (38) with seal (32) to adapter (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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Illustration 44g03357004

Note: Do not start the engine without the pump adapter lube hose (Q) in place.

Install Clips on the Hose Assembly

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Table 16
Required Parts
Group Number 418-9812 Pump Lines Gp (Rev. 01) 
Tool  Qty  Part Number  Part Description 
40  1  7D-1553  Clip 
41  1  6V-1889  Clip 
42  1  2V-2793  Clip 
43  1  097-4896  Spacer 
44  2  3E-4353  Hard Washers 
45  1  6V-5230  Bolt 
46  1  2Y-5829  Nut 
    Show/hide table
    Illustration 45g03357005
    Right Side of Truck Hydraulic Tank

  1. Install clip (42) on tube (R). Install clip (40) on charge pump suction hose (17). Install clip (41) on charge pump relief hose (38).
    Show/hide table
    Illustration 46g03357006

  2. Insert spacer (43) between clip (42) and clips (40) and (41). Insert bolt (45) with washer (44) through the clips and the spacer. Fasten the bolt in place with nut (46) and washer (44).

Install Clips on the Hose Assembly

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Table 17
Required Parts
Group Number 418-9812 Pump Lines Gp (Rev. 01) 
Tool  Qty  Part Number  Part Description 
47  1  7D-7233  Clip 
40  1  7D-1553  Clip 
48  1  6V-5386  Clip 
44  2  3E-4353  Hard Washers 
15  1  6V-5842  Bolt 
46  1  2Y-5829  Nut 
    Show/hide table
    Illustration 47g03357007

  1. Install clip (48) on hoist pump suction tube (R). Install clip (40) on charge pump suction hose (17). Install clip (47) on charge pump relief hose (38).
    Show/hide table
    Illustration 48g03357008

  2. Insert bolt (15) with washer (44) through the clips. Fasten the bolt in place with nut (46) and washer (44).

Install Fittings on the Plate Assembly

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Table 18
Required Parts
Group Number 418-9812 Pump Lines Gp (Rev. 01) 
Tool  Qty  Part Number  Part Description 
49  4  4J-5477  O-Ring Seals 
50  2  8C-8408  Elbows 
51  2  6V-9828  Cap As 
    Show/hide table
    Illustration 49g03357002
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    Illustration 50g03357003
    Rear View Of Bulkhead Plate
    (S) Motor signal port (green)
    (T) Motor pilot port (yellow)

  1. Connect one elbow (50) with seal (49) to the adapter in motor signal port (S). Tighten the elbow to a torque of 27 ± 4 N·m (20 ± 3 lb ft).

  2. Connect one elbow (50) with seal (49) to the adapter in motor pilot port (T). Tighten the elbow to a torque of 27 ± 4 N·m (20 ± 3 lb ft).

  3. Connect one temporary cap (51) with seal (49) to each elbow (50). Tighten the caps to a torque of 27 ± 4 N·m (20 ± 3 lb ft).

Install Fittings on the Plate Assembly

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Table 19
Required Parts
Group Number 418-9812 Pump Lines Gp (Rev. 01) 
Tool  Qty  Part Number  Part Description 
52  10  6V-8397  O-Ring Seals 
53  2  8C-8988  Elbows 
54  2  6V-9829  Cap As 
55  2  6V-9836  Swivel Tees 
    Show/hide table
    Illustration 51g03357327
    Rear View Of Bulkhead Plate
    (U) Spray head pilot return port (black)
    (V) Spray head pilot pressure port (brown)
    Show/hide table
    Illustration 52g03357331

  1. Connect one adapter (53) with seal (52) to the rear end of the adapter in spray head pilot return port (U). Connect one adapter (53) with seal (52) to the rear end of the adapter in spray head pilot pressure port (V).Tighten the adapters to a torque of 45 ± 5 N·m (33 ± 4 lb ft).

  2. Connect one cap (54) with seal (52) to each adapter (53). Tighten the caps to a torque of 45 ± 5 N·m (33 ± 4 lb ft).

  3. Connect one tee swivel (55) with seal (52) to the front end of the adapter in spray head pilot return port (U). Connect one tee swivel (55) with seal (52) to the front end of the adapter in spray head pilot pressure port (V).Tighten each tee swivel to a torque of 45 ± 5 N·m (33 ± 4 lb ft).

  4. Install seal (52) in each tee swivel. Install seal (52) in each tee swivel.

Filter Group Installation

Install Filter Group

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Table 20
Required Parts
Group Number 390-4265 Hydraulic Filter and Lines Gp (Rev. 04) 
Tool  Qty  Part Number  Part Description 
1  1  437-1909  Plate As 
2  1  177-6979  Oil Filter Gp 
3  4  8T-4121  Hard Washers 
4  4  8T-4137  Bolts 
    Show/hide table
    Illustration 53g03361215

  1. Mount filter group (2) to plate assembly (1) with bolts (4) and 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 21
Required Parts
Group Number 390-4265 Hydraulic Filter and Lines Gp (Rev. 04) 
Tool  Qty  Part Number  Part Description 
3  4  8T-4121  Hard Washers 
5  4  8T-4136  Bolts 
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    Illustration 54g03361234

  1. Install plate assembly (1) on the fuel tank with four bolts (5) and four 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 22
Required Parts
Group Number 390-4265 Hydraulic Filter and Lines Gp (Rev. 04) 
Tool  Qty  Part Number  Part Description 
6  1  3D-2824  O-Ring Seal 
7  1  6V-9007  Elbow 
8  3  6V-9746  O-Ring Seals 
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 55g03357336

  1. Install adapter (7) with seal (6) on the inlet fitting of filter group (2). Tighten the adapter to a torque of 220 ± 33 N·m (162 ± 24 lb ft).
    Show/hide table
    Illustration 56g06207330

  2. Attach adapter (9) with seal (8) to adapter (7). Tighten the adapter to a torque of 140 ± 21 N·m (103 ± 15 lb ft).

  3. Connect filter inlet hose (10) to adapter (9) with seal (8). Tighten the hose to a torque of 140 ± 21 N·m (103 ± 15 lb ft).

  4. Connect elbow (9) to Tee (27) with Fitting (26) and O-ring seal (25).
    Show/hide table
    Illustration 57g03357339

  5. Route filter inlet hose (10) to the charge pump discharge port. Connect this hose to the tee fitting on the charge pump discharge port with 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 23
Required Parts
Group Number 390-4265 Hydraulic Filter and Lines Gp (Rev. 04) 
Tool  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 
    Show/hide table
    Illustration 58g03357341

  1. Attach tee fitting (11) with seal (6) to outlet of filter group (2). Tighten the tee fitting to a torque of 220 ± 33 N·m (162 ± 24 lb ft).

  2. Install seal (16) in tee fitting (11).

  3. 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).
    Show/hide table
    Illustration 59g03357342

  4. Route WDS pump charge inlet hose (12) to the charge inlet port of the WDS hydraulic pump.
    Show/hide table
    Illustration 60g03357344

  5. Install elbow (14) with 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).

  6. Connect WDS pump charge inlet hose (12) to elbow (14) with 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 24
Required Parts
Group Number 418-9812 Pump Lines Gp (Rev. 01) 
Tool  Qty  Part Number  Part Description 
17  3  4J-5477  O-Ring Seals 
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.

    Show/hide table
    Illustration 61g03357345

  1. Connect green motor signal pressure hose (18) with 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).

  2. Connect yellow motor pilot pressure hose (19) with 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).
    Show/hide table
    Illustration 62g03357346

  3. Route green motor signal pressure hose (18) and motor pilot pressure hose (19) along the left frame rail toward the front of the machine.
    Show/hide table
    Illustration 63g03357349

  4. Route green motor signal pressure hose (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.

    Show/hide table
    Illustration 64g03357352

  5. Connect green motor signal pressure hose (18) with seal (17) to elbow (B).
    Show/hide table
    Illustration 65g03357353

  6. Connect motor pilot pressure hose (19) to tee fitting (11).

    Note: 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 25
Required Parts
Group Number 418-9812 Pump Lines Gp (Rev. 01) 
Tool  Qty  Part Number  Part Description 
20  1  6V-1889  Clip 
21  1  4K-8864  Clip 
22  2  3E-4352  Hard Washers 
23  1  6V-3940  Bolt 
24  1  5C-7261  Nut 
    Show/hide table
    Illustration 66g03357354

  1. Install clip (20) on filter inlet hose (10). Install clip (21) on motor signal pressure hose (18).
    Show/hide table
    Illustration 67g03357356

  2. Insert bolt (23) with washer (22) through the clips. Fasten the bolt in place with nut (24) and washer (22).

Install Spray Head Pilot Pressure and Pilot Return Hoses

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Table 26
Required Parts
Group Number 390-4263 Pilot Lines Gp (Rev. 03) 
Tool  Qty  Part Number  Part Description 
1  1  390-4577  Hose As 
2  1  390-4576  Hose As 
3  5  6V-8397  O-Ring Seals 
4  1  7X-3406  Cross Union 
5  2  6V-9829  Cap As 
6  1  4I-6287  Coupling 
7  3  3J-1907  O-Ring Seals 
8  1  126-6872  Tee 
9  1  9S-4191  O-Ring Plug 
    Show/hide table
    Illustration 68g03357357

  1. Disconnect hose (B) from adapter (C) on hoist valve (A).

  2. Disconnect hose (D) from adapter (C) on hoist valve (A).

  3. Remove adapter (C) from hoist valve (A).
    Show/hide table
    Illustration 69g03357360

  4. Install adapter (6) in hoist valve (A) with seal (7).

  5. Install cross adapter (4) into adapter (6) with seal (3). Tighten the adapter to a torque of 45 ± 5 N·m (33 ± 4 lb ft).
    Show/hide table
    Illustration 70g03357361

  6. Connect hose (B) to cross adapter (4) with seal (3).

  7. Connect hose (D) to cross adapter (4) with seal (3).

  8. Connect brown spray head pilot pressure hose (2) to cross adapter (4) with seal (3). Tighten this hose to a torque of 45 ± 5 N·m (33 ± 4 lb ft).
    Show/hide table
    Illustration 71g03357362

  9. Route brown spray head pilot pressure hose (2) along the left frame rail to spray head pilot pressure port (A).
    Show/hide table
    Illustration 72g03357365

  10. Connect brown spray head pilot pressure hose (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.

  11. Connect black spray head pilot return hose (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.

    Show/hide table
    Illustration 73g03357367
    Show/hide table
    Illustration 74g03357368

  12. Route black spray head pilot return hose (1) along the right frame rail to the machine hydraulic tank.
    Show/hide table
    Illustration 75g03357370

  13. Install adapter (8) with 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).

  14. Install plug (9) with seal (7) in adapter (8). Tighten the plug to a torque of 60 ± 1 N·m (44 ± 1 lb ft).

  15. Connect black spray head pilot return hose (1) with seal (3) to adapter (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 27
Required Parts
Group Number 418-9812 Pump Lines Gp (Rev. 01) 
Tool  Qty  Part Number  Part Description 
10  3  9U-0810  Blocks 
11  3  5K-5338  Clips 
12  3  4D-6466  Clips 
13  3  8T-4121  Hard Washers 
14  3  6V-5842  Bolts 
    Show/hide table
    Illustration 76g03357371
    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
    Show/hide table
    Illustration 77g03357372

  1. Install blocks (10) at location (G), location (H) and location (J) on the machine frame.

  2. For each location, install clip (11) on spray head pilot return hose (1) and spray head pilot pressure hose (2). Install clip (12) on motor signal pressure hose (K) and motor pilot pressure hose (L).

  3. 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 28
Required Parts
Group Number 418-9812 Pump Lines Gp (Rev. 01) 
Tool  Qty  Part Number  Part Description 
15  3  4D-7735  Clips 
16  7  7D-7233  Clips 
12  4  4D-6466  Clips 
13  14  8T-4121  Hard Washers 
17  7  6V-1820  Bolts 
18  7  2Y-5829  Nuts 
    Show/hide table
    Illustration 78g03357375
    Show/hide table
    Illustration 79g03357377

  1. Install three clips (15) on spray head pilot pressure hose (2). Install three clips (16) on pump high-pressure hose (N).

  2. Insert bolt (13) and washer (17) through each pair of clips (15) and (16). Fasten each bolt in place with nut (18) and washer (17).

  3. 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).

  4. Insert bolt (13) and washer (17) through each pair of clips (12) and (16). Fasten each bolt in place with nut (18) and washer (17).

Install Clips on the Hose Assembly

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Table 29
Required Parts
Group Number 418-9812 Pump Lines Gp (Rev. 01) 
Tool  Qty  Part Number  Part Description 
19  6  8T-2525  Grommets 
20  6  5P-7469  Clips 
21  6  5P-7468  Clips 
22  2  6V-1869  Grommets 
23  2  6V-1868  Clips 
24  2  6V-1867  Clips 
13  5  8T-4121  Hard Washers 
25  2  6V-4249  Bolts 
26  1  105-7781  Spacer 
27  1  6V-7730  Bolt 
18  2  2Y-5829  Nuts 
    Show/hide table
    Illustration 80g03357379
    Show/hide table
    Illustration 81g03357381

  1. 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.

  2. Install grommet (22) on tube (Q). Install clip (23) and clip (24) over the grommet.

  3. Insert bolt (25) and 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 washer (13).

  4. Install grommet (22) on tube (R). Install clip (23) and clip (24) over the grommet.

  5. Insert bolt (25) and 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 washer (13).

  6. Install spacer (26) on the machine cross tube at location (S). Insert bolt (25) and 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 30
Required Parts
Group Number 418-9812 Pump Lines Gp (Rev. 01) 
Tool  Qty  Part Number  Part Description 
15  1  4D-7735  Clip 
12  1  4D-6466  Clip 
28  1  8T-4224  Hard Washer 
29  1  6V-3940  Bolt 
30  1  3E-4352  Hard Washer 
31  1  5C-7261  Nut 
    Show/hide table
    Illustration 82g03357424

  1. Install clip (15) on motor signal pressure hose (K) and motor pilot pressure hose (L).

  2. Install clip (12) on spray head pilot pressure hose (2).
    Show/hide table
    Illustration 83g03357425

  3. Insert bolt (29) and washer (28) through these clips in order to clamp the three hoses together. Fasten the bolt in place with nut (31) and washer (30).

Install Clips on the Hose Assembly

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Table 31
Required Parts
Group Number 418-9812 Pump Lines Gp (Rev. 01) 
Tool  Qty  Part Number  Part Description 
32  1  6V-1889  Clip 
15  1  4D-7735  Clip 
13  2  8T-4121  Hard Washers 
17  1  6V-1820  Bolt 
18  1  2Y-5829  Nut 
    Show/hide table
    Illustration 84g03357427

  1. Install clip (32) on motor case drain hose (M).

  2. Install clip (15) on spray head pilot return hose (1).
    Show/hide table
    Illustration 85g03357428

  3. Insert bolt (17) and washer (13) through these clips in order to clamp the two hoses together. Fasten the bolt in place with nut (18) and washer (13).

Install Drive Shaft Guard Assembly

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Table 32
Required Parts
Group Number 417-5574 Water Spray Ar (Rev. 04) 
Tool  Qty  Part Number  Part Description 
1  1  435-5395  Guard As 
    Show/hide table
    Illustration 86g03366799

  1. Install guard assembly (1) over the drive shaft.

Hydraulic and Component Installation (Tank)

Water Pump Installation

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Table 33
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 34.

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Table 34
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
    Show/hide table
    Illustration 87g03357429
    Show/hide table
    Illustration 88g03357430

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

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

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

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

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

    Note: Mounting hardware must be provided by the customer.

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

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

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

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

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

    Show/hide table
    Illustration 89g03697323

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

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

    Show/hide table
    Illustration 90g03697384

  6. Install pressure sensor (3) onto spray bar at location shown in Illustration 90.

WDS Motor Installation

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Table 35
Required Parts
Group Number 371-2721 Piston Motor and Mounting Gp (Rev. 05) 
Tool  Qty  Part Number  Part Description 
1  1  358-0163  Piston Motor Gp 
2  2  8T-4122  Hard Washers 
3  2  7X-0347  Bolts 
    Show/hide table
    Illustration 91g03714847

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

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

    Show/hide table
    Illustration 92g03357434

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

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

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

    Show/hide table
    Illustration 93g03357435

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

  3. Fasten WDS motor (1) to water pump (A) with two bolts (3) and two 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 36
Required Parts
Group Number 372-1177 Motor Lines Gp (Rev. 04) 
Tool  Qty  Part Number  Part Description 
1  1  4J-0522  O-Ring Seal 
2  1  246-2951  Adapter 
3  2  1P-3703  Rectangular Seals 
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 Washers 
8  4  6V-8336  Bolts 
9  4  8T-4184  Bolts 
10  3  3J-1907  O-Ring Seal 
11  1  9S-4191  O-Ring Plug 
34  1  6V-8076  Elbow 
    Show/hide table
    Illustration 94g06207335
    Water Pump Motor
    (A) Motor high-pressure port (red)
    (B) Motor low-pressure port (blue)

  1. Install adapter (2) with seal (1) to elbow (34) with O-Ring Seal (10) in motor high pressure port (A).

  2. Connect red motor high-pressure hose (4) with seal (3) to motor high-pressure port (A). Install two flanges (6) around the hose.

  3. Connect blue motor low-pressure hose (5) with seal (3) to motor low-pressure port (B). Install two 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.

    Show/hide table
    Illustration 95g03357437

  4. Fasten the red motor high-pressure hose (4) and flanges (6) to the WDS motor with four bolts (8) and four washers (7). Tighten the bolts to a torque of 100 ± 20 N·m (74 ± 15 lb ft).

  5. Fasten the blue motor low-pressure hose (5) and flanges (6) to the WDS motor with four bolts (9) and four washers (7). Tighten the bolts to a torque of 100 ± 20 N·m (74 ± 15 lb ft).
    Show/hide table
    Illustration 96g03357438

  6. Install plug (11) with 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 37
Required Parts
Group Number 372-1177 Motor Lines Gp (Rev. 04) 
Tool  Qty  Part Number  Part Description 
3  2  1P-3703  Rectangular Seals 
    Show/hide table
    Illustration 97g03357439
    Rear View Of Bulkhead Plate
    (C) Pump low-pressure port (blue)
    (D) Pump high-pressure port (red)

  1. Route blue motor low-pressure hose (5) from the WDS motor to pump low-pressure port (C) on the bulkhead plate.

  2. Route red motor high-pressure hose (4) from the WDS motor to pump high-pressure port (D) on the bulkhead plate.
    Show/hide table
    Illustration 98g03357440
    Rear View Of Bulkhead Plate
    (C) Pump low-pressure port (blue)
    (D) Pump high-pressure port (red)

  3. Connect blue motor low-pressure hose (5) with 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).

  4. Connect red motor high-pressure hose (4) with 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 38
Required Parts
Group Number 372-1177 Motor Lines Gp (Rev. 04) 
Tool  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 
    Show/hide table
    Illustration 99g03357441

  1. Install adapter (13) with 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).

  2. Install seal (14) in adapter (13).

Connect WDS Motor Case Drain Hose to the Plate Assembly

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Table 39
Required Parts
Group Number 372-1177 Motor Lines Gp (Rev. 04) 
Tool  Qty  Part Number  Part Description 
15  1  469-1914  Hose As 
16  3  143-4299  Grommets 
17  3  7G-5984  Clips 
18  3  7G-5985  Clips 
19  3  7D-7233  Clip 
20  5  6V-5839  Washers 
21  3  0S-1594  Bolts 
22  2  6V-8801  Nuts 
    Show/hide table
    Illustration 100g06207339
    Vertical Mounting of WDS Motor
    Show/hide table
    Illustration 101g03357443
    Case Drain Port for Inverted Horizontal Mounting
    Show/hide table
    Illustration 102g03357444
    Case Drain Port for Horizontal Mounting

  1. Connect motor case drain hose (15) with seal (14) to adapter (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.

    Show/hide table
    Illustration 103g03357445

  2. Route motor case drain hose (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.

    Show/hide table
    Illustration 104g03357446
    Rear View Of Bulkhead Plate

  3. Connect motor case drain hose (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.

    Show/hide table
    Illustration 105g03357447

  4. Install three grommets (16) on motor low-pressure hose (5) and motor high-pressure hose (4).

  5. Install clips (17) and clips (18) over each grommet.

  6. Install three clips (19) on motor case drain hose (15).

  7. 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 40
Required Parts
Group Number 372-1177 Motor Lines Gp (Rev. 04) 
Tool  Qty  Part Number  Part Description 
23  2  6V-6560  O-Ring Seals 
24  2  8T-7489  Connectors 
25  3  6V-8397  O-Ring Seals 
26  1  6V-9850  Elbow 
27  2  124-2159  Permanent Coupling 
28  2  124-2111  Permanent Coupling 
29  5  100-4336  Clips 
30  5  8T-4121  Hard Washers 
31  5  7E-7606  Bolts 
32(1)  1  122-6867  Hose 
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(1) This component must be provided by the customer.
    Show/hide table
    Illustration 106g03357448
    WDS Motor
    (J) Motor signal port (green)
    (K) Motor pilot port (yellow)

  1. Install adapter (24) with 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).

  2. Connect adapter (26) with seal (25) to adapter (24). Tighten the adapter to a torque of 45 ± 5 N·m (33 ± 4 lb ft).
    Show/hide table
    Illustration 107g03357450
    WDS Motor
    (J) Motor signal port (green) - straight fitting
    (K) Motor pilot port (yellow) - 90 degree adapter

  3. Install adapter (24) with seal (23) in motor signal port (J) of the WDS motor. Tighten the adapter to a torque of 50 ± 8 N·m (37 ± 6 lb ft).

  4. 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.

  5. Create two hose assemblies as follows:

    • Yellow motor pilot pressure hose - install one coupling (27) on one end and install one coupling (28) on the other end

    • Green motor signal pressure hose - install one coupling (27) on one end and install one coupling (28) on the other end

    Note: Label both ends of both hoses before connecting.

  6. Connect the end of the yellow motor pilot pressure hose with elbow coupling (27) to adapter (26) in motor pilot port (K) with seal (25).

  7. Connect the end of the green motor signal pressure hose with elbow coupling (27) to adapter (24) in motor signal port (J) with seal (25).

  8. Route both hoses under the water tank to the plate assembly on the back of the truck.
    Show/hide table
    Illustration 108g03357452
    Rear View Of Bulkhead Plate
    (L) Motor signal line fitting (green)
    (M) Motor pilot pressure hose fitting (yellow)

  9. 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.

  10. 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.

  11. 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 washers (30).

Install Pump Breather Group

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Table 41
Required Parts
Group Number 420-4443 Breather Gp (Rev. 00) 
Tool  Qty  Part Number  Part Description 
1  1  6V-8641  Connector 
2  1  8T-4191  Bolt 
3  1  9G-5127  Breather 
4  1  4K-8864  Clip 
5  1  8T-1031  Connector 
6  1  422-9448  Hose As 
7  1  152-8181  Fitting As 
8  5  9S-4191  O-Ring Plugs 
9  9  3J-1907  O-Ring Seals 
10  1  4J-5477  O-Ring Seal 
11  2  8T-4121  Hard Washers 
    Show/hide table
    Illustration 109g03367416
    Vertically Mounted Water Pump
    Show/hide table
    Illustration 110g03368841
    Horizontally Mounted Water Pump

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

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

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

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

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

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

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

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

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

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

Spray Head Installation

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Table 42
Required Parts
Spray Head Installation 
Item  Qty  Part Number  Part Description 
1  5  416-9877  Water Control Valve Gp 
    Show/hide table
    Illustration 111g03714850

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

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

    Show/hide table
    Illustration 112g03714851
    Show/hide table
    Illustration 113g03714852

  2. Install water control valve group (1) on spray bar (D). Reinstall split flanges (A). Do not tighten the mounting bolts.
    Show/hide table
    Illustration 114g03697517
    (E) 152 mm (6 inch)
    Show/hide table
    Illustration 115g03714853

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

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

    Show/hide table
    Illustration 116g03682227

  4. Repeat the previous steps for the remaining spray heads on the rear spray bar.
    Show/hide table
    Illustration 117g03714854

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

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

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

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

Spray Head Installation

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Table 43
Required Parts
Group Number 421-7471 Water Control Valve Gp (Rev. 01) 
Tool  Qty  Part Number  Part Description 
1  7  416-9877  Water Control Valve Gp (STAINLESS STEEL) 
    Show/hide table
    Illustration 118g03357454

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

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

    Show/hide table
    Illustration 119g03357456
    Show/hide table
    Illustration 120g03357458

  2. Install valve group (1) on spray bar (D). Reinstall split flanges (A). Do not tighten the mounting bolts.
    Show/hide table
    Illustration 121g03357461
    Show/hide table
    Illustration 122g03357463

  3. Rotate 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.

    Show/hide table
    Illustration 123g03357464

  4. Repeat the previous steps for the remaining spray heads on the rear spray bar.
    Show/hide table
    Illustration 124g03357465

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

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

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

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

Chassis Harness Installation

Chassis Harness Assembly Routing

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Table 44
Required Parts
Group Number 423-1568 Sensor Wiring Gp (Rev. 02) 
Tool  Qty  Part Number  Part Description 
1  4  4P-7581  Clips 
2  3  4P-8134  Clips 
3  3  132-5789  Clips 
4  1  294-3313  Clip 
5  2  310-1898  Clips 
6  1  455-3054  Sensor Harness As 
7  7  200-6345  Mount 
8  58  7K-1181  Cable Straps 
9  14  204-2281  Cable Straps 
    Show/hide table
    Illustration 125g03358047

  1. Plug chassis harness assembly (6) into the receptacle on the rear bulkhead of the operator cab. Route the harness assembly along the truck chassis harness (A). Strap the harness assembly in place with cable straps (8).
    Show/hide table
    Illustration 126g03367784
    Show/hide table
    Illustration 127g03370709

  2. Route chassis harness assembly (6) under the operator cab. Route the harness assembly along the truck chassis harness (A). Strap the harness assembly in place with cable straps (8).
    Show/hide table
    Illustration 128g03362967

  3. Locate the portion (B) of harness assembly (6) that connects to the fan. Route this portion of the harness assembly up and over the deck plates to the cooler group (C).

  4. Fasten mounts (7) to the installed hoses with cable straps (9). Strap the harness assembly (6) to the mounts with cable straps.
    Show/hide table
    Illustration 129g03362966

  5. Fasten clip (4) to the mounting plate of the cooling group (C). Tie the harness assembly (6) to the clip with cable straps (8).

  6. Connect the fan power wire from harness assembly (6) to contact (D). Connect the fan ground wire to contact (E).
    Show/hide table
    Illustration 130g03358051

  7. Route the remainder of chassis harness assembly (6) along the truck chassis harness (A). Tie the cable in place with cable straps (8).
    Show/hide table
    Illustration 131g03358053

  8. Locate portion (F) of 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.

  9. Fasten clips (1) and (3) to the cross tube and the drive shaft cover. Tie the harness assembly (6) to the clips with cable straps (8).
    Show/hide table
    Illustration 132g03362969

  10. Plug harness assembly (6) into the solenoid connector (G) on the WDS pump.
    Show/hide table
    Illustration 133g03362972

  11. Route the remainder of chassis harness assembly (6) along the truck chassis harness (A). Tie the cable in place with cable straps (8).

  12. 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.

  13. Tie the harness assembly (6) to the truck chassis harness with cable straps (8).
    Show/hide table
    Illustration 134g03358058

  14. Locate the portion of harness assembly (6) that connects to the oil filter. Route this portion down the right frame rail to the oil filter.

  15. Install clips (3) and (5). Tie the harness assembly (6) to the clips with cable straps (8).

  16. Locate bypass switch connector (J) on the oil filter. Connect the wiring to the bypass switch.
    Show/hide table
    Illustration 135g03358056

  17. Locate the portion of harness assembly (6) that connects to the hoist valve. Route this portion along the right frame rail to the hoist valve. Tie the harness assembly (6) to the frame with cable straps (8).

  18. Connect the hoist lower connector of the harness assembly (6) to the hoist lower solenoid (K).

  19. Connect the hoist raise connector of the harness assembly (6) to the hoist raise solenoid (L).
    Show/hide table
    Illustration 136g03362980

  20. Locate the portion (M) of 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).
    Show/hide table
    Illustration 137g03362968

  21. Route 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).
    Show/hide table
    Illustration 138g03358055

  22. Route harness assembly (6) up and over the WDS hydraulic tank. Tie the cable in place with clips (2) and cable straps (8).

  23. Connect the temperature sensor wire to the temperature sensor connector (P).

  24. 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.

    Show/hide table
    Illustration 139g03358180

  25. Route the remainder of chassis 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 45
Required Parts
Group Number 423-1578 Electrical Installation Gp (Rev. 02) 
Tool  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 
    Show/hide table
    Illustration 140g06207341

  1. Fasten bracket (11) onto weld boss (13) to the right side of the rear truck frame with bolt (10) and washer (12) .
    Show/hide table
    Illustration 141g03362997

  2. Route the remainder of the 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 46
Required Parts
Group Number 382-7808 Control Manifold and Lines Gp (Rev. 02) 
Tool  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  Rods 
4(1)  3  8T-4205  Hard Washers 
5(1)  3  6V-8185  Nuts 
6(2)  10  6V-8647  Connectors 
7(2)  10  3J-7354  O-Ring Seals 
8(2)  20  4J-5477  O-Ring Seals 
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  Clips 
13(2)  10  3J-1907  O-Ring Seals 
14(2)  10  6V-8627  Elbows 
15(4)  2  6V-8636  Connectors 
16(4)  2  3J-1907  O-Ring Seals 
17(4)  2  6V-9836  Swivel Tees 
18(4)  6  6V-8397  O-Ring Seals 
19(4)  2  6V-9829  Cap As 
20(3)  1  122-6869  Hose 
21(4)  4  124-2114  Couplings 
22(4)  4  5K-5338  Clips 
23(4)  4  8T-4191  Bolts 
24(4)  4  8T-4121  Hard Washers 
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(1) These components come pre-assembled.
(2) These components are included with 354-7577 Hydraulic Oil Lines Gp. Each lines group contains components to connect one spray head.
(3) This component must be provided by the customer.
(4) These components are included with 372-1178 Pilot Lines Gp

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

    Show/hide table
    Illustration 142g03357466
    Rear Hydraulic Manifold (C)
    Show/hide table
    Illustration 143g03357467

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

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

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

    Show/hide table
    Illustration 144g03357469
    (A) Spray head open port
    (B) Spray head close port

  2. Locate adapters (6) for the spray head pressure lines. Install seal (7) on each adapter.

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

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

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

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

    Show/hide table
    Illustration 145g03357470

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

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

  6. Clamp the spray head hoses to water tank with clips (11).
    Show/hide table
    Illustration 146g03357471

  7. Install adapter (14) with seal (13) in each side of manifold (2). Repeat this step for both sides of all the manifolds.
    Show/hide table
    Illustration 147g03357473
    (A) Spray head - open "A"port
    (B) Spray head - close "B"port
    Show/hide table
    Illustration 148g03357475
    Reference Labels On Hydraulic Manifold
    (D) Spray valve "5A"
    (E) Spray valve "4A"
    (F) Spray valve "6A"
    (G) Spray valve "3A"
    (H) Spray valve "2A"
    (J) Spray valve "5B"
    (K) Spray valve "4B"
    (L) Spray valve "6"B
    (M) Spray valve "3B"
    (N) Spray valve "2B"
    Show/hide table
    Illustration 149g03357478
    (P) Spray head "2"
    (Q) Spray head "3"
    (R) Spray head "6"
    (S) Spray head "4"
    (T) Spray head "5"

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

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

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

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

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

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

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

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

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

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

    • Spray valve "2B" (N) - close (C) line of #2 spray head (P)
    Show/hide table
    Illustration 150g03357480
    ( U) Spray head pilot return port (black)
    (V) Spray head pilot supply port (brown)

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

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

  11. Connect one tee adapter (17) with seal (18) to each adapter (16).

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

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

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

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

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

  14. Connect one end of each hose assembly to the tee adapter at the bottom of the rear hydraulic manifold.
    Show/hide table
    Illustration 151g03357481
    (W) Spray head pilot return fitting (black)
    (X) Spray head pilot supply fitting (brown)

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

  16. Route the brown hose from spray head pilot supply port (V) to spray head pilot return fitting (X) in the plate assembly. Connect the hose assembly to port with seal (18).
    Show/hide table
    Illustration 152g03357482

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

Rear Harness Assembly Installation

Install Rear Hydraulics Control Group Mounting Plate

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Table 47
Required Parts
Group Number 423-1577 Control Wiring Gp (Rev. 02) 
Tool  Qty  Part Number  Part Description 
1  1  357-7152  Plate As 
2  4  7X-7729  Washers 
3  4  8T-4195  Bolts 
    Show/hide table
    Illustration 153g03357483

  1. 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.

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

Install Rear Electrical Control Group

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Table 48
Required Parts
Group Number 423-1577 Control Wiring Gp (Rev. 00) 
Tool  Qty  Part Number  Part Description 
4  4  242-9961  Plates 
5  1  423-1574  Control Box Gp 
6  4  5P-0537  Hard Washers 
7  4  8T-9808  Grommets 
    Show/hide table
    Illustration 154g03357484

  1. Mount control group (5) to plate assembly (1), with the connectors pointing down.
    Show/hide table
    Illustration 155g03357485

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

  3. Fasten control group (5) to plate assembly (1) with four bolts (7) and four washers (6).

Connect Rear Control Harness Assembly

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Table 49
Required Parts
Group Number 423-1577 Control Wiring Gp (Rev. 00) 
Tool  Qty  Part Number  Part Description 
8  1  335-5321  Pressure Sensor Gp 
9  1  423-1571  Sensor Harness As 
10  1  284-2728  Pressure Sensor Gp 
    Show/hide table
    Illustration 156g03357488

  1. Connect harness assembly (9) to control group (5).
    Show/hide table
    Illustration 157g03357487

  2. Remove plug and install pressure sensor group (8) on the motor inlet pressure tap.

  3. Route harness assembly (9) to sensor group (8). Connect the harness assembly to the pressure sensor.
    Show/hide table
    Illustration 158g03362982

  4. Install sensor group (10) on the rear spray bar.

  5. Route harness assembly (9) to sensor group (10). Connect the harness assembly to the pressure sensor.
    Show/hide table
    Illustration 159g03357489
    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"

  6. Locate the hydraulic manifold portion of 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.

  7. Connect 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
    Show/hide table
    Illustration 160g03361304

  8. Route the tank level sensor wires of 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 50
Required Parts
Group Number 423-1577 Control Wiring Gp (Rev. 00) 
Tool  Qty  Part Number  Part Description 
12  9  8T-4136  Bolts 
13  5  4P-7581  Clips 
14  1  303-4649  Clip 
15  4  310-1898  Clips 
16  11  7K-1181  Cable Straps 
17  9  8T-4121  Hard Washers 
    Show/hide table
    Illustration 161g03357493
    Rear of Water Tank

  1. Attach clips (13) to the rear of water tank with bolts (12) and washers (17).

  2. Attach clip (14) and clips (15) to the rear of water tank with bolts (12) and washers (17).

  3. Tie harness assembly (9) to the rear of water tank with cable straps (16).

Install Communication Harness

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Table 51
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  Clips 
20  19  8T-4121  Hard Washers 
21  19  8T-4136  Bolts 
22  1  310-1898  Clip 
23  20  7K-1181  Cable Straps 
    Show/hide table
    Illustration 162g03357496

  1. Connect cable (18) to connector (L) on bottom of control group (5).
    Show/hide table
    Illustration 163g03357497

  2. Route cable (18) with harness assembly (9) along the rear of the water tank.

  3. Install clips (22) and (19) on the rear and bottom of the water tank with bolts (21) and washers (20).

  4. Tie cable (18) and harness assembly (9) to the clips with cable straps (23).
    Show/hide table
    Illustration 164g03357498

  5. Locate the portion of cable (18) that connects to the chassis harness. Plug this portion into the connector on bracket (M).

  6. Install clips (19) on the bottom of the water tank with bolts (21) and washers (20).

  7. Route cable (18) along harness assembly (9) across and under the water tank.

  8. Tie cable (18) and harness assembly (9) to the clips with cable straps (23).
    Show/hide table
    Illustration 165g03362632

  9. Install clips (19) on the front of the water tank with bolts (21) and washers (20).

  10. Route cable (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 52
Required Parts
Group Number 426-1518 Control Wiring Gp (Rev. 00) 
Tool  Qty  Part Number  Part Description 
24  1  7J-8611  Pipe Elbow 
25  1  355-9448  Pressure Sensor 
    Show/hide table
    Illustration 166g03357490
    Show/hide table
    Illustration 167g03357491

  1. Install elbow (24) in the front of the water tank. Connect 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.

  2. Connect harness assembly (9) to the pressure sensor (25).

Front Hydraulic Manifold Installation

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Table 53
Required Parts
Group Number 382-7797 Control Manifold and Lines Gp (Rev. 01) 
Tool  Qty  Part Number  Part Description 
1(1)  3  7X-0268  Bolts 
2(1)  3  8T-4205  Hard Washers 
3(2)  4  6V-8627  Elbows 
4(2)  4  6V-8647  Connectors 
5(2)  8  8T-4136  Bolts 
6(2)  2  6V-9828  Caps 
7(2)  8  4D-6466  Clips 
8(2)  4  124-2111  Permanent Coupling 
9(2)  4  124-2140  Permanent Coupling 
10(2)  4  3J-1907  O-Ring Seals 
11(2)  4  3J-7354  O-Ring Seals 
12(2)  8  4J-5477  O-Ring Seals 
13(2)  8  8T-4121  Hard Washers 
14(1)  2  354-2266  Control Manifold Gp 
15(1)  1  354-7580  Control Manifold and Lines Gp 
16(1)  4  2H-3755  Bolts 
17(1)  4  5M-3062  Bolts 
18  4  8T-4191  Bolts 
19  4  8T-4121  Hard Washers 
20(3)  1  6V-9850  Elbow 
21(3)  1  6V-8724  Elbow 
22(3)  1  8T-9041  Connector 
23(3)  13  7E-7606  Bolts 
24(3)  13  5K-5338  Clips 
25(3)  4  124-2114  Couplings 
26(3)  2  3J-1907  O-Ring Seals 
27(3)  3  6V-8397  O-Ring Seals 
28(3)  13  8T-4121  Hard Washers 
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.
    Show/hide table
    Illustration 168g03357500
    Front Hydraulic Manifold (A)
    Show/hide table
    Illustration 169g03357501

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

    Show/hide table
    Illustration 170g03357502
    (B) Spray head pilot supply port (brown)
    (C) Spray head pilot return port (black)

  2. Connect adapter (22) with seal (26) to spray head pilot supply port (B).

  3. Connect adapter (20) with seal (27) to adapter (22).

  4. Connect adapter (21) with seal (26) to spray head pilot return port (C).

  5. Measure two lengths of bulk 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.

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

  7. Connect the black hose assembly to adapter (21) in spray head pilot return port (C) with seal (27).
    Show/hide table
    Illustration 171g03357503

  8. Route the hose assemblies down the front of the water tank. Clamp the hoses to the water tank with clips (24), bolts (23) and washers (26).
    Show/hide table
    Illustration 172g03357505

  9. 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 washers (26).
    Show/hide table
    Illustration 173g03357506
    (D) Spray head pilot return fitting
    (E) Spray head pilot supply fitting
    Show/hide table
    Illustration 174g03367810
    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.

  10. Connect the brown hose assembly from spray head pilot supply coupling (B) to spray head pilot supply fitting (E) with seal (8).

  11. Connect the black hose assembly from spray head pilot return coupling (C) to spray head pilot return fitting (D) with seal (8).
    Show/hide table
    Illustration 175g03357507
    (F) Spray head "7"
    Show/hide table
    Illustration 176g03357508
    (G) Spray head "1"

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

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

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

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

    Show/hide table
    Illustration 177g03357509
    Spray head "7" (F)
    ( H) Spray head - close "B" port
    (J) Spray head - open "A" port

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

  13. Install adapter (4) with seal (12) in spray head close port (H) and spray head open port (J) of spray valve "7" (F).
    Show/hide table
    Illustration 178g03357510
    Spray head "1" (G)
    ( K) Spray head - open "A" port
    (L) Spray head - close "B" port

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

  15. Connect the four hose assemblies to the spray heads. Connect the end of each hose assembly with straight coupling (8) to adapter (4) with seal (11).
    Show/hide table
    Illustration 179g03357511

  16. Install adapter (3) with seal (10) in each side of manifold (14). Repeat this step for both sides of both the manifolds.
    Show/hide table
    Illustration 180g03357512
    Reference Labels on Hydraulic Manifold
    (M) Spray valve "7B" - close port
    (N) Spray valve "1B" - close port
    (P) Spray valve "7A" - open port
    (Q) Spray valve "1A" - open port

  17. Connect the hose from each spray valve to the corresponding fitting on the front hydraulic manifold with 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)

  18. Clamp the hoses to the water tank with clips (7), bolts (5) and washers (13).

Cannon Group Installation

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Table 54
Required Parts
Group Number 421-8349 Water Cannon Ar (Rev. 03) 
Tool  Qty  Part Number  Part Description 
1  1  422-5872  Water Cannon Gp 
    Show/hide table
    Illustration 181g03357513
    Show/hide table
    Illustration 182g03357514

    Note: This safety message is located on the cannon.

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

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

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

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

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

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

    Show/hide table
    Illustration 183g03357515

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

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

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

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

    Show/hide table
    Illustration 184g03357516
    Water Cannon Position on the Machine
    Show/hide table
    Illustration 185g03357517

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

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

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

    Note: Mounting hardware must be provided by the customer.

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

Water Cannon Hydraulic Lines Routing

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Table 55
Required Parts
Group Number 355-8914 Hydraulic Oil Lines Gp (Rev. 01) 
Tool  Qty  Part Number  Part Description 
1  4  3J-1907  O-Ring Seals 
2  4  6V-8641  Connector 
3(1)  2  164-0193  Adapters 
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 Seals 
9  2  7X-5331  Elbows 
10  6  3J-7354  O-Ring Seals 
11  2  6V-8628  Elbows 
12  4  6V-8647  Connectors 
13  2  5P-4325  Clips 
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.
    Show/hide table
    Illustration 186g03357525

  1. Measure four lengths of bulk 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.

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

    • "DOWN" hose - install one coupling (7) on one end and install one coupling (5) on the other end

    • "UP" hose - install one coupling (7) on one end and install one coupling (5) on the other end

    • "LT" hose - install one coupling (7) on one end and install one coupling (5) on the other end

    • "RT" hose - install one coupling (7) on one end and install one coupling (5) on the other end.

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

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

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

    • "ON" hose - install one coupling (7) on each end of this hose

    • "OFF" hose - install one coupling (7) on each end of this hose.

    Note: Label both ends of all hoses before connecting.

    Show/hide table
    Illustration 187g06207344

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

    • "DOWN" fitting (F)

    • " UP" fitting (E)

    • " LT" fitting (G)

    • " RT" fitting (H)

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

  7. Install adapter (3) in each adapter (2).

  8. Connect the end of the "DOWN" hose with elbow coupling (5) to "DOWN" fitting (F) with seal (4).

  9. Connect the end of the "UP" hose with elbow coupling (5) to "UP" fitting (E) with seal (4).

  10. Connect the end of the "LT" hose with straight coupling (6) to "LT" fitting (G) with seal (4).

  11. Connect the end of the "RT" hose with straight coupling (6) to "RT" fitting (H) with seal (4).

  12. Route the four hoses from water cannon (B) to front manifold group (D).
    Show/hide table
    Illustration 188g03357527

  13. 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.

  14. Install adapter (12) and seal (10) in each of the four ports.

  15. Connect the end of the "DOWN" hose with straight coupling (7) to "DOWN" fitting (J) with seal (8).

  16. Connect the end of the "UP" hose with straight coupling (7) to "UP" fitting (K) with seal (8).

  17. Connect the end of the "LT" hose with straight coupling (7) to "LT" fitting (L) with seal (8).

  18. Connect the end of the "RT" hose with straight coupling (7) to "RT" fitting (M) with seal (8).
    Show/hide table
    Illustration 189g06207452

  19. 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.

  20. 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

  21. Connect the "OFF" hose to the "OFF" fitting (N) seal (8).

  22. Connect the "ON" hose to the "ON" fitting (P) with seal (8).

  23. Route the two hoses from shut-off valve (C) to front manifold group (D).
    Show/hide table
    Illustration 190g06207348

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

    • "OFF" (R)

    • " ON" (Q).

  25. Install adapter (11) with seal (10) in both of these ports.

  26. Connect the "OFF" hose to the "OFF" fitting (R) seal (8).

  27. Connect the "ON" hose to the "ON" fitting (Q) with seal (8).
    Show/hide table
    Illustration 191g06207350

  28. Fasten the shut-off valve hoses and the cannon operation hoses to water tank with clips (13).

Front Harness Assembly Installation

Install Front Electrical Control Group Mounting Plate

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Table 56
Required Parts
Group Number 423-1576 Control Wiring Gp (Rev. 00) 
Tool  Qty  Part Number  Part Description 
1  1  357-7152  Plate As 
2  4  7X-7729  Washers 
3  4  8T-4195  Bolts 
    Show/hide table
    Illustration 192g03357518

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

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

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

Install Front Hydraulics Control Group

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Table 57
Required Parts
Group Number 423-1576 Control Wiring Gp (Rev. 00) 
Tool  Qty  Part Number  Part Description 
4  4  242-9961  Plates 
5  1  423-1575  Control Box Gp 
6  4  5P-0537  Hard Washers 
7  4  8T-8908  Bolts 
8  1  423-1572  Control Harness As 
    Show/hide table
    Illustration 193g03357519

  1. Mount control group (5) to plate assembly (1), with the connectors pointing down.
    Show/hide table
    Illustration 194g03357520

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

  3. Fasten control group (5) to plate assembly (1) with four bolts (7) and four washers (6).

Connect Front Control Harness Assembly

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Table 58
Required Parts
Group Number 423-1576 Control Wiring Gp (Rev. 00) 
Tool  Qty  Part Number  Part Description 
9  10  8T-4136  Bolts 
10  10  4P-7581  Clips 
11  1  423-1573  Sensor Harness As 
12  10  7K-1181  Cable Straps 
13  10  8T-4121  Hard Washers 
    Show/hide table
    Illustration 195g03357522

  1. Connect harness assembly (11) to control group (5).
    Show/hide table
    Illustration 196g03357523
    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

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

  3. Connect 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.
    Show/hide table
    Illustration 197g03357524

  4. Attach harness (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 washer (13).
    Show/hide table
    Illustration 198g03367814

  5. Connect harness (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.

    Show/hide table
    Illustration 199g03362998

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

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

Cab and Chassis Electrical Installation

WAVS Camera System Installation

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Table 59
Required Parts 
Tool  Qty  Part Number  Part Description 
1  1  251-4168  Switch 
2  3  347-1668  Camera Gp 
3  3  276-2638  Bracket As 
4  3  274-4479  Cable As 

  1. Install WAVS monitor and cable. Reference Special Instruction, REHS7242.
    Show/hide table
    Illustration 200g03358188

  2. Mount switch assembly (1) on the inside of the right frame rail. Connect cable assembly (A) to the "MON" connector on the switch assembly.
    Show/hide table
    Illustration 201g03358189
    Rear View of Water Tank

  3. Mount camera (2) in location (B) shown.
    Show/hide table
    Illustration 202g03358190
    Top of Water Tank

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

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

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

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

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

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

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

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

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

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

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

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

Electronic Technician Setup

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

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

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

  4. Disconnect the laptop computer.

MD3 Setup

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

  2. Move the engine start switch to the ON position. Do not start the engine.
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    Illustration 203g03358191

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

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

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

    Note: The default language is English.

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

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

  8. In the "Main" display screen, press "F1" button (A) to select the "Adjust" menu.
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    Illustration 204g03358192

  9. In the "Adjust" screen, press "OK" button (E) to select the "SetUp" menu.
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    Illustration 205g03358193

  10. Enter the PIN code. Use up button (F) and down button (D) to select a digit. Use back button (G) to delete a digit. Use "OK" button (E) to enter the digit.
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    Illustration 206g03358194

  11. Select the "Truck Model" option in the "SetUp" menu. Press "OK" button (E).
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    Illustration 207g03358195

  12. Select the truck model and press "OK" button (E).
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    Illustration 208g03358196

  13. Select the "Spray Configuration Set Up" option in the "SetUp" menu. Press "OK" button (E).
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    Illustration 209g03358198

  14. Scroll down and select the spray configuration for the truck. Press OK button (E).
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    Illustration 210g03358199

  15. Select the "Tank Lift Option" option in the "SetUp" menu. Press "OK" button (E).
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    Illustration 211g03358201

  16. Scroll down and select the "Enable" option. Press "OK" button (E).
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    Illustration 212g03358202

  17. 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 213g03358203

  18. Scroll down and select the "Installed" option. Press "OK" button (E).
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    Illustration 214g03358204

  19. Scroll down and select the "Momentary Single" option. Press "OK" button (E).
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    Illustration 215g03358205

  20. Select the "Manual Mode Enable" option in the "SetUp" menu. Press "OK" button (E).
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    Illustration 216g03358206

  21. Scroll down and select the "Enabled" option. Press "OK" button (E).
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    Illustration 217g03358207

  22. Select the "Manual Speed Deactivation" option in the "SetUp" menu. Press "OK" button (E).
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    Illustration 218g03358209

  23. 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 219g03358212

  24. Select the "Intermittent Mode Enable" option in the "SetUp" menu. Press "OK" button (E).
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    Illustration 220g03358213

  25. Scroll down and select the "Enabled" option. Press "OK" button (E).
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    Illustration 221g03358214

  26. 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 60
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 222g03860632
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    Illustration 223g03860635
    View (A-A)
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    Illustration 224g03358215
    View (B-B)

    Note: Refer to Illustration 224. Port (A) is the S·O·S sample port. Port (B) is a gauge port for checking charge pump pressure.

  1. Refer to Illustration 223. Check the oil filter group to ensure tee (1) and test fitting (3) are installed. If installed, proceed to Step 4. If not installed, proceed to Step 2.

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

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

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

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

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

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

Bleeding Air From Spray Head Cylinders

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

  1. Start the truck and let the engine idle.

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

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    Illustration 225g03358216

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

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

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    Illustration 226g03358218

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

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

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

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

  7. Repeat this procedure for each spray head.

  8. Stop the engine.

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

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

Water Pump Fill Procedure

  1. Fill the water tank.

  2. Start the truck and let the engine idle.

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

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

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

  6. Stop the engine.

Water Pump Rotation

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

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

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

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

  1. Start the truck and let the engine idle.
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    Illustration 227g03358219

  2. Press cannon mode button (G).
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    Illustration 228g03358222

  3. Pull trigger (H) on the joystick to open the butterfly valve.
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    Illustration 229g03358223
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    Illustration 230g03358224
    Rotation Direction Indicator
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    Illustration 231g03358225
    Clockwise Pump Shaft Rotation

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

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

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

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 232g03358226

  1. In the "Main" display screen, press "F1" button (A) to select the "Adjust" menu.
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    Illustration 233g03358227

  2. In the "Adjust" screen, scroll down and press "OK" button (E) to select the "Spray Head Calibration" menu.
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    Illustration 234g03358228

  3. Enter the PIN code. Use "up" button (C) and "down" button (D) to select a digit. Use "back" button (E) to delete a digit. Use "OK" button (B) to enter the digit.
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    Illustration 235g03358229

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

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

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    Illustration 236g03358230

  5. Scroll down and select the "Enable" option. Press "OK" button (B). Press "back" button (E) to exit the screen.
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    Illustration 237g03358231

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

  7. When calibrating an individual spray head, adjust the head intensity until hydraulic pressure target light is solid green. If hydraulic pressure is low, increase the head intensity by pressing up arrow. If hydraulic pressure is high, decrease the head intensity value by pressing the down arrow. After adjusting the value for head intensity, press the "OK" button to accept the change. Check hydraulic pressure. If pressure is within 50 psi of the target pressure, the light will turn green. Continue adjusting head intensity until the light maintains green status a majority of the time.
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    Illustration 238g03358233

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

Water Tank Sensor Calibration

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    Illustration 239g03358234

  1. Press "F1" button (A) to display the tank level screen.

  2. Fill the water tank to a minimum level of approximately 1100 to 1900 L (300 to 500 US gal).
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    Illustration 240g03358235

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

  4. Press "F1" button (A) to select the "Adjust" menu.
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    Illustration 241g03358237

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

  6. Enter the PIN code. Use up button (E) and down button (C) to select a digit. Use "OK" button (D) to enter the digit.
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    Illustration 242g03358238

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

  23. Use up button (E) and down button (C) to adjust value (F) displayed on the screen. Enter a value greater than the "Tank Empty Value" so the system shuts off before the water tank is completely empty.

    Note: If "Tank Empty Value" is 0.1, set the "Low Water Shutoff" to 0.2.

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

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

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

  27. Scroll down to the "Tank full shut off" option. Press "OK" button (D).

  28. Use up button (E) and down button (C) to adjust value (F) displayed on the screen. Enter a value less than the "Tank Full Value" so the system shuts off before the water tank is 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

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

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

  3. Use up button (E) and down button (C) to scroll down and select the "Cannon Adjustments" menu. Press "OK" button (D).

  4. The cannon adjustments menu allows the operator to adjust the speed and sensitivity of the joystick.

Operating Pressures

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

  1. Charge pump pressure is 1930 kPa (280 psi) at normal operating temperatures. The charge relief valve will limit pressure to 3100 kPa (450 psi). Charge pump pressure will normally reach relief pressure when starting with cold oil.

  2. Pilot pressure to the spray heads and cannon manifolds is 3447 kPa (500 psi).

  3. Hydraulic pressure to open and close the spray heads will vary depending on the requested spray head opening.

  4. Pump 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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