Procedure to Install Caterpillar Water Delivery System (<B>S/N:</B>M3J) on the 777F Off-Highway Truck{5612, 5613, 7000} Caterpillar

Procedure to Install Caterpillar Water Delivery System (S/N:M3J) on the 777F Off-Highway Truck{5612, 5613, 7000}

Usage:

777F JXP

OEM:: CAT WDS (S/N: M3J1-UP)
Off-Highway Truck/Tractor:: 777F (S/N: JXP1-UP)

Introduction

This Special Instruction will provide the necessary steps to install a Caterpillar Water Delivery System (S/N:M3J) on the 777F Off-Highway Truck.

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: Deluxe kits include water cannon, additional spray heads, a joystick control group, and a front hydraulic manifold with electronic control group.

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

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

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

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NOTICE

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide", for tools and supplies suitable to collect and contain fluids in Caterpillar machines. Dispose of all fluids according to local regulations and mandates.

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 - These tools include the following: 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".

Hydraulic and Component Installation (Chassis)

Removal of Existing Steering Pump and Pump Adapter Group, and Installation of New Steering Pump and Pump Adapter Group

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Table 1
Required Parts Group Number 375-5832 Pump and Mounting Gp (Rev. 01)
Item	Qty	Part Number	Description
1	1	374-2586	Pump Drive Gp
2	8	8M-2530	Bolt
3	1	361-7692	Piston Pump Gp
4	1	6V-8260	O-Ring Seal
5	2	8T-4193	Bolts
6	2	9X-8257	Washers
7	1	381-1848	Tube As
8	3	4J-0524	O-Ring Seal
9	6	1P-4579	Half Flange
10	8	8T-8919	Bolt
11	16	8T-4223	Hard Washer
12	1	381-1852	Tube As
13	2	6V-3378	Clip
	2	7D-7233	Clip
	2	8T-4195	Bolt
	2	8T-4133	Nut
	2	8T-4121	Hard Washer
14	4	7X-0326	Bolt
15	1	371-3955	Hose As
16	1	6J-2680	O-Ring Seal
17	2	1P-4584	Half Flange
18	4	8T-4183	Bolt
19	1	6V-1869	Grommet
	1	6V-1867	Clip
	1	6V-1868	Clip
20	4	092-5524	Bolt
21	1	371-3954	Hose As (Steering Tank to Steering Pump)
22	1	1P-3704	Rectangular Seal
23	2	6V-0401	Half Flange
24	4	268-3205	Bolt
25	4	7M-0242	Hard Washer
26	1	4J-0520	O-Ring Seal
27	2	1P-4577	Half Flange
28	4	5S-7382	Bolt
29	4	8T-4896	Hard Washer

Drain the oil from the steering tank into a suitable container for storage or for disposal. Refer to Operation and Maintenance Manual,, "Steering Tank Oil - Change".

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Illustration 1	g02776698

Disconnect brake cooling tube (A) from pump (B) .

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Illustration 2	g02776699

Remove clamp (C) from brake cooling tube (A) .

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Illustration 3	g02776700

Place suitable container under bolts (D) in order to collect fluid. Remove the bolts.

Disconnect and remove brake cooling tube (A) .

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Illustration 4	g02776701

Disconnect hose assembly (F) from steering pump ( E). Remove the hose assembly.

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Illustration 5	g02776736

Disconnect hose assembly (H) from steering pump ( E). Remove the hose assembly.

Disconnect load sensing hose assembly (G) from steering pump (E). Leave this hose assembly connected to the machine.

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Illustration 6	g02776738

Disconnect case drain hose assembly (J) from steering pump (E). Leave this hose assembly connected to the machine.

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Illustration 7	g02776739

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Illustration 8	g02788390
Pump Drive Shown With Steering Pump And Adapter Removed

Attach a suitable lifting device to steering pump (E). Remove bolts (K) .

Remove steering pump (E) and pump adapter group.
Note: This pump weighs approximately 54 kg (120 lb).

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Illustration 9	g02776780
Pump Adapter Group Shown With Cover Plate Removed

Install pump adapter group (1) with eight bolts (2) .
Note: A cover plate and seal are included with the pump adapter group. Remove the cover plate, seal, and mounting hardware.

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Illustration 10	g02776782

Install steering pump (3) with seal (4). Fasten the steering pump to the pump adapter group with two bolts (5) and two washers (6) .
Note: The steering pump must be oriented with the suction line on the top.
Note: Use suitable lifting device to install the steering pump. This pump weighs approximately 45 kg (99 lb).

Connect load sensing hose assembly (G) to the steering pump.

Connect case drain hose assembly (J) to the steering pump.

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Illustration 11	g02788400

Install tube assembly (7) with seal (8) and two split flanges ( 9). Fasten the tube to pump with four bolts (10) and four washers (11) .

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Illustration 12	g02788412
Right Side of Engine Compartment

Connect tube assembly (12) to tube assembly (7) with seal (8) and two split flanges (9). Fasten the tube assemblies together with four bolts (10) and four washers (11) .

Clamp tube assembly (12) in place at location ( L) and location (M) with two clips (13)

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Illustration 13	g02788417
View From Beneath Engine Compartment

Connect tube assembly (12) to brake oil cooler (N) with seal (8) and two split flanges (9). Fasten the hose to pump with four bolts (14) and four washers (11) .

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Illustration 14	g02777197

Install hose (15) with seal (16) and two split flanges (17). Fasten the hose to pump with four bolts (18) and four washers (11) .

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Illustration 15	g02788422

Route hose (15) up through the engine compartment to the steering tank. Clamp the hose in place with hose clamp (19) .

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Illustration 16	g02788479

Connect hose (15) to steering tank suction connection (P) with seal (8) and two split flanges (9). Fasten the hose to connection with four bolts (20) and four washers (11) .

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Illustration 17	g02777204

Install hose (21) with seal (22) and two split flanges (23). Fasten the hose to pump with four bolts (24) and four washers (25) .

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Illustration 18	g02788492

Route hose (21) up through the engine compartment to brake control valve (Q). Connect the hose to valve with seal (26) and two split flanges (27). Fasten the hose to connection with four bolts (28) and four washers (29) .

Pump Group Installation

WDS Hydraulic Pump Installation

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Table 2
Required Parts Group Number 369-6025 Pump and Mounting Gp (Rev. 04)
Item	Qty	Part Number	Description
1	1	435-5902	Piston Pump Gp
2	1	4S-5898	O-Ring Seal
3	2	9X-8257	Washers
4	2	8T-7338	Bolts
5	1	6V-7970	O-Ring Seal
6	1	8C-4424	Plug

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Illustration 19	g03416902

Install WDS hydraulic piston pump group (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 piston pump must be oriented with pump controls (E) facing up.
Note: Use suitable lifting device to install the WDS hydraulic piston pump. This piston pump weighs approximately 76 kg (168 lb).

Install O-ring seal (2) to WDS hydraulic piston pump group (1) .

Fasten WDS hydraulic piston pump group (1) to drive group (B) with two bolts (4) and two washers (3). Tighten the bolts to a torque of 240 ± 40 N·m (177 ± 29 lb ft) using 24 mm bolts.

Install plug (6) and O-ring seal (5) 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 3
Required Parts Group Number 369-6025 Pump and Mounting Gp (Rev. 04)
Item	Qty	Part Number	Description
7	1	118-3122	O-Ring Seal
8	1	177-8924	Gear Pump Gp
9	2	8T-4223	Hard Washers
10	2	8T-4194	Bolts

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Illustration 20	g03416974

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

Install O-ring seal (7) around the pilot of the charge gear pump group (8). The O-ring seal provides a seal between the WDS hydraulic piston pump and the charge gear pump. Install the charge gear pump into the coupler on the back of WDS hydraulic piston pump (1) .
Note: The charge pump must be oriented with the large suction port to the left.

Fasten charge gear pump (8) to the WDS hydraulic piston pump with two bolts (10) and two hard washers (9). Tighten the bolts to a torque of 100 ± 20 N·m (75 ± 15 lb ft).

Cooling Group and WDS Hydraulic Tank Installation

Cooler Group Mounting

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Table 4
Required Parts Group Number 435-5852 Supplemental Cooling Gp (Rev. 01)
Item	Qty	Part Number	Description
1	1	443-6593	Cooling Gp
1a ⁽¹⁾	8	8D-8852	Spacers
1b ⁽¹⁾	8	8T-6871	Bolts
1c ⁽¹⁾	8	6V-8993	Unions
2	1	435-5884	Plate As

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^( 1 )

Included in 443-6593 Cooling Gp .

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Illustration 21	g03463436
Top view (A) 190 mm (7.5 inch) (B) 80 mm (3.1 inch)

Tack weld plate assembly (2) in position using dimensions (A) and (B) .

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Illustration 22	g03417049

Mount cooling group (1) on the cooler mounting plate assembly (2) .

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Illustration 23	g03418093

Fasten cooling group (1) to mounting plate assembly (2) with eight spacers (1a), eight bolts (1b) and eight washers (1c). Torque the bolts (1b) to 215 ± 40 N·m (160 ± 30 lb ft).

WDS Hydraulic Tank Installation

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Table 5
Required Parts Group Number 435-5852 Supplemental Cooling Gp (Rev. 01)
Item	Qty	Part Number	Description
3	1	443-6369	Hydraulic Tank and Mounting Gp
4	1	418-9806	Hose As
5	1	164-5608	Connector As
6	1	433-7852	Guard As
7	1	435-7977	Hose As
8	2	1S-0994	Clips
9	1	6V-9746	O-Ring Seal
10	1	2S-4078	O-Ring Seal
11	5	6V-5839	Washers
12	5	6V-6317	Bolts
13	5	7D-7233	Clips
14	1	8T-4178	Bolt
15	1	2S-4078	O-Ring Seal
16	1	118-0166	Fitting
17	1	8T-1687	Connector
18	1	6V-8398	O-Ring Seal
19	1	122-3606	Clip
20	1	250-1488	Tee As
21	1	435-5861	Bracket
22	18	8T-4121	Hard Washers
23	2	8T-4191	Bolts
24	1	435-5870	Hose As
25	2	5P-4107	Washers
26	1	6V-9172	Nut

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Illustration 24	g03418137

Mount hydraulic mounting tank group (3) on truck tank (B) and fasten in place with bolts.

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Illustration 25	g03418145

Connect the two ends of hose assembly (4) to hydraulic mounting tank group (3). Tighten both ends of the hose assembly to a torque of 220 ± 33 N·m (162 ± 24 lb ft).

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Illustration 26	g03418187

Position quick fill assembly (C) on the bottom of truck tank (B) .

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Illustration 27	g03418220

Position and install guard assembly (6) at the bottom of the truck tank (B).

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Illustration 28	g03418236

Secure the guard assembly with bolts (12) and washers (11). Tighten the bolts to torque of 55 ± 10 N·m (41 ± 7 lb ft).

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Illustration 29	g03418290

Attach connector (16) with O-ring seal (9) to guard assembly connector. Tighten the connector to a torque of 100 ± 30 N·m (74 ± 22 lb ft).

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Illustration 30	g03418299

Attach connector assembly (5) to hydraulic mounting tank group (3). Tighten the connector assembly to a torque of 100 ± 15 N·m (74 ± 11 lb ft)

Connect the other end of hose assembly (7) to connector assembly (5). Tighten the hose assembly to a torque of 65 ± 10 N·m (48 ± 7 lb ft).

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Illustration 31	g03418307

Connect one end of hose assembly (7) with O-ring seal (9) to guard assembly (6). Tighten the hose assembly to a torque of 140 ± 21 N·m (103 ± 15 lb ft).

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Illustration 32	g03418682

Mount bracket (21) to the support of the frame assembly. Fasten with bolts (23) and washers (22). Tighten the bolts to a torque of 55 ± 10 N·m (41 ± 7 lb ft).

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Illustration 33	g03418660

Install one end of hose assembly (24) to truck tank (B). Tighten the hose assembly to a torque of 220 ± 33 N·m (162 ± 24 lb ft).

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Illustration 34	g03418654

Place tee assembly (20) with washers (25) through bracket (21) as shown in illustration. Connect nut (26) with washer (25) to tee assembly (20) at the other side of the plate. Tighten nut (26) to a torque of 220 ± 33 N·m (162 ± 24 lb ft).

Connect hose assembly (24) to nut (26) .

Install Clips to the Hose

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Table 6
Required Parts Group Number 435-5852 Supplemental Cooling Gp (Rev. 01)
Item	Qty	Part Number	Description
27	1	4D-7388	Clip
28	5	8T-4195	Bolts
29	10	8T-6871	Bolts
30	3	6V-8993	Unions

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Illustration 35	g03418843

Install clips (13) to hose assembly (4) and hose assembly (24). Insert bolt (28) and washer (22) through the clips. Tighten nut (29) with washer (22) to a torque of 55 ± 10 N·m (41 ± 7 lb ft).

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Illustration 36	g03418890

Install clip (27) to hose assembly (24). Insert bolt (30) and washer (22) through clip (8) and clip (13). Tighten nut (29) with washer (22) to a torque of 55 ± 10 N·m (41 ± 7 lb ft).

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Illustration 37	g03418917

Install clip (8) to hose assembly (7) at the bottom of truck tank (B). Insert bolt (12) and washer (11) through clip (8). Tighten the bolt to a torque of 55 ± 10 N·m (41 ± 7 lb ft).

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Illustration 38	g03418920

Install clip (8) to hose assembly (7). Insert bolt (28) and washer (22) through clip (8) and clip (19). Tighten the nut (29) with washer (22) to a torque of 55 ± 10 N·m (41 ± 7 lb ft).

Install Hose to the Cooler and Mounting Tank

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Table 7
Required Parts Group Number 435-5852 Supplemental Cooling Gp (Rev. 01)
Item	Qty	Part Number	Description
31	1	435-5868	Hose As
32	1	435-5869	Hose As
33	6	5P-2369	Clips
34	12	5P-7470	Clips
35	12	5P-7471	Clips
36	12	5P-8182	Grommets
37	1	435-5856	Plate As
38	3	8T-4186	Bolts
39	8	7X-7729	Washers
40	2	8T-4185	Bolts
41	1	5P-7468	Clip
42	1	5P-7469	Clip
43	1	5P-8444	Grommet
44	1	435-5854	Bracket As
45	1	9X-8257	Washer
46	1	7X-2552	Bolt
47	1	138-7500	Spacer

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Illustration 39	g03418977

Remove one bolt and one washer from flange (A) located on the cooler. Open the flange and insert hose assembly (31). Relocate the flange, install the bolt and washer, and tighten the bolt.

Remove one bolt and one washer from flange (B) located on the cooler. Open the flange and insert hose assembly (32). Relocate the flange, install the bolt and washer, and tighten the bolt.

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Illustration 40	g03418984

Connect the other end of hose assembly (31) and hose assembly (32) to the hydraulic tank. Tighten the hose assemblies to a torque of 45 ± 5 N·m (33 ± 4 lb ft).

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Illustration 41	g03419078

Install clips (33) on hose assembly (31) and hose assembly (32). Install bolt (30) with washer (22) through the clips. Tighten nut (29) with washer (22) to a torque of 55 ± 10 N·m (41 ± 7 lb ft).

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Illustration 42	g03419100

Install three grommets (36), three clips (34) and three clips (35) on hose assembly (31). Install three grommets (36), three clips (34) and three clips (35) on hose assembly (32). Install bolts (38) with washers (39) through the clips. Install nuts (29) and washers (22) on the bolts. Tighten the nuts to a torque of 55 ± 10 N·m (41 ± 7 lb ft).

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Illustration 43	g03419110

Install grommet (36), clips (34) and clips (35) on hose assembly (31) and hose assembly (32). Install grommet (43), clip (41) and clip (42) to the cab panel. Install bolt (40), washers (39) and nut (29) through the clips. Tighten the nut to a torque of 55 ± 10 N·m (41 ± 7 lb ft).

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Illustration 44	g03419141

Install grommet (36), clips (34) and clips (32) on hose assembly (31) and hose assembly (32). Mount bracket (44) on the support of the truck frame assembly. Secure the bracket with bolt (46) and washer (45). Tighten the bolt to a torque of 240 ± 40 N·m (177 ± 30 lb ft).

Install clips (34) and clips (32) on bracket (44). Secure the clips with bolt (14), washer (39) and spacer (47). Tighten the bolt to a torque of 55 ± 10 N·m (41 ± 7 lb ft).

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Illustration 45	g03419158

Install grommet (36), clips (34) and clips (35) on hose assembly (31) and hose assembly (32). Mount bracket (37) in the center of the clips. Attach the clips to the bracket with bolts (28) and washers (39) .

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Illustration 46	g03419174

Install clip (13) on hose assembly (24). Install clip (33) on hose assembly (32). Install bolt (30), washers (22) and nuts (29) in the clips. Tighten the nut to a torque of 55 ± 10 N·m (41 ± 7 lb ft).

Install clip (13) on hose assembly (24). Install clip (33) on hose assembly (32). Install bolt (28), washers (22) and nuts (29) in the clips. Tighten the nut to a torque of 55 ± 10 N·m (41 ± 7 lb ft).

Pump Group Lines Installation

Relocate Position Sensor Assembly

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Illustration 47	g03371413

Remove position sensor assembly (A) .

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Illustration 48	g03371414

Cut mounting block (B) from the rear frame rail.

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Illustration 49	g03371416

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 be181 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 50	g03371417

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

Install Plate Assembly on Truck Frame

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Table 8
Required Parts Group Number 355-5910 Pump Lines Gp (Rev. 04)
Item	Qty	Part Number	Description
1	4	105-7781	Spacers
2	1	435-5307	Hydraulic Oil Lines Gp
3	4	6V-5839	Washers
4	4	6V-7981	Bolts

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Illustration 51	g03419284
Rear View of the Bulkhead Plate

Install plate for hydraulic lines mounting (2) on the rear left tail light mounting bosses with four spacers (1). Fasten the hydraulic lines mounting 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 the tail light assembly prior to installing the hydraulic lines mounting plate assembly. Relocate the tail light assembly to the water tank in accordance with the tank manufacturing location.

Connect Pressure Hoses to the WDS Hydraulic Pump

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Table 9
Required Parts Group Number 355-5910 Pump Lines Gp (Rev. 04)
Item	Qty	Part Number	Description
5	4	1P-3703	Rectangular Seals
6	1	369-6520	Hose As
7	1	438-3252	Hose As
8	4	6V-0400	Half Flange
9	8	5P-8245	Hard Washers
10	8	6V-5684	Bolts

Note: The ends of all pump-related hose assemblies are color coded.

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Illustration 52	g03419325

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

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

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

Connect WDS Pressure Hoses to Plate Assembly

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Illustration 53	g03419345
Front View of Hydraulic Lines Mounting Plate Pump low-pressure port (blue) Pump high-pressure port (red)

Note: Label both ends of all hoses before connecting.

Connect the red pump high-pressure hose assembly (6) to location (F) on plate hydraulic lines mounting (2) with an O-ring seal and two split flanges. Fasten the hose assembly to the pump with four bolts (10) and four washers (9). Tighten the bolts to a torque of 100 ± 20 N·m (74 ± 15 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.

Connect the blue pump low-pressure hose assembly (7) to location (G) on plate assembly (2) with a seal and two split flanges. Fasten the hose assembly to the pump with four bolts (10) and four washers (9). Tighten the bolts to a torque of 100 ± 20 N·m (74 ± 15 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.

Connect Charge Pump Inlet Hose to WDS hydraulic Tank

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Table 10
Required Parts Group Number 355-5910 Pump Lines Gp (Rev. 04)
Item	Qty	Part Number	Description
9	4	7X-3392	Hard Washers
16	1	4J-0522	O-Ring Seal
17	1	369-6518	Hose As
18	2	197-3295	Half Flange
19	4	6V-8675	Bolts
79	1	4J-0524	O-Ring Seal

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Illustration 54	g03419748

Connect hose assembly (17), O-ring seal (16) and two half flanges (18) and to the suction port of the charge pump. Attach the half flanges with four bolts (19) and four washers (9). Tighten the bolts to a torque of 100 ± 20 N·m (74 ± 15 lb ft).

Route hose assembly (17) under the left frame rail and up the side of the hydraulic tank.

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Illustration 55	g03419763

Route hose assembly (17) to suction port (K) on the WDS hydraulic tank.

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

Connect hose assembly (17) to suction port (K) with seal (79). Fasten the hose assembly to the WDS hydraulic tank with the two flanges, four bolts and four washers.

Connect Motor Case Drain Hose to the Plate Assembly

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Table 11
Required Parts Group Number 355-5910 Pump Lines Gp (Rev. 04)
Item	Qty	Part Number	Description
20	1	5K-9090	O-Ring Seal
24	1	369-6522	Hose As
25	1	142-0038	Elbow
26	1	153-6236	Reducer As

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Illustration 56	g03419766

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

Connect reducer (26) to the elbow on the mounting plate. Tighten the reducer to a torque of 220 ± 33 N·m (162 ± 24 lb ft).

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

Install Charge Pump Outlet Flange

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Table 12
Required Parts Group Number 355-5910 Pump Lines Gp (Rev. 04)
Item	Qty	Part Number	Description
5	1	1P-3703	Rectangular Seal
30	1	7Y-3731	Flange
3	4	6V-5839	Washers
31	4	6V-3822	Bolts

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Illustration 57	g03465956

Install flange (30) with seal (5) on the outlet port of the charge pump. Fasten the flange to the pump with four bolts (31) 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 13
Required Parts Group Number 355-5910 Pump Lines Gp (Rev. 04)
Item	Qty	Part Number	Description
20	1	5K-9090	O-Ring Seal
26	1	6V-9846	Swivel Tee
32	2	6V-9746	O-Ring Seals
33	1	6V-9839	Swivel Tee
34	1	7I-1036	Coupling As
35	2	3K-0360	O-Ring Seals
36	1	198-9219	Relief Valve Gp

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Illustration 58	g03465957

Assemble the cold start relief valve. Connect swivel tee (26) with O-ring seal (20) to flange (30) in the outlet port of the charge pump. Tighten the swivel tee to a torque of 220 ± 33 N·m (162 ± 24 lb ft).

Connect swivel tee (33) with O-ring seal (32) to swivel tee (26). Tighten the swivel tee to a torque of 140 ± 21 N·m (103 ± 15 lb ft).

Connect coupling assembly (34) with O-ring seal (32) to swivel tee (33). Tighten the coupling assembly to a torque of 140 ± 21 N·m (103 ± 15 lb ft).

Connect relief valve group (36) with O-ring seal (35) to coupling assembly (34). Tighten the relief 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 14
Required Parts Group Number 355-5910 Pump Lines Gp (Rev. 04)
Item	Qty	Part Number	Description
37	1	6V-9874	Connector
32	1	6V-9746	O-Ring Seal
38	1	369-6517	Hose As

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Illustration 59	g03420260

Connect connector (37) with O-ring seal (35) to relief valve group (36). Tighten the connector to a torque of 100 ± 15 N·m (74 ± 11 lb ft).

Connect charge pump relief hose assembly (38) with O-ring seal (32) to the adapter on the tank. Tighten the hose assembly to a torque of 140 ± 21 N·m (103 ± 15 lb ft).

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Illustration 60	g03420297

Route charge pump relief hose assembly (38) from the cold start relief valve to the left side of the machine. Route the hose assembly under the left frame rail and up to the WDS hydraulic tank.

Connect charge pump relief hose assembly (38) with O-ring seal (32) to connector (37). Tighten the hose assembly to a torque of 140 ± 21 N·m (103 ± 15 lb ft).

Install Clips on the Hose Assembly

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Table 15
Required Parts Group Number 355-5910 Pump Lines Gp (Rev. 01) 435-5852 Supplemental Cooling Gp (Rev. )
Item	Part Number	Description	Qty
40 ⁽¹⁾	5P-2369	Clip	1
41 ⁽¹⁾	9M-4972	Clip	1
44 ⁽²⁾	8T-4896	Hard Washer	1
45 ⁽²⁾	8T-9101	Bolt	1

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^( 1 )	Part of 355-5910 Pump Lines Gp
^( 2 )	Part of 435-5852 Supplemental Cooling Gp

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Illustration 61	g03420586
Hose Assembly (38) is not shown.

Install clip (40) on charge pump suction hose assembly (17). Install clip (41) on charge pump relief hose assembly (38) .

Insert bolt (45) with hard washer (44) through clips. Tighten the bolt to a torque of 47 ± 9 N·m (35 ± 7 lb ft).

Filter Group Installation

Install Filter Group

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Table 16
Required Parts Group Number 369-6026 Hydraulic Filter and Lines Gp (Rev. 03)
Item	Qty	Part Number	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

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Illustration 62	g03361215

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

Install Filter Mounting Plate

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Table 17
Required Parts Group Number 369-6026 Hydraulic Filter and Lines Gp (Rev. 03)
Item	Qty	Part Number	Part Description
3	4	8T-4121	Hard Washers
5	4	8T-4136	Bolts

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Illustration 63	g03361234

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

Connect Filter Group to Charge Pump Outlet

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Table 18
Required Parts Group Number 369-6026 Hydraulic Filter and Lines Gp (Rev. 03)
Item	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	6V-9853	Elbow
10	1	369-6502	Hose As

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Illustration 64	g03420768

Install elbow (7) with O-ring seal (8) on the inlet fitting of oil filter group (2). Tighten the elbow to a torque of 220 ± 33 N·m (162 ± 24 lb ft).

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

Connect oil filter inlet hose assembly (10) to elbow (9) with O-ring seal (8). Tighten the hose assembly to a torque of 140 ± 21 N·m (103 ± 15 lb ft).

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Illustration 65	g03420792

Route oil filter inlet hose assembly (10) to the charge pump discharge port. Connect this hose assemble to the tee fitting on the charge pump discharge port with O-ring seal (8). Tighten the hose assembly to a torque of 140 ± 21 N·m (103 ± 15 lb ft).

Connect Filter Group to WDS Pump

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Table 19
Required Parts Group Number 369-6026 Hydraulic Filter and Lines Gp (Rev. 03)
Item	Qty	Part Number	Part Description
6	1	3D-2824	O-Ring Seal
11	1	8T-2883	Tee
12	1	6V-8397	O-Ring Seal
8	1	6V-9746	O-Ring Seal
13	1	369-6503	Hose As
14	1	7J-9108	O-Ring Seal
15	1	227-0057	Elbow
16	1	6V-7970	O-Ring Seal
17	1	148-8393	Elbow As

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Illustration 66	g03420962

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

Install O-ring seal (12) in tee (11) .

Connect WDS pump charge inlet hose assembly (13) to tee (11) with O-ring seal (8). Tighten the hose assembly to a torque of 140 ± 21 N·m (103 ± 15 lb ft).

Route WDS pump charge inlet hose assembly (13) to the charge inlet port of the WDS hydraulic pump.

Install elbow (15) with O-ring seal (16) in the charge inlet port of the WDS hydraulic pump. Tighten the elbow to a torque of 140 ± 21 N·m (103 ± 15 lb ft).

Install elbow assembly (17) to elbow (15). Tighten the elbow assembly to a torque of 110 ± 17 N·m (81 ± 13 lb ft).

Connect WDS pump charge inlet hose assembly (13) to elbow assembly (17). Tighten the hose assembly to a torque of 110 ± 17 N·m (81 ± 13 lb ft).

Install Clips to the Filter Inlet Hose

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Table 20
Required Parts Group Number 369-6026 Hydraulic Filter and Lines Gp (Rev. 03)
Item	Qty	Part Number	Part Description
18	1	7S-8920	Clip
19	1	7S-8921	Clip
20	2	9M-4972	Clips
21	1	8T-4121	Hard Washer
22	1	8T-4195	Bolt
23	1	160-8503	Nut

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Illustration 67	g03421023

Install clip (18) and clip (19) on the valve group hose assembly.

Install clips (20) on the filter inlet hose assembly and the WDS pump charge inlet hose assembly.

Insert bolts (23) with hard washer (21) through the clips. Secure the clips with nut (23). Tighten the nut to a torque of 55 ± 10 N·m (41 ± 7 lb ft).

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

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Table 21
Required Parts Group Number 355-5910 Pump Lines Gp (Rev. 01)
Item	Qty	Part Number	Part Description
17	2	6V-8397	O-Ring Seals
18	1	369-6524	Hose As
19	1	369-6523	Hose As
46	2	304-7975	Adapters
47	2	6V-8398	O-Ring Seals
48	2	6V-8936	Reducers

Note: Color codes for hose assemblies are indicated on the WDS hydraulic piston pump, motor and bulkhead adapters.

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Illustration 68	g03421261

Install one adapter (46) on green motor signal pressure port and one adapter (46) on the yellow motor pilot pressure port. Tighten the adapters to a torque of 27 ± 4 N·m (20 ± 3 lb ft).

Connect one reducer (48) with O-ring seal (47) to the adapter on the green motor signal pressure port. Connect one reducer (48) with O-ring seal (47) to the adapter on the yellow pilot pressure port. Tighten the reducers to a torque of 65 ± 10 N·m (48 ± 7 lb ft).

Connect green motor signal pressure hose assembly (18) with O-ring (47) to the adapter in the motor signal port of the plate assembly. Tighten the hose assembly to a torque of 45 ± 5 N·m (33 ± 4 lb ft).

Connect yellow motor pilot pressure hose assembly (19) with O-ring (17) to the adapter in the motor pilot port of the plate assembly. Tighten the hose assembly to a torque of 45 ± 5 N·m (33 ± 4 lb ft).

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Illustration 69	g03421267

Route green motor signal pressure hose assembly (18) along the left frame rail toward the front of the machine. Route motor pilot pressure hose assembly (19) along the left frame rail toward the front of the machine.

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Illustration 70	g03421357

Route green motor signal pressure hose assembly (18) to the bottom of WDS hydraulic piston pump (A) .
Note: Connect green motor signal pressure hose assembly to the left port of the pump in order to achieve proper water pump operation.

Connect green motor signal pressure hose assembly (18) with O-ring seal (17) to elbow (B) .

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Illustration 71	g03421407

Connect motor pilot pressure hose assembly (19) to tee (11) .
Note: O-ring seal (16) was previously installed in tee (11). Verify that the O-ring seal is in place prior to connecting the hose assembly.

Install Spray Head Pilot Pressure and Pilot Return Hoses

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Table 22
Required Parts Group Number 355-5911 Pilot Lines Gp (Rev. 03)
Item	Qty	Part Number	Part Description
1	1	369-6526	Hose As
2	1	369-6525	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	1	3J-1907	O-Ring Seal
8	1	6V-9175	Tee
9	1	3D-2824	O-Ring Seal
10	1	6V-9746	O-Ring Seal
11	1	7J-9108	O-Ring Seal
12	1	6V-9832	Cap As
13	1	6V-8555	Face Seal Nut
14	1	6V-8938	O-Ring Reducer

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Illustration 72	g03357357

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

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

Remove adapter (C) from hoist valve (A) .

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Illustration 73	g03357360

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

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).

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Illustration 74	g03357361

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

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

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).

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Illustration 75	g03357362

Route brown spray head pilot pressure hose (2) along the left frame rail to spray head pilot pressure port (A) .

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Illustration 76	g03357365

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.

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.

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Illustration 77	g03357367

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Illustration 78	g03357368

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Illustration 79	g03421565

Route black spray head pilot return hose (1) along the right frame rail to the machine hydraulic tank.

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Illustration 80	g03421573

Install tee (8) with O-ring seal (9) in the port of the machine hydraulic. Tighten the tee to a torque of 220 ± 33 N·m (162 ± 24 lb ft).

Install cap assembly (12) with O-ring seal (10) on the adapter. Tighten the cap assembly to a torque of 200 ± 30 N·m (148 ± 22 lb ft).

Connect the reducer (14) with O-ring seal to the adapter. Tighten the reducer to a torque of 45 ± 5 N·m (33 ± 4 lb ft).

Connect the nut (13) to the adapter and tighten the nut to a torque of 110 ± 17 N·m (81 ± 13 lb ft).

Connect black spray head pilot return hose assembly (1) with O-ring seal (3) to tee (8). Tighten the hose assembly to a torque of 45 ± 5 N·m (33 ± 4 lb ft).

Install Hose to the Hydraulic Pump

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Table 23
Required Parts Group Number 355-5910 Pump Lines Gp (Rev. 04)
Item	Qty	Part Number	Part Description
49	1	6V-7970	O-Ring Seal
50	1	8T-7492	Connector
20	1	5K-9090	O-Ring Seal
25	1	142-0038	Elbow
51	1	369-6521	Hose As
52	1	6V-9746	O-Ring Seal

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Illustration 81	g03421642

Install connector (50) with O-ring seal (49) to the hydraulic pump. Tighten the connector to a torque of 140 ± 21 N·m (103 ± 15 lb ft).

Connect hose assembly (51) with O-ring seal (52) to connector (50). Tighten the hose assembly to a torque of 140 ± 21 N·m (103 ± 15 lb ft).

Install elbow (25) to the adapter of cooling group. Tighten the elbow to a torque of 220 ± 33 N·m (162 ± 24 lb ft).

Connect the other end of hose assembly (51) with O-ring seal (20) to elbow (25). Tighten the hose assembly to a torque of 220 ± 33 N·m (162 ± 24 lb ft).

Install Clips on the Hose Assembly

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Table 24
Required Parts Group Number 355-5910 Pump Lines Gp (Rev. 04) 355-5911 Pilot Lines Gp (Rev. 03)
Item	Qty	Part Number	Part Description
53 ⁽¹⁾	3	6V-1889	Clips
41 ⁽¹⁾	1	9M-4972	Clip
54 ⁽¹⁾	5	174-5907	Clips
55 ⁽¹⁾	4	188-0960	Spacers
56 ⁽¹⁾	2	6V-1819	Bolts
3 ⁽¹⁾	12	6V-5839	Washers
57 ⁽²⁾	5	6D-4246	Clips
2 ⁽²⁾	1	369-6525	Hose As
58	1	1S-0994	Clip
59	3	2Y-5829	Nuts
60	5	6V-4248	Bolts
61	7	7D-7233	Clips
62	1	119-5916	Clip
63	2	6V-1820	Bolts
64	1	205-7299	Clip
65	2	119-5916	Clips
66	2	4D-6466	Clips
67	2	5K-5338	Clips
68	2	8T-0644	Bolts

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^( 1 )	Part of 355-5910 Pump Lines Gp .
^( 2 )	Part of 355-5911 Pilot Lines Gp .

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Illustration 82	g03421689

Secure and mount two clips (53) on hose assembly (24). Hose assembly (24) is clamped along with the transmission hose.

Mount one clip (41) on hose assembly (51). Fasten the bolt to the frame support.

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Illustration 83	g03421738

Install three clips (54) on hose assembly (19) and three clips (57) on hose assembly (2). Insert two spacers (55) below the clips. Fasten bolts (56) with washers (3) to a torque of 55 ± 10 N·m (41 ± 7 lb ft).

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Illustration 84	g03421780

Install three clips (58) and three clips (54) on hose assembly (19). Insert bolt (60) with washer (3) through the clips and fasten the nut (59) with washer (3). Tighten the bolt to a torque of 55 ± 10 N·m (41 ± 7 lb ft).

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Illustration 85	g03421827

Install one clip (61) on hose assembly (6). Install one clip (61) on hose assembly (7). Mount clip (62) between the two clips and insert bolt (63), washer (3) and nut (59). Tighten the nut to a torque of 55 ± 10 N·m (41 ± 7 lb ft).

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Illustration 86	g03421860

Install another clip (61) on hose assembly (6). Mount clip (64) on hose assembly (18). Mount clip (54) on hose assembly (19). Mount clip (57) on hose assembly (2). Insert bolt (63), washer (3) and nut (59). Tighten the nut to a torque of 55 ± 10 N·m (41 ± 7 lb ft).

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Illustration 87	g03421907

Mount brackets (65) to the frame and fasten bolts (60) with washers (3) .

Install two clips (61) on hose assembly (7). Install two clips (61) on hose assembly (6). Fasten bolts (60) with washers (3) through the clips and bracket (65). Tighten the bolts to a torque of 55 ± 10 N·m (41 ± 7 lb ft).

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Illustration 88	g03422053

Install two clips (66) on hose assembly (19). Install one clip (67) on hose assembly (1) and hose assembly (2). Install another clip (67) on hose assembly (1) and hose assembly (2) at the other side as shown in image. Install clip (53) on hose assembly (24). Mount spacers (55) and install bolts (68) with washers (3). Tighten the bolts to a torque of 55 ± 10 N·m (41 ± 7 lb ft).

Hydraulic and Component Installation (Tank)

Water Pump Installation

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Table 25
Required Parts ⁽¹⁾ Group Number 428-7861 Pump and Drive Gp (Rev. 04)
Item	Qty	Part Number	Part Description
1	1	428-7857	Water Pump Gp
2	1	452-2338	Coupling As
3	1	284-2728	Pressure Sensor Gp
4	1	437-3854	Gasket Kit

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^( 1 )

If stainless steel water pump is ordered, refer to Table 26.

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Table 26
Required Parts Group Number 448-5559 Pump and Drive Gp (Rev. 03) - Stainless Steel Kit
Item	Qty	Part Number	Part Description
1	1	436-2443	Water Pump Gp
2	1	452-2338	Coupling As
3	1	448-3671	Pressure Sensor Gp
4	1	436-2444	Gasket Kit

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Illustration 89	g03350017

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Illustration 90	g03350020

Install water pump adapter (A) on the water tank outlet.
Note: Water pump adapter must be fabricated and installed by the customer. The dimensions of the adapter and mounting method must be determined with regards to the specific water tank.
Note: Gaskets are provided with each water pump. Refer to the service repair kit for gasket part numbers if replacements are required.

Bolt water pump and drive group (1) onto water pump adapter (A) on the water tank.
Note: Use the provided inlet gasket from gasket kit (4) when bolting the water pump to the adapter.
Note: Mounting hardware must be provided by the customer.

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

Connect outlet of water pump and drive group (1) to adapter (C) on the spray bar.
Note: Spray bar adapter must be fabricated and installed by the customer. Connecting hardware must be provided by the customer.
Note: Use the provided outlet gasket from gasket kit (4) when connecting the water pump to the spray bar.
Note: Make sure that the water pump bearings have been properly lubricated before starting the WDS system.

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Illustration 91	g03697323

Use coupling assembly (2) for attaching water pump shaft with shaft on motor.
Note: This is a wet coupling pump. Coupling compartment must be filled with oil.

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Illustration 92	g03697384

Install pressure sensor (3) onto spray bar at location shown in Illustration 92.

WDS Motor Installation

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Table 27
Required Parts Group Number 371-2721 Piston Motor and Mounting Gp (Rev 01)
Item	Qty	Part Number	Part Description
(1)	1	358-0163	Piston Motor Gp
(2)	2	8T-4122	Hard Washer
(3)	2	7X-0347	Bolt

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Illustration 93	g03714786

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

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Illustration 94	g03350024

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

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

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

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Illustration 95	g03375720

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

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

Water Pump Motor to Bulkhead Lines Routing

Connect WDS Motor Pressure Hoses

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Table 28
Required Parts Group Number 372-1177 Motor Lines Gp (Rev. 01)
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	1	3J-1907	O-Ring Seal
11	1	9S-4191	O-Ring Plug

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Illustration 96	g03357436
Water Pump Motor (A) Motor high-pressure port (red) (B) Motor low-pressure port (blue)

Install adapter (2) with seal (1) in motor high-pressure port (A) .

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

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.

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Illustration 97	g03357437

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).

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).

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Illustration 98	g03357438

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.

Connect WDS Motor Pressure Hoses to Plate Assembly

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Table 29
Required Parts Group Number 372-1177 Motor Lines Gp (Rev. 01)
Tool	Qty	Part Number	Part Description
3	2	1P-3703	Rectangular Seals

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Illustration 99	g03357439
Rear View Of Bulkhead Plate (C) Pump low-pressure port (blue) (D) Pump high-pressure port (red)

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

Route red motor high-pressure hose (4) from the WDS motor to pump high-pressure port (D) on the bulkhead plate.

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Illustration 100	g03357440
Rear View Of Bulkhead Plate (C) Pump low-pressure port (blue) (D) Pump high-pressure port (red)

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).

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 30
Required Parts Group Number 372-1177 Motor Lines Gp (Rev. 01)
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

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Illustration 101	g03357441

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).

Install seal (14) in adapter (13) .

Connect WDS Motor Case Drain Hose to the Plate Assembly

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Table 31
Required Parts Group Number 372-1177 Motor Lines Gp (Rev. 01)
Tool	Qty	Part Number	Part Description
15	1	369-6506	Hose As
16	3	143-4299	Grommets
17	3	7G-5984	Clips
18	3	7G-5985	Clips
19	3	6V-1889	Clips
20	5	6V-5839	Washers
21	3	0S-1594	Bolts
22	2	6V-8801	Nuts

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Illustration 102	g03357442
Vertical Mounting of WDS Motor

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Illustration 103	g03357443
Case Drain Port for Inverted Horizontal Mounting

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Illustration 104	g03357444
Case Drain Port for Horizontal Mounting

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.

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Illustration 105	g03357445

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.

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Illustration 106	g03357446
Rear View Of Bulkhead Plate

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.

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Illustration 107	g03357447

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

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

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

Insert bolt (21) and washer (20) through each set of clips in order to clamp the three hoses together. Fasten each bolt in place with nut (22) and washer (20) .

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

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Table 32
Required Parts Group Number 372-1177 Motor Lines Gp (Rev. 01)
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.

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Illustration 108	g03357448
WDS Motor (J) Motor signal port (green) (K) Motor pilot port (yellow)

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).

Connect adapter (26) with seal (25) to adapter (24). Tighten the adapter to a torque of 45 ± 5 N·m (33 ± 4 lb ft).

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Illustration 109	g03357450
WDS Motor (J) Motor signal port (green) - straight fitting (K) Motor pilot port (yellow) - 90 degree adapter

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).

Measure two lengths of bulk hose (32) from the WDS motor to the plate assembly on the rear of the truck. Cut the hoses to length.
Note: Ensure that each hose has adequate length in order to accommodate lifting and lowering of the water tank.

Create two hose assemblies as follows:
- Yellow motor pilot pressure hose - install one 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.

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) .

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) .

Route both hoses under the water tank to the plate assembly on the back of the truck.

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Illustration 110	g03357452
Rear View Of Bulkhead Plate (L) Motor signal line fitting (green) (M) Motor pilot pressure hose fitting (yellow)

Connect the green motor signal line to bulkhead adapter (L) with seal (4) .
Note: The seal was previously installed in this adapter. Verify that the seal is in place prior to connecting the hose.

Connect the yellow motor pilot pressure hose to bulkhead adapter (M) with seal (4) .
Note: The seal was previously installed in this adapter. Verify that the seal is in place prior to connecting the hose.

Clip the yellow motor pilot pressure hose and the green motor signal pressure hose together with five clips (29). Fasten the clips in place with bolts (31) and washers (30) .

Install Pump Breather Group

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Table 33
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

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Illustration 111	g03367416
Vertically Mounted Water Pump

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Illustration 112	g03368841
Horizontally Mounted Water Pump

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

Install connector (5) with seal (9).

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

Install adapter (1) with seal (9) .

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

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

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

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

Use the quick disconnect fitting to fill the pump couple cavity with SAE 60W oil. Monitor the oil level at port (A) and replace the plug when the cavity is full of oil.
Note: For horizontally mounted water pumps, add oil until the pump cavity is half full.

Spray Head Installation

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Table 34
Required Parts Spray Head Installation
Item	Qty	Part Number	Part Description
1 ⁽¹⁾	5 ⁽²⁾	431-9716	Water Control Valve Gp

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^( 1 )	These parts are fabricated with aluminum. Stainless steel components 416-9877 are available
^( 2 )	Kits are available with 3, 5, or 7 water control valve groups.

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Illustration 113	g03714795

Locate water control valve group (1). Loosen bolts (B) on one split flange (A). Remove the other split flange (not shown).
Note: Make sure that valve group O-ring seal (C) is in place.

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Illustration 114	g03714799

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Illustration 115	g03714801

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

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Illustration 116	g03697517
(E) 152 mm (6 inch)

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Illustration 117	g03714803

Rotate water control valve group (1) on spray bar (D) in order to obtain the desired direction for water spray. Tighten the mounting bolts on both flanges to a torque of 55 ± 10 N·m (41 ± 7 lb ft).
Note: Orient the spray heads as shown with each spray head angled 20 degrees away from the center line. Refer to the reference marks on the bottom of the stainless steel spray heads.

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Illustration 118	g03682227

Repeat the previous steps for the remaining spray heads on the rear spray bar.

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Illustration 119	g03714804

Install water control valve group (1) on front spray bar (F). Reinstall split flanges (A). Do not tighten the mounting bolts.
Note: Two spray heads can be installed on the front of the truck. The spray head on the left side of the truck is shown above.

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

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

Chassis Harness Installation

Chassis Harness Assembly Routing

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Table 35
Required Parts Group Number 423-1568 Sensor Wiring Gp (Rev. 01)
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	433-2207	Chassis Harness As
7	7	200-6345	Mount
8	58	7K-1181	Cable Straps
9	14	204-2281	Cable Straps

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Illustration 120	g03422323

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Illustration 121	g03422365

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), mounts (7) and cable straps (9) .

Route the harness along the control brake group hose. Strap the harness assembly in place with cable straps (8), mounts (7) and cable straps (9).

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) .

Fasten mounts (7) to the installed hoses with cable straps (9). Strap the harness assembly (6) to the mounts with cable straps.

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Illustration 122	g03362966

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

Connect the fan power wire from harness assembly (6) to contact (D). Connect the fan ground wire to contact (E) .

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Illustration 123	g03422673

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

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Illustration 124	g03482379

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.

Fasten clips (1) and clip (3) to the cross tube and the drive shaft cover. Secure harness assembly (6) to the clips with cable straps (8) .

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Illustration 125	g03482383

Plug harness assembly (6) into the solenoid connector (G) on the WDS pump.

Fasten clips (1) and clip (3) to the inlet of the charge pump. Secure harness assembly (6) to the clips with cable straps (8) .

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Illustration 126	g03424185

Route the remainder of chassis harness assembly (6) along the truck chassis harness (A). Secure the cable with cable straps (8) .

Locate portion (H) of harness assembly (6) that connects to the hoist valve and the oil filter. Route this portion of the harness assembly over the drive shaft cover and down to the oil filter.

Secure the harness assembly (6) to the truck chassis harness with cable straps (8) .

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Illustration 127	g03358058

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Illustration 128	g03422687

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.

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

Locate bypass switch connector (J) on the oil filter. Connect the harness assembly to the bypass switch.

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Illustration 129	g03358056

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. Secure the harness assembly (6) to the frame with cable straps (8) .

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

Connect the hoist raise connector of the harness assembly (6) to the hoist raise solenoid (L) .

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Illustration 130	g03362980

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. Secure the harness assembly to the frame with cable straps (8) .

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Illustration 131	g03362968

Route harness assembly (6) under the left frame rail and up the side of the truck hydraulic tank. Secure the harness assembly to the frame with mount (7) and cable straps (9) .

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Illustration 132	g03358055

Route harness assembly (6) up and over the WDS hydraulic tank. Secure the cable with clip (2) and cable straps (8) .

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

Connect the tank level sensor wire to tank level sensor connector (N).
Note: Proper connections of the temperature sensor and level sensor wiring is of critical importance.

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Illustration 133	g03358180

Route the remainder of chassis harness assembly (6) along the left frame rail to the rear of the machine. Secure the cable with cable straps (8) .

Rear Hydraulic Manifold Installation

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Table 36
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.

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Illustration 134	g03357466
Rear Hydraulic Manifold (C)

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Illustration 135	g03357467

Mount rear hydraulic manifold (C) on the rear of the water tank.
Note: Mounting bosses must be provided with the tank. Refer to Tank Requirements Guide, REHS7098.
Note: Many water tanks include a protective lining on the interior of the tank that can be damaged by welding directly onto the tank.

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Illustration 136	g03357469
(A) Spray head open port (B) Spray head close port

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

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.

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Illustration 137	g03357470

Measure length of bulk hose (9) from each spray head to the rear hydraulic manifold. Cut the hose to length and create hose assembly with 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.

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

Clamp the spray head hoses to water tank with clips (11) .

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Illustration 138	g03357471

Install adapter (14) with seal (13) in each side of manifold (2). Repeat this step for both sides of all the manifolds.

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Illustration 139	g03357473
(A) Spray head - open "A"port (B) Spray head - close "B"port

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Illustration 140	g03357475
Reference Labels On Hydraulic Manifold (D) Spray valve "5A" (E) Spray valve "4A" (F) Spray valve "6A" (G) Spray valve "3A" (H) Spray valve "2A" (J) Spray valve "5B" (K) Spray valve "4B" (L) Spray valve "6"B (M) Spray valve "3B" (N) Spray valve "2B"

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Illustration 141	g03357478
(P) Spray head "2" (Q) Spray head "3" (R) Spray head "6" (S) Spray head "4" (T) Spray head "5"

Connect the hose from each spray valve to the corresponding fitting on the rear hydraulic manifold with seal (8). Configure the connections as shown:
- Spray valve "5A" (D) - open (B) line of #5 spray head (T)
- Spray valve "4A" (E) - open (B) line of #4 spray head (S)
- Spray valve "6A" (F) - open (B) line of #6 spray head (R)
- Spray valve "3A" (G) - open (B) line of #3 spray head (Q)
- Spray valve "2A" (H) - open (B) line of #2 spray head (P)
- Spray valve "5B" (J) - close (C) line of #5 spray head (T)
- Spray valve "4B" (K) - close (C) line of #4 spray head (S)
- Spray valve "6B" (L) - close (C) line of #6 spray head (R)
- Spray valve "3B" (M) - close (C) line of #3 spray head (Q)
- Spray valve "2B" (N) - close (C) line of #2 spray head (P)

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Illustration 142	g03357480
(U) Spray head pilot return port (black) (V) Spray head pilot supply port (brown)

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

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

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

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

Measure two lengths of bulk hose (20) from rear manifold group (1) to the plate assembly on the rear of the truck. Cut the hoses to length and create two hose assemblies with coupling (21) on each end.
Note: Ensure that each hose has adequate length in order to accommodate routing the hose and strapping the hose in place.
Note: Ensure that each hose has adequate length in order to accommodate lifting and lowering of the water tank.
Note: Clearly mark each end of both hoses for identification purposes, using color codes provided for mating components.

Connect one end of each hose assembly to the tee adapter at the bottom of the rear hydraulic manifold.

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Illustration 143	g03357481
(W) Spray head pilot return fitting (black) (X) Spray head pilot supply fitting (brown)

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

Route the brown hose from spray head pilot supply port (V) to spray head pilot return fitting (X) in the plate assembly. Connect the hose assembly to port with seal (18) .

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Illustration 144	g03357482

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 37
Required Parts Group Number 423-1577 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

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Illustration 145	g03357483

Mount plate assembly (1) to the rear of the water tank.
Note: Mounting bosses must be provided with the tank. Reference the Tank Requirements Guide, REHS7098.

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

Install Rear Electrical Control Group

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Table 38
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

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Illustration 146	g03357484

Mount control group (5) to plate assembly (1), with the connectors pointing down.

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Illustration 147	g03357485

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

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 39
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

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Illustration 148	g03357488

Connect harness assembly (9) to control group (5) .

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Illustration 149	g03357487

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

Route harness assembly (9) to sensor group (8). Connect the harness assembly to the pressure sensor.

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Illustration 150	g03362982

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

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

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Illustration 151	g03357489
Reference Labels on Hydraulic Manifold (A) Spray valve "5A" (B) Spray valve "4A" (C) Spray valve "6A" (D) Spray valve "3A" (E) Spray valve "2A" (F) Spray valve "5B" (G) Spray valve "4B" (H) Spray valve "6B" (J) Spray valve "3B" (K) Spray valve "2B"

Locate the hydraulic manifold portion of harness assembly (9). This portion of the harness assembly can be identified by eight connectors at the end. Route this portion of the harness to the rear hydraulic manifold.

Connect harness assembly (9) to the rear hydraulic manifold as shown:
- Spray valve "5A" (A) - J750-OR wire
- Spray valve "4A" (B) - L944-GY wire
- Spray valve "6A" (C) - L937-OR wire
- Spray valve "3A" (D) - J747-BU wire
- Spray valve "2A" (E) - L949-BU wire
- Spray valve "5B" (F) - J751-GN wire.
- Spray valve "4B" (G) - L947-BR wire
- Spray valve "6B" (H) - L942-GN wire
- Spray valve "3B" (J) - J748-PK wire
- Spray valve "2B" (K) - L951-GN wire

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Illustration 152	g03361304

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 40
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

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Illustration 153	g03357493
Rear of Water Tank

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

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

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

Install Communication Harness

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Table 41
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

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Illustration 154	g03357496

Connect cable (18) to connector (L) on bottom of control group (5) .

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Illustration 155	g03357497

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

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

Secure cable (18) and harness assembly (9) to the clips with cable straps (23) .

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Illustration 156	g03357498

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

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

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

Secure cable (18) and harness assembly (9) to the clips with cable straps (23) .

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Illustration 157	g03362632

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

Route cable (18) up the front of the water tank. Secure 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 42
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

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Illustration 158	g03357490

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Illustration 159	g03357491

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.

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

Front Hydraulic Manifold Installation

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Table 43
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.

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Illustration 160	g03357500
Front Hydraulic Manifold (A)

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Illustration 161	g03357501

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.

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Illustration 162	g03357502
(B) Spray head pilot supply port (brown) (C) Spray head pilot return port (black)

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

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

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

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.

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

Connect the black hose assembly to adapter (21) in spray head pilot return port (C) with seal (27) .

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Illustration 163	g03357503

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) .

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Illustration 164	g03357505

Route the hose assemblies under the water tank to the plate assembly on the back of the truck. Clamp the hoses to the water tank with clips (24), bolts (23) and washers (26) .

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Illustration 165	g03357506
(D) Spray head pilot return fitting (E) Spray head pilot supply fitting

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Illustration 166	g03367810
Alternate Connection Locations On Rear Hydraulic Manifold (D) Spray head pilot return port (black) (E) Spray head pilot supply port (brown)

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

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

Connect the black hose assembly from spray head pilot return coupling (C) to spray head pilot return fitting (D) with seal (8) .

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Illustration 167	g03357507
(F) Spray head "7"

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Illustration 168	g03357508
(G) Spray head "1"

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.

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Illustration 169	g03357509
Spray head "7" (F) (H) Spray head - close "B" port (J) Spray head - open "A" port

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

Install adapter (4) with seal (12) in spray head close port (H) and spray head open port (J) of spray valve "7" (F) .

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Illustration 170	g03357510
Spray head "1" (G) (K) Spray head - open "A" port (L) Spray head - close "B" port

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

Connect the four hose assemblies to the spray heads. Connect the end of each hose assembly with straight coupling (8) to adapter (4) with seal (11) .

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Illustration 171	g03357511

Install adapter (3) with seal (10) in each side of manifold (14). Repeat this step for both sides of both the manifolds.

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Illustration 172	g03357512
Reference Labels on Hydraulic Manifold (M) Spray valve "7B" - close port (N) Spray valve "1B" - close port (P) Spray valve "7A" - open port (Q) Spray valve "1A" - open port

Connect the hose from each spray valve to the corresponding fitting on the front hydraulic manifold with seal (19). Configure the connections as shown:
- Spray valve "7B" (M) - close (H) line of #7 spray head (F)
- Spray valve "1B" (N) - close (L) line of #1 spray head (G)
- Spray valve "7A" (P) - open (J) line of #7 spray head (F)
- Spray valve "1A" (Q) - open (K) line of #1 spray head (G)

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

Cannon Group Installation

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Table 44
Required Parts Group Number 421-8349 Water Cannon Ar (Rev. 02)
Tool	Qty	Part Number	Part Description
1	1	422-5872	Water Cannon Gp

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Illustration 173	g03357513

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Illustration 174	g03357514

Note: This safety message is located on the cannon.

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

Verify safety label (A) is properly installed on water cannon (1) .
Note: There are several specific safety messages on this machine. The exact location of the hazards and the description of the hazards are reviewed in this section. Become familiarized with all safety messages.
Note: Make sure that all of the safety messages are legible. Clean the safety messages or replace the safety messages if the words or the images become unreadable. When you clean the safety messages, use a cloth, water, and soap. Do not use solvent, gasoline, or other harsh chemicals to clean the safety messages. Solvents, gasoline, or harsh chemicals could loosen the adhesive that secures the safety message. Loose adhesive will allow the safety message to separate from the machine.
Note: Replace any safety message that is damaged, or missing. If a safety message is attached to a part that is replaced, install a safety message on the replacement part. Any Cat^® dealer can provide new safety messages.

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Illustration 175	g03357515

Verify the position of rotation and elevation stops (B) for the water cannon turret.
Note: The rotation and elevation stops set the boundaries for the area in which the cannon is allowed to travel.
Note: The cannon is shipped with rotation stops at 90 degrees right and at 90 degrees 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.

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Illustration 176	g03357516
Water Cannon Position on the Machine

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Illustration 177	g03357517

Install butterfly valve (H) on the tank connection.
Note: Butterfly valve must be provided by the customer. This component is not included with the WDS kit.

Assemble water cannon (1) to the flange mount on the butterfly valve. The front of the cannon should be 45 degrees to right of center line (E). The cannon is shipped with the first stop assembled at 90 degrees. The cannon cannot rotate past the 90 degrees 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 45
Required Parts Group Number 355-8914 Hydraulic Oil Lines Gp (Rev. 00)
Tool	Qty	Part Number	Part Description
1	4	3J-1907	O-Ring Seals
2	4	7X-0902	Connectors
3	4	164-0193	Adapters
4	4	6V-8397	O-Ring Seals
5	2	124-2141	Permanent Coupling
6	2	124-2113	Permanent Coupling
7	8	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 ⁽¹⁾	1	122-6867	Hydraulic Hose

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^( 1 )

This component must be provided by the customer.

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Illustration 178	g03357525

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.

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.

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

Create two hose assemblies for the cannon shut-off valve as follows:
- "ON" hose - install one 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.

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Illustration 179	g03357526

Locate cannon operation fittings on the water cannon. The fittings are identified as follows:
- "DOWN" fitting (F)
- "UP" fitting (E)
- "LT" fitting (G)
- "RT" fitting (H)

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

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

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

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

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

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

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

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Illustration 180	g03357527

Locate cannon operation fittings on the front hydraulic manifold. The hydraulic ports are labeled as follows:
- "DOWN" (J)
- "UP" (K)
- "LT" (L)
- "RT" (M) .
Note: Reference the markings stamped on the manifold.

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

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

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

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

Connect the end of the "RT" hose with straight coupling (7) to "RT" fitting (M) with seal (8) .

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Illustration 181	g03357528

Locate the hydraulic fittings on the butterfly valve. The fittings are identified as follows:
- "OFF" (N) - rod end of the hydraulic cylinder
- "ON" (P) - head end of the hydraulic cylinder.

Install elbow (9) in each of the fittings on the butterfly valve.
Note: Customer supplied valve may contain pre-installed fittings. Replace pre-installed fittings with elbows (9) provided

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

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

Route the two hoses from shut-off valve (C) to front manifold group (D) .

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Illustration 182	g03357529

Locate shut-off valve fittings on the front hydraulic manifold. The hydraulic ports are labeled as follows:
- "OFF" (R)
- "ON" (Q) .

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

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

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

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Illustration 183	g03357530

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 46
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

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Illustration 184	g03357518

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

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

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

Install Front Hydraulics Control Group

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Table 47
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

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Illustration 185	g03357519

Mount control group (5) to plate assembly (1), with the connectors pointing down.

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Illustration 186	g03357520

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

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 48
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

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Illustration 187	g03357522

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

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Illustration 188	g03357523
Reference Labels on Manifold and Solenoids (A) Spray valve "7B" (B) Spray valve "1B" (C) Cannon "RIGHT" (D) Cannon "UP" (E) Cannon "DOWN" (F) Spray valve "7A" (G) Spray valve "1A" (H) Cannon "LEFT" (J) Cannon shutoff valve

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

Connect harness assembly (11) to the front hydraulic manifold as shown:
- Spray valve "7B" (A) - J741-GY wire
- Spray valve "1B" (B) - J739-GN wire
- Cannon "RIGHT" (C) - J736-OR wire
- Cannon "UP" (D) - J729-GN wire
- Cannon "DOWN" (E) - J730-BU wire
- Spray valve "7A" (F) - J742-BR wire
- Spray valve "1A" (G) - J738-BU wire
- Cannon "LEFT" (H) - J735-PU wire.
- Cannon Shutoff Valve (J) - T805-GY wire.

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Illustration 189	g03357524

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) .

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Illustration 190	g03367814

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.

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Illustration 191	g03362998

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

Installation of the Cab Bulkhead Plate

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Table 49
Required Parts Group Number 433-2204 Wiring Gp Cab (Rev. 00)
Tool	Qty	Part Number	Part Description
1	1	435-1473	Plate As
2	1	257-8536	Gasket

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Illustration 192	g02789989

Remove engine access panels (A) above the cab electrical cables in order to provide access to the cab wiring.

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Illustration 193	g02789992
Bulkhead Plate Viewed From Inside The Cab

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Illustration 194	g02789993
Bulkhead Plate Viewed From Right Side Of The Cab

Locate bulkhead plate (B) .

Disconnect all of cables from bulkhead plate (B). Carefully label all of the cables in order to facilitate proper reconnection.

Remove bulkhead plate (B) .

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Illustration 195	g03422848

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Illustration 196	g03424023

Install bulkhead plate (1) with the existing hardware. Reconnect all the wiring connections on both sides of the plate.

Replace engine access panels (A) .

Install gasket (2) to plate (1) .

Cab Electrical Systems Installation

Cab Preparation

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Illustration 197	g03467756

Lift two vents (B) in the right upper portion of gearshift trim panel (A). Cut the plastic ties that hold the vents in place.

Remove the mounting screws from trim panel (A). Lift the trim panel slightly to unplug the wires to the rocker switches and cigarette lighter.

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Illustration 198	g03467757

Move gearshift lever (C) to the "N" position in order to provide additional clearance.

Remove trim panel (A) .
Note: Maybe necessary to remove instrument panel in order to provide clearance to remove the trim panel.

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Illustration 199	g03467758

Remove the mounting screws from rear trim panel (D). Remove the rear trim panel.

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Illustration 200	g03467759

Disconnect connectors (F) and (G) from control lever assembly (E) .

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Illustration 201	g03467760

Remove the mounting screws from control lever assembly (E). Remove the assembly.

Install Relay Assemblies

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Table 50
Required Parts Group Number 433-2204 Wiring Gp Cab (Rev. 00)
Tool	Qty	Part Number	Part Description
1	1	435-1391	Plate As
2	1	3E-6328	Alarm Gp
3	3	231-3930	Relay As
4	7	114-6658	Washers
5	4	9X-2043	Screws

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Illustration 202	g03424111

Mount three relay assemblies (3) on plate assembly (1) with screws (5) and washers (4). Tighten the screws to a torque of 12 ± 3 N·m (9 ± 29 lb ft).

Mount alarm group (2) on plate assembly (1) with screw (5) and washer (4). Tighten the screws to a torque of 12 ± 3 N·m (9 ± 29 lb ft).

Install Control Module

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Table 51
Required Parts Group Number 433-2204 Wiring Gp Cab (Rev. 00)
Tool	Qty	Part Number	Part Description
6	1	274-7921	Machine Electronic Control Module
7	2	9X-8256	Washers
8	2	8T-4138	Bolts

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Illustration 203	g03423177

Install machine electronic control module (6) on bottom of plate assembly (1). Fasten the control group to the plate assembly with two bolts (8) and two washers (7). Tighten the bolts to a torque of 6 ± 1 N·m (4 ± 0.7 lb ft).

Install Plate Assembly

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Illustration 204	g03471856
Right rear view of cab - behind operator seat

Fasten plate assembly (1) of the control group assembly to the bottom of the cab mounting plate with four screws (4) and four washers (3) .

Install Gear Shift

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Table 52
Required Parts Group Number 433-2204 Wiring Gp Cab (Rev. 00)
Tool	Qty	Part Number	Part Description
9	1	361-6595	Transmission Control Gp
10	4	8C-8585	Screws

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Illustration 205	g03467776

Install transmission control group (9) in the side console. Fasten the control group in place with four screws (10) .

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Illustration 206	g03467777

Reconnect the harness connector (G) to transmission control group (9). Tighten the screws to a torque of 55 ± 10 N·m (41 ± 7 lb ft).

Install Display Module

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Table 53
Required Parts Group Number 433-2204 Wiring Gp Cab (Rev. 00)
Tool	Qty	Part Number	Part Description
4	1	114-6658	Washers
11	1	382-7849	Plate As
12	4	161-6984	Screws
13	4	4B-4274	Washers
14	1	9X-2045	Screws
15	1	366-0242	Monitor Electronic Control Module
16	4	131-3987	Screws

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Illustration 207	g03423271

Install plate assembly (11) on the cab side structure. Secure the base plate assembly with four screws (12) and washers (13). Tighten the screws to a torque of 7.5 ± 1.5 N·m (5.5 ± 1 lb ft). Secure the top of the plate assembly with one screw (14) and washer (4) .

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Illustration 208	g03423337

Place monitor electronic control module (15) on plate assembly (11). Secure the monitor electronic control module with four screws (16) .

Joystick Installation

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Table 54
Required Parts Group Number 433-2204 Wiring Gp Cab (Rev. 00)
Tool	Qty	Part Number	Part Description
17	1	355-9440	Joystick Control Gp

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Illustration 209	g03467778

Install joystick control group (17) on the transmission control group (9) using the bolts provided with the joystick.

Cab Harness Installation

Install Cab Electrical Harness

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Table 55
Required Parts Group Number 433-2204 Wiring Gp Cab (Rev. 00)
Tool	Qty	Part Number	Part Description
4	2	114-6658	Washers
5	2	9X-2043	Screws
18	1	433-2205	Cab Harness As
19	38	7K-1181	Cable Straps
20	1	3E-3364	Receptacle
21	3	3S-2093	Cable Straps
22	1	270-5322	Voltage Control Gp
23	1	284-3659	Rocker Switch
24	2	113-8491	Fuses
25	1	113-8490	Fuse
26	1	352-1143	Resistor

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Illustration 210	g03423375

Connect cab harness assembly (18) to bulkhead (H) and route the harness assembly as shown. Secure the cab harness assembly with cable straps (19). Connect the plugs on the cab harness assembly to the joystick control group and the other control groups. Install receptacle (20) and strap (21).

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Illustration 211	g03423369

Connect cab harness assembly (18) to the controls. Connect the cab harness assembly plugs to the installed relays (3). Connect voltage control group (22) to the cab harness assembly. Secure the cab harness assembly and voltage control group with cable straps (19) .

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Illustration 212	g03423417

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Illustration 213	g03423456

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Illustration 214	g03423471

Route cab harness assembly (18) through the cab as shown. Secure the cab harness assembly with cable straps (19). Connect switch (23) to the cab harness assembly. Secure the section of the cab harness assembly routed to the switch with two cable straps (21) .

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Illustration 215	g03488599
Location of Washer Rocker Switch

Install washer rocker switch (23) in bezel as shown.

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Illustration 216	g03423510

Locate holder assembly (H) on the cab harness assembly (18). Fasten holder assembly (H) to the relay plate assembly (1) with two screws (4) and two washers (5). Install the bracket to the plate with screws (5) and washers (4). Tighten the screws to a torque of 12 ± 3 N·m (9 ± 2 lb ft). Install two fuses (24), one fuse (25) and resistor (26) .

Install Keypad

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Table 56
Required Parts Group Number 433-2204 Wiring Gp Cab (Rev. 00)
Tool	Qty	Part Number	Part Description
27	1	376-3871	Cover
28	1	377-4675	Keypad Module Gp
14	7	9X-2045	Screws
29	1	9X-2044	Screw
30	6	4E-8722	Nuts
31	7	9X-2038	Washers
32	1	386-1518	Film Joystick Control
33	1	290-7164	Film
34	1	169-2876	Film

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Illustration 217	g03467796

Install keypad module group (28) into trim panel cover (27) .

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Illustration 218	g03467797

Install trim panel cover (27) .

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Illustration 219	g03467798

Connect the keypad connector of cab harness assembly (18) to the connector on the bottom of the keypad module group (28) .

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Illustration 220	g03423343

Install joystick film (32) for the joystick control group to cab trim group cover (27) .

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Illustration 221	g03422895

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Illustration 222	g03422905

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Illustration 223	g03749276
(33) 290-7164 Film X msn shift (34) 169-2876 Film Ident (12V)

Install cover (27) with six screws (14), one screw (29), washers (31) and nuts (30). Tighten the screws to a torque of 12 ± 3 N·m (9 ± 2 lb ft).

WAVS Camera System Installation (Optional)

Note: WAVS camera system installation is an optional attachment

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Table 57
Required Parts Group Number 436-2188 Visibility Ar (Rev 00)
Qty	Part Number	Part Description
1	309-5339	Cab Wiring Gp
1	435-8004	Cab Wiring Gp
1	436-2187	Camera Wiring Gp
1	435-4013	Installation Field Gp

309-5339 Cab Wiring Group Installation

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Table 58
Required Parts Group Number 309-5339 Cab Wiring Gp (Rev 06)
Item	Qty	Part Number	Part Description
(1)	2	259-4399	Base
(2)	1	270-3311	Clamp Gp
(3)	1	333-8153	Electronic Connector Gp
(4)	1	344-2733	Display Module Gp
(5)	1	367-4855	Cable As
(6)	1	372-6064	Wiring Harness
(7)	4	161-6984	Screw
(8)	1	162-9112	Split Grommet
(9)	8	4B-4274	Washer
(10)	4	7Y-7388	Screw

Note: Reference Special Instruction, REHS7242

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Illustration 224	g03381934
Right rear view of cab

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Illustration 225	g03381925
Inside cab view

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Illustration 226	g03389216
Right side of cab

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Illustration 227	g03384064
Monitor mount location - right front of cab

Install display module group (4) on mounting location as shown in Illustration 225 to Illustration 227.

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Illustration 228	g03389489
Right side view of cab

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Illustration 229	g03391418
Right font view of cab

Connect male end of cable assembly (5) to connector (A) of display module group (4). Route cable assembly (5) along the main wiring harness on the right side of cab as shown in Illustration 228 and Illustration 229.

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Illustration 230	g03384062
Right side view of cab

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Illustration 231	g03389447
Right rear corner view of cab

Route cable assembly (5) through split grommet (8). Route cable assembly (5) along the main wiring harness around the back right corner of the cab as shown in Illustration 230 and Illustration 231.

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Illustration 232	g03389443
Rear view of cab

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Illustration 233	g03391398
Left rear view of cab

Route cable assembly (5) along the back of the cab. Connect female end of cable assembly (5) to electronic connector group (3) as shown in Illustration 232 and Illustration 233.

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Illustration 234	g03389468
Right side view of cab

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Illustration 235	g03391725

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

Cable Straps Installation

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Table 59
Required Parts Group Number 309-5339 Cab Wiring Gp (Rev 06)
Item	Qty	Part Number	Part Description
(11)	19	7K-1181	Cable Strap

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Illustration 236	g03390145

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

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Illustration 237	g03390526

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Illustration 238	g03390538

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

435-8004 Cab Wiring Group Installation

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Table 60
Required Parts Group Number 435-8004 Cab Wiring Gp (Rev 00)
Item	Qty	Part Number	Part Description
(1)	1	113-8490	Fuse
(2)	1	284-3659	Rocker Switch
(3)	1	435-6161	Switch Harness As

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Illustration 239	g03381936
Right rear view of cab

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Illustration 240	g03384726
Location of Washer Rocker Switch

Install washer rocker switch (2) in bezel as shown in Illustration 240.

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Illustration 241	g03384115
Right front view of cab

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Illustration 242	g03384111
Right side view of cab

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Illustration 243	g03384113
Rear view of cab

Route switch harness assembly (3) along the side of the main wiring harness as shown in Illustration 241 to Illustration 243. Switch harness assembly (3) splits and connects to ground (A) and fuse (1) .

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Illustration 244	g03390716
Fuse box location in cab

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Illustration 245	g03390698

Terminate "A-T1" pink wire to G5 of connector "MC-C90" (B) .

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Illustration 246	g03383834
Right rear view of cab

Route switch harness assembly (3) along the side of the main wiring harness as shown in Illustration 246.

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Illustration 247	g03390820
Left rear view of cab

Route switch harness assembly (3) to connector "CC-C2" (C) as shown in Illustration 247.

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Illustration 248	g03390733

Terminate "A-T3" black wire to pin 1 of connector "CC-C2" (C) .

Terminate "A-T4" yellow wire to pin 2 of connector "CC-C2" (C) .

Install 10 amp fuse (1) inside fuse box (B) using fuse location "F25".

Cable Straps Installation

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Table 61
Required Parts Group Number 435-8004 Cab Wiring Gp (Rev 00)
Item	Qty	Part Number	Part Description
(4)	40	7K-1181	Cable Strap

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Illustration 249	g03390061

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

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Illustration 250	g03390079
Right front view of cab

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Illustration 251	g03390121
Right side view of cab

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

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Illustration 252	g03390102
Rear view of cab

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

436-2187 Camera Wiring Group Installation

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Table 62
Required Parts Group Number 436-2187 Camera Wiring Gp (Rev 00)
Item	Qty	Part Number	Part Description
(1)	1	251-4168	Switch
(2)	3	347-1668	Camera Gp
(3)	3	276-2638	Bracket As
(4)	3	274-4479	Cable As

Install WAVS monitor and cable. Reference Special Instruction, REHS7242.

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Illustration 253	g03384035

Mount switch (1) on the inside of the right frame rail. Connect cable assembly (A) to the "MON" connector on the switch assembly

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Illustration 254	g03384037
Rear View of Water Tank

Mount camera group (2) in location (B) as shown in Illustration 254.

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Illustration 255	g03384039
Top of Water Tank

Mount two additional camera groups (2) onto the top of the water tank. Mount one camera on the rear of water tank at location (E). Point this camera forward at tank fill hole (D). Mount second camera at location (C) position 90° to camera at location (E). Point this camera at tank fill hole (D) .
Note: Bracket assemblies (3) are recommended to provide protection for cameras.

Connect one cable assembly (4) to each camera group (2). Route these cable assemblies down the rear of the water tank. Strap the cables to existing bosses on the water tank. Route cable assemblies (4) under the water tank to switch (1) .
Note: Ensure that the cables have adequate length in order to accommodate the lifting and lowering of the water tank.

Connect cable assemblies (4) to switch (1) in the following configuration:
- Camera "1" (B) - connect to terminal "C1"
- Camera "2" (C) - connect to terminal "C2"
- Camera "3" (E) - connect to terminal "C3".
Note: The factory default setting for the WAVS monitor is for a single camera configuration.

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

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

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

WAVS Camera System Installation

436-2187 Camera Wiring Group Installation

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Table 63
Required Parts Group Number 436-2187 Camera Wiring Gp (Rev 00)
Item	Qty	Part Number	Part Description
(1)	1	251-4168	Switch
(2)	3	347-1668	Camera Gp
(3)	3	276-2638	Bracket As
(4)	3	274-4479	Cable As

Install WAVS monitor and cable. Reference Special Instruction, REHS7242.

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Illustration 256	g03384035

Mount switch (1) on the inside of the right frame rail. Connect cable assembly (A) to the "MON" connector on the switch assembly

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Illustration 257	g03384037
Rear View of Water Tank

Mount camera group (2) in location (B) as shown in Illustration 257.

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Illustration 258	g03384039
Top of Water Tank

Mount two additional camera groups (2) onto the top of the water tank. Mount one camera on the rear of water tank at location (E). Point this camera forward at tank fill hole (D). Mount second camera at location (C) position 90° to camera at location (E). Point this camera at tank fill hole (D) .
Note: Bracket assemblies (3) are recommended to provide protection for cameras.

Connect one cable assembly (4) to each camera group (2). Route these cable assemblies down the rear of the water tank. Strap the cables to existing bosses on the water tank. Route cable assemblies (4) under the water tank to switch (1) .
Note: Ensure that the cables have adequate length in order to accommodate the lifting and lowering of the water tank.

Connect cable assemblies (4) to switch (1) in the following configuration:
- Camera "1" (B) - connect to terminal "C1"
- Camera "2" (C) - connect to terminal "C2"
- Camera "3" (E) - connect to terminal "C3".
Note: The factory default setting for the WAVS monitor is for a single camera configuration.

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

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

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

WAVS Washer Group Installation (Optional)

Note: WAVS washer group installation is an optional attachment

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Table 64
Required Parts Group Number 436-2188 Visibility Ar (Rev 00)
Qty	Part Number	Part Description
1	435-4013	Installation Field Gp

435-4013 Installation Field Gp for WAVS Camera Cleaning System

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

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

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

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

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

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

Proper Welding Procedure on Machines and Engines with Electronic Controls

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

Turn off the engine. Put the key start switch in the OFF position.

If the machine has a battery disconnect switch, open the switch. If the machine does not have a battery disconnect switch, disconnect the negative battery cable at the battery.

Connect the ground cable for the welder directly to the actual machine component that will be welded. Attach the clamp for the ground cable as close as possible to the area that is being welded in order to reduce the chance of damage from welding current to the components that follow: bearings, hydraulic components and electrical components.
Note: Do Not use ground points for electronic components as a ground point for the welder.

Protect the wiring harnesses from the weld splatter.

Required Parts

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Table 65
Required Parts Group Number 435-4013 Installation Field Gp (Rev 00)
Item	Qty	Part Number	Part Description
(1)	1	2L-8071	Terminal
(2)	1	3K-8782	Fuse
(3)	4	4E-8266	Boss
(4)	60ft	5P-0651	Electrical Wire
(5)	10ft	5P-0653	Wire
(6)	5	5P-4115	Hard Washer
(7)	15ft	6A-3361	Electrical Wire
(8)	5	6V-7357	Bolt (M6x1x25)
(9)	1	8D-8719	Holder and Wire Assembly
(10)	40	8L-8413	Cable Strap
(11)	4	8T-4138	Bolt (M6x1x20)
(12)	6	8T-8730	Connector Socket
(13)	5	9X-8267	Washer
(14)	3	129-3178	Locknut (M6x1)
(15)	4	136-4877	Wire Splice
(16)	10ft	144-0195	Hose
(17)	3	155-2270	Connecting Plug Kit
(18)	3	204-2581	Check Valve As
(19)	21	228-5009	Clip
(20)	1	236-4631	Bezel
(21)	1	245-7434	Connecting Plug Kit
(22)	1	284-3659	Rocker Switch
(23)	3	307-3001	Bracket
(24)	3	307-3003	Extension Plate
(25)	3	307-4415	Clip
(26)	3	307-6218	Nozzle
(27)	3	307-6221	Fitting
(28)	1	368-5695	Washer Bottle Gp
(29)	1	5P-9085	Clip

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Illustration 259	g03385004
Parts Identification

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Illustration 260	g03385002
Parts Identification

Installation Procedure

Identify a location for installation of washer bottle group (28). Ensure that the location for installation is protected. Ensure that the location of washer bottle group (28) is lower than nozzle (26) .
Follow the steps that are listed below in order to install washer bottle group (28) .
1. Position nozzle (26) in a horizontal position that is less than 3.0m (10 ft) away from washer bottle group (28) .
1. Position washer bottle group (28) no lower than 1.5 m (5 ft) from nozzle (26) .

Inspect the location for the installation and ensure that welding in the location will not damage any of the nearby components.

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Illustration 261	g03383209
Location of Washer Bottle

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Illustration 262	g03384722
Location of Bosses for Washer Bottle (A) 306 ± 1.5 mm (12 ± 0.1 inch) (B) 150 ± 1 mm (5.9 ± 0.04 inch)

Weld bosses (3) onto the frame in order to mount washer bottle group (28) .

Install washer bottle group (28) for the cleaning system.

Mount nozzle (26) .
The following requirements need to be followed for the installation of nozzle (26) .
1. For optimal performance install nozzle (26) within 25 mm (1 inch) of the camera lens.
  Note: When installing nozzle (26) ensure that nozzle (26) is not viewable in the camera image.
1. Nozzle (26) will need to be angled at 45 degrees from the surface of the lens.
1. Mount spray nozzle (26) so that the projection of the spray cuts at the base of the glass.

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Illustration 265	g01341873
Typical Installation of the Sensor Harness Assembly

Install sensor harness assembly (C) along the WDS chassis harness on the side of the frame rail.

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Illustration 266	g03396487
(C) 419-5591 Sensor harness assembly (D) Connector plug

The power and ground for the washer bottle pump connects to connector plug (D) on sensor harness assembly (C) at the cab-chassis interface bulkhead behind the cab.

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Illustration 267	g03395944

Install ground wire in pin 1 of connector plug (D). Connector plug (D) is located on 419-4491 sensor harness assembly (C) that was installed in section ""Chassis Harness Installation" " within this document.

Install power wire in pin 2 of connector plug (D). Connector plug (D) is located on 419-4491 sensor harness assembly (C) that was installed in section ""Chassis Harness Installation" " within this document.

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Illustration 268	g03384984
Check Valve

Note: You must prime the pump before installing check valve assembly (18). In order to prime the pump allow the water to flow out of the line in order to purge the air out of the line.

Route the fluid line from the pump to nozzle (26). Cut the fluid line and install check valve assembly (18) no more than 304 mm (12 inch) away from water bottle group (28). Ensure that the arrow on check valve assembly (18) is pointed away from the pump.

Check the operation of the system.

Monitor Setup

Electronic Technician Setup

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

Launch the Cat^® ET program on the computer.

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

Disconnect the laptop computer.

MD3 Setup

Move the battery disconnect switch to the ON position.

Move the engine start switch to the ON position. Do not start the engine.

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Illustration 269	g03358191

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

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

Use up button (F) and down button (D) to select the preferred language.
Note: The default language is English.

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

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

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

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Illustration 270	g03358192

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

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Illustration 271	g03358193

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

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Illustration 272	g03697620

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

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Illustration 273	g03358195

Select the truck model and press "OK" button (E) .

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Illustration 274	g03697624

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

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Illustration 275	g03697629

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

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Illustration 276	g03697664

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Illustration 277	g03697699

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Illustration 278	g03697665

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Illustration 279	g03697667

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Illustration 280	g03697668

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Illustration 281	g03697669

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Illustration 282	g03697708

Select "Water Pump Selection" then choose type of pump.

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Illustration 283	g03697710

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Illustration 284	g03697715

Select "Spray Head Type" then choose type of spray head.

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Illustration 285	g03697720

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Illustration 286	g03697727

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

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Illustration 287	g03358201

Scroll down and select the "Enable" option. Press "OK" button (E) .
Note: It is recommended that the tank lift function to be selected as "Disabled" during normal operation. "Enable" Tank Lift for servicing purposes only.

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Illustration 288	g03697729

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

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Illustration 289	g03358203

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

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Illustration 290	g03697730

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Illustration 291	g03697731

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

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Illustration 292	g03697732

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Illustration 293	g03358204

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

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Illustration 294	g03697733

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

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Illustration 295	g03358206

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

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Illustration 296	g03358207

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

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Illustration 297	g03358209

Select the manual speed deactivation value. This feature disables manual operation of the system when machine speed is greater than the deactivation value.
Note: This feature can be used at work sites that desire system operation to be disabled while operating at road speeds.

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Illustration 298	g03358212

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

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Illustration 299	g03358213

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

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Illustration 300	g03358214

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

WDS Initial System Startup

Circuit Fill and Prime Procedure

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

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Table 66
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 301	g03860179

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Illustration 302	g03860180
View (A-A)

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Illustration 303	g03358215
View (B-B)

Note: Refer to Illustration 303. Port (A) is the S·O·S sample port. Port (B) is a gauge port for checking charge pump pressure.

Refer to Illustration 302. Check the oil filter group to ensure tee (1) and test fitting (3) are installed. If installed, proceed to Step 4. If not installed, proceed to Step 2.

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

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

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

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

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

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

Bleeding Air From Spray Head Cylinders

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

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

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Illustration 304	g03358216

Place a drip pan under the spray head being bled. Loosen upper fitting (C) approximately one turn. Ensure that lower fitting (D) is tight. DO NOT OPEN the bottom fitting.
Note: When the spray heads are opened, the upper fitting is under low pressure and the bottom fitting is pressurized up to 3400 kPa (500 psi). Opening the bottom fitting may result in a dangerous release of pressure.

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Illustration 305	g03358218

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

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

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

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

Repeat this procedure for each spray head.

Stop the engine.

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

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

Water Pump Fill Procedure

Fill the water tank.

Start the truck and let the engine idle.

Press head clean button (E) on the keypad.

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

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

Stop the engine.

Water Pump Rotation

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

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

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

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

Start the truck and let the engine idle.

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Illustration 306	g03358219

Press cannon mode button (G) .

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Illustration 307	g03358222

Pull trigger (H) on the joystick to open the butterfly valve.

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Illustration 308	g03358223

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Illustration 309	g03375251
Rotation Direction Indicator

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Illustration 310	g03375247
Clockwise Pump Shaft Rotation

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

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

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

Calibrations

Spray Head Calibration

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

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

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

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

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Illustration 311	g03358226

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

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Illustration 312	g03358227

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

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Illustration 313	g03358228

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

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Illustration 314	g03358229

Scroll down and select the "2-5 Spray Head Calibration" option. Press "OK" button (B) .
Note: The "167 Spray Head Calibration" option is performed for the auxiliary spray head options. This calibration does not affect water coverage but can be used to obtain a more consistent spray.

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Illustration 315	g03358230

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

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Illustration 316	g03358231

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

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

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Illustration 317	g03358233

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

Water Tank Sensor Calibration

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Illustration 318	g03358234

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

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

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Illustration 319	g03358235

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

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

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Illustration 320	g03358237

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

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

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Illustration 321	g03358238

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

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

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

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

Fill the water tank to the desired full level.

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

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

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

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

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

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

Adjust value (F) until the tank level screen shows 100%.
Note: The low water warning value is set at 10%. The low water warning value is adjustable and can be changed by selecting the option, then increasing or decreasing the value.

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

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

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

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

Use up button (E) and down button (C) to adjust value (F) displayed on the screen. Enter a value greater than the "Tank Empty Value" so the system shuts off before the water tank is completely empty.
Note: If "Tank Empty Value" is 0.1, set the "Low Water Shutoff" to 0.2.

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

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

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

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

Use up button (E) and down button (C) to adjust value (F) displayed on the screen. Enter a value less than the "Tank Full Value" so the system shuts off before the water tank is completely full.
Note: This value depends how fast the fill station operates and the time required to shut the fill valve. The WDS system can transmit a signal to the fill valve automatically when this percentage is achieved. A value of 95% is normal.

Cannon Adjustments

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

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

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

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

Operating Pressures

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

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

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

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

Pump and motor inlet and outlet pressure should be approximately 1930 kPa (280 psi) when the engine is at low idle and the WDS system is NOT activated. Pump relief pressure is 28000 kPa (4100 psi). Software limits system pressure to 24000 kPa (3500 psi).