- 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.
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
Required Parts Group Number 375-5832 Pump and Mounting Gp (Rev. 01)     |
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---|---|---|---|
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".
- Disconnect brake cooling tube (A) from pump (B) .
Illustration 1 | g02776698 |
- Remove clamp (C) from brake cooling tube (A) .
Illustration 2 | g02776699 |
- Place suitable container under bolts (D) in order to collect fluid. Remove the bolts.
Illustration 3 | g02776700 |
- Disconnect and remove brake cooling tube (A) .
- Disconnect hose assembly (F) from steering pump ( E). Remove the hose assembly.
Illustration 4 | g02776701 |
- Disconnect hose assembly (H) from steering pump ( E). Remove the hose assembly.
Illustration 5 | g02776736 |
- Disconnect load sensing hose assembly (G) from steering pump (E). Leave this hose assembly connected to the machine.
- Disconnect case drain hose assembly (J) from steering pump (E). Leave this hose assembly connected to the machine.
Illustration 6 | g02776738 |
- Attach a suitable lifting device to steering pump (E). Remove bolts (K) .
Illustration 7 | g02776739 |
Illustration 8 | g02788390 |
Pump Drive Shown With Steering Pump And Adapter Removed |
- Remove steering pump (E) and pump adapter group.
Note: This pump weighs approximately 54 kg (120 lb).
- 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.
Illustration 9 | g02776780 |
Pump Adapter Group Shown With Cover Plate Removed |
- 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).
Illustration 10 | g02776782 |
- Connect load sensing hose assembly (G) to the steering pump.
- Connect case drain hose assembly (J) to the steering pump.
- 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) .
Illustration 11 | g02788400 |
- 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) .
Illustration 12 | g02788412 |
Right Side of Engine Compartment |
- Clamp tube assembly (12) in place at location ( L) and location (M) with two clips (13)
- 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) .
Illustration 13 | g02788417 |
View From Beneath Engine Compartment |
- Install hose (15) with seal (16) and two split flanges (17). Fasten the hose to pump with four bolts (18) and four washers (11) .
Illustration 14 | g02777197 |
- Route hose (15) up through the engine compartment to the steering tank. Clamp the hose in place with hose clamp (19) .
Illustration 15 | g02788422 |
- 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) .
Illustration 16 | g02788479 |
- Install hose (21) with seal (22) and two split flanges (23). Fasten the hose to pump with four bolts (24) and four washers (25) .
Illustration 17 | g02777204 |
- 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) .
Illustration 18 | g02788492 |
Pump Group Installation
WDS Hydraulic Pump Installation
Required Parts Group Number 369-6025 Pump and Mounting Gp (Rev. 04)     |
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---|---|---|---|
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     |
- 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).
Illustration 19 | g03416902 |
- 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
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     |
- Remove temporary cover and seal from WDS hydraulic piston pump group (1) .
Illustration 20 | g03416974 |
- 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
Required Parts Group Number 435-5852 Supplemental Cooling Gp (Rev. 01)     |
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---|---|---|---|
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     |
( 1 ) | Included in 443-6593 Cooling Gp . |
- Tack weld plate assembly (2) in position using dimensions (A) and (B) .
Illustration 21 | g03463436 |
Top view (A) 190 mm (7.5 inch) (B) 80 mm (3.1 inch) |
- Mount cooling group (1) on the cooler mounting plate assembly (2) .
Illustration 22 | g03417049 |
- 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).
Illustration 23 | g03418093 |
WDS Hydraulic Tank Installation
Required Parts Group Number 435-5852 Supplemental Cooling Gp (Rev. 01)     |
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---|---|---|---|
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     |
- Mount hydraulic mounting tank group (3) on truck tank (B) and fasten in place with bolts.
Illustration 24 | g03418137 |
- 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).
Illustration 25 | g03418145 |
- Position quick fill assembly (C) on the bottom of truck tank (B) .
Illustration 26 | g03418187 |
- Position and install guard assembly (6) at the bottom of the truck tank (B).
Illustration 27 | g03418220 |
- Secure the guard assembly with bolts (12) and washers (11). Tighten the bolts to torque of 55 ± 10 N·m (41 ± 7 lb ft).
Illustration 28 | g03418236 |
- 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).
Illustration 29 | g03418290 |
- 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)
Illustration 30 | g03418299 |
- 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).
- 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).
Illustration 31 | g03418307 |
- 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).
Illustration 32 | g03418682 |
- 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).
Illustration 33 | g03418660 |
- 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).
Illustration 34 | g03418654 |
- Connect hose assembly (24) to nut (26) .
Install Clips to the Hose
Required Parts Group Number 435-5852 Supplemental Cooling Gp (Rev. 01)     |
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---|---|---|---|
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     |
- 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).
Illustration 35 | g03418843 |
- 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).
Illustration 36 | g03418890 |
- 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).
Illustration 37 | g03418917 |
- 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).
Illustration 38 | g03418920 |
Install Hose to the Cooler and Mounting Tank
Required Parts Group Number 435-5852 Supplemental Cooling Gp (Rev. 01)     |
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---|---|---|---|
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     |
- 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.
Illustration 39 | g03418977 |
- 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.
- 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).
Illustration 40 | g03418984 |
- 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).
Illustration 41 | g03419078 |
- 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).
Illustration 42 | g03419100 |
- 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).
Illustration 43 | g03419110 |
- 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).
Illustration 44 | g03419141 |
- 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).
- 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) .
Illustration 45 | g03419158 |
- 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).
Illustration 46 | g03419174 |
- 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
- Remove position sensor assembly (A) .
Illustration 47 | g03371413 |
- Cut mounting block (B) from the rear frame rail.
Illustration 48 | g03371414 |
- 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.
Illustration 49 | g03371416 |
- Reinstall position sensor assembly (A) on mounting block (B) .
Illustration 50 | g03371417 |
Install Plate Assembly on Truck Frame
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     |
- 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.
Illustration 51 | g03419284 |
Rear View of the Bulkhead Plate |
Connect Pressure Hoses to the WDS Hydraulic Pump
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     |
- 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).
Note: The ends of all pump-related hose assemblies are color coded.
Illustration 52 | g03419325 |
- 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
- 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.
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 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
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     |
- 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).
Illustration 54 | g03419748 |
- Route hose assembly (17) under the left frame rail and up the side of the hydraulic tank.
- Route hose assembly (17) to suction port (K) on the WDS hydraulic tank.
Illustration 55 | g03419763 |
- 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
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     |
- 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).
Illustration 56 | g03419766 |
- 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
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     |
- 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).
Illustration 57 | g03465956 |
Install Cold Start Relief Valve
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     |
- 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).
Illustration 58 | g03465957 |
- 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
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     |
- 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).
Illustration 59 | g03420260 |
- 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).
- 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.
Illustration 60 | g03420297 |
- 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
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     |
( 1 ) | Part of 355-5910 Pump Lines Gp |
( 2 ) | Part of 435-5852 Supplemental Cooling Gp |
- Install clip (40) on charge pump suction hose assembly (17). Install clip (41) on charge pump relief hose assembly (38) .
Illustration 61 | g03420586 |
Hose Assembly (38) is not shown. |
- 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
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     |
- 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.
Illustration 62 | g03361215 |
Install Filter Mounting Plate
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     |
- 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).
Illustration 63 | g03361234 |
Connect Filter Group to Charge Pump Outlet
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     |
- 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).
Illustration 64 | g03420768 |
- 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).
- 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).
Illustration 65 | g03420792 |
Connect Filter Group to WDS Pump
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     |
- 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).
Illustration 66 | g03420962 |
- 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
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     |
- Install clip (18) and clip (19) on the valve group hose assembly.
Illustration 67 | g03421023 |
- 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
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     |
- 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).
Note: Color codes for hose assemblies are indicated on the WDS hydraulic piston pump, motor and bulkhead adapters.
Illustration 68 | g03421261 |
- 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).
- 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.
Illustration 69 | g03421267 |
- 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.
Illustration 70 | g03421357 |
- Connect green motor signal pressure hose assembly (18) with O-ring seal (17) to elbow (B) .
- 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.
Illustration 71 | g03421407 |
Install Spray Head Pilot Pressure and Pilot Return Hoses
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     |
- Disconnect hose assembly (B) from adapter (C) on hoist valve (A) .
Illustration 72 | g03357357 |
- Disconnect hose assembly (D) from adapter (C) on hoist valve (A) .
- Remove adapter (C) from hoist valve (A) .
- Install adapter (6) in hoist valve (A) with seal (7) .
Illustration 73 | g03357360 |
- 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).
- Connect hose (B) to cross adapter (4) with seal (3) .
Illustration 74 | g03357361 |
- 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).
- Route brown spray head pilot pressure hose (2) along the left frame rail to spray head pilot pressure port (A) .
Illustration 75 | g03357362 |
- 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.
Illustration 76 | g03357365 |
- 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.
- Route black spray head pilot return hose (1) along the right frame rail to the machine hydraulic tank.
Illustration 77 | g03357367 |
Illustration 78 | g03357368 |
Illustration 79 | g03421565 |
- 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).
Illustration 80 | g03421573 |
- 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
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     |
- 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).
Illustration 81 | g03421642 |
- 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
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     |
( 1 ) | Part of 355-5910 Pump Lines Gp . |
( 2 ) | Part of 355-5911 Pilot Lines Gp . |
- Secure and mount two clips (53) on hose assembly (24). Hose assembly (24) is clamped along with the transmission hose.
Illustration 82 | g03421689 |
- Mount one clip (41) on hose assembly (51). Fasten the bolt to the frame support.
- 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).
Illustration 83 | g03421738 |
- 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).
Illustration 84 | g03421780 |
- 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).
Illustration 85 | g03421827 |
- 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).
Illustration 86 | g03421860 |
- Mount brackets (65) to the frame and fasten bolts (60) with washers (3) .
Illustration 87 | g03421907 |
- 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).
- 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).
Illustration 88 | g03422053 |
Hydraulic and Component Installation (Tank)
Water Pump Installation
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     |
( 1 ) | If stainless steel water pump is ordered, refer to 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     |
- 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.
Illustration 89 | g03350017 |
Illustration 90 | g03350020 |
- 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.
- 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.
Illustration 91 | g03697323 |
- Install pressure sensor (3) onto spray bar at location shown in Illustration 92.
Illustration 92 | g03697384 |
WDS Motor Installation
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     |
- 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.
Illustration 93 | g03714786 |
- Mount WDS piston motor group (1) onto water pump (A). Ensure that the spline of motor engages coupler (B) .
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).
- 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).
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.
Water Pump Motor to Bulkhead Lines Routing
Connect WDS Motor Pressure Hoses
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     |
- Install adapter (2) with seal (1) in motor high-pressure port (A) .
Illustration 96 | g03357436 |
Water Pump Motor (A) Motor high-pressure port (red) (B) Motor low-pressure port (blue) |
- 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.
- 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).
Illustration 97 | g03357437 |
- 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).
- 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.
Illustration 98 | g03357438 |
Connect WDS Motor Pressure Hoses to Plate Assembly
Required Parts Group Number 372-1177 Motor Lines Gp (Rev. 01)     |
|||
---|---|---|---|
Tool     | Qty     | Part Number     | Part Description     |
3     | 2     | 1P-3703     | Rectangular Seals     |
- Route blue motor low-pressure hose (5) from the WDS motor to pump low-pressure port (C) on the bulkhead plate.
Illustration 99 | g03357439 |
Rear View Of Bulkhead Plate (C) Pump low-pressure port (blue) (D) Pump high-pressure port (red) |
- Route red motor high-pressure hose (4) from the WDS motor to pump high-pressure port (D) on the bulkhead plate.
- 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).
Illustration 100 | g03357440 |
Rear View Of Bulkhead Plate (C) Pump low-pressure port (blue) (D) Pump high-pressure port (red) |
- 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
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     |
- 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).
Illustration 101 | g03357441 |
- Install seal (14) in adapter (13) .
Connect WDS Motor Case Drain Hose to the Plate Assembly
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     |
- 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.
Illustration 102 | g03357442 |
Vertical Mounting of WDS Motor |
Illustration 103 | g03357443 |
Case Drain Port for Inverted Horizontal Mounting |
Illustration 104 | g03357444 |
Case Drain Port for Horizontal Mounting |
- 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.
Illustration 105 | g03357445 |
- 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.
Illustration 106 | g03357446 |
Rear View Of Bulkhead Plate |
- Install three grommets (16) on motor low-pressure hose (5) and motor high-pressure hose (4) .
Illustration 107 | g03357447 |
- 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
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     |
( 1 ) | This component must be provided by the customer. |
- 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).
Illustration 108 | g03357448 |
WDS Motor (J) Motor signal port (green) (K) Motor pilot port (yellow) |
- Connect adapter (26) with seal (25) to adapter (24). Tighten the adapter to a torque of 45 ± 5 N·m (33 ± 4 lb ft).
- 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).
Illustration 109 | g03357450 |
WDS Motor (J) Motor signal port (green) - straight fitting (K) Motor pilot port (yellow) - 90 degree adapter |
- 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.
- Yellow motor pilot pressure hose - install one coupling (27) on one end and install one coupling (28) on the other end
- 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.
- 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.
Illustration 110 | g03357452 |
Rear View Of Bulkhead Plate (L) Motor signal line fitting (green) (M) Motor pilot pressure hose fitting (yellow) |
- 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
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     |
- Install five plugs (8) with seal (9) in the water pump.
Illustration 111 | g03367416 |
Vertically Mounted Water Pump |
Illustration 112 | g03368841 |
Horizontally Mounted 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
Required Parts Spray Head Installation     |
|||
---|---|---|---|
Item     | Qty     | Part Number     | Part Description     |
1 (1)     | 5 (2)     | 431-9716     | Water Control Valve Gp     |
( 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. |
- 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.
Illustration 113 | g03714795 |
- Install water control valve group (1) on spray bar (D). Reinstall split flanges (A). Do not tighten the mounting bolts.
Illustration 114 | g03714799 |
Illustration 115 | g03714801 |
- 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.
Illustration 116 | g03697517 |
(E) 152 mm (6 inch) |
Illustration 117 | g03714803 |
- Repeat the previous steps for the remaining spray heads on the rear spray bar.
Illustration 118 | g03682227 |
- 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.
Illustration 119 | g03714804 |
- 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
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     |
- 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) .
Illustration 120 | g03422323 |
Illustration 121 | g03422365 |
- 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.
- Fasten clip (4) to the mounting plate of the cooling group (C). Tie the harness assembly (6) to the clip with cable straps (8) .
Illustration 122 | g03362966 |
- Connect the fan power wire from harness assembly (6) to contact (D). Connect the fan ground wire to contact (E) .
- Route the remainder of chassis harness assembly (6) along the truck chassis harness. Tie the cable in place with cable straps (8) .
Illustration 123 | g03422673 |
- 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.
Illustration 124 | g03482379 |
- 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) .
- Plug harness assembly (6) into the solenoid connector (G) on the WDS pump.
Illustration 125 | g03482383 |
- Fasten clips (1) and clip (3) to the inlet of the charge pump. Secure harness assembly (6) to the clips with cable straps (8) .
- Route the remainder of chassis harness assembly (6) along the truck chassis harness (A). Secure the cable with cable straps (8) .
Illustration 126 | g03424185 |
- 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) .
- 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.
Illustration 127 | g03358058 |
Illustration 128 | g03422687 |
- 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.
- 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) .
Illustration 129 | g03358056 |
- 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) .
- 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) .
Illustration 130 | g03362980 |
- 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) .
Illustration 131 | g03362968 |
- Route harness assembly (6) up and over the WDS hydraulic tank. Secure the cable with clip (2) and cable straps (8) .
Illustration 132 | g03358055 |
- 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.
- 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) .
Illustration 133 | g03358180 |
Rear Hydraulic Manifold Installation
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     |
( 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.
- 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.
Illustration 134 | g03357466 |
Rear Hydraulic Manifold (C) |
Illustration 135 | g03357467 |
- Locate adapters (6) for the spray head pressure lines. Install seal (7) on each adapter.
Illustration 136 | g03357469 |
(A) Spray head open port (B) Spray head close port |
- 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.
- 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.
Illustration 137 | g03357470 |
- 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) .
- Install adapter (14) with seal (13) in each side of manifold (2). Repeat this step for both sides of all the manifolds.
Illustration 138 | g03357471 |
- 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)
- Spray valve "5A" (D) - open (B) line of #5 spray head (T)
Illustration 139 | g03357473 |
(A) Spray head - open "A"port (B) Spray head - close "B"port |
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" |
Illustration 141 | g03357478 |
(P) Spray head "2" (Q) Spray head "3" (R) Spray head "6" (S) Spray head "4" (T) Spray head "5" |
- Install adapter (16) with seal (15) in spray head pilot return port (U) of rear hydraulic manifold (A) .
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 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.
- 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) .
Illustration 143 | g03357481 |
(W) Spray head pilot return fitting (black) (X) Spray head pilot supply fitting (brown) |
- 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) .
- Clamp the spray head pilot hoses to water tank with clips (22). Secure the clips in place with bolts (23) and washers (24) .
Illustration 144 | g03357482 |
Rear Harness Assembly Installation
Install Rear Hydraulics Control Group Mounting Plate
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     |
- 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.
Illustration 145 | g03357483 |
- Fasten plate assembly (1) in place with four bolts (3) and four washers (2) .
Install Rear Electrical Control Group
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     |
- Mount control group (5) to plate assembly (1), with the connectors pointing down.
Illustration 146 | g03357484 |
- Insert spacers (4) between control group (5) and plate assembly (1) .
Illustration 147 | g03357485 |
- Fasten control group (5) to plate assembly (1) with four bolts (7) and four washers (6) .
Connect Rear Control Harness Assembly
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     |
- Connect harness assembly (9) to control group (5) .
Illustration 148 | g03357488 |
- Remove plug and install pressure sensor group (8) on the motor inlet pressure tap.
Illustration 149 | g03357487 |
- Route harness assembly (9) to sensor group (8). Connect the harness assembly to the pressure sensor.
- Install sensor group (10) on the rear spray bar.
Illustration 150 | g03362982 |
- Route harness assembly (9) to sensor group (10). Connect the harness assembly to the pressure sensor.
- 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.
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" |
- 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
- Spray valve "5A" (A) - J750-OR wire
- 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.
Illustration 152 | g03361304 |
Install Straps Along Harness Assembly
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     |
- Attach clips (13) to the rear of water tank with bolts (12) and washers (17).
Illustration 153 | g03357493 |
Rear of Water Tank |
- 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
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     |
- Connect cable (18) to connector (L) on bottom of control group (5) .
Illustration 154 | g03357496 |
- Route cable (18) with harness assembly (9) along the rear of the water tank.
Illustration 155 | g03357497 |
- 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) .
- Locate the portion of cable (18) that connects to the chassis harness. Plug this portion into the connector on bracket (M) .
Illustration 156 | g03357498 |
- 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) .
- Install clips (19) on the front of the water tank with bolts (21) and washers (20) .
Illustration 157 | g03362632 |
- 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
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     |
- 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.
Illustration 158 | g03357490 |
Illustration 159 | g03357491 |
- Connect harness assembly (9) to the pressure sensor (25) .
Front Hydraulic Manifold Installation
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     |
( 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. |
- 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.
Illustration 160 | g03357500 |
Front Hydraulic Manifold (A) |
Illustration 161 | g03357501 |
- Connect adapter (22) with seal (26) to spray head pilot supply port (B) .
Illustration 162 | g03357502 |
(B) Spray head pilot supply port (brown) (C) Spray head pilot return port (black) |
- 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) .
- 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) .
Illustration 163 | g03357503 |
- 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) .
Illustration 164 | g03357505 |
- Connect the brown hose assembly from spray head pilot supply coupling (B) to spray head pilot supply fitting (E) with seal (8) .
Illustration 165 | g03357506 |
(D) Spray head pilot return fitting (E) Spray head pilot supply fitting |
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 black hose assembly from spray head pilot return coupling (C) to spray head pilot return fitting (D) with seal (8) .
- 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.
Illustration 167 | g03357507 |
(F) Spray head "7" |
Illustration 168 | g03357508 |
(G) Spray head "1" |
- Install adapter (4) with seal (12) in spray head close port (H) and spray head open port (J) of spray valve "7" (F) .
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 (L) and spray head open port (K) of spray valve "1" (G) .
Illustration 170 | g03357510 |
Spray head "1" (G) (K) Spray head - open "A" port (L) Spray head - close "B" port |
- 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) .
- Install adapter (3) with seal (10) in each side of manifold (14). Repeat this step for both sides of both the manifolds.
Illustration 171 | g03357511 |
- 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)
- Spray valve "7B" (M) - close (H) line of #7 spray head (F)
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 |
- Clamp the hoses to the water tank with clips (7), bolts (5) and washers (13) .
Cannon Group Installation
Required Parts Group Number 421-8349 Water Cannon Ar (Rev. 02)     |
|||
---|---|---|---|
Tool     | Qty     | Part Number     | Part Description     |
1     | 1     | 422-5872     | Water Cannon Gp     |
- 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.
Illustration 173 | g03357513 |
Illustration 174 | g03357514 |
Note: This safety message is located on the cannon.
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 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.
Illustration 175 | g03357515 |
- 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.
Illustration 176 | g03357516 |
Water Cannon Position on the Machine |
Illustration 177 | g03357517 |
- 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
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     |
( 1 ) | This component must be provided by the customer. |
- 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.
Illustration 178 | g03357525 |
- 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.
- "DOWN" hose - install one coupling (7) on one end and install one coupling (5) on the other end
- 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.
- "ON" hose - install one coupling (7) on each end of this hose
- 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)
- "DOWN" fitting (F)
Illustration 179 | g03357526 |
- 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) .
- 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.
- "DOWN" (J)
Illustration 180 | g03357527 |
- 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) .
- 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.
- "OFF" (N) - rod end of the hydraulic cylinder
Illustration 181 | g03357528 |
- 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) .
- Locate shut-off valve fittings on the front hydraulic manifold. The hydraulic ports are labeled as follows:
- "OFF" (R)
- "ON" (Q) .
- "OFF" (R)
Illustration 182 | g03357529 |
- 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) .
- Fasten the shut-off valve hoses and the cannon operation hoses to water tank with clips (13) .
Illustration 183 | g03357530 |
Front Harness Assembly Installation
Install Front Electrical Control Group Mounting Plate
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     |
- Mount plate assembly (1) to the front of the water tank.
Illustration 184 | g03357518 |
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 Front Hydraulics Control Group
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     |
- Mount control group (5) to plate assembly (1), with the connectors pointing down.
Illustration 185 | g03357519 |
- Insert spacers (4) between control group (5) and plate assembly (1) .
Illustration 186 | g03357520 |
- Fasten control group (5) to plate assembly (1) with four bolts (7) and four washers (6) .
Connect Front Control Harness Assembly
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     |
- Connect harness assembly (11) to control group (5) .
Illustration 187 | g03357522 |
- 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.
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 |
- 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.
- Spray valve "7B" (A) - J741-GY wire
- 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) .
Illustration 189 | g03357524 |
- 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.
Illustration 190 | g03367814 |
- Connect communication cable (K) to control group (5) .
Note: This harness was installed and routed with the rear control harness assembly.
Illustration 191 | g03362998 |
Cab and Chassis Electrical Installation
Installation of the Cab Bulkhead Plate
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     |
- Remove engine access panels (A) above the cab electrical cables in order to provide access to the cab wiring.
Illustration 192 | g02789989 |
- Locate bulkhead plate (B) .
Illustration 193 | g02789992 |
Bulkhead Plate Viewed From Inside The Cab |
Illustration 194 | g02789993 |
Bulkhead Plate Viewed From Right Side Of The Cab |
- Disconnect all of cables from bulkhead plate (B). Carefully label all of the cables in order to facilitate proper reconnection.
- Remove bulkhead plate (B) .
- Install bulkhead plate (1) with the existing hardware. Reconnect all the wiring connections on both sides of the plate.
Illustration 195 | g03422848 |
Illustration 196 | g03424023 |
- Replace engine access panels (A) .
- Install gasket (2) to plate (1) .
Cab Electrical Systems Installation
Cab Preparation
- Lift two vents (B) in the right upper portion of gearshift trim panel (A). Cut the plastic ties that hold the vents in place.
Illustration 197 | g03467756 |
- Remove the mounting screws from trim panel (A). Lift the trim panel slightly to unplug the wires to the rocker switches and cigarette lighter.
- Move gearshift lever (C) to the "N" position in order to provide additional clearance.
Illustration 198 | g03467757 |
- Remove trim panel (A) .
Note: Maybe necessary to remove instrument panel in order to provide clearance to remove the trim panel.
- Remove the mounting screws from rear trim panel (D). Remove the rear trim panel.
Illustration 199 | g03467758 |
- Disconnect connectors (F) and (G) from control lever assembly (E) .
Illustration 200 | g03467759 |
- Remove the mounting screws from control lever assembly (E). Remove the assembly.
Illustration 201 | g03467760 |
Install Relay Assemblies
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     |
- 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).
Illustration 202 | g03424111 |
- 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
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     |
- 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).
Illustration 203 | g03423177 |
Install Plate Assembly
- 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) .
Illustration 204 | g03471856 |
Right rear view of cab - behind operator seat |
Install Gear Shift
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     |
- Install transmission control group (9) in the side console. Fasten the control group in place with four screws (10) .
Illustration 205 | g03467776 |
- 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).
Illustration 206 | g03467777 |
Install Display Module
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     |
- 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) .
Illustration 207 | g03423271 |
- Place monitor electronic control module (15) on plate assembly (11). Secure the monitor electronic control module with four screws (16) .
Illustration 208 | g03423337 |
Joystick Installation
Required Parts Group Number 433-2204 Wiring Gp Cab (Rev. 00)     |
|||
---|---|---|---|
Tool     | Qty     | Part Number     | Part Description     |
17     | 1     | 355-9440     | Joystick Control Gp     |
- Install joystick control group (17) on the transmission control group (9) using the bolts provided with the joystick.
Illustration 209 | g03467778 |
Cab Harness Installation
Install Cab Electrical Harness
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     |
- 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).
Illustration 210 | g03423375 |
- 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) .
Illustration 211 | g03423369 |
- 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) .
Illustration 212 | g03423417 |
Illustration 213 | g03423456 |
Illustration 214 | g03423471 |
- Install washer rocker switch (23) in bezel as shown.
Illustration 215 | g03488599 |
Location of Washer Rocker Switch |
- 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) .
Illustration 216 | g03423510 |
Install Keypad
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     |
- Install keypad module group (28) into trim panel cover (27) .
Illustration 217 | g03467796 |
- Install trim panel cover (27) .
Illustration 218 | g03467797 |
- Connect the keypad connector of cab harness assembly (18) to the connector on the bottom of the keypad module group (28) .
Illustration 219 | g03467798 |
- Install joystick film (32) for the joystick control group to cab trim group cover (27) .
Illustration 220 | g03423343 |
- 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).
Illustration 221 | g03422895 |
Illustration 222 | g03422905 |
Illustration 223 | g03749276 |
(33) 290-7164 Film X msn shift (34) 169-2876 Film Ident (12V) |
WAVS Camera System Installation (Optional)
Note: WAVS camera system installation is an optional attachment
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
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
Illustration 224 | g03381934 |
Right rear view of cab |
- Install display module group (4) on mounting location as shown in Illustration 225 to Illustration 227.
Illustration 225 | g03381925 |
Inside cab view |
Illustration 226 | g03389216 |
Right side of cab |
Illustration 227 | g03384064 |
Monitor mount location - right front 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.
Illustration 228 | g03389489 |
Right side view of cab |
Illustration 229 | g03391418 |
Right font 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.
Illustration 230 | g03384062 |
Right side view of cab |
Illustration 231 | g03389447 |
Right rear corner 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.
Illustration 232 | g03389443 |
Rear view of cab |
Illustration 233 | g03391398 |
Left rear view of cab |
- 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) .
Illustration 234 | g03389468 |
Right side view of cab |
Illustration 235 | g03391725 |
Cable Straps Installation
Required Parts Group Number 309-5339 Cab Wiring Gp (Rev 06)     |
|||
---|---|---|---|
Item     | Qty     | Part Number     | Part Description     |
(11)     | 19     | 7K-1181     | Cable Strap     |
- Fasten cable assembly (5) in place with cable straps (11) .
Illustration 236 | g03390145 |
- Fasten cab harness assembly (5) in place with cable straps (11) .
Illustration 237 | g03390526 |
Illustration 238 | g03390538 |
435-8004 Cab Wiring Group Installation
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     |
- Install washer rocker switch (2) in bezel as shown in Illustration 240.
Illustration 239 | g03381936 |
Right rear view of cab |
Illustration 240 | g03384726 |
Location of Washer Rocker Switch |
- 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) .
Illustration 241 | g03384115 |
Right front view of cab |
Illustration 242 | g03384111 |
Right side view of cab |
Illustration 243 | g03384113 |
Rear view of cab |
- Terminate "A-T1" pink wire to G5 of connector "MC-C90" (B) .
Illustration 244 | g03390716 |
Fuse box location in cab |
Illustration 245 | g03390698 |
- Route switch harness assembly (3) along the side of the main wiring harness as shown in Illustration 246.
Illustration 246 | g03383834 |
Right rear view of cab |
- Route switch harness assembly (3) to connector "CC-C2" (C) as shown in Illustration 247.
Illustration 247 | g03390820 |
Left rear view of cab |
- Terminate "A-T3" black wire to pin 1 of connector "CC-C2" (C) .
Illustration 248 | g03390733 |
- 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
Required Parts Group Number 435-8004 Cab Wiring Gp (Rev 00)     |
|||
---|---|---|---|
Item     | Qty     | Part Number     | Part Description     |
(4)     | 40     | 7K-1181     | Cable Strap     |
- Fasten cab harness assembly (3) in place with cable straps (4) .
Illustration 249 | g03390061 |
- Fasten cab harness assembly (3) in place with cable straps (4) .
Illustration 250 | g03390079 |
Right front view of cab |
Illustration 251 | g03390121 |
Right side view of cab |
- Fasten cab harness assembly (3) in place with cable straps (4) .
Illustration 252 | g03390102 |
Rear view of cab |
436-2187 Camera Wiring Group Installation
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.
- Mount switch (1) on the inside of the right frame rail. Connect cable assembly (A) to the "MON" connector on the switch assembly
Illustration 253 | g03384035 |
- Mount camera group (2) in location (B) as shown in Illustration 254.
Illustration 254 | g03384037 |
Rear View 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.
Illustration 255 | g03384039 |
Top of Water Tank |
- 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.
- Camera "1" (B) - connect to terminal "C1"
- 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
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.
- Mount switch (1) on the inside of the right frame rail. Connect cable assembly (A) to the "MON" connector on the switch assembly
Illustration 256 | g03384035 |
- Mount camera group (2) in location (B) as shown in Illustration 257.
Illustration 257 | g03384037 |
Rear View 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.
Illustration 258 | g03384039 |
Top of Water Tank |
- 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.
- Camera "1" (B) - connect to terminal "C1"
- 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
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.
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. |
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
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     |
Illustration 259 | g03385004 |
Parts Identification |
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) .
- Position nozzle (26) in a horizontal position that is less than 3.0m (10 ft) away from washer bottle group (28) .
- 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.
- Weld bosses (3) onto the frame in order to mount washer bottle group (28) .
Illustration 261 | g03383209 |
Location of Washer Bottle |
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) |
- 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) .
- 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.
Show/hide tableIllustration 263 g03384989
Typical Installation of the Nozzle
- Nozzle (26) will need to be angled at 45 degrees from the surface of the lens.
- Mount spray nozzle (26) so that the projection of the spray cuts at the base of the glass.
Show/hide tableIllustration 264 g01338194
Nozzle
- For optimal performance install nozzle (26) within 25 mm (1 inch) of the camera lens.
- Install sensor harness assembly (C) along the WDS chassis harness on the side of the frame rail.
Illustration 265 | g01341873 |
Typical Installation of the Sensor Harness Assembly |
- 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.
Illustration 266 | g03396487 |
(C) 419-5591 Sensor harness assembly (D) Connector plug |
- 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.
Illustration 267 | g03395944 |
- 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.
- 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.
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.
- 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.
- Press menu button (C) on the MD3 display module.
Illustration 269 | g03358191 |
- 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.
- In the "Adjust" screen, press "OK" button (E) to select the "SetUp" menu.
Illustration 270 | g03358192 |
- 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.
Illustration 271 | g03358193 |
- Select the "Truck Model" option in the "SetUp" menu. Press "OK" button (E) .
Illustration 272 | g03697620 |
- Select the truck model and press "OK" button (E) .
Illustration 273 | g03358195 |
- Select the "Spray Configuration Set Up" option in the "SetUp" menu. Press "OK" button (E) .
Illustration 274 | g03697624 |
- Scroll down and select the spray configuration for the truck. Press OK button (E) .
Illustration 275 | g03697629 |
- Select "Water Pump Selection" then choose type of pump.
Illustration 276 | g03697664 |
Illustration 277 | g03697699 |
Illustration 278 | g03697665 |
Illustration 279 | g03697667 |
Illustration 280 | g03697668 |
Illustration 281 | g03697669 |
Illustration 282 | g03697708 |
- Select "Spray Head Type" then choose type of spray head.
Illustration 283 | g03697710 |
Illustration 284 | g03697715 |
- Select the "Tank Lift Option" option in the "SetUp" menu. Press "OK" button (E) .
Illustration 285 | g03697720 |
Illustration 286 | g03697727 |
- 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.
Illustration 287 | g03358201 |
- If the water cannon is installed as part of the system, select "Cannon Install Option" in the "SetUp" menu. Press "OK" button (E) .
Illustration 288 | g03697729 |
- Scroll down and select the "Installed" option. Press "OK" button (E) .
Illustration 289 | g03358203 |
- Scroll down and select the "Momentary Single" option. Press "OK" button (E) .
Illustration 290 | g03697730 |
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.
Illustration 292 | g03697732 |
Illustration 293 | g03358204 |
- Select the "Manual Mode Enable" option in the "SetUp" menu. Press "OK" button (E) .
Illustration 294 | g03697733 |
- Scroll down and select the "Enabled" option. Press "OK" button (E) .
Illustration 295 | g03358206 |
- Select the "Manual Speed Deactivation" option in the "SetUp" menu. Press "OK" button (E) .
Illustration 296 | g03358207 |
- 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.
Illustration 297 | g03358209 |
- Select the "Intermittent Mode Enable" option in the "SetUp" menu. Press "OK" button (E) .
Illustration 298 | g03358212 |
- Scroll down and select the "Enabled" option. Press "OK" button (E) .
Illustration 299 | g03358213 |
- If the PIN code needs to be changed, select the "Config Change PIN code" option in the "SetUp" menu. Press "OK" button (E) .
Illustration 300 | g03358214 |
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.
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     |
- 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.
Illustration 301 | g03860179 |
Illustration 302 | g03860180 |
View (A-A) |
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.
- 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."
- 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.
Illustration 304 | g03358216 |
- Press head clean button (E) on the keypad. in order to activate the head clean mode.
Illustration 305 | g03358218 |
- 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.
- Press cannon mode button (G) .
Illustration 306 | g03358219 |
- Pull trigger (H) on the joystick to open the butterfly valve.
Illustration 307 | g03358222 |
- 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.
Illustration 308 | g03358223 |
Illustration 309 | g03375251 |
Rotation Direction Indicator |
Illustration 310 | g03375247 |
Clockwise Pump Shaft Rotation |
- 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.
Note: Running the water pump backwards may loosen the impeller bolt.
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.
- In the "Main" display screen, press "F1" button (A) to select the "Adjust" menu.
Illustration 311 | g03358226 |
- In the "Adjust" screen, scroll down and press "OK" button (E) to select the "Spray Head Calibration" menu.
Illustration 312 | g03358227 |
- 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.
Illustration 313 | g03358228 |
- 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.
Illustration 314 | g03358229 |
- Scroll down and select the "Enable" option. Press "OK" button (B). Press "back" button (E) to exit the screen.
Illustration 315 | g03358230 |
- 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.
Illustration 316 | g03358231 |
- 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.
- 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.
Illustration 317 | g03358233 |
Water Tank Sensor Calibration
- Press "F1" button (A) to display the tank level screen.
Illustration 318 | g03358234 |
- Fill the water tank to a minimum level of approximately 1100 to 1900 L (300 to 500 US gal).
- Press Menu button (B) to open the main display page.
Illustration 319 | g03358235 |
- 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) .
Illustration 320 | g03358237 |
- Enter the PIN code. Use up button (E) and down button (C) to select a digit. Use "OK" button (D) to enter the digit.
- Scroll down to the "Tank Empty Value" option. Press "OK" button (D) .
Illustration 321 | g03358238 |
- 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).