ATS Water boy User manual

11/10
/
NO
T
Thre
Plea
cust
o
the
e
WA
R
Exh
a
inje
c
/
2008
T
E:
A
mong
ad) tap an
d
se read all
o
mer, pass
e
nd.
R
NING: T
h
a
ust Gas T
e
c
tion (mixtu
r
Please re
a
Fig
u
other stan
d
a 21/64"
d
instruction
s
this manu
a
h
e ATS Wa
t
e
mperatur
e
r
es of wate
Installati
o
Water
All mak
a
d all inst
r
u
re 1 – W
a
dard tools,
d
rill bit to p
e
s
before st
a
a
l along to
t
t
er Boy is
d
e
(EGT). It
r with wind
s
o
n Manua
l
Boy - Sta
g
es and m
o
r
uctions b
e
a
ter Boy Ki
you will n
e
e
rform this
a
rting. If in
t
hem. The
d
esigned fo
is not to b
e
s
hield was
h
l
v1.3:
g
e 3
o
dels
e
fore insta
t Content
s
e
ed a 1/8"-
2
installation
stalling thi
s
re is a trou
b
r water inj
e
e
used for
w
h
er fluid).
U
1000
-
llation.
s
2
7 NPT (N
a
.
s
system fo
b
leshootin
g
e
ction to co
w
ater/meth
a
U
sing
-
102-930 - IN
S
a
tional Pipe
r a
g
section a
t
ntrol
a
nol
S
T
1
t

11/10/2008 1000-102-930 - INST
2
water/methanol, or any other mixture of water with combustible fluids, can
harm your vehicle's motor and the Water Boy components.Testing done by
ATS Diesel showed that injecting water/methanol causes a dangerous spike in
cylinder pressures. You can make more (and safer) power by adding fuel
through more aggressive E-Power Tuning and/or ATS Injectors/Fuel Systems
than you can by using water/methanol injection. The Water Boy can control the
increased EGT that would result from adding fuel.
DO NOT USE WATER/METHANOL WITH THE ATS WATER BOY
How the Water Boy Works
This kit is designed to progressively inject three stages of water. When the
system is armed with the power switch, the LED will be green. The first stage
activates when the EGT probe senses a temperature above the setting chosen
on the electronics box. A smaller "A" nozzle should be used for stage one if you
are using more than one size nozzle. When stage one is active, the LED will be
yellow. The second stage will activate when the EGT probe senses a
temperature above the setting for level two, AND approximately 10 psi of boost
or more (or 25 psi if the pink wire is not connected-See section below on Boost
Level Setting). The LED will change to Orange when Stage 2 is active (during
stage 2, the stage 1 nozzle will also be active). The third stage will activate when
the EGT probe senses a temperature above the box setting AND the boost
sensor measures approximately 15 psi (or 30-see Boost Level Setting section) of
boost or more. During stage 3, all three nozzles will be active and the LED will
be Red. When the tank is close to empty, the float switch will cut off supply power
to the pump. This will be indicated by a typical flickering of the LED. This will stop
pump “air-locking” which will help prevent the premature pump failure.
Boost Level Setting
In the Water Boy wiring harness, you will notice a purple wire. If you connect this
wire to a good ground the boost settings will be approximately 10 psi for stage 2
and 15 psi for stage 3. If this wire is not connected the boost setting will be
approximately 25 psi for stage 2 and 30 psi for stage 3. The harness is
assembled at ATS with the purple wire connected to ground. If the higher boost
levels are desired, then cut the purple wire. Choose the boost settings to suit
your vehicle’s performance. If the vehicle produces less than 35 psi of boost,
then use the lower settings.
Adjusting the Water Boy
The EGT settings at which each stage will activate can be adjusted to dial in the
Water Boy response to fit your needs and driving style. There are three small
Phillips head screws on the electronics board. Turning the screw counter-
clockwise will increase the temperature. Adjust the screws so that they will
activate progressively (stage one will be the lowest of the three temperatures).

11/10/2008 1000-102-930 - INST
3
Four nozzles are included with the kit, 1 "A" nozzle (smaller) and 3 "B" nozzles
(larger). ATS recommends installing an "A" nozzle for Stage 1 and "B" nozzles
for Stages 2 and 3. If more cooling is required from Stage 1, replace the "A"
nozzle with a "B" nozzle. If more cooling is required after adding the “B” nozzle
and adjusting the 3 stages with the EGT settings, you can get "C" and "D"
nozzles from ATS, however these are used on highly modified vehicles and
require precise EGT settings. Using 3 "B" nozzles with proper EGT settings will
effectively cool most applications.
NOTE: Solder and shrink-wrap all electrical connections (especially for all
connections made outside of the cab) for the most reliable results.
NOTE: When making the push-in connections with the 3/8" and 1/4" plastic line,
push the line in firmly and make sure the plastic line is pushed in all of the way (it
will go in approximately 1/2" to 3/4" into the fitting).
NOTE: Before drilling or installing self tapping screws, check both sides of the
work piece to check that no other vehicle systems are damaged during
installation.
Installation:
1. Please make sure no parts are missing from ATS Stage 3 WaterBoy Kit. A
complete corresponding list of parts can be found on page 11. Each bag in
Figure 1 represents a different subassembly.
2. Disconnect the (-) negative terminal from the battery(s).
3. Mount the Water Boy electronics box in a convenient location in the
engine compartment using the supplied hardware. Try mounting it such
that the adjustment screws can be accessed with a screwdriver.
4. Drill a 21/64" hole in the exhaust manifold and tap it to 1/8" x 27 NPT
(National Pipe Thread). ATS recommends removing the exhaust manifold
to do this. Drilling and threading can cause small metal chips to fall into
the manifold. If left inside, the chips can cause serious damage to your
turbocharger and exhaust. Make sure manifold is free of chips prior to
reinstallation.
5. Install the 1/8" NPT fitting supplied with the pyrometer probe.
6. Install the pyrometer probe into the NPT fitting.
7. Connect the Pyrometer 2-pin male socket to the corresponding electronics
box socket and connect the White wire ring terminal to a suitable ground.
8. Plug the 8-pin socket of the supplied wiring harness into the electronics
box.

11/10/2008 1000-102-930 - INST
4
9. Find a suitable/visible location to mount the L.E.D. such as the dash or a
gauge pillar.
10.Drill a hole just large enough to fit the plastic sleeve through and push the
LED through to secure it. A 1/4" drill bit will work best.
11.Find a suitable location for the supplied power switch and install it. The
switch requires a 13/16” hole to mount properly.
12.Feed the four-wire group (Red, Black, Yellow, Blue) extending from the
Water Boy harness through a rubber grommet in the firewall into the cab.
13.Connect the Red wire of the four-wire group to the center terminal of the
switch with a spade connector. The wire should be labeled; “To Middle
Terminal Switch”.
14.Connect the remaining three wires of the four-wire group to the L.E.D.
color for color.
15.Connect the supplied Black wire to the brass-colored terminal of the
switch with the spade connector. Connect the other end of the black wire
to a good ground under the dash.
16.Connect the supplied Pink wire to the remaining switch terminal and
attach it to a 12V source under the dash that is only energized when the
key is turned on. Use a voltmeter to find a suitable wire.
17.At a convenient location under the dash, cut the Pink wire connected to
the switch and splice in the supplied in-line fuse holder. Use the supplied
15A fuse.
18.Find suitable locations for both the pump and tank. Depending on the size
of the tank and the vehicle make, a spot under the hood might be hard to
find. If the tank cannot be mounted in the engine compartment, mount the
tank in the bed and the pump on the frame rail. Mount the tank above the
pump so that gravity will feed the pump (this will help eliminate "air-
locking" of the pump). If the tank will be mounted in the bed, mount it on
the same side as the intake manifold (Cummins- Driver’s side, Duramax-
Passenger’s side). This will make it easier to route the 3/8” plastic line.

11/10
/
Fig
u
1
2
2
2
2
2
N
n
3
2
2
/
2008
u
re 2 - Tan
k
mou
9.
A
ttach t
h
0.Extendi
n
RED 12
V
on the p
u
1.Mount t
h
manifold
2.Connect
to the p
o
the sup
p
and a 1
5
3.Connect
to the p
o
the sup
p
and the
3
4.Connect
ring ter
m
N
ote: If yo
u
ozzles and
0 regardin
g
5.Remove
intercool
intake s
y
engine.
6.Drill thre
e
spaced.
from the
"mock-
u
k
mounted
nted belo
w
h
e Black w
i
n
g from the
V
” extends
u
mp.
h
e solenoid
using sup
p
the Yello
w
o
sitive term
i
p
lied fuse h
o
5
Afuse.
the Yello
w
o
sitive term
i
p
lied fuse h
o
3
0A fuse.
the group
o
m
inal.
u
have a D
o
boost line
g
the boost
the Intake
e
r
pipe an
d
y
stem is ap
a
e
(3) 21/64
Keep in m
manifold a
u
p" the no
z
in front-p
a
w
on a su
p
i
re from th
e
Water Bo
y
from Rela
y
and relay
a
p
lied hard
w
w
wire from
i
nal on the
o
lder in a c
o
w
wire from
i
nal on the
o
lder in a c
o
o
f Black w
o
dge with
a
fitting. Ski
line.
manifold f
r
d
engine to
a
rt. Debris,
" holes in t
h
ind that th
e
good dist
a
z
zles. Mak
e
a
ssenger
s
p
port (Dur
a
e
pump to
a
y
harness,
a
y
1. Conne
a
ssembly
a
w
are.
Relay 2 la
battery. C
u
o
nvenient l
Relay 1 la
battery. C
u
o
nvenient l
ires to a g
o
a
n ATS Arc
-
p steps 25,
r
om the ve
h
prevent d
e
small or l
a
h
e manifol
d
e
nozzles a
n
a
nce. Plac
e
e
sure yo
u
s
ide corn
e
a
max)
a
chassis g
r
a
red wire l
a
ct this Red
a
s near as
p
beled “TO
u
t the Yell
o
ocation. U
beled “TO
3
u
t the Yell
o
ocation. U
o
od ground
-
Flow, it is
p
26, 27 bu
t
h
icle. Make
e
bris from
e
a
rge, can s
e
d
in positio
n
n
d the sup
p
e
the mani
u
have cle
a
1000
-
e
r o
f
bed a
n
r
ound
a
beled, “T
O
wire to th
e
p
ractical to
15A FUSE
o
wwire an
d
se the hol
d
3
0A FUSE
o
wwire an
d
se the hol
d
using the
a
p
re-tapped
t
you must
f
sure to bl
o
e
ntering wh
i
e
verely da
m
n
s that are
p
ly lines wi
l
fold on th
e
a
rance bef
o
-
102-930 - IN
S
n
d pump
O
PUMP-
e
Red wire
the intake
BATTER
Y
d
splice in
d
er provide
d
BATTER
Y
d
splice in
d
er provide
d
a
ttached
for the
f
ollow step
o
ck or cove
r
i
le the
m
age the
properly
l
l extend o
u
e
engine t
o
o
re drillin
g
S
T
5
Y
”
d
Y
”
d
r
u
t
o
g
.