F 2899 PDF

Form Number F-2899 Issue Date: Sept 22, 2020
Revision Date: Aug 16, 2021
Medium-Duty Model T-Transmissions

Overhaul Instructions
Waterous Company • 125 Hardman Avenue South • South Saint Paul, MN 55075 • (651) 450-5000
www.waterousco.com
Table of Contents
Safety 4 Assembly 15
Safety Precautions 4 Preparing to Assemble the Transmission 15
Tools Required 15
Introduction 5

Best Practices 15

Using this Document 5
Assembling the Transmission Components 15

Viewing the Document Electronically 5
Installing the Transmission 15

Printing the Document 5
Understanding the Illustrations 15

Symbols 5
CP-2, CP-4, CLR, CLV, and CLS Pumps with One Piece Impeller Shaft 16

Identifying Exterior Components—Pump Side 6
Assembling the Bearing Housing 17

Identifying Exterior Components—Input Side 7
Assembling the Impeller Shaft 18

Identifying Exterior Components—Oil Pan Side 8
Installing the Driven Gear Assembly 19

Disassembly 9 Installing the Drive Components 20

Preparing to Disassemble the Transmission 9 Installing the Bearing Cover 21
Tools Required 9 Installing the Oil-Pan
22
Preparing the Apparatus 9 Installing the Oil Seal 23
Best Practices 9 Installing the Bellhousing Adapter 24
Removing the Transmission 9 CP-3 Pump with Separable Shaft 26
Disassembling the Transmission Components 9 Assembling the Bearing Housing 27
Draining the Gear Oil 10 Assembling the Driven Shaft 28
Removing the Bellhousing Adapter 11 Installing the Driven Shaft Assembly 29
Removing the Oil Pan 12 Installing the Drive Components 30
Removing the Drive Components 13 Installing the Bearing Cover 31
Removing the Impeller Shaft Assembly 14 Installing the Oil Pan
32
Installing the Oil Seal 33
Installing the Bellhousing Adapter 34
Adding Oil to the Transmission 35
Safety Introduction Disassembly Assembly
Safety Precautions
• Read and understand this document before you begin the overhaul.
• Read and understand all the notices and safety precautions.
• Be aware that these instructions are only guidelines and are not meant to be
definitive. Contact Waterous when you have questions.
• Do not overhaul this equipment if you are not familiar with the tools and skills
needed to safely perform required procedures.
• Do not modify the equipment.
Hot Surface
• Waterous reserves the right to make modifications to the instructions without
notice.
• Hot surface can burn you.
• Do not touch the surface
during operation—allow
it to cool after operating.
High Pressure
• Liquid ejected at high
pressure can cause
serious injury.
• Drain the pump after use
and before servicing.
4 | 36
Use this document to overhaul your Waterous equipment. Please understand Symbols
the following conditions:
Symbols are use to illustrate additional tools or operations that are required to
• Be aware that these instructions are only guidelines and are not meant to be complete the instruction.
definitive. Contact Waterous when you have questions.
Arbor press—This symbol tells you to use an arbor press to
• Understand that your configuration may require additional steps, that are not complete this step.
described in the illustrations or instructions, to perform the overhaul.
• The equipment described in this document is intended to be overhauled by
a person or persons with the necessary skills and knowledge to perform the Discard—This symbol tells you to discard or recycle the part in
overhaul. accordance with local regulations.
This document is divided into the following sections:
Safety Finger tight, then quarter turn—This symbol tells you to secure the
hardware to finger tight, then use a wrench to turn the hardware
This section describes general precautions and alert symbols that are in this
an additional quarter turn.
document.
High-pressure grease—This symbol tells you to apply high-
Introduction
pressure grease to the surfaces that you are pressing together.
This section is an overview of the document.
Disassembly
Lubricant—This symbol tells you to apply an appropriate lubricant
This section describes disassembly procedures.
to the part.
Assembly
This section describes assembly procedures. Sealant—This symbol tells you to apply an appropriate sealant to
the part.
Using this Document
Use the guidelines below when viewing this document.
Torque to specification—This symbol tells you to torque the
Viewing the Document Electronically hardware to the specified value.
• View this document in landscape orientation.
• Use the table of contents to navigate directly to that section.
• Text with this appearance is linked to a reference.
Printing the Document

• The document is viewed the best when printed in color.
• The print on both sides and flip on long edge features can provide the
best results.
• Use a 3-ring binder to store the document.
5 | 36
Identifying Exterior Components—Pump Side

Use the illustration to identify various components
on the transmission.
1 Mounting hardware
10
2 Bearing housing
3 Impeller shaft—varies by application
4 Oil level plug—location varies by application
5 Bearing cover
6 Oil level plug—location varies by application
1 9 7 Serial number plate
8 Case
9 Oil fill plug—location varies by application
10 Bellhousing adapter—varies by application
2
8
3
7
4
6 | 36
Identifying Exterior Components—Input Side

1 Bellhousing adapter hardware
2 Drive shaft
7 | 36
Identifying Exterior Components—Oil Pan Side

1 Oil pan hardware
2 Oil pan drain
3 Oil pan
4 Breather—location varies by application
5 Oil pan cooler fitting—optional
6 Oil drain plug—location varies by application
2
5
3
8 | 36
Preparing to Disassemble the Transmission Removing the Transmission

• Read and understand the instructions before disassembling the equipment. Removing the transmission for overhaul varies by application. Your application
• Prepare a workspace suitable to accommodate and support the transmission. may require components such as cooling lines, support brackets, plumbing
• Gather the necessary tools, cleaning cloths, brushes, and penetrating fluids. connections, and other accessories be removed or disconnected before
removing the transmission.
• Understand that your configuration may require additional steps that are not
described in the illustrations or instructions to perform the disassembly. Furthermore, some applications require you to remove the transmission and
pump together before separating the transmission from the pump. Other
• This equipment is intended to be disassembled by a person or persons with
applications allow you to separate the transmission without removing the pump
the basic knowledge of servicing similar equipment. Contact Waterous with
from the apparatus. Refer to the pump instructions before proceeding.
questions.
Record the process used to remove the equipment from the apparatus. Use
Tools Required this information to install the equipment into the apparatus after the overhaul.
• Typical automotive mechanics hand tools.
Disassembling the Transmission Components
• Suitable arbor press.
• Refer to the service parts list (SPL) for part identification and disassemble
• Suitable support and lifting equipment. order.
Preparing the Apparatus • The SPL specific to your application is determined by the following:
• Park the apparatus on a level surface in a well-lit area. • The pump connected to the transmission.
• Engage the parking brake. • The transmission drive method.
• Shut off the engine and remove the key from the ignition switch. Note: Documents specific to your application are available through the
MyWaterous login at Waterousco.com by entering the serial number
• Allow the apparatus to cool before servicing.
for your system. Depending on the application, the serial number for
Best Practices your equipment is located on the operator panel, or the pump, or the
transmission, or some combination of the three.
• Remove any dirt, sand, grease, or oil from the enclosure before you
disassemble the transmission. Surface debris can transfer into the pump • Use established industry practices to disassemble the transmission.
interior and prematurely wear internal parts. • Record or mark components as you remove them to make sure that you
• Only use a clean, lint-free cloth, a debris-free work surface, and properly install them in the same orientation.
maintained tools to perform the disassembly. • Discard or recycle drained fluids collected during the overhaul in accordance
• Replace any gaskets and O-ring seals during the overhaul. with local regulations.
• Do not reuse the self-locking nuts.
• Apply penetrating oil to screws and nuts before disassembly.
9 | 36
Draining the Gear Oil

Use the illustrations and instructions to drain the
gear oil.
Note: The illustrations may not represent the
orientation of your specific transmission.
Refer to the SPL for your application to locate
the oil drain plug.
1 To drain the gear oil, do the following:
• Locate the oil level plug to approximate the
amount of oil in the transmission.
• Place a suitable container under the
transmission to collect the drained oil.
• Locate and remove the oil drain plug.
• Allow the oil to drain.
2 Install the oil drain plug.
Note: Make sure that you do not over-tighten
the plug.
1
2
10 | 36
Removing the Bellhousing Adapter

Use the illustrations and instructions to remove the
bellhousing adapter.
1
1 To separate the transmission from the engine,
do the following:
2 • Drain any fluids, then disconnect the cooling
lines that will be affected when you separate
the transmission and engine.
• Remove the hardware securing the
bellhousing adapter to the engine.
2 Remove the bellhousing adapter hardware.
3 Remove the bellhousing adapter and bushing.
4 Press the bushing out of the bellhousing
adapter.
5 Remove and discard the oil seal.
Note: You can also remove the oil seal during
the drive shaft disassembly.
11 | 36
Removing the Oil Pan

oil pan.
1 Remove the hardware securing the oil pan to
the transmission case.
2 Remove and discard the O-ring.
12 | 36
Removing the Drive Components

drive components.
2
1 Remove the hardware and bearing cover
1 from the transmission case, then remove and
discard the O-ring.
2 Remove the drive shaft retaining ring.
3 Press the drive shaft from the assembly.
4 Remove the drive gear.
5 Press the drive shaft bearing from the case.
13 | 36
Removing the Impeller Shaft Assembly

impeller shaft assembly.
1 To remove the impeller shaft assembly from
the transmission case, do the following:
• Insert locally sourced jacking screws (3/8-24
1
x 1-1/2 inches) into the jacking screw holes.
• Alternate applying a quarter turn to each
jacking screw until the impeller shaft
assembly is free from the case.
2 After removing the impeller shaft assembly, do
the following:
• Remove and discard the O-ring and oil seal.
• Use an arbor press to separate the
remaining components.
14 | 36
Preparing to Assemble the Transmission Assembling the Transmission Components

• Read and understand the instructions before assembling the transmission. • Refer to the service parts list (SPL) for part identification.
• Prepare a workspace suitable to accommodate and support the transmission. • The SPL specific to your application is determined by the attached pump.
• Gather the necessary tools and assembly aids. Note: Documents specific to your application are available through the
• Gather the overhaul components such as, lubricant, bearings, seals, MyWaterous login at Waterousco.com by entering the serial number
O-rings—only use equivalent components. for your system. Depending on the application, the serial number for
• Understand that your configuration may require additional steps that are not your equipment is located on the operator panel, or the pump, or the
described in the illustrations or instructions to perform the assembly. transmission, or some combination of the three.
• This equipment is intended to be assembled by a person or persons with the • Use established industry practices to assemble the transmission.
basic knowledge of servicing similar equipment. Contact Waterous for more • Tighten hardware to industry standard torque specification—unless otherwise
information. noted.
• Make sure that you do not over-tighten plugs.
Tools Required • Install retaining rings with the flat face toward the component you are
• Typical automotive mechanics hand tools. retaining.
• Suitable arbor press. • Replace items such as O-rings, bearings, gaskets, oil seals, lubricants, and
• Suitable support and lifting equipment. locknuts with their equivalent.
Best Practices Installing the Transmission

• Remove any dirt, sand, grease, or oil from the enclosure before you begin the Use the information that you recorded when you removed the equipment to
overhaul. Surface debris can transfer into the pump interior and prematurely install it into the apparatus.
wear internal parts.
• Replace any gaskets and O-ring seals during the assembly. Understanding the Illustrations
• Do not reuse the self-locking nuts. The assembly illustrations depict a typical application. Plugs, breathers, cooling
hoses and fittings are not illustrated—as they may be in a different location in
• Apply anti-seize to the self-locking nut threads before installation.
your application. Refer to the SPL for your application to identify the various
plug locations.
15 | 36
CP-2, CP-4, CLR, CLV, and CLS Pumps with One Piece Impeller Shaft
16 | 36
Assembling the Bearing Housing
Use the illustrations and instructions to assemble
the bearing housing.
1 Apply grease to the outer bearing race, then
press the bearing into the bearing housing.
2 Apply lubricant to the O-ring groove, then
install the O-ring around the bearing housing.
17 | 36
Assembling the Impeller Shaft
the impeller shaft.
1 1 Apply grease to the inner bearing race, then
press the driven gear and bearing together.
2 Insert the key into the keyway.
4 3 Apply grease to the shaft, then align the
driven gear with the key on the shaft and
press the components together.
100 ft-lb 4 To install the impeller shaft hardware, do the
(136 N∙m) following:
• Install the washer onto the shaft.
• Apply medium-duty threadlocker to the
5
threads, then install the locknut.
2 • Torque the locknut to 100 ft-lb (136 N∙m).
5 Apply grease to the shaft, then install the
spacer.
6 Apply grease to the inner bearing race, then
press the shaft into the bearing house.
3 6
18 | 36
Installing the Driven Gear Assembly
Use the illustration and instructions to install the
impeller shaft assembly.
press the impeller shaft assembly into the
transmission case.
19 | 36
Installing the Drive Components
Use the illustrations and instructions to install the
drive shaft assembly and associated components.
4 1 To install the bearing, do the following:
• Apply grease to the inner and outer bearing
races.
• Press the bearing into the bore.
Note: The bearing should sit deeper than the
inner flange on the bearing cover.
1
2 To temporarily install the bearing cover, do the
following:
• Make sure that you removed the O-ring
5 from the bearing cover.
2 • Use the hardware that you removed earlier
to install the bearing cover.
3 To install the drive gear, do the following:
• Flip over the transmission case.
• Apply grease to the bore and keyway.
• Align the drive gear over the bearing.
4 To install the drive shaft, do the following:
• Install the key into the keyway.
• Apply grease to the drive shaft.
• Align the key on the drive shaft with the
6 keyway on the drive gear, then press the
assembly together.
5 To install the retaining ring, do the following:
3 • Remove the hardware and bearing cover.
6 Install the retaining ring.
20 | 36
Installing the Bearing Cover
bearing cover.
install the O-ring around the bearing cover.
2 Use the hardware that you removed earlier to
install the bearing cover.
21 | 36
Installing the Oil-Pan
Use the illustrations and instructions to install the oil
1 pan.
Note: Refer to the SPL for your application to
determine the orientation of the oil pan.
1 Apply lubricant to the O-ring, then install it
around the oil pan.
install the oil pan.
22 | 36
Installing the Oil Seal
Use the illustration and instructions to install the oil
seal.
1 Apply sealant to the oil seal, then install it onto
the impeller shaft.
Note: The oil seal should sit flush with the oil
seal housing.
23 | 36
Installing the Bellhousing Adapter
Use the illustrations and instructions to the install
the shaft at least 1/2 inch (12 mm) into the
bore.
2 Apply grease to the bushing, then press it into
3 the bellhousing adapter.
3 Use the hardware that you removed earlier
to secure the bellhousing adapter to the
transmission case.
1 4 Use the hardware that you removed earlier to
secure the bellhousing adapter to the engine.
24 | 36
Notes
CP-3 Pump with Separable Shaft
26 | 36

Assembling the Bearing Housing
the bearing housing.
press the bearing into the bearing housing.
install the O-ring around the bearing housing.
27 | 36

Assembling the Driven Shaft
the driven shaft.
1 Apply grease to the inner bearing race,
then press the driven shaft into the bearing
housing.
4 2 Apply grease to the shaft, then install the
spacer onto the shaft.
1
3 Apply grease to the inner bearing race, then
press the driven gear and bearing together.
4 Insert the key into the keyway.
5 Apply grease to the shaft, then align the
driven gear with the key on the shaft and
press the components together.
6 To install the driven shaft hardware, do the
following:
5 • Install the washer.
• Apply medium-duty threadlocker onto the
2 threads, then install the locknut.
• Torque the locknut to 100 ft-lb (136 N∙m).
100 ft-lb
(136 N∙m)
3
28 | 36

Installing the Driven Shaft Assembly
Use the illustration and instructions to install the
driven shaft assembly.
press the driven shaft assembly into the
transmission case.
29 | 36

Installing the Drive Components
drive shaft and associated components.
4 1 To install the bearing, do the following:
• Apply grease to the inner and outer bearing
races.
• Press the bearing into the bore.
Note: The bearing should sit deeper than the
inner flange on the bearing cover.
1
2 To temporarily install the bearing cover, do the
following:
• Make sure that you removed the O-ring
from the bearing cover.
2 5
• Use the hardware that you removed earlier
to install the bearing cover.
3 To install the drive gear, do the following:
• Apply grease to the bore and keyway.
• Align the drive gear over the bearing.
4 To install the drive shaft, do the following:
• Insert the key into the keyway.
• Apply grease to the drive shaft.
• Align the key on the drive shaft with the
6 keyway on the drive gear, then press the
components together.
5 To install the retaining ring, do the following:
• Remove the hardware and bearing cover.
3
6 Install the retaining ring.
30 | 36

Installing the Bearing Cover
bearing cover.
install the O-ring around the bearing cover.
install the bearing cover.
31 | 36

Installing the Oil Pan
Use the illustrations and instructions to install the oil
pan.
1
Note: Refer to the SPL for your application to
determine the orientation of the oil pan.
1 Apply lubricant to the O-ring, then install it
around the oil pan.
install the oil pan.
32 | 36

Installing the Oil Seal
Use the illustration and instructions to install the oil
seal.
the impeller shaft.
Note: The oil seal should sit flush with the oil
seal housing.
33 | 36

Installing the Bellhousing Adapter
Use the illustrations and instructions to the install
the shaft.
2 Apply grease to the bushing, then press it into
the bellhousing adapter.
3
3 Use the hardware that you removed earlier
to secure the bellhousing adapter to the
transmission case.
1 secure the bellhousing adapter to the engine.
34 | 36
Adding Oil to the Transmission

Use the illustrations and instructions to add oil to
1 the transmission.
Note: The illustrations may not represent the
orientation of your transmission. Refer to
the SPL for your application to locate the
oil fill and oil level plugs.
Refer to the documentation provided with
your equipment to determine the correct
type and amount of lubricant for your
application.
2 1 Remove and set aside the oil fill plug.
2 Remove and set aside the oil level plug.
3 Add lubricant to the transmission.
Note: After pouring some oil into the case,
allow it to settle before adding more to
avoid over-filling.
4 Install the oil level plug.
5 Install the oil fill plug.
4
35 | 36
Waterous Company
125 Hardman Avenue South
South Saint Paul, MN 55075
(651) 450-5000
www.waterousco.com

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Form Number F-2899 Issue Date: Sept 22, 2020

Revision Date: Aug 16, 2021

Medium-Duty Model T-Transmissions

Disassembly  9 Installing the Drive Components  20

Printing the Document

Identifying Exterior Components—Pump Side

Identifying Exterior Components—Input Side

Identifying Exterior Components—Oil Pan Side

Preparing to Disassemble the Transmission Removing the Transmission

Draining the Gear Oil

Removing the Bellhousing Adapter

Removing the Oil Pan

Removing the Drive Components

Removing the Impeller Shaft Assembly

Preparing to Assemble the Transmission Assembling the Transmission Components

Best Practices Installing the Transmission

CP-3 Pump with Separable Shaft

CP-3 Pump with Separable Shaft

CP-3 Pump with Separable Shaft

CP-3 Pump with Separable Shaft

CP-3 Pump with Separable Shaft

CP-3 Pump with Separable Shaft

CP-3 Pump with Separable Shaft

CP-3 Pump with Separable Shaft

CP-3 Pump with Separable Shaft

Adding Oil to the Transmission

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Disassembly 9 Installing the Drive Components 20