Waterous K Series Manual

K, T, TK, TA and KC Series
Operation and Maintenance Instructions
Table of Contents
Introduction...........................................................................................1
General Description for K, T , TK & TA Series .................................1
K Series Transmission . . . . .. . . .. . . .. . . .. . . .. . . .. . . . .. . . .. . . .. . 1
T, TA Series Transmission ...................................................................1
TK Series Power Take-Off....................................................................1
Tachometer Drive . . . . .. . . .. . . .. . . .. . . .. . . .. . . . .. . . .. . . .. . . .. . 1
Operating Instructions for K, T , TK & TA Series . . . . . . .. . . .. . . . 2
Maintenance.........................................................................................2
Lubrication............................................................................................2
General Description for KC Series.....................................................3
Tachometer Drive . . . . .. . . .. . . .. . . .. . . .. . . .. . . . .. . . .. . . .. . . .. . 3
Operating Instructions for KC Series...............................................3
Maintenance.........................................................................................4
Hydraulic Fluid Repair...........................................................................4
Read through the Operation instructions carefully
before using your Waterous Transmission.
NOTE: Instructions subject to change without notice F-1031, Section 2206 (Revised: 3/13/20)
Waterous Company, 125 Hardman Avenue South, South St. Paul, Minnesota 55075 USA [phone]
www.waterousco.com

F-1031, Section 2206
Page 1 of 4
Introduction
This section contains operation and maintenance instructions for Waterous
K, KC, T, TK and TA series gear drive transmissions. The term “series” used
here refers to related transmissions or a basic type of transmission used with
several types of pumps. The T, TA series transmission, for instance, has two
basic gear sizes and several different bellhousings and drive shafts available
for the various pump and engine sizes, yet all of the same basic construction.
Although the transmissions differ in detail, they are all similar in general de-
sign.
The information in this section applies to the transmission and related equip-
ment only. Refer to the pump instructions for data on the rest of the main
pump, and to the accessory instructions for information on the pump acces-
sories.
For E301-A and E302-A motor pump models, refer to instructions for T series
transmissions.
General Description for K, T, TK & TA Series Transmissions
Each series is available with different shafts and gears for medium and heavy
duty applications. The medium duty transmission is normally used for the
smaller, high speed pumps rated 500 gpm or less, while the heavy duty trans-
mission is intended mainly for larger, slower pumps rated at 500 gpm through
1250 gpm. An extra heavy duty K series transmission is available for pumps
rated above 1250 gpm.
The two helical gears in each transmission are properly sized to provide an
adequate safety factor. Ball bearings are used throughout each transmission.
Several gear ratios are available to permit closely matching the impeller shaft
speed and power requirements to individual engine performance. The vari-
ous transmissions are described in greater detail below:
K Series Transmission
This transmission is designed primarily to be driven by a power take-off or
power divider. The medium-duty case has a 1-1/8 in. straight keyed shaft
while the heavy duty case has a 1-3/8 in. 10 spline shaft, and the extra heavy
duty case has a 1-1/2 in. 10 spline shaft.
TK Series Power Take-Off
This PTO allows the rear mounting of a fire pump. TK PTO is identical to the
K-series, except that it has companion flanges on the drive and driven shafts.
T, TA Series Transmission
This case is identical to the K series, except that it includes a bell housing
flange and the proper drive shaft for direct mounting on an engine bell hous-
ing.
Mechanical Tachometer Drive
A tachometer drive is available as an option for the K and T series transmis-
sions. This accessory includes a drive gear and a driven gear with extension
which operates at half the input shaft speed. The driven gear extension pro-
trudes from its housing at a 15 degree angle from horizontal.

F-1031, Section 2206
Page 2 of 4
CAUTION
Oil temperature hazard.
May cause premature seal wear and
0
damage.
Oil temperature should not exceed 250° for an extended period
of time in order to prevent seal wear and damage.
CAUTION
If oil level is low, locate the source of the leak and repair. If the
oil level is high, loosen the drain plug until the oil drops to the
proper level. If excessive water drains out, change the oil and
determine the source of the water leakage and repair.
IL2155
Operating Instructions for K, T, TK & TA Series Transmissions
Since the K, T, TK and TA gear cases are designed to be driven by a PTO,
power divider, or directly by the engine crankshaft, refer to the instruction manual supplied with the unit or to the apparatus manufacturer's manual for specific information.
Lubrication Maintenance
An oil splash system, within the gear case, lubricates the gears and other
moving parts. Check oil level monthly by removing the square head pipe plug
on side of gear case marked OIL LEVEL. The oil should be level with the bot-
tom of the hole.
To add oil, remove filler plug or breather at top of gear case, and pour oil
through opening until oil comes out the oil level hole. DO NOT OVERFILL.
Use a SAE 80W-90 gear oil.
Drain gear case by removing magnetic drain plug from bottom, and refill with
new lubricant annually or after each 100 hours of operation, whichever
comes first. (Under severe service conditions, where pump has been
used continuously at high output, change oil more frequently.) The capacity
is approximately one quart. Be sure to clean drain plug and breather.
Figure 1. K Series Transmission Figure 2. T Series Transmission
(Vertical Mounting Position) (Vertical Mounting Position)
IL1529
Figure 3. TK Series Power Take-Off
(Vertical Mounting Position)
IL3885
Figure 4. TA Series Transmission
(Vertical Mounting Position)
NOTE: Location of oil level plug, drain plug and breather will vary depending on the transmission mounting position. See the Service Parts List drawing
for further details.
NOTICE
NOTICE

F-1031, Section 2206
Page 3 of 4
General Description for KC Series Transmission
The KC transmission is similar to the K and T transmission discussed earlier,
but includes a hydraulically engaged multiple disc wet clutch. A 12 volt hy-
draulic pump with control switch and indicator light allows the operator to en-
gage or disengage the clutch with the movement of a toggle switch.
Electronic Tachometer Drive
An electronic tachometer with a magnetic pick-up is available as an option for
the KC transmission. This electronic pick-up senses the impeller shaft speed
not the input shaft speed.
The magnetic pick-up in the transmission mates with an Amphenol connector
(P/N MS3106A-10SL-4S). This connector may be wired to a wall mount re-
ceptacle on the operator's panel with a cable available from Waterous Com-
pany.
The number of teeth on the driven gear (pulse generator) varies with the dif-
ferent gear ratios and affects the frequency that the tachometer picks up.
The number of teeth on the driven gear can be determined from the table be-
low.
Ratio
3.40
2.83
2.45
2.14
1.88
1.65
1.56
1.38
1.30
1.16
Number of
Teeth
25
18
20
22
24
26
27
29
30
32
Correction
Factor (K)
2.4
3.333
3.0
2.727
2.5
2.308
2.22
2.07
2.0
1.875
The rotational speed of the impeller shaft can be calculated by multiplying the
frequency from the tachometer sensor by the correction factor, K.
(Hz) x K = RPM
To Engage Clutch
Operating Instructions for KC Series Transmission
To Disengage Clutch
Set switch in the engage position. This will turn the hydraulic unit on to engage
the clutch. Once the clutch is engaged, the green light will turn on, the hydrau-
lic pump will stop and the system will maintain the fluid pressure.
Set switch in the disengaged position.
Clutch engagement and disengagement is only recommended at low engine
speeds. The operator should be aware of the resulting pump load and the re-
lated effects before operating the clutch.

F-1031, Section 2206
Page 4 of 4
Maintenance
An oil splash system, within the gear case, lubricates the gears and other
moving parts. Check oil level monthly by removing the square head pipe
plug on side of gear case marked OIL LEVEL. The oil should be level with
the bottom of the hole.
Figure 4. KC Transmission (Vertical Mounting Shown)
Electronic Tachometer Sensor
To add oil, remove filler plug or breather at top of gear case, and pour oil
through opening until oil comes out the oil level hole. DO NOT OVERFILL.
Use SAE 80w-90 gear oil.
Drain gear case by removing magnetic drain plug from bottom, and refill with
new lubricant after each accumulated 100 hours of pump operation, or at
least every spring and fall. (Under severe service conditions, where pump
has been used continuously at high output, change oil more frequently.)
The capacity is approximately 2-1/4 quarts. Be sure to clean drain plug and
breather.
Hydraulic Fluid Reservoir
Keep the fluid reservoir of the hydraulic power unit filled. The capacity is 1/2
quart. Drain and replace the fluid only if it becomes dirty or contaminated. Use
ATF (Automatic Transmission Fluid) or equivalent.
Annually check accumulator's gas pre-charge pressure.
1. Bleed off hydraulic system pressure.
2. If the gas precharge pressure is below 100 psi., the
accumulator should be replaced.
Figure 5. KC Hydraulic Pump Shift Unit
Pressure Adjusting Screw.
Factory Set at 525 psi.
If Adjustment is Required,
Turn Clockwise to Increase
Pressure.
Pressure Switch
IL1527 IL2175
CAUTION
Oil temperature hazard.
May cause premature seal wear and
0
damage.
Oil temperature should not exceed 250 for an extended period
of time in order to prevent seal wear and damage.
If foil level is low, locate the source of the leak and repair. If the
oil level is high, loosen the drain plug until the oil drops to the
proper level. If excessive water drains out, change the oil and
determine the source of the water leakage and repair.
NOTICE
NOTICE