Waterous TC20 Series User manual

Read through the safety information
and overhaul instructions carefully
before repairing your Waterous TC20
Power Take-Off.
NOTE: Instructions subject to change without notice
Waterous Company, 125 Hardman Avenue South, South St. Paul, Minnesota 55075 USA [phone]
www.waterousco.com
T-365 (Revised: 9/24/20)
Table of Contents
TC20 Chain Driven Power Take-Off
Overhaul Instructions
Section Page
Introduction 4
Ordering Repair Parts 4
General Information 5
Special Tools 6
Disassembly See Page 2
Reassembly See Page 3

Page 2 of 75T-365
Table Of Contents
Disassembly
Drain Fluid from Transmission 9...................
Disconnect Output Shaft
End Yoke Output 10............................
Hydraulic Pump on Rear or Front Output 10........
Disconnect Optional Accessories:
Tachometer Cable 11...........................
Drain Valve 11.................................
Priming Pump:
Disconnect Wiring and Hoses 11.................
Remove from Transmission 11..................
Shift Unit 12...................................
Oil Temperature Sensor 12......................
Eclipse™ ES CAFS on Rear Output:
Draining Compressor and Oil Cooler 13...........
Removal of Air Filter, Hoses and Cables 14........
Disconnect Wiring 15...........................
Remove PTO from Vehicle 16...........
Remove Eclipse™ ES Unit from PTO 17.
Removal of Driveline from Case:
End Yokes or Companion Flanges 18.............
Oil Pan 18.....................................
Chain 18......................................
Shift Unit 19....................................
Shift Fork 19...................................
Removal of Coupling (Output) Shaft 21............
Removal of Drive (Input) Shaft:
Shift Collar Retaining Ring (Input Shaft Only
Configurations) 22.............................
Pressing Out Drive Shaft 23.....................
Removing Drive Shaft, Sprocket and Housing 24...
Disassembly of Driveline Components:
Drive (Input) Shaft:
Shaft 25......................................
Housing 25...................................
Sprocket 25...................................
Shift Fork Shoes 25............................
Coupling (Output) Shaft:
Input Shaft Only Configurations 26...............
Input and Output Shaft Configurations 26..........
Removal of Output Shaft 27...............
Remove Cap from Case:
TC20B, TC20C, TC20D, TC20E and
TC20F Models: 28..............................
Disassemble Cap:
End Yoke on Front of PTO 29......................
End Yoke on Rear of PTO 30......................
Hydraulic Pump on Front of PTO 31................
Hydraulic Pump on Rear of PTO 32.................
Eclipse™ ES CAFS on Rear of PTO 33.............
End Yoke on Front and Hydraulic Pump on Rear 34..
Hydraulic Pump on Front and End Yoke on Rear 35..
For Reassembly of the PTO, See the Index on the next page.

Page 3 of 75T-365
Reassembly
Inspection and Repair 36.........................
Bearings, Oil Seals and O-rings 36.................
Assembly of Cap:
End Yoke on Front of PTO 37...................
End Yoke on Rear of PTO 38....................
Hydraulic Pump on Front of PTO 39..............
Hydraulic Pump on Rear of PTO 40..............
Eclipse™ CAFS Rear of PTO 41.................
End Yoke on Front and Hydraulic Pump on Rear 42
Hydraulic Pump on Front and End Yoke on Rear 43
Attach Cap to Case:
Apply Sealant to Flanges (All PTO Models) 44.....
TC20B, TC20C, TC20D, TC20E and
TC20F Models: 45............................
Assemble Driveline Components:
Drive Sprocket 46..............................
Drive Shaft 46.................................
Drive Shaft Housing 46.........................
Shift Fork Shoes 46............................
Coupling Shaft:
Input Shaft Only Configurations 47..............
Input and Output Shaft Configurations 47.........
Installation of Driveline in Case:
Drive (Input) Shaft:
Install Drive Shaft Housing on Case 48...........
Install Tachometer Ring in Tool 48...............
Install Case on Installation Tool 49..............
Install Drive Sprocket 50.......................
Install Drive Shaft in Case 51...................
Shift Collar:
Input and Output Shaft Configurations 52.........
Input Shaft Only Configurations 52..............
Chain 53.....................................
Coupling (Output) Shaft:
Input and Output Shaft Configurations
Wave Spring Design Prior to March 12, 2013 54.
Shim Design After March 12, 2013 55..........
Input Shaft Only Configurations 56..............
Oil Seals 57..................................
Tachometer Sensor 57........................
Shift Fork 58.................................
Shift Unit 59..................................
Oil Pan 60...................................
End Yokes or Companion Flanges 60............
Cross-Section Diagrams:
Input and Output Shaft Configurations 61.........
Input Shaft Only Configurations 62..............
Installation of Eclipse™ ES Unit:
Eclipse™ ES Unit on PTO 63...................
Adjusting Belt Tension 64......................
Installation of PTO in Vehicle 65.......
Connection of Propeller Shaft (Driveline) 66.......
Connection of Optional Accessories:
Hydraulic Pump on Rear or Front Output 67......
End Yoke on Front or Rear Output 67............
Tachometer Cable 68.........................
Drain Valve 68...............................
Priming Pump:
Mounting on Transmission 68.................
Hose Connections 68........................
Wiring Connections 69.......................
Shift Unit 70..................................
Oil Temperature Sensor 70.....................
Eclipse™ ES CAFS on Rear Output:
Hoses and Air Filter 71.......................
Electrical Wiring 72..........................
Schematic 73...............................
Lubrication:
TC20 PTO 74...............................
Eclipse ES CAFS Unit 74.....................
Final Checks:
Shift Indication Light Operation 75..............
Eclipse™ ES CAFS Unit 75...................

Page 4 of 75T-365
Introduction
This instruction provides the necessary steps involved to overhaul the TC20 Series PTO's. Note that the instructions are divided into Disassembly and Reassembly instructions.
Ordering Repair Parts
Refer to TC20 Series PTO Service Parts List furnished with your PTO for identification of individual components. When ordering repair parts, furnish the reference number of the compon
ent (from Service Parts List) along with the PTO Model serial number. Gasket and O-ring repair kit (Part No. K-1117) is available from Waterous that includes all the gaskets and O-rings
required for a complete overhaul. Note that this kit does not include shims installed between the cap and case which must be ordered separately (see Pages 31-32, 59 and 61).
Refer to the serial plate diagrams below for Model and Serial Number locations:
Serial Plate Located on Operator's Panel
Serial Plate Located on PTO
MODEL TC20C SERIAL NO. 123456
DATE SEP-2009 RATIO 2.27
MODEL TC20C DATE SEP-2009
SERIAL NO. 123456 RATIO 2.27

T-365 Page 5 of 75
General Overhaul Information
WARNING
!
Rotating Parts Hazard or Unexpected Truck Movement. May result in
serious personal injury or death.
Stop the engine, set parking brake and chock the wheels before attempting to
remove or repair the PTO.
WARNING
!
PTO Temperature Hazard. May result in serious burns.
The PTO may be warm from operation. Make sure that the PTO has cooled
sufficiently prior to removal or repair.
Tools and Equipment
The following tools and equipment may be needed to overhaul your PTO:
1. Usual automotive mechanic's hand tools.
2. An arbor press for assembling or disassembling components.
3. A suitable hoist and slings.
4. Torque capability up to 325 lb-ft.
While no special tools and equipment are required, a few special items are
illustrated or described on Pages 6 through 8 so the mechanic can make them
or they are available from the apparatus manufacturer or the Waterous Com
pany. These special items are not absolutely necessary, but they will make the
mechanic's work much easier.
Cleaning
Satisfactory operation depends to a great extent upon the cleanliness of its
internal parts. Sand, dirt or other abrasive material will wear gears and related
parts. Before disassembling a PTO for repairs, be sure to clean its exterior.
Make sure the working space, benches and tools are clean. Use only clean,
lint-free cloths to wipe off components. Before reassembling, be sure to clean
all components thoroughly.
Bearings, Gaskets, Seals and O-rings
Parts of this nature are frequently damaged during removal or disassembly. In
addition, they sometimes deteriorate or lose their effectiveness because of
age or misuse. Replacing these parts whenever overhauling a PTO is a good
policy.
Installing Ball Bearings
Most Waterous PTOs are designed so that ball bearings fit tightly on their
shafts and have relatively loose fits in the bearing housings. When mounting
these bearings on shafts, always apply force to the inner races. When bear
ings have tight fit in the housings, and a heavy force is necessary to install
them, be sure to apply force only to the outer bearing races. For either type of
fit, applying force to the wrong bearing race may damage the balls and race.
End Yoke and Companion Flange Nuts
Do not reuse self-locking nuts. Apply lubrication oil to the threads before re
moving. Apply anti-seize to the threads before installing a new self-locking nut.

T-365 Page 6 of 75
S
p
ecial Tools
Case Support Bracket Drive (Input) Shaft Removal Sleeve
Material: 1/4 in. and 1/2 in. Mild Steel Plate
Material: 4 in. Schedule 40 PVC Pipe
Reference Page 18.
Bracket is not available from Waterous and must be fabricated.
NOTE: Provisions must be made to secure
bracket to jack. Fasteners used must not
interfere with case mounting. The bracket
may be larger if necessary
Waterous Part No. 63431

T-365 Page 7 of 75
S
p
ecial Tools Continued
Transmission Case Support Bracket
Pipe Flange
Material: 4.50 in. Diameter Mild Steel Bar Stock
Assembly Sleeve
Material: 2-1/2 in. ANSI Class 125 Pipe Flange
(2-1/2 NPT x 7.00 in. O.D.
Pipe Nipple
Material: 2-1/2 NPT x 4.00 in. Long Pipe Nipple
Drive (Input) Shaft Installation Sleeve Assembly
Waterous Part No. 63432
Reference pages 48-52 and 54-56.
This sleeve is used when installing the Driveline in the PTO case.
This sleeve is available from Waterous or may be fabricated per the diagrams
below.
(Reference Waterous Part No. W 6040-64)
(Reference Waterous Part No. 63432)
(Reference Waterous Part No. V 3743)
(Reference Waterous Part No. 63599)

T-365 Page 8 of 75
S
p
ecial Tools Continued
Silicone Sealant Application Tools TC20 PTO Tool Kit
Material: 1.250 Diameter Mild Steel Bar Stock
Waterous Part No. V 3722
Reference page 58.
This tool is a 1/16 in. (2mm) notched trowel used to apply silicone sealant to
the case and cap flanges.
Waterous Part No. 63596
Reference page 58.
This tool is to be used to ensure a 1-1/8 in. (29mm) area around the lubrica
tion return holes in the case and cap are free of silicone.
This tool is available from Waterous or may be fabricated per the diagram be
low.
Waterous Part No. K1151
Includes the following tools:
Drive (Input) Shaft Removal Sleeve
Waterous Part No. 63431
Drive (Input) Shaft Installation Sleeve Assembly
Waterous Part No. 63432
Silicone Sealant Application Tools
Waterous Part No.'s V 3722 and 63596

T-365 Page 9 of 75
Disassembl
y
Drain Fluid from PTO Disconnect Propeller Shaft (Driveline)
Driveline
Input
Driveline
Output
(Not required if PTO is configured
with an input shaft only.)
Disconnect propeller shaft (driveline) at the PTO input and output shafts and the
PTO output shaft.
NOTE: Driveline is furnished and installed by the truck builder, therefore
configuration may vary from what is shown in the diagram.

T-365 Page 10 of 75
Disassembl
y
- Disconnect Out
p
ut Shaft
End Yoke Output Hydraulic Pump or Rear or Front Output
Disconnect
Output Shaft
Disconnect hydraulic pump from
PTO. Remove two (2) 1/2-13
screws and lockwashers. Slide hy
draulic pump away from PTO to dis
engage splines on shafts.
NOTE: Hydraulic Pump is furnished
and installed by the truck builder,
therefore configurations may vary
from what is shown in the diagram.

T-365 Page 11 of 75
Disassembl
y
- Disconnect O
p
tional Accessories
Tachometer and Drain Valve Priming Pump (if equipped) - Disconnect Wiring and Hoses
Output Side of PTO
Disconnect the Drain Valve
from PTO
Input Side
of PTO
Disconnect Tachometer Cable.
Unscrew cable from pick-up
sensor on case.
Priming Pump - Remove Priming Pump from Transmission
Power
Cable to
Battery
Ground
Cable to
Chassis
Wiring to Priming Valve
Hose to
Priming
Valve
Optional
Lubricant
Line
Input Side
of PTO
Four (4) 3/8-16 x
1 in. Screws and
Lockwashers
(1-1/4 in. screws
used on units
with Eclipse™
ES CAFS.
Two (2) 3/8-16 x 1 in.
Screws and Lockwashers
Tachometer (if equipped):
Drain Valve (if equipped):
1
1
2
Remove pick-up
sensor. Loosen
lock nut and un
screw from case.
2
Bracket and spacer
used on units with
Eclipse™ ES CAFS.

T-365 Page 12 of 75
Disassembl
y
- Disconnect O
p
tional Accessories
Shift Unit Oil Temperature Sensor

Draining Compressor and Oil Cooler
1. Drain compressor oil and oil cooler water. System holds approximately
2 to 3 gallons of oil (continued on next page).
Water Drain Oil Drains
Oil Drain
Compressor Oil
Sump
NOTE: The Oil Cooler and Compressor Sump are
mounted remotely from the PTO in the vehicle.
Oil Cooler
T-365 Page 13 of 75
Disassembl
y
- Disconnect O
p
tional Accessories
Eclipse™ ES CAFS on Rear Output
WARNING
!
Electrical Hazard. Possible electrical shock.
Disconnect electrical power to EclipsetES unit (wire connected to Terminal No.
1 on Electrical Relay Panel (see Page 15) to prevent possible electrical shock.

T-365 Page 14 of 75
Disassembl
y
- Disconnect O
p
tional Accessories
Eclipse™ ES CAFS on Rear Output (Continued)
Removal of Air Filter, Hoses and Cables
2. Remove air filter to ease removal of pump from vehicle.
3. Disconnect hose 3a through 3e from unit.
NOTE: Label hoses to ease reassembly.
4. Disconnect cable to Auto-Sync panel.
Air line from Air/Oil Separator,
#4 JIC Connection
Oil Scavenger line from Air/Oil
Separator, #4 JIC Connection
Cable to Auto-Sync Panel
4
Air line from vehicle air supply,
1/4 NPT Connection
Air Filter and Clamp
2
View of Compressor Behind Panel
Oil line from Oil Cooler,
#8 JIC Fitting
Air/Oil line from Sump,
#24 JIC Connection
3a
3b
3c
3e
3d
Electrical Relay Panel. Mounted
on this side of unit. See Steps 5
and 6 on the next page.

T-365 Page 15 of 75
Disassembl
y
- Disconnect O
p
tional Accessories
Eclipse™ ES CAFS on Rear Output (Continued)
Disconnect Wiring
5. Disconnect wiring from Terminals 1 through 8 along with
ground wire from electrical relay panel.
NOTE: Label wires to ease reassembly.
6. Disconnect wires from Oil Temperature Switch located on
the compressor oil sump.
Compressor Oil Sump
(Mounted remotely from pump on the vehicle.
Oil Temperature Switch
Ground
Green Wire
(Large Terminal)
Yellow Wire
(Small Terminal)
6
5
Note that (3) wires are connected to Terminal No. 4
Power
Electrical Relay Panel

T-365 Page 16 of 75
Disassembl
y
- Remove PTO from Vehicle
Removing PTO from Vehicle
PTO
PTO Case Bracket, See Page 6
for construction details. Must be
secured to PTO jack.
Drain Tap
1
1. Remove drain plug from case.
2. Place a PTO jack with PTO case support bracket attached (see Page 6 for construction
details) under the PTO.
3. Free PTO from all mounting brackets securing it to the chassis. Brackets will normally be
attached at the locations shown.
4. Lower PTO from vehicle.
5. Remove bracket and re-install drain plug once PTO is clear of the vehicle
3
3(2) Holes (both sides)
(8) Holes

T-365 Page 17 of 75
Disassembl
y
- Remove Ecli
p
setUnit from PTO
Belt Cover
1
Ten (10) 1/4-20 x 3/4 in.
Screws and Washers
End Yoke
Idler Sprocket Ad
justment Screw
3/8-16 x 1-1/4 in. Screw
PTO
Eclipse ES™ Unit
Two (2) M16 x 30mm
Screws and Lockwashers
1. Remove belt cover. Remove ten (10) 1/4-20 x 3/4 in. screws and washers.
2. Disconnect air line at the air clutch.
3. Disconnect the clutch anti-rotation bracket. Remove the 3/8-16 x 1-1/4 in. screw.
4. Relieve tension on the belt.
a. Loosen the large hex head screw on the idler pulley.
b. Relieve tension on the belt by turning the idler adjustment screw.
5. Remove the belt.
6. Remove the air clutch.
a. Remove the end yoke and nut.
b. Remove end yoke sleeve.
c. Remove the 3/8-16 set screw on the clutch hub. Access set screw through slot in sprocket.
d. Slide the air clutch off of the shaft.
e. Remove the clutch key from the shaft.
7. Remove the Eclipse ES unit from the PTO.
a. Attach a hoist to the Eclipse ES unit. Two (2) eyebolts are provided on the top of the unit for this purpose. Also install a strap under the compressor for a 3-point connection.
b. Remove the five (5) 3/8-16 x 1 in. screws and washers from the ES unit side of the PTO.
c. Remove the two (2) M16 x 30mm screw and washer from the opposite side of the PTO.
d. Remove the Eclipse ES unit.
7c
4b
Idler Pulley
4a
Remove EclipsetES CAFS Unit from PTO
6a
5
Belt
Air Clutch
6d
Set Screw
6c
3b
Clutch Key
6e
Five (5) 3/8-16 x 1 in.
Screws and Lockwashers
7b
Eye Bolt
7a
Air Line
2
Sleeve
6b
Anti-Rotation Bracket
3a

T-365 Page 18 of 75
Disassembl
y
- Removal of Driveline from Case
Oil Pan
Chain
End Yokes or Companion Flanges
1. Remove end yoke or
companion flange from input
and output shafts. Note that the
oil seal will remain in
the housing.
2. Discard lock nuts as they are not
to be re-used. Note that new lock
nuts are included in gasket kit
Waterous Part No. K1117.
1. Remove twelve (12) 3/8-16 x 1 in.
screws from oil pan.
2. Remove oil pan and gasket.
3. If a new O-ring is required, note that
a new O-ring is included in gasket
kit Waterous Part No. K1117.
Drive Shaft
Connecting Rocker
Spirol Pin
Connecting Pin
Spirol Pin
Connecting Pin
Connecting Rocker
1. Rotate drive shaft until connecting pin in chain is visible.
2. Drive out one spirol pin in end of connecting pin.
3. Drive the connecting pin and connecting rocker from the chain.
4. Separate ends of chain and pull out of PTO.
Spirol Pin

T-365 Page 19 of 75
Disassembl
y
- Removal of Driveline from Case
(
Continued
)
Shift Unit Shift Fork - Step 1
1. Place shift unit in ROAD Mode by pushing override rod in.
2. Remove the four (4) 3/8-16 x 1 in. mounting screws and washers.
3. Pull shift unit straight back as far as possible.
4. Rotate shift unit towards case to disengage clevis from shift fork.
3/8 in. Hex Socket Shift collar to PUMP (PTO)
position. Remove 3/4 in.
shoulder screw and discard.
Screw is self-locking and is
not to be re-used. Note that a
new should screw is included
in gasket kit Waterous Part
No. K1117.
Step 1

T-365 Page 20 of 75
Disassembl
y
- Removal of Driveline from Case
(
Continued
)
Shift Fork - Step 2 Shift Fork - Step 3
Rotate fork and pull down
to remove fork from case.
Step 3
Push slotted end of shift fork
towards sprocket to clear
mounting bracket.
Step 2