Cummins ISX11.9 CM2250 – Service Manual 009-022   REPTO

WARNING  Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last.

• Disconnect the batteries. Refer to the OEM service manual.
• Remove the power takeoff (PTO) shaft and OEM components to gain access to the REPTO unit. Refer to the OEM service manual.

WARNING  This component or assembly weighs greater than 23 kg [50 lb]. To prevent serious personal injury, be sure to have assistance or use appropriate lifting equipment to lift this component or assembly.

Remove the tail support brackets.

Remove the REPTO mounting capscrews.

Use a rubber hammer to loosen the REPTO housing.

Remove the REPTO assembly and seal.

Remove any Loctite™ sealant from the area around the retainer capscrew.

Use gear locking tool, Part Number 4919732, to prevent the output shaft from turning while removing the retainer capscrew.

Remove the capscrew and washer that secures the output flange to the output shaft.

Install the capscrew on the output shaft hand-tight.

Use puller, Part Number ST-647, to remove the output shaft.

NOTE: Save the original shims for rebuild purposes. The shims will be used to set the proper end clearance on the output shaft and bearing assembly.

Set the REPTO housing flange on wooden blocks, approximately 37 mm (1.5 in) in height. The output shaft sub-assembly should be free to fall onto a wooden surface.

Use a rawhide hammer to hit the end of the output shaft to remove the output shaft sub-assembly from the REPTO housing.

Remove the output shaft sub-assembly from the REPTO housing.

Use a dent puller to remove the oil seal. Do not damage the surface of the housing or the seal bore.

NOTE: Remove the inner race only if it is damaged or if it is a planned replacement.

WARNING  When using solvents, acids, or alkaline materials for cleaning, follow the manufacturer’s recommendations for use. Wear goggles and protective clothing to reduce the possibility of personal injury.

WARNING  Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause personal injury.

Clean the REPTO housing, output shaft assembly, output flange, and bearings with solvent.

Dry with compressed air.

Inspect the REPTO housing for cracks.

Replace the housing if it is cracked.

Inspect the REPTO housing nose and gear housing mating face for frets and burrs.

Remove any frets or burrs with a crocus cloth.

Inspect the bearing outer races for wear and other damage.

If the outer bearing races in the housing bore are worn or otherwise damaged, replace the whole housing assembly.

WARNING  Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause personal injury.

Use a bristle brush to clean the oil drilling in the REPTO housing.

Blow out the oil drillings with compressed air.

Inspect the output flange for damage or wear grooves from the oil seal.

Replace the flange, if necessary.

Inspect the output shaft assembly and bearing for wear or other damage.

Replace the assembly, if necessary.

NOTE: If required, use a bearing separator tool to remove the bearing from the shaft.

Use assembly lubricant, Part Number 3163087, Lubriplate™ 105 or equivalent, to lubricate the output shaft and larger bearing.

If removed, install the larger bearing onto the output shaft.

Lay the output shaft assembly on a table with the gear end down.

Install the housing over the output shaft assembly.

The correct end clearance (rolling resistance) is determined by the number and thickness of shims (1) used between the two bearings.

When the shim thickness is increased, there is more shaft end clearance and less rolling resistance.

When the shim thickness is decreased, there is less shaft end clearance and more rolling resistance.

Install the original thickness of shims. If the original thickness of shims is not available for reuse, a beginning thickness of 1.092 mm [0.043 in] can be used.

Use assembly lubricant, Part Number 3163087, Lubriplate™ 105, or equivalent, to lubricate the smaller bearing.

Install the smaller bearing onto the output shaft.

Temporarily install the output flange before installing the oil seal.

Install the flat washer and capscrew.

Use the gear locking tool, Part Number 4919732, to hold the output shaft while tightening the capscrew.

Measure the output shaft end play.

Output Shaft End Play

Use a torque wrench to check the output shaft rolling resistance.

If the rolling resistance is not within specification, remove the output flange and smaller bearing.

Add or subtract shims to obtain the correct rolling resistance.

NOTE: Adding more shims will decrease the resistance and removing shims will increase resistance. Any combination of shims can be used.

Once the correct rolling resistance is obtained, remove the output flange.

Use gear locking tool, Part Number 4919732, to prevent the output shaft from turning when removing the retainer capscrew.

Apply a thin coat of Loctite™ 277, or equivalent, around the outside circumference of the oil seal.

Press the oil seal flush with the housing surface.

Install the output flange on the output shaft spline.

Apply a generous amount of Loctite™ 5999, or equivalent, to the output flange capscrew and under the washer.

Install the output flange flat washer and capscrew.

Use the gear locking tool, Part Number 4919732, to hold the output shaft while tightening the capscrew.

Tighten the capscrew.

WARNING  This component or assembly weighs greater than 23 kg [50 lb]. To prevent serious personal injury, be sure to have assistance or use appropriate lifting equipment to lift this component or assembly.

Install the press-in seal into the gear housing.

Rotate the output flange to align the output gear to the idler gear in the rear gear housing.

Engage the gears and insert the REPTO housing into the rear gear housing.

NOTE: Gear timing is not required.

Hand-tighten the capscrews. Do not tighten to the final torque value at this time.

Install the two support brackets on the rear of the REPTO housing and flywheel housing.

Tighten the REPTO mounting capscrews.

Tighten the two support brackets on the rear of the REPTO housing and flywheel housing.

WARNING  Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last.

• Install the power takeoff (PTO) shaft and OEM components to gain access to the REPTO unit. Refer to the OEM service manual.
• Connect the batteries. Refer to the OEM service manual.
• Operate the engine and check for leaks.