Centinel System – Repair Manual – 016-007   Flywheel Housing, REPTO

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

WARNING  Some state and federal agencies have determined that used engine oil can be carcinogenic and cause reproductive toxicity. Avoid inhalation of vapors, ingestion, and prolonged contact with used engine oil. If not reused, dispose of in accordance with local environmental regulations.

WARNING  To reduce the possibility of personal injury, avoid direct contact of hot oil with your skin.

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.

• Disconnect the batteries or air supply to the starter to prevent accidental engine starting.
• Drain the oil.
  Refer to Procedure 007-025 (Lubricating Oil Pan) in Section 7.
• Remove the transmission, clutch, and all related components. Refer to the equipment manufacturer’s instructions.
• Remove the flywheel.
  Refer to Procedure 016-005 (Flywheel) in Section 16.
• Remove the starter motor.
  Refer to Procedure 013-020 (Starting Motor) in Section 13.

Remove the three capscrews from the rear of the oil pan.

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 10 10-mm capscrews from the hydraulic housing.

Remove the hydraulic housing from the REPTO flywheel housing.

Remove the spray nozzle from the oil supply line hole.

Remove the 12 capscrews (1) from the seal carrier.

Remove the seal carrier (2) from the REPTO flywheel housing.

Remove oil seal (4) and discard.
Refer Procedure 001-024 (Crankshaft Seal, Rear) in Section 1.

Remove the o-ring (3) from the groove on the REPTO flywheel housing.

Remove the four plugs (1) and o-rings (2) from the REPTO flywheel housing.

Remove the crankshaft gear.

Remove the idler gear shaft capscrew and washer.

Remove the three guide pins.

If the idler gear shaft can
not be removed with the handle, a slide hammer similar to Snap-On, Part Number CJ114, can be used.

Position the replacer idler plate, Part Number 3164762, on the idler gear shaft. Install and tighten the two idler gear capscrews. Install the handle, Part Number 3163089.

Remove the idler shaft, idler gear, and bearing from the REPTO flywheel housing.

Remove two capscrews from the REPTO flywheel housing.

Install the two guide pins, Part Number 3164764.

Install the two eye bolts, Part Number 3164767, on the top of the REPTO flywheel housing. Install the lifting slings to the eye hooks. Adjust the hoist until there is tension in the lifting sling.

Remove the remaining capscrews.

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.

Use a mallet to tap the REPTO flywheel housing off the two locating dowels. Remove and discard the gasket.

CAUTION  Immediately upon removal of the flywheel housing assembly, a plug must be inserted into the cylinder block oil passage drillings. Failure to insert the oil passage plug can result in a bearing failure, crankshaft failure, or both.

The reusable plug, Part Number 4918321, is included in Protective Plug Kit, Part Number 4918319. This plug is necessary to prevent debris from entering the lubrication system during the repair.

Plug the block oil passage with plug Part Number 4918321.

Firmly push the plug into the oil passage to prevent all debris from entering the lubricating system when cleaning the gasket surface.

CAUTION  Do not allow dirt or foreign material to enter oil passages in the cylinder block when cleaning the gasket sealing surfaces. Main or connecting rod bearing failures can be caused if debris is introduced into the lubrication system. Therefore, use of power tools combined with abrasive pads to clean gasket surfaces is not recommended.

Clean the gasket surfaces by hand with a gasket scraper or cleaning pad, Part Number 3823258. If the residue gasket material can
not be felt with a finger, the surface is ready to accept the new gasket.

WARNING  When using a steam cleaner, wear safety glasses or a face shield, as well as protective clothing. Hot steam can cause serious personal injury.

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.

Use steam or solvent to clean the REPTO flywheel housing.

Dry with compressed air.

Inspect all surfaces for nicks, burrs, or cracks.

Use a crocus cloth to remove small nicks and burrs.

Inspect all threaded capscrew holes for damage.

Repair or replace the housing if the capscrew holes are damaged.

Inspect the idler shaft, bearing, and gear for nicks, burrs, or cracks. Replace if damaged.

Inspect the four o-rings from the plugs and the one large o-ring from the REPTO flywheel housing for cuts or tears. Replace the o-rings if damaged.

Remove the protective plug from the block oil passages. Make sure no debris enters the lubrication system.

Use a clean shop towel to carefully wipe out the oil passage and inspect to make sure no debris is left in the passage.

Install the two guide pins (3), Part Number 3164764, into the cylinder block.

Position the flywheel housing gasket to the rear of the cylinder block using guide pins.

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 two eye hooks (4) in the top of the REPTO flywheel housing. Install the lifting slings to the eye hooks and push the REPTO flywheel housing onto the two guides pins (3).

Install the six short capscrews (2) and four long capscrews (1) in the locations shown.

Remove the two guide pins and install the two other long capscrews.

Tighten capscrews (1), (2), (9) and (10).

Tighten the remaining capscrews in the sequence shown.

CAUTION  The REPTO flywheel housing bore and face must be in alignment with the crankshaft to prevent possible damage to the engine, the clutch, or the transmission.

Use the measure step in this procedure to align the housing.

Tighten the capscrews.

Install the three oil pan capscrews.

Install the large o-ring seal (1) and the small o-ring seal (2) onto the idler shaft.

Assemble the replacer idler shaft plate and handle.

Install the two capscrews in the idler shaft holes and tighten.

Use clean 15W-40 oil to lubricate the idler shaft.

The two cones (2) are loose and will fall out if
not contained.

Make sure the gear (4), two bearing snap rings (1), and the two cups (3) are pressed in place before inserting the assemblies through the center or sides of the REPTO flywheel housing openings.

Use clean 15W-40 oil to lubricate the bearing snap rings, cones, cups, idler shaft, and gear.

Make sure the idler shaft plug (1) is facing upward when installing it into the bore.

Install the gear and bearing assembly through the center or sides of the REPTO flywheel housing holes. Position the bearing races together and insert the idler shaft with the tool through the first bear bore. The running clearance is 0 to 0.025 mm [0.000 to 0.001 in].

Make sure the idler shaft is properly aligned and seated against the shoulder of the internal bore.

Repeat the procedure if installing a second gear.

Remove the two capscrews, replacer idler plate, and handle from the idler shaft.

Lubricate the threads and under the capscrew head with clean 15W-40 oil.

Install the washer and capscrew and tighten capscrew.

A second idler gear can be installed or an insert shaft can be used without the idler gear and roller.

Install the o-rings onto the insert shaft. Lubricate the o-rings with clean 15W-40 oil.

Install the insert shaft into the flywheel housing hole where the cover plate will be installed (opposite pump location). Align the hole with the tapped hole in the block.

Lubricate the threads and under the capscrew head with clean 15W-40 oil.

Install the washer and capscrew and tighten capscrew.

Install the three guide pins, Part Number 3164765, equally spaced through the crankshaft gear and into the crankshaft.

Rotate the idler gears, as necessary, to mesh the crankshaft gear with the idler gear(s).

Install the crankshaft gear.

Make sure the o-rings are properly seated into the groove before installation.

Use clean 15W40 oil to lubricate the o-rings.

Install four plugs (1) with o-rings (2) into the REPTO flywheel housing holes.

Install the o-ring in the REPTO flywheel housing groove.

Install the seal carrier over the two dowels pins on the REPTO flywheel housing.

Install the 12 capscrews.

Tighten the capscrews in the sequence shown to secure the seal carrier.

Install the three flywheel mounting capscrews and spacers. Tighten the flywheel mounting capscrews.

Remove the three flywheel mounting capscrews and spacers.

CAUTION  The rear crankshaft seal must be pressed evenly into the bore. If the crankshaft and crankshaft seal is not pressed evenly into the bore, the oil seal can cause equipment damage.

Install the rear crankshaft oil seal over the rear crankshaft seal replacer, Part Number 3164780, and onto the three guide pins.

Install three flywheel mounting capscrews (without the washers) through the three holes in the rear crankshaft seal replacer.

CAUTION  To reduce the possibility of damage to the oil seal and crankshaft, never use a hammer or mallet to install the rear crankshaft oil seal.

Do
not use lubricants during the installation process. Apply a 10 percent soap solution to the outer ribbed surface of the rear crankshaft oil seal.

Tighten the flywheel mounting capscrews no more than ½ revolution at a time, alternating capscrews in a
clockwise pattern, until the rear crankshaft seal replacer, Part Number 3164780, seats against the REPTO flywheel housing.

Remove the rear crankshaft seal replacer and the three flywheel mounting capscrews.

Install the flywheel.
Refer to Procedure 016-005 (Flywheel) in Section 16.

If one side of the REPTO flywheel housing cover access hole does
not use a hydraulic housing, the opening
must be covered in conjunction with the oil supply line hole and plugging the straight thread plug hole.

Install the 1/8-inch pipe plug (1) into the oil supply line hole. Make sure the pipe plug is flush with the mounting surface.

Install the straight thread plug (2) into the flywheel housing hole. Make sure pipe plug is flush with the mounting surface.

Install the diamond seal (1) on the REPTO flywheel housing cover access hole.

Apply a small amount of RTV on the two ends (2) where the diamond seal comes together and a small amount of 15W-40 oil on the diamond seal.

Install the cover plate to the REPTO flywheel housing cover access hole. Install the 10 capscrews and tighten.

Make sure the idler gear is locked in position. Use a dial gauge to check the backlash.

If the backlash is
not within specifications, replace the idler gear, REPTO hub gear, or both.

NOTE: The spray nozzle and diamond seal are
only installed if a hydraulic housing is used.

Install the spray nozzle (1) into the oil supply line hole. Tighten the spray nozzle.

Install the diamond seal (2) on the REPTO flywheel housing cover access hole.

Apply a small amount of RTV on the two ends (3) where the diamond seal comes together and a small amount of clean 15W-40 oil on the diamond seal.

Apply clean 15W-40 oil on the gear teeth and bearings.

Install the hydraulic housing over the dowel pins. The gear inside the hydraulic housing is free to rotate and will locate the position of the idler gear as the hydraulic housing is being installed over the dowel pins.

Install the 10 capscrews and tighten in the sequence shown.

Verify that backlash exists between the Hydrive housing gear and idler gear by inserting a tool into the spline to help rotate the gear.

A small amount of backlash
must be present, although obtaining a measurement is
not required.

If no backlash is present, disassemble the Hydrive housing from the flywheel housing, and assemble the Hydrive housing to the opposite flywheel housing mounting pad and check for backlash.

If no backlash is present when assembled on either flywheel housing mounting pad, the Hydrive housing
must be replaced.

If backlash is present on
only one side, the flywheel housing
must be replaced.

Install the threaded plug (1) in the bottom hole of the hydraulic housing. Tighten the threaded plug.

Install the oil line hose on the straight connectors. Tighten the hose and check for leaks.

Attach a dial indicator to the crankshaft. Use mounting tool, Part Number ST-1325, and indicator Part Number 3376050.

The dial indicator can be mounted by any method that holds the extension bar of the indicator rigid so it does
not sag. If the bar sags or the indicator slips, the readings obtained will
not be accurate.

Position the indicator in the 6:00 o’clock position and the gauge at zero.

Slowly rotate the crankshaft. Record the readings obtained at the 9:00 o’clock, 12:00 o’clock, and 3:00 o’clock positions as (a), (b), and (c) in the concentricity work sheet. Recheck zero at the 6:00 o’clock position.

The values for (a), (b), and (c) can be positive or negative. Refer to the accompanying figure to determine the correct sign when recording these values.

CAUTION  Do not force the crankshaft beyond the point where the bearing clearance has been removed. Do not pry against the flywheel housing. These actions can cause false bearing clearance reading.

Rotate the crankshaft until the dial indicator is at the 12-o’clock position and zero the gauge.

Use a pry bar to raise the rear of the crankshaft to its upper limit. Record the value as (d) in the concentricity work sheet. This is the vertical bearing clearance adjustment and will
always be positive.

Use the concentricity work sheet (see the accompanying illustration) to determine the total vertical and horizontal values.

The total horizontal is equal to the 9:00 o’clock reading (1) minus the 3 :00 o’clock reading (c).

The total vertical is equal to the 12:00 o’clock reading (b) plus the bearing clearance (d).

Example:

6:00 o’clock = reference = 0

9:00 o’clock = [a ] = 0.004

12:00 o’clock = [b ] = 0.003

3:00 o’clock =[c] = -0.002.

Use the work sheet and the numbers from the example. The total horizontal value equals 0.006, and the total vertical value equals 0.005.

Mark the total horizontal value on the horizontal side of the chart and the total vertical on the vertical side of the chart.

Use a straightedge to find the intersection point of the total horizontal and total vertical values. The intersection point
must fall within the shaded area for the flywheel housing concentricity to be within specification.

Using the total horizontal and total vertical values from the previous example, the intersection point falls within the shaded area. Therefore, the flywheel housing concentricity is within specification.

Use the accompanying chart for SAE 1, 2, and 3 flywheel housings.

Use the accompanying chart for SAE 0 and ½ flywheel housings.

Use the accompanying chart for SAE 00 flywheel housings.

If the intersection point falls outside the shaded area, the ring dowels
must be removed and the housing repositioned.

The ring dowels are
not required to maintain concentricity of the housing; the clamping force of the capscrews holds the housing in place.

After the ring dowels are discarded, install the flywheel housing on the engine.

To position the housing, tighten the capscrews enough to hold the flywheel housing in place, but loose enough to enable small movement when struck lightly with a mallet.

Recheck the concentricity. When concentricity is within specification, tighten the capscrews to the specified value.

CAUTION  The dial indicator tip must not enter the capscrew holes, or the gauge will be damaged.

Install a dial indicator as illustrated.

The extension bar for the indicator
must be rigid for an accurate reading. It
must not sag. Position the indicator at the 12:00 o’clock position. Adjust the dial until the needle points to zero.

Slowly rotate the crankshaft. Record the readings at the 3:00 o’clock, 6:00 o’clock, and 9:00 o’clock positions.

The crankshaft
must be pushed toward the front of the engine to remove the crankshaft end clearance each time a position is measured.

Continue to rotate the crankshaft until the indicator is at the 12:00 o’clock position. Check the indicator to make sure that the needle points to zero. If it does
not, the readings will be incorrect.

Determine the total indicator runout.

The maximum allowable total indicator reading is determined by the diameter of the housing bore. If out of specifications, replace the housing.

Install the remaining capscrews. Tighten all capscrews in two steps using the sequence shown.

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.

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

• Install the starting motor.
  Refer to Procedure 013-020 (Starting Motor) in Section 13.
• Connect the batteries or air starter supply.
• Fill the engine with clean oil.
  Refer to Procedure 007-025 (Lubricating Oil Pan) in Section 7.
• Install the transmission, clutch, and all related components. Refer to the equipment manufacturer’s instructions.