Caterpillar Cat C27 Industrial Engine (Prefix RAM) Service Repair Manual (RAM00001 and up).pdf

Service Repair Manual
Models
C27 Industrial Engine

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Product: INDUSTRIAL ENGINE
Model: C27 INDUSTRIAL ENGINE RAM
Configuration: C27 Industrial Engine RAM00001-UP
Disassembly and Assembly
C27 and C32 Industrial Engines
Media Number -KENR8167-05 Publication Date -01/08/2015 Date Updated -30/04/2018
i05933887
Gear Group (Front) - Remove
SMCS - 1206-011
Removal Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A
8S-2241 Camshaft Bearing Tool Group 1
6V-4869 Adapter 1
6V-6174 Plug 1
Start By:
a. Remove the front housing. Refer to Disassembly and Assembly, "Housing (Front) -
Remove".
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
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Illustration 1 g01147593
1. Remove bolts (5) and gear assembly (4).
2. Remove bolts (3) and plate (2). Remove gear assembly (1).
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3. Remove bolts (6) and shaft (7).
Note: The crankshaft will have to be removed to remove and install bushings (8) and
(9). Refer to Disassembly and Assembly, "Crankshaft - Remove".
4. If necessary, use Tooling (A) to remove bushing (8) and (9).
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All Rights Reserved.
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Wed Jun 17 23:15:43 UTC+0800 2020
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i06280625
Gear Group (Front) - Install
SMCS - 1206-012
Installation Procedure
Table 1
Required Tools
A
8S-2241 Camshaft Bearing Tool Group 1
6V-4869 Adapter 1
6V-6174 Plug 1
NOTICE
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1. Use Tooling (A) to install bushings (8) and (9) . Install bushing (8) to a Dimension (B) .
Dimension (B) is 236.7 ± 0.5 mm (9.32 ± 0.02 inch). Install bushing (9) to a Dimension
(A) . Dimension (A) is 40.4 ± 0.5 mm (1.59 ± 0.02 inch). Install the crankshaft. Refer to
Disassembly and Assembly, "Crankshaft - Install".
2. Apply clean engine oil to shaft (7) , the bearing bore, and the thrust faces prior to
installation. Install shaft (7) and bolts (6) . Tighten bolts (6) to a torque of 55 ± 10 N·m (41
± 7 lb ft).
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3. Position gear assembly (1) on the shaft. Install plate (2) and bolts (3) .
4. Install gear assembly (4) and bolts (5) .
End By: Install the front housing. Refer to Disassembly and Assembly, "Housing (Front) -
Install".
Wed Jun 17 23:16:39 UTC+0800 2020
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i02292574
Housing (Front) - Remove
SMCS - 1151-011
Removal Procedure
Table 1
Required Tools
A 185-3630 Strap Wrench As 1
Start By:
a. Remove the water pump. Refer to Disassembly and Assembly, "Water Pump - Remove".
b. Remove the crankshaft front seal. Refer to Disassembly and Assembly, "Crankshaft Front
Seal - Remove".
c. Remove the water temperature regulator housing. Refer to Disassembly and Assembly,
"Water Temperature Regulator Housing - Remove and Install".
d. Remove the front engine support. Refer to Disassembly and Assembly, "Engine Trunnion -
Remove and Install".
NOTICE
Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting, and repair
of the product. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component
containing fluids.
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Refer to Special Publication, NENG2500, "Dealer Service Tool
Catalog" for tools and supplies suitable to collect and contain fluids on
Cat products.
Dispose of all fluids according to local regulations and mandates.
NOTICE
1. Remove covers (1).
2. Disconnect harness assembly (2).
3. Remove three bolts (3).
4. Loosen bolt (4) and reposition the filter housing assembly. Tighten bolt (4).
5. Use Tooling (A) to remove engine oil filter (5).
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6. Remove bolts (6) and dampers (7).
7. Remove bracket (8) and engine trunnion (9).
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8. Disconnect bracket (10) and elbows (11).
9. Remove adapters (12) and bolts (13).
10. Attach a suitable lifting device to front housing (14). The weight of front housing (14) is
approximately 70 kg (154 lb).
11. Remove bonnet (15).
12. Remove bolts (16) and bolts (17).
13. Remove front housing (14) and the gasket.
Wed Jun 17 23:17:34 UTC+0800 2020
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i06746008
Housing (Front) - Install
SMCS - 1151-012
Table 1
Required Tools
B Loctite 598 1
NOTICE
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1. Apply Tooling (B) to the bottom of front housing (14) at the junction of the cylinder block
and the engine oil pan.
2. Attach a suitable lifting device to front housing (14). The weight of front housing (14) is
approximately 70 kg (154 lb). Position the gasket and front housing (14) on the dowel pins
on the cylinder block.
3. Install bolts (16) and bolts (17).
4. Install bonnet (15).
5. Trim the gasket between the front housing and the cylinder block even with the bottom of
the front housing.
6. Install bolts (13) and adapters (12).
7. Connect elbows (11) and bracket (10).
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8. Install engine trunnion (9) and bracket (8).
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9. Install dampers (7) and bolts (6).
10. Tighten the bolts to a torque of 240 ± 40 N·m (177 ± 30 lb ft). Tighten the bolts in the
following sequence: 1, 4, 2, 5, 3, 6, 1, 4.
11. Install engine oil filter (5).
12. Reposition the filter housing assembly and tighten bolt (4).
13. Install bolts (3).
14. Connect harness assembly (2).
15. Install covers (1).
End By:
a. Install the front engine support. Refer to Disassembly and Assembly, "Engine Trunnion -
Remove and Install".
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b. Install the water temperature regulator housing. Refer to Disassembly and Assembly,
"Water Temperature Regulator Housing - Remove and Install".
c. Install the crankshaft front seal. Refer to Disassembly and Assembly, "Crankshaft Front
Seal - Install".
d. Install the water pump. Refer to Disassembly and Assembly, "Water Pump - Install".
Wed Jun 17 23:18:30 UTC+0800 2020
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i04032306
Housing (Rear) - Remove
SMCS - 1157-011
Removal Procedure
Start By:
a. Remove the rear gear group.
b. Remove the fuel transfer pump.
NOTICE
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1. Remove elbow assemblies (1)
2. Remove the bolts (2) that hold the engine oil pan to the rear housing (3).
3. Disconnect hose assembly (4). Remove bolts (5).
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4. Remove bracket assembly (7). Remove clip (8).
5. Attach a suitable lifting device to rear housing (3). The weight of rear housing (3) is
6. Remove bolts (6).
7. Remove rear housing (3) and the gasket.
Wed Jun 17 23:19:26 UTC+0800 2020
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i07362121
Housing (Rear) - Install
SMCS - 1157-012
Table 1
Required Tools
A 4C-9612 Silicone Sealant 1
B — Loctite LV Core Plug Sealant 1
NOTICE
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1. If cup plugs (11) were removed or the rear housing is being replaced, use Tooling (B) on
cup plugs (11) and install to Dimension (X).
Dimension (X) ... 1.25 ± 0.25 mm (0.05 ± 0.01 inch)
2. Apply Tooling (A) to the bottom of the rear housing at the junction of the cylinder block
and the engine oil pan.
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Bolt tightening sequence
3. Attach a suitable lifting device to rear housing (3). The weight of rear housing (3) is
4. Position the gasket on rear housing (3).
5. Position rear housing (3) on the cylinder block. Install bolts (6). Tighten bolts (3) in a
numerical sequence to a torque of 55 ± 10 N·m (41 ± 7 lb ft).
6. Trim the gasket between the rear housing and the cylinder block even with the bottom of the
rear housing.
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7. Install bolts (4).
8. Connect hose assembly (5).
9. Install bolts (2) that hold the engine oil pan to rear housing (3).
10. Tighten all the bolts that hold the engine oil pan evenly to raise the engine oil pan into
position.
End By:
a. Install the rear gear group. Refer to Disassembly and Assembly, "Gear Group (Rear) -
Install".
Wed Jun 17 23:20:22 UTC+0800 2020
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i06258895
Fumes Disposal Filter - Remove and Install - Flywheel
Housing
SMCS - 1317-010
Removal Procedure
Table 1
Required Tools
A − LOCTITE 5900 1
B − KRYTOX LS23 1
1. Remove clips (2), and (6) .
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2. Remove bracket assembly (3) and tube (4) .
3. Remove bolts (5) and fumes disposal group (1) .
4. Remove plate (10) .
5. Remove element (9) and remove O-ring seal (8) from base (7) .
1. Install fumes disposal group (1) in reverse order.
a. Apply Tooling (A) at Location (X). Location (X) is the sealing surface between the
base and the plate.
b. Apply Tooling (B) to O-ring seal (8) .
Wed Jun 17 23:21:17 UTC+0800 2020
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Shutdown SIS
Previous Screen
i06258903
Fumes Disposal Filter - Remove and Install
SMCS - 1317-010
Removal Procedure
1. Disconnect hose assemblies (1), (4), and (5) .
2. Remove brackets (3) and remove the fumes disposal group (2) .
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