Caterpillar Cat 299D2XHP Compact Track Loader (Prefix DX9) Service Repair Manual (DX900001 and up).pdf

Service Repair Manual
Models
299D2 XHP COMPACT
TRACK LOADER

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Product: COMPACT TRACK LOADER
Model: 299D2 XHP COMPACT TRACK LOADER DX9
Configuration: 299D2 and 299D2XHP Compact Track Loader DX900001-UP (MACHINE) POWERED BY C3.8 Engine
Disassembly and Assembly
C3.8 Engines for Caterpillar Built Machines
Media Number -UENR0129-08 Publication Date -01/09/2015 Date Updated -19/05/2016
i04801361
Idler Gear - Remove and Install
SMCS - 1206
Removal Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 393-2572 Flywheel Stopper 1
B 393-2573 Driver 1
Start By:
a. Remove the front housing.
1. Ensure that number four piston is at the top center position on the compression stroke. Refer
to Systems Operation, Testing and Adjusting, "Finding Top Center Position for No. 4
Piston".
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2019/10/28
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Illustration 1 g02871716
2. Ensure that timing marks on the gears are aligned.
Alternatively, make temporary timing marks on the gears in order to show alignment.
3. Install Tooling (A) onto the flywheel. Remove bolts (1) and plate (2).
4. Remove idler gear (3), shaft (4), and plate (5).
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5. Use Tooling (B) to remove bushing (6) from idler gear (3).
Installation Procedure
1. Install idler gear (3) in the reverse order of removal.
a. Apply clean engine oil onto the bore of idler gear (3) and bushing (6).
b. Ensure that edge of bushing (6) is flush with the edge of the bore that is in idler gear
(3).
c. Tighten bolts (1) to a torque of 25.5 ± 1.5 N·m (18.8 ± 1.1 lb ft).
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Mon Oct 28 21:42:53 UTC+0800 2019
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i06662240
Idler Gear - Remove and Install
SMCS - 1206
S/N - BL21-UP
S/N - BL71-UP
S/N - BY41-UP
S/N - DX21-UP
S/N - DX91-UP
S/N - FD21-UP
S/N - HP21-UP
S/N - MD21-UP
Removal Procedure
Table 1
Required Tools
Start By:
a. Remove the front housing.
1. Ensure that number four piston is at the top center position on the compression stroke. Refer
to Systems Operation, Testing and Adjusting, "Finding Top Center Position for No. 4
Piston".
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2. Ensure that timing marks on the gears are aligned.
Alternatively, make temporary timing marks on the gears to show alignment.
3. Install Tooling (A) onto the flywheel. Remove bolts (2) and idler gear (3).
4. Remove nuts (1) and idler gear (4).
1. Install the idler gears in the reverse order of removal.
a. Tighten nuts (1) to a torque of 24 N·m to 27 N·m (212 lb in to 239 lb in).
b. Tighten bolts (2) to a torque of 24 N·m to 27 N·m (212 lb in to 239 lb in).
Mon Oct 28 21:43:48 UTC+0800 2019
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i06618977
Housing (Front) - Remove and Install
SMCS - 1151-010
Removal Procedure
Table 1
Required Tools
B - Three Bond 1217H -
1. Remove bolts (1), retainer (2), and crankshaft pulley (3).
2. Disconnect speed sensors (4). Remove belt (5).
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3. Disconnect wire assembly (6), cable assembly (7), and harness assembly (8).
4. Remove bolts (9) to remove alternator (10).
5. Remove bolts (11) to remove cover (12) and the gasket.
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6. Install Tooling (A) onto the flywheel. Remove bolt (13) to remove crankshaft pulley (14).
7. Remove bolts (15) to remove front housing (16).
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Note: If the front cover is replaced, check the air gap of the crankshaft position sensor.
1. Apply Tooling (B) onto the mating surface of front housing (16). Install front housing (16).
Install bolts (15). Tighten bolts (15) to a torque of 25.5 ± 1.5 N·m (18.8 ± 1.1 lb ft).
a. For the SSL, MTL, and CTL models that end in D2 models (BL2, MD2, BL7, HP2,
FD2, DX2, DX9, and BY4), tighten bolts (15) to a torque of 34.5 ± 1.5 N·m
(25 ± 1 lb ft).
b. For all other models, tighten bolts (15) to a torque of 25.5 ± 1.5 N·m (227 ± 13 lb in).
2. Install Tooling (A) on the flywheel. Install crankshaft pulley (14). Apply clean engine oil
onto bolt (13). Install bolt (13). Tighten bolt (13) to a torque of 264.5 ± 9.5 N·m
(195.1 ± 7.0 lb ft).
3. Install cover (12) and a new gasket. Install bolts (11). Tighten bolts (11) to a torque of
25.5 ± 1.5 N·m (18.8 ± 1.1 lb ft).
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4. Install alternator (10). Install bolts (9).
5. Connect harness assembly (8), cable assembly (7), and wire assembly (6).
6. Install belt (5). Connect harness assemblies (4).
7. Install pulley (3), retainer (2), and bolts (1).
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i06285512
Fumes Disposal Filter - Remove and Install
SMCS - 1317-010
Removal Procedure
Start By:
a. Remove the air cleaner.
1. Remove hose (1).
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2. Disconnect hoses (2).
3. Remove bolt (3).
4. Remove hose (5). Remove fumes disposal filter (4) with bracket attached.
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1. Install fumes disposal filter (4) in the reverse order of removal.
Mon Oct 28 21:45:40 UTC+0800 2019
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i06552041
Valve Mechanism Cover - Remove and Install
SMCS - 1107-010
Removal Procedure
1. Disconnect tube assemblies (1).
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2. Disconnect harness assemblies (2) and hose (3).
3. Remove tube assembly (4).
4. Mark the terminal leads of wire assemblies (5) for installation purposes. Remove nuts (6) to
disconnect wire assemblies (5)
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5. Remove bolts (7). Remove cover (8) and gasket (9).
6. Remove bolts (10) to remove valve mechanism cover (11).
7. Remove gasket (12).
1. Install valve mechanism cover (11) in the reverse order of removal.
a. Tighten bolts (10) to a torque of 6.9 ± 11.2 N·m (61 ± 99 lb in).
b. Tighten nuts (6) to a torque of 1.6 ± 2.2 N·m (14 ± 19 lb in).
c. Tighten bolts (7) to a torque of 9.8 ± 11.2 N·m (87 ± 99 lb in).
d. Tighten tubes (1) to a torque of 23 ± 36 N·m (204 ± 319 lb in).
Mon Oct 28 21:46:36 UTC+0800 2019
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i06619028
Valve Mechanism Cover - Remove and Install
SMCS - 1107-010
S/N - BL21-UP
S/N - BL71-UP
S/N - BY41-UP
S/N - DX21-UP
S/N - DX91-UP
S/N - FD21-UP
S/N - HP21-UP
S/N - MD21-UP
Removal Procedure
1. Tilt the radiator. Refer to Operation and Maintenance Manual, "Radiator - Tilting".
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2. Disconnect tube assemblies (1).
3. Disconnect harness assemblies (2). Remove bracket (3).
4. Disconnect harness assemblies (4). Remove bracket (5) and bracket (6).
5. Remove hose (6).
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6. Mark the terminal leads of wire assemblies (7) for installation purposes. Remove nuts (8) to
disconnect wires assemblies (7).
7. Remove bolts (9). Remove cover (10) and gasket (11).
8. Remove bolts (12) to remove valve cover mechanism (13).
9. Remove gasket (14).
1. Install valve mechanism cover (13) in the reverse order of removal.
a. Tighten bolts (12) to a torque of 6.9 ± 11.2 N·m (61 ± 99 lb in).
b. Tighten nuts (8) to a torque of 1.6 ± 2.2 N·m (14 ± 19 lb in).
c. Tighten bolts (9) to a torque of 9.8 ± 11.2 N·m (87 ± 99 lb in).
d. Tighten tube (1) to a torque of 23 ± 36 N·m (204 ± 319 lb in).
Mon Oct 28 21:47:32 UTC+0800 2019
3/3
2019/10/28

Shutdown SIS
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i04663909
Rocker Shaft and Pushrod - Remove
SMCS - 1102-011; 1208-011
Removal Procedure
Start By:
a. Remove the valve mechanism cover.
1. Remove nuts (1) to remove nozzle clamps (2). If necessary, remove electronic unit injectors
(3). Refer to Disassembly and Assembly, "Electronic Unit Injector - Remove".
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2. Progressively loosen nuts (4). Begin at the ends of the rocker shaft assembly and work
toward the center. Remove nuts (4).
Note: To avoid distortion of the rocker shaft assembly, each nut should be loosened by a
quarter of a turn at one time. Repeat the procedure until all nuts are loosened.
3. Remove rocker shaft assembly (5).
4. Place temporary identification marks on valve arm bridges (6) and pushrods (7).
Note: Identification will ensure that the valve arm bridges and pushrods can be reinstalled
in the correct position. Do not interchange the positions of used pushrods or pads.
5. Remove valve arm bridges (6) from the valve stems. Remove pushrods (7) from the
cylinder head.
Mon Oct 28 21:48:27 UTC+0800 2019
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