Caterpillar Cat 299D2 XHP COMPACT TRACK LOADER (Prefix DX2) Service Repair Manual (DX200001 and up).pdf

Service Repair Manual
Models
299D2 XHP COMPACT
TRACK LOADER

Shutdown SIS
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Product: COMPACT TRACK LOADER
Model: 299D2 XHP COMPACT TRACK LOADER DX2
Configuration: 299D2 XHP & 299D2 Compact Track Loader DX200001-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
i06611151
Fuel Injection Pump - Remove
SMCS - 1251-011
Removal Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 278-4138 Fuel System Protection Gp(1)
1
(1)
This tool can only be used one time.
Do not open the high pressure fuel system without allowing the fuel
system to purge. After the engine has shut down, allow the fuel system to
purge for ten minutes. This operating fuel system contains high
pressure. Exposure to high pressure fuel can result in personal injury.
Note: Use Caterpillar Electronic Technician (ET) to verify that the fuel system pressure is at zero
before opening the fuel system.
Note: Use Tooling (A) after any fuel line has been disconnected.
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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299D2 XHP & 299D2 Compact Track Loader DX200001-UP (MACHINE) POWERE...
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Illustration 1 g02871416
2. Remove bolts (1) to remove cover (2) and the gasket.
3. Mark the alignment of the pump gear and the idler gear for installation purposes. Remove
nut (3). Use a suitable gear puller to remove gear (4).
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4. Disconnect tube assemblies (5) and tube assembly (6).
5. Remove nuts (7) to remove fuel injection pump (8).
Copyright 1993 - 2019 Caterpillar Inc.
All Rights Reserved.
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Tue Oct 29 20:58:53 UTC+0800 2019
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Shutdown SIS
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i06622292
Fuel Injection Pump - Remove
SMCS - 1251-011
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
A 278-4138 Fuel System Protection Gp(1)
1
(1)
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Note: Use Tooling (A) after any fuel line has been disconnected.
Piston".
2. Remove bolts (1) and cover (2).
3. Mark the alignment of the pump gear and the idler gear for installation purposes. The
alignment mark is shown at the location with the arrow in Illustration 2. Remove nut (4).
Use a suitable gear puller to remove gear (3).
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4. Disconnect tube assembly (6), tube assembly (9), and hose assembly (5).
5. Remove nuts (7) and fuel injection pump (8).
Tue Oct 29 20:59:49 UTC+0800 2019
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Shutdown SIS
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i06275722
Fuel Injection Pump - Install
SMCS - 1251-012
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
Installation Procedure
Piston".
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2. Install fuel injection pump (8). Install nuts (7). Tighten nuts (7) to a torque of
25.5 ± 1.5 N·m (226 ± 13 lb in).
3. Connect overflow return tube (5) to a torque of 16 N·m to 19 N·m (142 lb in to 168 lb in),
tube assembly (6) to a torque of 23 N·m to 36 N·m (17 lb ft to 27 lb ft), and tube assembly
(9) to a torque of 8 N·m to 12 N·m (71 lb in to 106 lb in).
4. Ensure the alignment mark shown in Illustration 2 is aligned between the pump gear and the
idler gear.
5. Replace the O-ring seal between the pump and the engine.
6. Line up the key of the supply pump gear and install the supply pump with a gear puller.
7. Remove gear puller and tighten nut (4) to a torque of 64 ± 5 N·m (47 ± 3 lb ft).
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8. Install cover (2) and bolts (1). Tighten bolts (1) to a torque of 25.5 ± 1.5 N·m
(226 ± 13 lb in).
Note: If a new supply pump is installed, a "Fuel Pump Calibration Override" must be
performed using CAT Refer to Troubleshooting, UENR3423, "CAT ET Service Features,
Fuel Pump Calibration".
Tue Oct 29 21:00:45 UTC+0800 2019
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Shutdown SIS
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i06283437
Fuel Injection Pump - Install
SMCS - 1251-012
Piston".
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2. Install fuel injection pump (8). Install nuts (7). Tighten nuts (7) to a torque of
25.5 ± 1.5 N·m (18.8 ± 1.1 lb ft).
3. Connect tube assembly (6) and tube assemblies (5). Tighten tube assembly (6) to a torque of
17.5 ± 1.5 N·m (154.9 ± 13.3 lb in). Tighten tube assemblies (5) to a torque of
29.5 ± 6.5 N·m (21.8 ± 4.8 lb ft).
4. Install gear (4). Install nut (3). Tighten nut (3) to a torque of 63.5 ± 4.5 N·m
(46.9 ± 3.3 lb ft).
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5. Install cover (2) and a new gasket. Install bolts (1). Tighten bolts (1) to a torque of
25.5 ± 1.5 N·m (18.8 ± 1.1 lb ft).
Note: If a new supply pump is installed, a "Fuel Pump Calibration Override" must be
performed using CAT Refer to Troubleshooting, UENR3423, "CAT ET Service Features,
Fuel Pump Calibration".
Tue Oct 29 21:01:40 UTC+0800 2019
3/3
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Shutdown SIS
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i06616120
Electronic Unit Injector - Remove and Install
SMCS - 1290-010
Removal Procedure
Table 1
Required Tools
A 5F-4764 Pry Bar 1
B 278-4138 Fuel System Protection Gp(1)
1
(1)
Start By:
a. Remove the valve mechanism cover.
Note: Use Tooling (B) after any fuel line has been disconnected.
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Note: If new injectors are installed or if injectors are switched between cylinders, refer to
REHS9707 to install new injector trim codes in the Engine ECM and to register them on-line.
1. Remove overflow joint screws (4) and overflow pipe (1).
2. Remove nut (2) to remove injector clamp (3).
3. Use Tooling (A) to remove electronic unit injector (5).
4. Remove seal (6) from unit injector (5).
5. Repeat Steps 2 through 3 for the remaining electronic unit injectors.
1. Install electronic unit injector (5) in the reverse order of removal.
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a. Install a new seal (6) onto electronic unit injector (5). Install electronic unit injector
(5).
b. Install nozzle clamp (3). Install nut (2). Tighten nut (2) to a torque of 26 ± 2 N·m
(19 ± 1 lb ft).
c. Install overflow pipe (1). Tighten overflow joint screws (4) to a torque of 11 ± 1 N·m
(97 ± 9 lb in).
End By:
a. Install valve mechanism cover.
Tue Oct 29 21:02:36 UTC+0800 2019
3/3
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Shutdown SIS
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i07568873
Turbocharger - Remove and Install
SMCS - 1052-010
Removal Procedure
Table 1
Required Tools
A - Loctite C5A Copper Anti-Seize 1
Note: Machines with engine serial number 2HS00001-Up will have bolts, washers, and
nuts.
1. Using a suitable stud puller or double nut remove nuts and studs (1).
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2. Remove tube assembly (2). Disconnect tune assembly (3) and hose (4).
3. Remove nuts (5) and bolts (6). Remove turbocharger (7) and the gasket.
1. Refer to Systems Operation, Testing and Adjusting, "Turbocharger - Inspect" for more
information. If the turbocharger is worn, the complete turbocharger must be replaced.
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2. Install turbocharger (7) in the reverse order of removal.
a. Apply Tooling (A) to the threads of bolts (6) and nuts (5).
Tue Oct 29 21:03:32 UTC+0800 2019
3/3
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Shutdown SIS
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i06622343
Pressure Sensor (Mass Air Flow) - Remove and Install
SMCS - 1058; 1408; 1439-010; 1923-010; 7400
Removal Procedure
Removal Procedure
1. Disconnect harness assembly (1). Remove clip (2). Loosen clamps (3).
Note: For Skid Steer Loader, Multi-Terrain Loader, and Compact Wheel Loader models
built in 2012 and 2013, the two adjacent intake hoses may not be notched which sets the
orientation of the sensor. If the intake hoses are not notched, then mark the position of the
mass air flow pressure sensor for installation purposes.
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Location for Skid Steer Loader, Multi-Terrain Loader, and Compact Wheel Loader models.
Location for Compact Wheel Loader models.
2. Disconnect hoses (4). Remove mass air flow sensor assembly (5).
3. Remove screws (6). Remove mass airflow pressure sensor (7).
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1. Install mass airflow pressure sensor (7) in the reverse order of removal.
a. Tighten screws (6) to a torque of 1.17 N·m to 1.77 N·m (10.36 lb in to 15.67 lb in)
Tue Oct 29 21:04:28 UTC+0800 2019
3/3
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Shutdown SIS
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i04770346
Exhaust Gas Recirculation Valve - Remove and Install
SMCS - 108N-010
Removal Procedure
1. Disconnect tube assembly (1), hose (2), and harness assembly (3).
2. Remove bolts (4) and nuts (5).
3. Remove exhaust gas recirculation valve (6) and the gasket.
1. Install exhaust gas recirculation valve (6) and a new gasket in the reverse order of removal.
Tue Oct 29 21:05:23 UTC+0800 2019
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Caterpillar Cat 299D2 XHP COMPACT TRACK LOADER (Prefix DX2) Service Repair Manual (DX200001 and up).pdf

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Caterpillar Cat 299D2 XHP COMPACT TRACK LOADER (Prefix DX2) Service Repair Manual (DX200001 and up).pdf