Caterpillar cat 297 d xhp multi terrain loader (prefix hp7) service repair manual (hp700001 and up)

Service Repair Manual
Models
297D XHP MULTI TERRAIN
LOADER

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Product: MULTI TERRAIN LOADER
Model: 297D XHP MULTI TERRAIN LOADER HP7
Configuration: 297D/297D XHP Multi Terrain Loader HP700001-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".
1/3297D/297D XHP Multi Terrain Loader HP700001-UP (MACHINE) POWERED BY ...
2019/10/26https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis...

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).

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.
Private Network For SIS Licensees.
Sat Oct 26 09:19:18 UTC+0800 2019

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i06283437
Fuel Injection Pump - Install
SMCS - 1251-012
Installation Procedure
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".

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).

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".
Sat Oct 26 09:20:14 UTC+0800 2019

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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)
This tool can only be used one time.
Start By:
a. Remove the valve mechanism cover.
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 (B) after any fuel line has been disconnected.

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.

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.
Sat Oct 26 09:21:10 UTC+0800 2019

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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).

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.

2. Install turbocharger (7) in the reverse order of removal.
a. Apply Tooling (A) to the threads of bolts (6) and nuts (5).
Sat Oct 26 09:22:05 UTC+0800 2019

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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.

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).

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)
Sat Oct 26 09:23:01 UTC+0800 2019

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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.
Sat Oct 26 09:23:57 UTC+0800 2019

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i06285667
Exhaust Manifold - Remove and Install
SMCS - 1059-010
Removal Procedure
Start By:
a. Remove turbocharger.
1. Remove bolts (2) and tube assembly (1).

2. Remove nuts (3), bolts (6), bolts (7), and cover (8) to remove exhaust manifold (5) and
gasket (4).
1. Install exhaust manifold (5) in the reverse order of removal.
a. If, below BZZ999 tighten bolts (6) to a torque of 24 N·m to 27 N·m
(212 lb in to 239 lb in).
b. If, above BY0001 or if above 2CL001 tighten bolts (6) to a torque of
30 N·m to 34 N·m (266 lb in to 301 lb in).
Note: Refer to REHS7930 to understand the serial number format.
Sat Oct 26 09:24:53 UTC+0800 2019

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i04861859
Diesel Particulate Filter - Disassemble
SMCS - 108F-015
Disassembly Procedure
Wear goggles, gloves, protective clothing, and a National Institute for
Occupational Safety and Health (NIOSH) approved P95 or N95 half-
face respirator when handling a used Diesel Particulate Filter or
Catalytic Converter Muffler. Failure to do so could result in personal
injury.
NOTICE
Do not strike any part of the assembly of the Diesel Particulate Filter
(DPF). Do not allow any object to contact the internal element of the
DPF. If the internal element of the DPF becomes damaged, the
assembly must be replaced.
1. Mark the position of components for installation purposes.

Caterpillar cat 297 d xhp multi terrain loader (prefix hp7) service repair manual (hp700001 and up)

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Caterpillar cat 297 d xhp multi terrain loader (prefix hp7) service repair manual (hp700001 and up)