The document provides instructions for removing and installing an idler gear on a Caterpillar 299D2 XHP compact track loader. The removal procedure involves removing the front housing, ensuring the piston and gear timing marks are aligned, installing a flywheel stopper tool, and removing bolts and plates. The installation procedure specifies cleaning and lubricating parts, ensuring components are flush, and tightening bolts to the specified torque using a flywheel stopper tool.
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Discover the reasons why your BMW’s Active Steering malfunction warning might come on. From electrical glitches to mechanical failures and software anomalies, addressing these promptly with professional inspection and maintenance ensures continued safety and performance on the road, maintaining the integrity of your driving experience.
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5 Warning Signs Your BMW's Intelligent Battery Sensor Needs AttentionBertini's German Motors
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𝘼𝙣𝙩𝙞𝙦𝙪𝙚 𝙋𝙡𝙖𝙨𝙩𝙞𝙘 𝙏𝙧𝙖𝙙𝙚𝙧𝙨 𝙞𝙨 𝙫𝙚𝙧𝙮 𝙛𝙖𝙢𝙤𝙪𝙨 𝙛𝙤𝙧 𝙢𝙖𝙣𝙪𝙛𝙖𝙘𝙩𝙪𝙧𝙞𝙣𝙜 𝙩𝙝𝙚𝙞𝙧 𝙥𝙧𝙤𝙙𝙪𝙘𝙩𝙨. 𝙒𝙚 𝙝𝙖𝙫𝙚 𝙖𝙡𝙡 𝙩𝙝𝙚 𝙥𝙡𝙖𝙨𝙩𝙞𝙘 𝙜𝙧𝙖𝙣𝙪𝙡𝙚𝙨 𝙪𝙨𝙚𝙙 𝙞𝙣 𝙖𝙪𝙩𝙤𝙢𝙤𝙩𝙞𝙫𝙚 𝙖𝙣𝙙 𝙖𝙪𝙩𝙤 𝙥𝙖𝙧𝙩𝙨 𝙖𝙣𝙙 𝙖𝙡𝙡 𝙩𝙝𝙚 𝙛𝙖𝙢𝙤𝙪𝙨 𝙘𝙤𝙢𝙥𝙖𝙣𝙞𝙚𝙨 𝙗𝙪𝙮 𝙩𝙝𝙚 𝙜𝙧𝙖𝙣𝙪𝙡𝙚𝙨 𝙛𝙧𝙤𝙢 𝙪𝙨.
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2. Shutdown SIS
Previous Screen
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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3. 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).
Illustration 2 g02872045
4. Remove idler gear (3), shaft (4), and plate (5).
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4. Illustration 3 g02920337
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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5. Shutdown SIS
Previous Screen
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
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
Tool Part Number Part Description Qty
A 393-2572 Flywheel Stopper 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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6. Illustration 1 g06066040
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).
Installation Procedure
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).
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7. Shutdown SIS
Previous Screen
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
i06618977
Housing (Front) - Remove and Install
SMCS - 1151-010
Removal Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 393-2572 Flywheel Stopper 1
B - Three Bond 1217H -
Illustration 1 g02865846
1. Remove bolts (1), retainer (2), and crankshaft pulley (3).
2. Disconnect speed sensors (4). Remove belt (5).
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8. Illustration 2 g02865956
3. Disconnect wire assembly (6), cable assembly (7), and harness assembly (8).
Illustration 3 g02866018
4. Remove bolts (9) to remove alternator (10).
Illustration 4 g02866036
5. Remove bolts (11) to remove cover (12) and the gasket.
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9. Illustration 5 g02866067
6. Install Tooling (A) onto the flywheel. Remove bolt (13) to remove crankshaft pulley (14).
7. Remove bolts (15) to remove front housing (16).
Installation Procedure
Illustration 6 g02866067
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10. Illustration 7 g02891536
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).
Illustration 8 g02866036
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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14. 1. Install fumes disposal filter (4) in the reverse order of removal.
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15. Shutdown SIS
Previous Screen
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
i06552041
Valve Mechanism Cover - Remove and Install
SMCS - 1107-010
Removal Procedure
Illustration 1 g02864717
1. Disconnect tube assemblies (1).
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16. Illustration 2 g02864757
2. Disconnect harness assemblies (2) and hose (3).
Illustration 3 g02864776
3. Remove tube assembly (4).
Illustration 4 g02890636
4. Mark the terminal leads of wire assemblies (5) for installation purposes. Remove nuts (6) to
disconnect wire assemblies (5)
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17. Illustration 5 g02864996
5. Remove bolts (7). Remove cover (8) and gasket (9).
6. Remove bolts (10) to remove valve mechanism cover (11).
7. Remove gasket (12).
Installation Procedure
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).
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18. Thank you very much for
your reading. Please Click
Here. Then Get COMPLETE
MANUAL. NO WAITING
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19. Shutdown SIS
Previous Screen
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
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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21. Illustration 4 g06054816
6. Mark the terminal leads of wire assemblies (7) for installation purposes. Remove nuts (8) to
disconnect wires assemblies (7).
Illustration 5 g06054846
7. Remove bolts (9). Remove cover (10) and gasket (11).
8. Remove bolts (12) to remove valve cover mechanism (13).
9. Remove gasket (14).
Installation Procedure
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).
Copyright 1993 - 2019 Caterpillar Inc.
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22. Shutdown SIS
Previous Screen
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
i04663909
Rocker Shaft and Pushrod - Remove
SMCS - 1102-011; 1208-011
Removal Procedure
Start By:
a. Remove the valve mechanism cover.
Illustration 1 g02867016
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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23. Illustration 2 g02867022
Illustration 3 g02867180
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.
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