299D2 XHP COMPACT TRACK LOADER
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Product: COMPACT TRACK LOADER
Model: 299D2 XHP COMPACT TRACK LOADER HLM
Configuration: 299D2 XHP & 299D2 Compact Track Loader HLM00001-UP (MACHINE) POWERED BY C3.8 Engine
Disassembly and Assembly
C3.8 Engines for Caterpillar Built Machines
Media Number -UENR0129-09
Publication Date -01/09/2015 Date Updated -26/03/2019
Air Inlet Heater - Remove and Install
SMCS - 1090-010
Removal Procedure
Illustration 1 g02870556
1. Disconnect harness assemblies (1).
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Illustration 2
2. Disconnect harness assembly (2) and cable assembly (3).
Illustration 3 g02870576
3. Remove bolts (4) and bolts (5). Remove flange (6), valve assembly (7), air inlet heater (8), and the gaskets.
Installation Procedure
1. Install new gaskets, air inlet heater (8), valve assembly (7), and flange (6) in the reverse order of removal.
a. Tighten the nut for cable assembly (3) to a torque of 4.4 ± 0.9 N·m (38.9 ± 8.0 lb in). Copyright 1993 - 2023 Caterpillar Inc.
Tue Feb 14 01:27:57 UTC+0530 2023
SIS Licensees.
Product: COMPACT TRACK LOADER
Model: 299D2 XHP COMPACT TRACK LOADER HLM
Configuration: 299D2 XHP & 299D2 Compact Track Loader HLM00001-UP (MACHINE) POWERED BY C3.8 Engine
Disassembly and Assembly
C3.8 Engines for Caterpillar Built Machines
Media Number -UENR0129-09 Publication Date -01/09/2015 Date Updated -26/03/2019
i06043451
Alternator - Remove and Install
SMCS - 1405-010
S/N - AN91-UP
S/N - BX91-UP
S/N - CY91-UP
S/N - DY91-UP
S/N - GJ21-UP
S/N - HLM1-UP
S/N - HX21-UP
S/N - LB31-UP
S/N - XES1-UP
Removal Procedure
1. Tilt the radiator. Refer to Operation and Maintenance Manual, "Radiator Tilting".
2. Refer to Operation and Maintenance Manual, "Belts - Inspect/Adjust/Replace".
Illustration 1
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3. Remove guard (1).
Illustration 2
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4. Remove hose (2).
Illustration 3
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5. Remove clip (3). Disconnect cable assembly (4) and harness assembly (5).
Illustration 4
6. Remove bolts (6). Remove alternator (7).
Installation Procedure
1. Install alternator (7) in the reverse order of removal.
a. Tighten cable assembly (4) to a torque of 8 ± 2 N·m (71 ± 18 lb in).
b. Tighten clip (3) to a torque of 6 ± 1 N·m (53 ± 9 lb in). Copyright 1993 - 2023 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees. Tue Feb 14 01:35:52 UTC+0530 2023
Product: COMPACT TRACK LOADER
Model: 299D2 XHP COMPACT TRACK LOADER HLM
Configuration: 299D2 XHP & 299D2 Compact Track Loader HLM00001-UP (MACHINE) POWERED BY C3.8 Engine
Disassembly and Assembly
C3.8 Engines for Caterpillar Built Machines
Media Number -UENR0129-09
Publication Date -01/09/2015 Date Updated -26/03/2019
Boost Pressure Sensor - Remove and Install
SMCS - 1917-010
Removal Procedure
Illustration 1
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g02893620
1. Disconnect harness assembly (1). Remove hose (2). Remove bolts (3) to remove boost pressure sensor (4).
Installation Procedure
1. Install boost pressure sensor (4) in the reverse order of removal.
a. Tighten bolts (3) to a torque of 4 N·m to 5 N·m (35 ± 44 lb in).
Copyright 1993 - 2023 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees.
Tue Feb 14 01:35:30 UTC+0530 2023
Product: COMPACT TRACK LOADER
Model: 299D2 XHP COMPACT TRACK LOADER HLM
Configuration: 299D2 XHP & 299D2 Compact Track Loader HLM00001-UP (MACHINE) POWERED BY C3.8 Engine
Disassembly and Assembly
C3.8 Engines for Caterpillar Built Machines
Media Number -UENR0129-09
Publication Date -01/09/2015 Date Updated -26/03/2019
Camshaft - Remove and Install
SMCS - 1210-010
Removal Procedure
Start By:
a. Remove the front housing.
b. Remove the rocker shaft and pushrods.
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1. Refer to Systems Operation, Testing and Adjusting, "Finding Top Center Position for No.4 Piston".
Illustration 1
2. Mark the alignment of gear (1) and gear (2) for installation purposes.
3. Remove bolts (3) and pulsar gear (4).
2 g02863959
4. Remove bolts (5). Remove camshaft assembly (6).
Installation Procedure
1. Lubricate the camshaft assembly with clean engine oil prior to installation.
2. Ensure that the camshaft assembly is clean and free from wear or damage.
Illustration 3
g02863959
NOTICE
Do not damage the lobes or the bearings when the camshaft is removed or installed.
3. Install camshaft assembly (6). Install bolts (5). Tighten bolts (5) to a torque of 25.5 ± 1.5 N·m (18.8 ± 1.1 lb ft).
Illustration
4
4. Install pulsar gear (4) and screws (3). Tighten screws (3) to a torque of 5.2 ± 0.5 N·m (45.6 ± 4.0 lb in)Ensure that gear (1) and gear (2) are aligned.
5. Lubricate the teeth of the gears with clean engine oil.
6. Refer to Specifications, "Camshaft" for more information.
End By:
a. Install the front housing.
b. Install the rocker shaft and pushrods.
Product: COMPACT TRACK LOADER
Model: 299D2 XHP COMPACT TRACK LOADER HLM
Configuration: 299D2 XHP & 299D2 Compact Track Loader HLM00001-UP (MACHINE) POWERED BY C3.8 Engine
Disassembly and Assembly
C3.8 Engines for Caterpillar Built Machines
Media Number -UENR0129-09
Publication Date -01/09/2015
Camshaft Gear - Remove and Install
SMCS - 1210-010-GE
Removal Procedure
Start By:
a. Remove the camshaft assembly from the engine.
Date Updated -26/03/2019
i04663712
Illustration 1 g01350917
1. Place the camshaft assembly on a suitable support. Use a press to remove camshaft gear (1) from camshaft (4).
2. Remove thrust plate (2) and woodruff key (3) from camshaft (4). Note the orientation of the thrust plate for installation.
Installation Procedure
1. Ensure that all components of the camshaft assembly are clean and free from damage.
Illustration 2 g01350917
2. Install woodruff key (3) and thrust plate (2) to camshaft (4).
Note: Ensure that the machined face of the thrust plate is toward the camshaft.
Always wear protective gloves when handling parts that have been heated.
3. Raise the temperature of camshaft gear (1). Align the camshaft gear with woodruff key (3) and install the camshaft gear to camshaft (4).
4. Refer to Specifications, "Camshaft" for more information.
End By:
a. Install the camshaft assembly to the engine.
Copyright 1993 - 2023 Caterpillar Inc.
Network For SIS Licensees. Tue Feb 14 01:33:03 UTC+0530 2023
Product: COMPACT TRACK LOADER
Model: 299D2 XHP COMPACT TRACK LOADER HLM
Configuration: 299D2 XHP & 299D2 Compact Track Loader HLM00001-UP (MACHINE) POWERED BY C3.8 Engine
Disassembly and Assembly
C3.8 Engines for Caterpillar Built Machines
Media Number -UENR0129-09
Publication Date -01/09/2015
Date Updated -26/03/2019
Camshaft Position Sensor - Remove and Install
SMCS - 1912-010
Removal Procedure
Illustration 1 g02893160
1. Disconnect harness assembly (1).
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2. Remove bolt (2) to remove position sensor (3) and the O-ring seal.
Installation Procedure
1. Install camshaft position sensor (3) and a new O-ring seal in the reverse order of removal.
a. Tighten bolt (2) to a torque of 4.5 ± 0.5 N·m (39.8 ± 4.4 lb in).
1993 - 2023 Caterpillar Inc.
Product: COMPACT TRACK LOADER
Model: 299D2 XHP COMPACT TRACK LOADER HLM
Configuration: 299D2 XHP & 299D2 Compact Track Loader HLM00001-UP (MACHINE) POWERED BY C3.8 Engine
Disassembly and Assembly
C3.8 Engines for Caterpillar Built Machines
Media Number -UENR0129-09 Publication Date -01/09/2015 Date Updated -26/03/2019
Catalyst (SCR) - Remove and Install
SMCS - 1091-010
Removal Procedure
Start By:
a. Remove radiator.
b. Remove air cooler.
c. Remove hydraulic oil cooler.
d. Remove DEF injector.
Illustration 1
i06256854
g03874018
1. Disconnect harness assemblies (4). Remove bolts (1) and reposition sensors (2).
Note: The two NOx sensors have different color coded cables. The outlet NOx temperature sensor is gray and the inlet NOx sensor is black. Mark harness assemblies (4) to ensure that they are installed to the correct NOx sensor during reassembly.
2. Remove bolts (5) and exhaust extension (3).
Illustration 2
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3. Disconnect harness assembly (6) for the Pre NOx sensor, Post NOx Sensor, and SCR Inlet Temperature Sensor.
Illustration 3
4. Remove bolts (7) and bolts (8).
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Illustration 4
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5. Use a suitable lifting device to remove catalyst assembly (10). The weight of catalyst assembly (10) is approximately ().
6. Remove bolts (9) and catalyst assembly (10).
Illustration 5
7. Remove bolts (11) and brackets (12).
g03874645
Illustration 6
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8. Remove clamp assembly (14) and pipe assembly (13).
Illustration 7
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9. Remove bolts (18) and engine lifting eye (17).
10. Remove bolt (19) and bracket (15).
11. Remove bolts (16), bolt (20), bolts (22), and bracket assembly (21).
Illustration 8
12. Remove bolts (24) and bracket (25).
g03875070
13. Remove nuts (26), bolt (27), and base bracket (23).
9
14. Remove bolt (29), bolt (30), nuts (31), and base bracket (28).
Installation Procedure
1. Install catalyst assembly (10) in the reverse order of removal.
a. Tighten nuts (31), bolt (30), bolt (29), bolt (27), nuts (26) to a torque of 124 - 147 N·m (91 - 108 lb ft).
b. Tighten bolts (22), bolts (20), bolt (19), bolts (16), and bolts (18) to a torque of 49 - 55 N·m (36 - 41 lb ft).
c. Tighten clamp assembly (14) and clamp assembly (13) to a torque of 15 ± 2 N·m (133 ± 18 lb in).
d. Tighten bolts (11), bolts (9), bolts (8), and bolts (7) to a torque of 49 - 55 N·m (36 - 41 lb ft).
Copyright 1993 - 2023 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees. Tue Feb 14 01:26:17 UTC+0530 2023
Product: COMPACT TRACK LOADER
Model: 299D2 XHP COMPACT TRACK LOADER HLM
Configuration: 299D2 XHP & 299D2 Compact Track Loader HLM00001-UP (MACHINE) POWERED BY C3.8 Engine
Disassembly and Assembly
C3.8 Engines for Caterpillar Built Machines
Media Number -UENR0129-09 Publication Date -01/09/2015 Date Updated -26/03/2019
Catalyst (SCR) - Remove and Install
SMCS - 1091-010
S/N - AN91-UP
S/N - BX91-UP
S/N - CY91-UP
S/N - DY91-UP
S/N - GJ21-UP
S/N - HLM1-UP
S/N - HX21-UP
S/N - LB31-UP
S/N - XES1-UP
Removal Procedure
Start By:
a. Remove the radiator, air cooler, and hydraulic oil cooler.
i06031915
1
1. Disconnect harness assemblies (2). Remove bolts (1) and reposition sensors (3).
2
2. Disconnect hose assemblies (4) and disconnect harness assembly (5).
Illustration 3
3. Remove bolts (7) and remove exhaust extension (6).
Illustration
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Illustration
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g03782359
4
4. Disconnect harness assembly (10). Remove clamps (8) and remove tube assembly (9).
5
5. Remove mounting bolts (11) and remove catalyst (SCR) (12).
Installation Procedure
1. Install catalyst (SCR) (12) in the reverse order of removal.
Copyright 1993 - 2023 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees. Tue Feb 14 01:25:58 UTC+0530 2023
Illustration
g03782360
Illustration
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Product: COMPACT TRACK LOADER
Model: 299D2 XHP COMPACT TRACK LOADER HLM
Configuration: 299D2 XHP & 299D2 Compact Track Loader HLM00001-UP (MACHINE) POWERED BY C3.8 Engine
Disassembly and Assembly
C3.8 Engines for Caterpillar Built Machines
Media Number -UENR0129-09
Publication Date -01/09/2015 Date Updated -26/03/2019
Coolant Temperature Sensor - Remove and Install
SMCS - 1906-010
Removal Procedure
Illustration 1
1. Disconnect harness assembly (1) .
2. Remove coolant temperature sensor (2) .
Installation Procedure
g02851436
1. Install coolant temperature sensor (2) in the reverse order of removal.
a. Tighten temperature sensor (2) to a torque of 17.5 ± 5.5 N·m (155 ± 49 lb in).
Copyright 1993 - 2023 Caterpillar Inc. All Rights Reserved. Tue Feb 14 01:35:10 UTC+0530 2023
i04815979
Product: COMPACT TRACK LOADER
Model: 299D2 XHP COMPACT TRACK LOADER HLM
Configuration: 299D2 XHP & 299D2 Compact Track Loader HLM00001-UP (MACHINE) POWERED BY C3.8 Engine
Disassembly and Assembly
C3.8 Engines for Caterpillar Built Machines Media Number -UENR0129-09
Crankshaft - Install
SMCS - 1202-012
Installation Procedure Table 1
Required Tools
B 138-7575 Link Bracket 2
C - Three Bond 1217D -
1. Refer to Specifications, "Crankshaft" for more information. If necessary, replace the crankshaft or recondition the crankshaft.
i06620851
2. Ensure that the parent bores for the crankshaft bearings in the cylinder block are clean. Ensure that the threads for the bearing bolts in the cylinder block are clean and free from damage.
3. Clean the crankshaft bearings and the thrust washers. Inspect the bearings and the thrust washers for wear or damage. If necessary, replace the bearings and the thrust washers.
Note: If the crankshaft bearings are replaced, check whether oversize bearings were previously installed. If the thrust washers are replaced, check whether oversize thrust washers were previously installed.
4. Ensure that all of the lubrication passages are clean and free of debris.
This is the sample of the manual click on the download link for complete manual
DOWNLOAD LINK
For some reason if link does not work download this pdf and then click