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
Air Inlet Heater - Remove and Install
SMCS - 1090-010
Removal Procedure
Illustration 1 g02870556
1. Disconnect harnessassemblies(1).
Date Updated -19/05/2016
i04770500
2
2. Disconnect harnessassembly (2) and cable assembly (3).
3
3. Remove bolts (4) and bolts(5). Remove flange (6), valve assembly (7), air inlet heater (8), and the gaskets.
Installation Procedure
1. Install newgaskets, 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 - 2020 Caterpillar Inc.
Fri Jun 5 12:26:09 UTC+0530 2020
Illustration
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
i06621882
Alternator - Remove and Install
SMCS - 1405-010
Removal Procedure
1. Refer to Operation and Maintenance Manual, "Radiator Tilting".
2. Refer to Operation and Maintenance Manual, "Belts - Inspect/Adjust/Replace".
3. Refer to Operation and Maintenance Manual, "Battery or Battery Cable - Inspect/Replace".
Illustration 1 g06050364 SSL, MTL, andCTLmodels.
Illustration 2 g06050387 CWLmodels.
4. For SSL, MTL, and CTL models refer to illustration 1. Loosen quarter turn fasteners (2) and remove guard (1).
For the CWL models, refer to illustration 2. Remove bolts(2) and guard (1).
Illustration 3 g06050407
5. For the SSL, MTL, and CTL models, remove hose (3). For the CWL (910K/914K) go to Step 6.
4
6. Disconnect wire assembly (4), cable assembly (5), and wire assembly (6).
Illustration 5
7. Remove bolts (7). Remove alternator (8).
g06050420
Installation Procedure
1. Install alternator (8) in the reverse order of removal.
a. Tighten bolts (7) to a torque of 69 N·m ± 10 N·m (51 ± 7 lb ft). Copyright 1993 - 2020 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees.
Illustration
g06050414
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
Boost Pressure Sensor - Remove and Install
SMCS - 1917-010
Removal Procedure
Illustration 1
i06621308
g02893620
1. Disconnect harnessassembly (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 - 2020 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees.
Fri Jun 5 12:41:11 UTC+0530 2020
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
i04663730
Camshaft - Remove and Install
SMCS - 1210-010
Removal Procedure
Start By:
a. Remove the front housing.
b. Remove the rocker shaft and pushrods.
1. Refer to SystemsOperation, 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).
This is the sample of the manual
Click on the download link for complete Manual
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 isclean and free from wear or damage.
Illustration 3
g02863959
NOTICE
Do not damage the lobes or the bearings whenthe 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 gearswith 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 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
i04663712
Camshaft Gear - Remove and Install
SMCS - 1210-010-GE
Removal Procedure
Start By:
a. Remove the camshaft assembly from the engine.
Illustration 1 g01350917
1. Place the camshaft assembly on a suitable support. Use a pressto 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 istoward the camshaft.
Always wear protective gloveswhen 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.
1993 - 2020 Caterpillar Inc.
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
Camshaft Position Sensor - Remove and Install
SMCS - 1912-010
Removal Procedure
Illustration 1 g02893160 1. Disconnect harnessassembly (1).
i04783390
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).
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
Catalyst (SCR) - Remove and Install
SMCS - 1091-010
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
Start By:
a. Remove radiator.
b. Remove air cooler.
c. Remove hydraulic oil cooler.
d. Remove DEF injector.
i06256854
1
g03874018
1. Disconnect harnessassemblies(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
g03874275
3. Disconnect harnessassembly (6) for the Pre NOx sensor, Post NOx Sensor, and SCR Inlet Temperature Sensor.
Illustration
3
4. Remove bolts (7) and bolts(8).
Illustration 4
g03874500
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
6
8. Remove clamp assembly (14) and pipe assembly (13).
Illustration 7
g03874689
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 - 2020 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees. Fri Jun 5 12:24:49 UTC+0530 2020
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
Coolant Temperature Sensor - Remove and Install
SMCS - 1906-010
Removal Procedure
Illustration 1 g02851436
1. Disconnect harnessassembly (1) .
2. Remove coolant temperature sensor (2) .
Installation Procedure
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 - 2020 Caterpillar Inc. All Rights Reserved. Fri Jun 5 12:40:20 UTC+0530 2020
i04815979
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
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 bearingsand the thrust washers.
Note: If the crankshaft bearings are replaced, check whether oversize bearings were previously installed. If the thrust washersare replaced, check whether oversize thrust washers were previously installed.
4. Ensure that all of the lubrication passages are clean and free of debris.
1
5. Install the upper thrust bearing (10) and the upper main bearings (9).
Note: The upper thrust bearing (10) is installed at the Number (4) bearing cap with the oil groove facing outward.
2
g02861360
6. Use a suitable lifting device to install crankshaft (8). The weight of crankshaft (8) is approximately 32 kg (70 lb).
Note: Do not damage the finished surfaceson the crankshaft.
Illustration
g02861383
Illustration
Illustration 3 g02861257
7. Apply clean engine oil onto bolts (4). Install bearing caps(5) and install bolts(4).Tighten bolts (4) to a torque of 142.5 ± 4.5 N·m (105.1 ±3.3 lb ft).
8. Install the lower thrust bearing (7) and the lower main bearings (6).
Note: The lower thrust bearing (7) is installed at the Number (4) bearing cap with the oil groove facing outward.
Illustration 4
g02861239
9. Apply Tooling (C) onto the mating surface of crankcase (3). Use Tooling (B) and a suitable lifting device to install crankcase (3). Install bolts(2). Tighten bolts (2) to a torque of 52 ± 3 N·m (38.4 ± 2.2 lb ft).
10. Rotate engine (1) to the upright position.
11. Check the crankshaft end play, side clearance, and oil clearance. Refer to Specifications, "Crankshaft" for more information.
12. If the crankshaft has been reground or if the crankshaft has been replaced, the height of the piston above the cylinder block must be inspected to determine the correct head gasket thickness. Refer to Specification, "Cylinder Head" and the section on Selecting the Correct Cylinder Head Gasket.
13. Remove engine (1) from Tooling (A).
End By:
a. Install the pistons and connecting rods.
b. Install the front housing.
c. Install the flywheel housing.
d. Install the oil strainer.
e. Install the cylinder head
This is the sample of the manual
Click on the download link for complete Manual
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
Crankshaft - Remove
SMCS - 1202-011
Removal Procedure Table 1
Required Tools
Start By:
a. Remove the cylinder head
b. Remove the oil strainer.
c. Remove the flywheel housing.
d. Remove the front housing.
e. Remove the pistons and connecting rods.
NOTICE
If the crankshaft has been reground or if the crankshaft has been replaced, the height of the piston above the cylinder blockmust be inspectedto determine the correct head gasket thickness. Refer to Specification, "Cylinder Head"and the section on Selecting the Correct Cylinder Head Gasket.
i06620815
