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

Service Repair Manual

Models

299D2 XHP COMPACT TRACK LOADER

299D2 XHP & 299D2 Compact Track Loader DX200001-UP (MACHINE) POWERE...

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Shutdown SIS Previous Screen 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...

Illustration 1

g02871416

2. Remove bolts (1) to remove cover (2) and the gasket.

Illustration 2

g02871419

Illustration 3

g02890104

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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299D2 XHP & 299D2 Compact Track Loader DX200001-UP (MACHINE) POWERE...

Illustration 4

g02871477

Illustration 5

g02871957

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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.

Tue Oct 29 20:58:53 UTC+0800 2019

All Rights Reserved.

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299D2 XHP & 299D2 Compact Track Loader DX200001-UP (MACHINE) POWERE...

1/3

Shutdown SIS Previous Screen 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

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 Tool

Part Number

Part Description

Qty

A

278-4138

Fuel System Protection Gp(1)

1

(1)

This tool can only be used one time.

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299D2 XHP & 299D2 Compact Track Loader DX200001-UP (MACHINE) POWERE...

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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".

Illustration 1

g03880533

2. Remove bolts (1) and cover (2).

Illustration 2

g06050644

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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299D2 XHP & 299D2 Compact Track Loader DX200001-UP (MACHINE) POWERE...

Illustration 3

3/3

g03880622

4. Disconnect tube assembly (6), tube assembly (9), and hose assembly (5).

5. Remove nuts (7) and fuel injection pump (8).

Copyright 1993 - 2019 Caterpillar Inc.

Tue Oct 29 20:59:49 UTC+0800 2019

All Rights Reserved.

Private Network For SIS Licensees.

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299D2 XHP & 299D2 Compact Track Loader DX200001-UP (MACHINE) POWERE...

1/3

Shutdown SIS Previous Screen 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

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 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...

Illustration 1

2/3

g03880622

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).

Illustration 2

g06050644

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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299D2 XHP & 299D2 Compact Track Loader DX200001-UP (MACHINE) POWERE...

Illustration 3

3/3

g03880533

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".

Copyright 1993 - 2019 Caterpillar Inc.

Tue Oct 29 21:00:45 UTC+0800 2019

All Rights Reserved.

Private Network For SIS Licensees.

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2019/10/29

299D2 XHP & 299D2 Compact Track Loader DX200001-UP (MACHINE) POWERE...

1/3

Shutdown SIS Previous Screen 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

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".

Illustration 1

g02871957

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299D2 XHP & 299D2 Compact Track Loader DX200001-UP (MACHINE) POWERE...

Illustration 2

2/3

g02871477

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).

Illustration 3

g02871419

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).

Illustration 4

g02871416

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299D2 XHP & 299D2 Compact Track Loader DX200001-UP (MACHINE) POWERE...

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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".

Copyright 1993 - 2019 Caterpillar Inc.

Tue Oct 29 21:01:40 UTC+0800 2019

All Rights Reserved.

Private Network For SIS Licensees.

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2019/10/29

299D2 XHP & 299D2 Compact Track Loader DX200001-UP (MACHINE) POWERE...

1/3

Shutdown SIS Previous Screen 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

i06616120

Electronic Unit Injector - Remove and Install SMCS - 1290-010

Removal Procedure Table 1 Required Tools Tool

Part Number

A

5F-4764

Pry Bar

1

B

278-4138

Fuel System Protection Gp(1)

1

(1)

Part Description

Qty

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.

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2019/10/29

299D2 XHP & 299D2 Compact Track Loader DX200001-UP (MACHINE) POWERE...

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.

Illustration 1

g06054347

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).

Illustration 2

g06046967

4. Remove seal (6) from unit injector (5).

5. Repeat Steps 2 through 3 for the remaining electronic unit injectors.

Installation Procedure 1. Install electronic unit injector (5) in the reverse order of removal.

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299D2 XHP & 299D2 Compact Track Loader DX200001-UP (MACHINE) POWERE...

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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.

Copyright 1993 - 2019 Caterpillar Inc.

Tue Oct 29 21:02:36 UTC+0800 2019

All Rights Reserved.

Private Network For SIS Licensees.

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2019/10/29

299D2 XHP & 299D2 Compact Track Loader DX200001-UP (MACHINE) POWERE...

1/3

Shutdown SIS Previous Screen 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

i07568873

Turbocharger - Remove and Install SMCS - 1052-010

Removal Procedure Table 1 Required Tools Tool

Part Number

Part Description

Qty

A

-

Loctite C5A Copper Anti-Seize

1

Illustration 1

g02797291

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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299D2 XHP & 299D2 Compact Track Loader DX200001-UP (MACHINE) POWERE...

Illustration 2

g02797290

2. Remove tube assembly (2). Disconnect tune assembly (3) and hose (4).

Illustration 3

g02797292

Illustration 4

g02797293

3. Remove nuts (5) and bolts (6). Remove turbocharger (7) and the gasket.

Installation Procedure 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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299D2 XHP & 299D2 Compact Track Loader DX200001-UP (MACHINE) POWERE...

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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).

Copyright 1993 - 2019 Caterpillar Inc.

Tue Oct 29 21:03:32 UTC+0800 2019

All Rights Reserved.

Private Network For SIS Licensees.

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2019/10/29

299D2 XHP & 299D2 Compact Track Loader DX200001-UP (MACHINE) POWERE...

1/3

Shutdown SIS Previous Screen 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

i06622343

Pressure Sensor (Mass Air Flow) - Remove and Install SMCS - 1058; 1408; 1439-010; 1923-010; 7400

Removal Procedure Removal Procedure

Illustration 1

g03098499

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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299D2 XHP & 299D2 Compact Track Loader DX200001-UP (MACHINE) POWERE...

Illustration 2

g06050677

Location for Skid Steer Loader, Multi-Terrain Loader, and Compact Wheel Loader models.

Illustration 3

g06050682

Location for Compact Wheel Loader models.

2. Disconnect hoses (4). Remove mass air flow sensor assembly (5).

Illustration 4

g03098530

3. Remove screws (6). Remove mass airflow pressure sensor (7).

Installation Procedure

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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) Copyright 1993 - 2019 Caterpillar Inc.

Tue Oct 29 21:04:28 UTC+0800 2019

All Rights Reserved.

Private Network For SIS Licensees.

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299D2 XHP & 299D2 Compact Track Loader DX200001-UP (MACHINE) POWERE...

1/1

Shutdown SIS Previous Screen 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

i04770346

Exhaust Gas Recirculation Valve - Remove and Install SMCS - 108N-010

Removal Procedure

Illustration 1

g02870501

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.

Installation Procedure 1. Install exhaust gas recirculation valve (6) and a new gasket in the reverse order of removal.

Copyright 1993 - 2019 Caterpillar Inc.

Tue Oct 29 21:05:23 UTC+0800 2019

All Rights Reserved.

Private Network For SIS Licensees.

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2019/10/29