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The CE plate is installed on machines for EEC countries only. It is located on the muffler guard and contains the following information:
Machine PIN ____________________
Model ____________________
Engine Power ____________________
Machine Weight ____________________
Copyright 1993 - 2024 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees. Tue Nov 26 22:07:51 UTC+0530 2024
Product: ARTICULATED TRUCK
Model: D20D ARTICULATED TRUCK 9MG
Configuration: D20D & D250D ARTICULATED TRUCK 9MG00001-UP (MACHINE) POWERED BY 3116 ENGINE
Operation and Maintenance Manual
D20D AND D250D ARTICULATED TRUCK
Media Number -SEBU6516-02
Specifications
Publication Date -21/03/1995 Date Updated -11/10/2001
Basic machine shipping specifications are listed below.
D20D
Approximate Weight ... 15000 kg (33100 lbs)
Overall Height ... 3280 mm (129 in)
Overall Width ... 2750 mm (108 in)
Overall Length ... 8435 mm (332 in)
D250D
Approximate Weight ... 17000 kg (37500 lbs)
Overall Height ... 3215 mm (127 in)
Overall Width ... 2485 mm (98 in)
Overall Length ... 9620 mm (379 in)
Copyright 1993 - 2024 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees.
Tue Nov 26 22:07:35 UTC+0530 2024
Product: ARTICULATED TRUCK
Model: D20D ARTICULATED TRUCK 9MG
Configuration: D20D & D250D ARTICULATED TRUCK 9MG00001-UP (MACHINE) POWERED BY 3116 ENGINE
Operation
and Maintenance Manual
D20D AND D250D ARTICULATED TRUCK
Media Number -SEBU6516-02
Model Views
Publication Date -21/03/1995 Date Updated -11/10/2001
Hydraulic Tank (1), Cab (2), Engine (3).
Batteries (4), Fuel Tank (5), Transmission (6), Oscillating Hitch (7).
Copyright 1993 - 2024 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees.
Tue Nov 26 22:07:19 UTC+0530 2024
Product: ARTICULATED TRUCK
Model: D20D ARTICULATED TRUCK 9MG
Configuration: D20D & D250D ARTICULATED TRUCK 9MG00001-UP (MACHINE) POWERED BY 3116 ENGINE
Operation and Maintenance Manual
D20D AND D250D ARTICULATED TRUCK
Media Number -SEBU6516-02 Publication Date -21/03/1995 Date Updated -11/10/2001
Foreword
Literature Information
This manual should be stored in the operators compartment in the literature holder or seat back storage area.
This manual contains safety, operation, transportation, lubrication and maintenance information.
Some photographs or illustrations in this publication show details or attachments that may be different from your machine. Guards and covers may have been removed for illustrative purposes.
Continuing improvement and advancement of product design may have caused changes to your machine which are not included in this publication. Read - study - and keep this manual with the machine.
Whenever a question arises regarding your machine, or this publication, please consult your Caterpillar dealer for the latest available information.
Safety
The safety section lists basic safety precautions. In addition, this section identifies the text and locations of warning labels used on the machine.
Read and understand the basic precautions listed in the safety section before operating or performing lubrication, maintenance and repair on this product.
Operation
The operation section is a reference for the new operator and a refresher for the experienced one. This section includes a discussion of gauges, switches, machine controls, attachment controls, transportation and towing information.
Illustrations guide the operator through correct procedures for checking, starting, operating and stopping the machine.
Operating techniques outlined in this publication are basic. Skill and techniques develop as the operator gains knowledge of the machine and its capabilities.
Maintenance
The maintenance section is a guide to equipment care. The illustrated, step-by-step instructions are grouped by servicing interval. Items without specific intervals are listed under "When Required" topics. Items in the "Maintenance Intervals" chart are referenced to detailed instructions that follow.
Maintenance Intervals
Use the service hour meter to determine servicing intervals. Calendar intervals shown (daily, weekly, monthly, etc.) may be used instead of service hour meter intervals if they provide more convenient servicing schedules and approximate the indicated service hour meter reading. Recommended service should always be performed at the interval that occurs first.
Under extremely severe, dusty or wet operating conditions, more frequent servicing than is specified in the "Maintenance Interval" chart may be necessary.
Perform service on items at multiples of the original requirement. For example, at "Every 500 Service Hours or 3 Months", also service those items listed under "Every 250 Service Hours or Monthly", "Every 50 Service Hours or Weekly" and "Every 10 Service Hours or Daily".
Machine Description
This machine is powered by a 3116 direct injection diesel engine. It has a full power shift planetary transmission with five forward and two reverse gears. All wheels are driven and the machine has a lockable, inter-axle differential. The machine has disc brakes on all axles and hydraulic power amplifier steering.
The machine is designed primarily for hauling materials in a wide variety of applications.
Machine Storage
For complete storage information refer to Special Instruction SEHS9031, "Storage Procedure for Caterpillar Products".
Copyright 1993 - 2024 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees. Tue Nov 26 22:05:51 UTC+0530 2024
Product: ARTICULATED TRUCK
Model: D20D ARTICULATED TRUCK 9MG
Configuration: D20D & D250D ARTICULATED TRUCK 9MG00001-UP (MACHINE) POWERED BY 3116 ENGINE
Operation and Maintenance Manual
D20D AND D250D ARTICULATED TRUCK Media Number -SEBU6516-02
Literature Reference Section
Caterpillar Reference Material
The following literature can be obtained through any Caterpillar Dealer.
SEBD0518, "Know Your Cooling System"
SEBD0970, "Coolant and Your Engine"
SEBD0717, "Diesel Fuels and Your Engine"
SEHS7067, "Fuels Recommendations for Caterpillar Diesel Engines"
SEBU5898, "Cold Weather Recommendations Operation and Maintenance Manual"
SEBD0640, "Oil and Your Engine"
SENR8225, Service Manual
SEBP8506, Parts Manual
SEHS7392, "Storage of Diesel Engines"
SEHS9031, "Storage Procedure for Caterpillar Products"
SEBF8029, "Guidline for Reuseable Parts and Salvage Operations" (An index of publications on reuseability or salvage of used parts.)
SEBU5935, Safety Manual
Additional Reference Material
ASTM D2896 TBN Measurements (Can normally be obtained from your local technological society, library or college.)
SAE J313 Diesel Fuels (Found in the SAE handbook or can be obtained from any local library, college or technological society.)
SAE J754 Nomenclature (Normally found in the SAE handbook.)
SAE J183 Classification (Normally found in the SAE handbook.)
Machine Decommissioning and Disposal
Machine decommissioning and disposal will vary with local regulations. Contact the nearest Caterpillar dealer for additional information. Copyright 1993 - 2024 Caterpillar Inc.
Product: ARTICULATED TRUCK
Model: D20D ARTICULATED TRUCK 9MG
Configuration: D20D & D250D ARTICULATED TRUCK 9MG00001-UP (MACHINE) POWERED BY 3116 ENGINE
Operation and Maintenance Manual
D20D AND D250D ARTICULATED TRUCK
Media Number -SEBU6516-02
Publication Date -21/03/1995
Cooling System Specifications
Coolant Information
Date Updated -11/10/2001
Diesel engine operating temperatures have increased to improve engine efficiency. This means proper cooling system maintenance is especially important. Overheating, overcooling, pitting, cavitation erosion, cracked heads, piston seizures and plugged radiators can result from cooling system failures. Proper coolant is critical, as is the quality of fuel and lubricating oil. Maintenance practices may need to be re-evaluated to properly maintain the engine's cooling system. It is important that this section be read carefully.
NOTICE
Never operate an engine without a thermostat in the cooling system. The thermostat maintains the engine coolant at the proper operating temperature.
Never add coolant or water to an overheated engine, engine damage can result. Allow the engine to cool first. Filling at over 5 U.S. gallon (20L) per minute can cause air pockets in the cooling system.
DO NOT use Dowtherm 209 Full-Fill coolant.
Caterpillar does not recommend the use of cooling system solutions that are intended to stop leaks. Use of these products may result in engine damage.
Caterpillar recommends that the coolant mixture contain a minimum of 30% Caterpillar Antifreeze, or equivalent.
The cooling system should be protected with a minimum of 3% concentration of liquid supplemental cooling additive at all times, regardless of the concentration of antifreeze.
If the engine is to be stored in, or shipped to, an area with freezing temperatures, the cooling system must be protected to the lowest expected outside (ambient) temperature.
Check the specific gravity of the coolant solution frequently in cold weather to ensure adequate freeze protection.
Coolant Mixture for Caterpillar Engines
Proper engine coolant is a combination of water, antifreeze and supplemental cooling additive. Each ingredient of the mixture must meet specific guidelines for the engine coolant to perform properly. The coolant mixture used in Caterpillar engines must provide the following functions:
* Adequate heat transfer.
* Cavitation erosion protection.
* Freeze and boil protection.
* Sludge and scale protection.
* Corrosion protection.
* Compatibility with system hoses and seals.
Coolant Water
All water is corrosive at engine operating temperature. Distilled or deionized water is recommended because of less mineral drop out than hard or tap water. Tap water, even artificially softened with salt, is not recommended for use in your engine's cooling system.
Calcium, magnesium, chlorides and sulphates are all minerals that make up the disolved solids in the water. Excessive amounts of these minerals in hard water can combine with supplemental coolant additives (silicates and phosphates) to form sludge or scale deposits. The mineral deposits (silicates, phosphates, calcium and magnesium) reduce the effectiveness of the cooling system, especially after a number of heating and cooling cycles. They may collect on hot internal surfaces of the engine and cooling system to reduce the effectiveness of the cooling system.
If distilled or de-ionized water is NOT available, use water that meets the minimum acceptable requirements in the chart. To determine your water characteristics, contact the local water department, agricultural agent or an independent laboratry to perform the testing service.
Antifreeze
If an engine is operated with supplemental additive treated water and no glycol, do NOT add Caterpillar antifreeze. The increase in supplemental additive in the coolant could cause damage to the cooling system.
NOTICE
Caterpillar recommends a coolant mix comprising a minimum of 30% Caterpillar Antifreeze with distilled or deionized water. Antifreeze concentration should provide protection to the lowest expected outside (ambient) temperature.
Check the specific gravity of the antifreeze solution frequently in cold weather to ensure adequate freeze protection. Premix coolant solution to provide protection to the lowest expected outside (ambient) temperature. Pure undiluted antifreeze will freeze at -23°C (-10°F).
Do not exceed a coolant mixture of 60% antifreeze to water since a concentration above 60% antifreeze will reduce the engine's freeze protection, and increase the possibility of deposit formation in the cooling system due to failure to absorb the higher concentration of supplemental additive.
Use Caterpillar Antifreeze or any low silicate (ethylene or propylene glycol) antifreeze that meets ASTM D4985-89 (GM Specification 6038-M) requirements. Most commercial antifreezes are formulated for gasoline engine applications and have high silicate content. Caterpillar Antifreeze is formulated with a low silicate content and the proper coolant additives for heavy duty diesel engines. It is available through your Caterpillar dealer as follows:
Adding pure antifreeze as a make up solution for cooling system top-up is an unacceptable practice. Add antifreeze premixed with acceptable water to the same freeze protection as your cooling system.
Use the antifreeze concentration chart to assist in determining the concentration of Caterpillar antifreeze to use.
Check the coolant solution frequently in cold weather for glycol concentration with the 5P0957 or 5P3514 Coolant Tester (for Caterpillar products) to ensure adequate freeze protection. The testers are identical apart from the temperature scales (°C or °F) and give immediate readings for antifreeze/coolants that contain ethylene or propylene glycol.
If propylene glycol based antifreeze is used, DO NOT allow concentration greater than 50/50 antifreeze to water mixture. The measurement must be made with a refractive - type tester (5P0957 or 5P3514 Coolant Tester), rather than commercially available hydrometer - type testers. The hydrometer type can be used for testing ethylene glycol based antifreeze mixtures.
Supplemental Coolant Additive (Conditioner or Inhibitor)
The cooling system must contain supplemental coolant additives (conditioner or inhibitor) to control corrosion, cavitation and deposits. It is also necessary to prevent rust, scale, pitting and/or corrosion of engine parts contacted by coolant. The cooling system should be protected with a minimum of 3% concentration at all times, regardless of the concentration of antifreeze. Use supplemental coolant additive OR an element, (if equipped) to maintain 3-6% concentration in the system.
NOTICE
Never use an antifreeze/water coolant only, in Caterpillar engines. Supplemental additives must be used regardless of the antifreeze concentration.
Caterpillar or other manufactures products can be used as the supplemental additive. Do not mix Caterpillar Supplemental Additive (conditioner) liquid or elements with the other commercial products available; select a cooling system treatment and use it exclusively.
Excessive concentration of supplemental coolant additive can form deposits which may cause engine damage, reduce the engines heat transfer characteristics and could also accelerate water pump seal wear.
Use an 8T5296 Test Kit to check and monitor the SCA concentration for antifreeze/water coolant mixture. The Caterpillar 8T5296 Test Kit checks for concentration of nitrates in the coolant solution. Note: Some other manufactures supplemental coolant additives are phosphate based and the 8T5296 Test Kit will not provide accurate results. Caterpillar recommends that their test kit be used to check coolant solution concentration.
If other than Caterpillar products are used as the supplemental additive, follow the manufactures recommendation for cooling system treatment and test evaluation. Commercial supplemental additive products must contain silicates and a minimum of 70gr/U.S. gallon (1200ppm) nitrites.
Supplemental coolant additive must be added every 250 service hours between initial fill and the every 300 service hours cooling system maintenance interval. Install a supplemental coolant additive maintenance element (if equipped) OR .47 liter (1 U.S. pint/16 oz) for each 75 liter (19.5 gal) of cooling system capacity, every 250 service hours.
Caterpillar liquid supplemental cooling additive (conditioner) is available through your Caterpillar dealer in the following quantities:
Pre - Charge
Caterpillar antifreeze DOES NOT require supplemental coolant additive added at initial coolant fill, however additive is required on a maintenance basis. For systems equipped with supplemental coolant additive elements, the last MAINTENANCE element should not be replaced at FLUSH & FILL or overhaul until the next 250 hour interval.
Although Caterpillar recommends a minimum concentration of 30% antifreeze, a coolant mixture of acceptable water and Supplemental Coolant additive (SCA) can be used in applications where conditions do not require freeze protection (or where antifreeze is not available).
A coolant mixture of water and SCA will cool, and will provide some protection for engine components. It will not, however, provide normal engine service life. Antifreeze/water mixtures provide better performance life than water-only coolant.
If the engine cooling system is filled with water ONLY, the supplemental coolant additive (conditioner) concentration must be maintained at 6 to 8% maximum concentration. Check with supplemental coolant additive test kit.
Maintenance of the water only coolant is the same as maintainance of the antifreeze/water coolant. The 8T5296 Test Kit can be used to evaluate the SCA concentration of the water only coolant with the following modifications to steps 3 and 5.
STEP 3 - Add tap water to the vial up to the 20 ml mark.
STEP 5 - With the defined procedure, the 6 to 8% concentration will yield a 20 to 27 drop range. Less drops will indicate under concentration of SCA and more drops will indicate over concentration. Adjust the concentration accordingly to maintain the proper concentration.
NOTE: If the concentration is greater than the maximum of 8%, drain some of the coolant and refill with acceptable water, then retest the concentration level.
Cooling System Cleaning
Clean the system according to the Maintenance Schedule or sooner if the coolant is contaminated, if the engine overheats or if foaming is observed in the radiator. Disregard for the proper maintenance of the cooling system can cause overheating problems which could result in severe damage to the engine and its components. If testing and proper maintenance of antifreeze and/or SCA concentrations are not performed as recommended in the Maintenance Schedule, the system drain interval must be shortened.
Coolant should be drained, the system cleaned and new coolant added by fuel consumption interval, every 3000 service hours or two years, whichever comes first for the engine being maintained. If not using Caterpillar Antifreeze and supplemental coolant additive as recommended, the drain interval must be shortened to every 1500 service hours or one year.
When the system is drained and flushed, small particles, undesirable chemicals, scale and other deposit formations are removed. These deposits reduce the necessary heat transfer characteristics of the cooling system and accelerate wear of the water pump seal. Refer to the Cooling System (Clean/Flush Coolant) topic in the Maintenance Section of this manual.
Caterpillar Cooling System Cleaners are designed to clean the system of harmful scale and corrosion. Mineral scale, corrosion products, light oil contamination and sludge is dissolved. Cooling system cleaners are available from your Caterpillar dealer in the quantities listed. Follow the label directions for proper usage.
Copyright 1993 - 2024 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees. Tue Nov 26 22:15:52 UTC+0530 2024
Product: ARTICULATED TRUCK
Model: D20D ARTICULATED TRUCK 9MG
Configuration: D20D & D250D ARTICULATED TRUCK 9MG00001-UP (MACHINE) POWERED BY 3116 ENGINE
Operation and Maintenance Manual
D20D AND D250D ARTICULATED TRUCK
Media Number -SEBU6516-02 Publication Date -21/03/1995 Date Updated -11/10/2001
Every 10 Service Hours or Daily
You must read and understand the warnings and instructions contained in the Safety section of this manual before performing any operation or maintenance procedures.
Walk Around Inspection
Inspect Machine
1. Inspect the lights for broken bulbs and lenses. Replace if broken.
2. Inspect the condition of all steps and hand holds. Repair any damaged steps and hand holds and ensure they are clean.
3. Inspect the operator's compartment for cleanliness, remove trash or debris. Check for broken gauges or indicator lights. Ensure that all windows, mirrors and light lenses are clean.
4. Inspect the cooling system for leaks and trash build up around the radiator and grille. Check the condition of radiator hoses, the fan belt and the coolant pump drive belt.
5. Inspect the engine compartment for leaks and trash build up.
6. Inspect the cab for damage. If repair is necessary, consult your Caterpillar dealer.
7. Inspect the hydraulic system for leaks and damaged hoses or fittings.
8. Inspect the transmission, axles and transfer drive for leaks.
9. Inspect the tires for damage and ensure they are inflated to the correct pressure. Consult your tire supplier for correct inflation pressures for your particular application. Replace any missing valve caps. Have damaged tires inspected and repaired by your tire dealer.
10. Look around and under the machine for items such as loose or missing bolts, trash buildup etc.
Seat Belt
Inspect for Damage
Always check the condit)on of the seat belts, seat tie down belts and mounting hardware before operating the machine. Replace any damaged or worn parts.
Replace the seat belts after three years of use, regardless of appearance.
1. Check the belt webbing (1) for wear or fraying. Replace if damaged.
2. Check the buckles (2) for correct operation. The buckles should snap firmly shut and release promptly.
3. Check that the seat belt hardware (3) and tie down belt hardware (4) are secure.
Engine
Measure Oil Level
NOTICE
Do not overfill the crankcase to avoid engine damage.
1. Raise the hood.
2. With the engine stopped the oil level must be between ADD and FULL on dipstick (1).
3. If necessary, remove filler cap (2) and add oil.
4. Install the filler cap.
Refer to the topics "Lubricant Specifications" and "Lubricant Viscosities and Refill Capacities".
Cooling System
Check Coolant Level
1. Raise the hood.
2. Remove the expansion tank cap slowly to relieve pressure. Maintain the coolant level to the base of the filler neck. Coolant should always be visible.
3. Clean and inspect the filler cap. If the seal is damaged, install a new one.
4. Close the hood.
If it is necessary to add make-up water daily, inspect for leaks.
Refer to the topics "Cooling System Specifications" and "Lubricant Viscosities and Refill Capacities".
Transmission
Measure Oil Level
Measure the transmission oil level with the machine level. The oil must be hot and the engine operating at low idle.
The dipstick is located on the left side of the machine.
1. Install the steering lock links (1).
2. With the transmission oil at normal operating temperature, run the engine at low idle for five minutes to allow the oil level to stabilize.
3. Check the oil level on the dipstick (2). The level must be between the LOW and FULL marks on the dipstick.
4. If necessary, remove the filler cap (3) and add oil through the filler tube.
5. Install the filler cap.
6. Refer to the topics "Lubricant Specifications and Refill Capacities".
Hydraulic Tank
Check Oil Level
The hydraulic oil level must be checked with the body fully lowered.
1. Check the oil level on the sight glass. The level must be in the middle of the sight glass.
2. If necessary, slowly remove the filler cap and add oil.
Refer to the topics "Lubricant Specifications" and "Lubricant Viscosities and Refill Capacities".
Headlights, Turn Signals, Horn, Back-up Alarm, Indicators and Gauges
Test for Proper Function
1. Check that all gauges and indicators are intact. Replace any which are broken.
2. Sound the horn to ensure it works.
3. Operate the hazard light switch and machine lights to ensure they work.
4. Turn the start switch to energise the electrical circuits but do not start the engine. Check that the indicators operate correctly.
5. Shift the transmission to REVERSE and listen for the back-up alarm. Shift the transmission back to neutral.
6. Start the engine and check that all indicators and gauges operate correctly.
7. Check that the turn signals operate correctly.
8. Have any faulty item repaired or replaced.
Fuel Tank
Drain Water and Sediment
Do not fill the fuel tank to the top. Fuel expands as it gets warm and may overflow.
Fill the fuel tank at the end of each shift to drive out moist air and prevent condensation.
Drain water and sediment from the fuel tank at the beginning of the shift or after the tank has been filled and allowed to stand for ten minutes.
The fuel tank is located on the right side of the machine.
1. Open the bleed valve until water or fuel starts to flow.
2. Allow water and sediment to flow into a suitable container.
3. Close the bleed valve.
Suspension, Oscillating Hitch and Tailgate (If equipped)
Lubricate Bearings and Pins
NOTICE
The oscillating hitch bearings must be lubricated regularly. Rapid wear will result from inadequate lubrication.
Wipe all fittings clean before lubricating.
If regular lubrication is carried out at the recommended interval the suspension pivot bearings, oscillating hitch pins and tailgate pins (if equipped) should only take one or two shots. The hitch bearings will take up to twenty shots.
1. Start the engine and fully raise the dump body. This takes the load off the hitch bearings and allows the grease to penetrate better.
2. Stop the engine and install the steering frame lock links.
3. Lubricate the hitch bearings through two fittings. The middle fitting is provided to initially fill the cavity between the two hitch bearings. This fitting does not require regular lubrication.
4. Lubricate the front axle suspension pivot pins through two fittings.
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