Bulletin No. 6.

1
File Under Off-Highway Trucks
®

FLUID ANALYSIS GUIDE

Machine Profiles
793 and 793B Constuction and Mining Trucks

Description
These are construction and mining trucks with
a dump body capacity of 240 tons.
Serial Number Range
793: 3SJ
793B: 1HL
Lubrication Recommendations
For complete information concerning lubrication
recommendations, refer to Caterpillar Machine
Recommendations, Form SEBU6250.
Oil Sampling Procedures
Early models of these machines were not initially
equipped with oil sampling valves. If sampling
valves are desired, please refer to Special
Instruction SEHS9043.
Filter Inspection
Recommend that filters be saved for inspection.
Plastic bags are convenient for retaining the filters
until they can be cut open for inspection. The
4C5084 Filter Cutting Tool is available for this
purpose. Be alert for visible pieces of metal or
synthetic friction material which may indicate a
problem.
CONFIDENTIAL
This document contains unpublished confidential
proprietary, and trade secret information of Caterpillar Inc.,
and is intended for distribution only to parties specifically
authorized by Caterpillar. Unauthorized copying, distri-
bution, or use is specifically prohibited.
© 1997 CATERPILLAR INC. ALL RIGHTS RESERVED
NOTICE
Specific information supplied by this document
concerning the machine/compartment and wear limits
contained in this document are intended to be used
only as general guidelines for interpretation.
Model-specific information supplied by this document
is subject to change and may vary on a machine-by-
machine basis. Most often, changes to major
components changes are delineated by specific serial
number breaks and/or prefix changes. Equipment
changes and updates are frequent; therefore, you
may need to consult current Operations &
Maintenance Manuals, Parts Manuals, Service
Manuals or other reference materials for details for a
specific serial number machine.
Wear tables, provided elsewhere by Caterpillar, were
developed for average conditions and are intended to
reflect expected values at normal oil change periods.
They may be too high or too low for some specific
machine applications. Interpretations should be
based on the trend of wear values in each
compartment whenever possible.
Blank wear tables are provided for entry of either
Caterpillar or dealer established guidelines. Note that
Sodium and Molybdenum are not included in these
blank wear tables because these elements are often
present in oil additives and, therefore, must be
trended for meaningful analysis.

1
Printed in U.S.A. (12/95)
 ENGINE Iron
Crankshaft
Serial No. Range: 793: 3SJ and 793B: 1HL Camshaft
Engine Model: 3516 TA Valves, valve seat, guides and push rods
Horsepower Rating: 2057 FWHP Cylinder liners
Timing gears
Oil Change Interval: 250 Hrs.
Oil pump shafts, gears and body
Filter Change Interval: 250 Hrs. Air Compressor
Sump Capacity: 212 Liters (56 Gal.)
Chromium
Engine Oil Cooler: Water
Piston rings
Cooling System: 568 Liters (150 Gal.)
Oil Transfer Possibilities: Lead
Engine to converter housing, which is hydraulic Main and rod bearings
system oil, through a damaged rear crankshaft seal. Tin
Notes: Main and rod bearings
1. Recommend Caterpillar Diesel Engine Oil (DEO). Camshaft bearings
Water pump bearings
2. Fuel injectors are under valve cover. Leakage
could show as fuel dilution in the oil sample. Aluminum
Main and rod bearings
WEAR ELEMENT SOURCES Timing gear bushings
Piston
Camshaft bearings
Copper Oil pump bushings
Oil cooler core leaching (no failure oil side) Dirt Entry (clay soils)
Rocker arm bushings Anti-seize compounds (no failure)
Wrist pin bushings Air compressor bearings
Governor drive and bushings Rear cluster gear bearings
Timing gear thrust bearings
Turbocharger bearings Silicon
Camshaft lifter roller pins Dirt entry
Air compressor bearings Silicon grease (no failure)
Rear cluster gear bearings Oil additives (no failure)
Scavenge pump screen (earlier models) Condensation
Oil additives (no failure)
Molybdenum
Anti-seize compounds (no failure)
Cooling system leaks from oil cooler, gaskets Top piston ring plasma coated
or aftercooler Sodium
Water or coolant entry
Oil additives (no failure)
Condensation

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Printed in U.S.A. (12/95)
 TRANSMISSION WEAR ELEMENT SOURCES
Serial No. Range: 793: 3SJ and 793B: 1HL Copper
Type: 6 Speed Electronically controlled Automatic Brass pump parts
Planetary Power Shift Cooler core leaching (no failure)
Speeds: 6F - 1R Oil additives (no failure)
Anti-seize compounds (no failure)
Oil Change Interval: 1000 Hrs. Bronze clutch discs - transmission
Filter Change Interval: 500 Hrs.
Iron
Capacity:
Transmission Reservoir: 102 Liters (27 Gal) Gears
Total System: 227 Liters (60 Gal.) Roller bearings
Pump bearings
Transmission Pump Type: 3 Section Gear
Clutch plates
Oil Cooler Type: Water Splines
Disc Material: Bronze and Cellulose Fiber Shafts
Common Sump With: Separate Pump housing
Oil Transfer Possibilities: Chromium
1. Transmission oil can transfer to final Roller bearings
drive/differential through damaged pinion shaft Pump bearings
seal.
Lead
2. Transmission oil to hydraulics through damaged
pump seal. Friction bonding agent (early models)
Additional Information: Tin
First forward and reverse are torque converter drive Roller bearings
with lockup clutch engaging in upper speed range of Pump bearings
first gear. Gears two through six are direct drive.
Aluminum
Notes: Anti-seize compounds (no failure)
1. Recommend Caterpillar Transmission / Drive Dirt entry (clay soils)
Train Oil (TDTO).
Silicon
Dirt entry
Silicon grease (no failure)
Oil additives (no failure)

Sodium
Oil additives (no failure)
Water or coolant entry
Condensation

3
Printed in U.S.A. (12/95)
 TORQUE CONVERTER, BRAKES WEAR ELEMENT SOURCES
AND HOIST HYDRAULICS Copper
Serial No. Range: 793: 3SJ and 793B: 1HL Brass pump parts
Oil Change Interval: 2000 Hrs. Oil additives (no failure)
Anti-seize compounds (no failure)
Filter Change Interval: 250 Hrs. Cooler core leaching (no failure)
Capacities: Lockup clutch discs
Reservoir: 580 Liters (153 Gal.) Torque converter bushings
Total System: 1137 Liter (300 Gal.)
Iron
Oil Cooler Type: Water
Pump housing
Pump Type(s):
Gears
Gear Pump controls flow to: Main Hydraulics
Roller bearings
Gear Pump controls flow to: Brake Cooling
Pump bearings
Gear Pump controls flow to: Converter Cooling
Clutch plates
Gear Pump controls flow to: Converter Scavenge
Splines
Common Sump: Hoist hydraulics, torque converter Shafts
and brakes share a common sump. Cylinder wear
Brakes: Pump wear
Front and Rear - Wet Multiple Disc Brake hub
Brake plates
Disc Friction Material:
Lockup Clutch: Sintered Bronze Chromium
Front and Rear Brakes: Cellulose Fiber and Cork Roller bearings
Oil Transfer Possibilities: Pump bearings
1. Oil can transfer between engine and converter Cylinder rods
housing at rear crankshaft seal.
Lead
2. Steering system oil can transfer to the hydraulic Friction bonding agent (early models)
oil at the pump drive housing by passing through
a damaged steering pump shaft seal. Tin
Roller bearings
Notes:
Pump bearings
1. Recommend Caterpillar Hydraulic Oil (HYDO).
2. Brake discs are non-metallic and will not show in Aluminum
wear metal analysis. Wear particles can be seen Torque converter impeller
in filters, and will be noted in particle count. Torque converter turbine
Dirt entry (clay soils)
Isolation plate (gear pump)
Pump body wear (gear pump)
Anti-seize compounds (no failure)

Silicon
Dirt entry
Silicon grease (no failure)
Oil additives (no failure)

Sodium
Coolant leak
Condensation
Water entry
Oil additives (no failure)

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Printed in U.S.A. (12/95)
 STEERING HYDRAULICS WEAR ELEMENT SOURCES
Serial No. Range: 793: 3SJ and 793B: 1HL Copper
Oil Change Interval: 2000 Hrs. Brass pump parts
Filter Change Interval: 500 Hrs. Oil additives (no failure)
Anti-seize compounds (no failure)
Capacities: Cooler core leaching (no failure)
Reservoir: 129 Liters (34 Gal.)
Total System: 190 Liters (50 Gal.) Iron
Oil Cooler Type: None Pump housing
Pump Type(s): Gears
Bearings
Steer Metering Pump: Valves
Cylinder wear
Axial Piston Pump: Steer Valves
Pump wear
Common Sump: Separate Brake discs
Oil Transfer Possibilities:
Chromium
Steering oil to main hydraulic oil at the oil pump
Pump bearings
drive for steering and hoist pumps through steer
Cylinder rods
pump shaft seal
Additional Information: Tin
Used with nitrogen charged, bladder-type Pump bearings
accumulators
Aluminum
Notes: Dirt entry (clay soils)
1. Recommend Caterpillar Hydraulic Oil (HYDO). Pump body wear (gear pump)
Anti-seize compounds (no failure)

Silicon
Dirt entry
Silicon grease (no failure)
Oil additives (no failure)

Sodium
Coolant leak
Condensation
Water entry
Oil additives (no failure)

5
Printed in U.S.A. (12/95)
 DIFFERENTIAL WEAR ELEMENT SOURCES
AND FINAL DRIVES Copper
Serial No. Range: 793: 3SJ and 793B: 1HL Oil additives (no failure)
Oil Change Interval: 2000 Hrs. Anti-seize compounds (no failure)
Differential thrust washers
Capacities: Final drive thrust washers
Differential 663 Liters (175 Gal.) Sleeve bearings - Differential
Final Drive (each): 114 Liters (30 Gal.) Sleeve bearings - Final drive gears
Total Common Sump: 891 Liters (235 Gal.)
Final Drive Type: Double Reduction Planetary Iron
Common Sump: Differential, bevel gear and final Gears
drives share a common sump. Roller bearings
Splines
Oil Transfer Possibilities:
Carriers
1. If brake hydraulic oil (10W) transfers into the Shafts
differential/final drive sump through a failed Duo- Carriers
Cone seal, the lighter weight oil can cause a final Differential thrust button
drive failure. Recommend that a viscosity test be Axle thrust button
performed on transmission/final drive samples. If
maintenance staff detect overfull final drives they Chromium
should be alert for hydraulic oil transfer. Roller bearings
2. Oil can transfer between the transmission and
Tin
differential/final drive through a damaged bevel
pinion shaft seal. Oil transfer could occur in either Roller bearings
direction. Aluminum
Notes: Dirt entry (clay soils)
1. Recommend Caterpillar Transmission / Drive Anti-seize compounds (no failure)
Train Oil (TDTO). Silicon
2. When operating in water, check for water and/or Dirt entry
silicon entry. Silicon grease (no failure)
3. Wheel spin is controlled by automatic electronic Oil additives (no failure)
traction aid, which modulates brake action on
spinning wheel. Excessive tire spin causes Sodium
differential and tire wear. Water entry
Oil additives (no failure)
4. Recommend that oil samples be taken at the
differential and both final drives. Although there is
oil transfer within the axle housing, the oil
samples may show considerable different levels
of wear particles, especially for particle count.
5. Check the magnetic plug on each final drive
cover. Some metallic fuzz is normal. Metallic
chips or flakes indicate abnormal wear.
6. It is important that a particle count be performed
on each final drive sample. Wear metal analysis
may not detect synthetic or large particles which
can warn of impending failure.

6
Printed in U.S.A. (12/95)
 FRONT WHEELS WEAR ELEMENT SOURCES
Serial No. Range: 793: 3SJ and 793B: 1HL Copper
Oil Change Interval: 1000 Hrs. Oil additives (no failure)
Pump Type: Gear Thrust washers
Anti-seize compounds (no failure)
Sump Capacity: Each 23 Liters (6 Gal.)
Common Sump: Separate Iron
Oil Transfer Possibilities: Brake cooling oil (10W Roller bearings
Hydraulic Oil) may transfer to front wheel bearing Shaft
compartment through a defective inner Duo-Cone Chromium
seal. This will reduce the viscosity of the front wheel
Roller bearings
bearings oil and could lead to failure.
Tin
Notes:
Roller bearings
1. Recommend Caterpillar Transmission/Drive Train
Pump bearings
Oil (TDTO).
Aluminum
Dirt entry (clay soils)
Anti-seize compounds (no failure)

Silicon
Dirt entry
Silicon grease (no failure)
Silicon additives (no failure)

Sodium
Water entry
Oil additives (no failure)

7
Printed in U.S.A. (12/95)