File Under Construction and Mining

FLUID ANALYSIS GUIDE

Machine Profiles
793, 793B and 793C Construction and Mining Trucks
Description 1. If the machine is under a Customer Support
These are construction and mining trucks with a dump body Agreement (CSA).
capacity of 240 tons. 2. If the machine application is more severe than normal.
3. If the machine is under a “close follow” to monitor wear
Serial Number Range O&MM levels to ascertain whether a failure mode is in
progress.
793: 3SJ SEBU6333
4. If an oil change interval has been altered from the
01-97 interval recommended in the Operation & Maintenance
793B: 1HL SEBU6519 Guide.
06-98
793C: ATY, 4GZ SEBU7175
05-00

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.

Recommended Oil Sampling Intervals:

Engine: 500 hours - Sampling Valve
Transmission and Torque Converter: 500 hours - Sampling Valve
Steering: 500 hours - Sampling Valve
Hoist & Brake: 500 hours
Differential and Final Drive: 500 hours
Front Wheel: 500 hours

Recommended Oil Sampling Intervals:

The recommended oil sampling intervals for this machine model
is 250 hours for the engine and 500 hours for all other systems.
Caterpillar dealers or users may wish to consider a 250 hour
sampling interval for all systems, particularly under the following
circumstances:
 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This document contains unpublished confidential proprietary,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, distribution, or use is
specifically prohibited.

 2002 CATERPILLAR INC. ALL RIGHTS RESERVED

NOTICE
Information supplied by this document is intended to be
used only as a general guideline 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 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.

2 Printed in U.S.A. 04/15/02

ENGINE
Machine Models: 793, 793B and 793C
Serial No. Range: 793: 3SJ; 793B: 1HL and 793C: ATY, 4GZ
Chromium
Piston rings
Engine Model: 3516 TA
Horsepower Rating: 2057 FWHP
793C: 1615kW/2166 FWHP
Oil Change Interval: 250 Hrs. Lead
Filter Change Interval: 250 Hrs. Main and rod bearings
Sump Capacity: 212 Liters (56 Gal.)
793C: 291 liters (77 Gal.)
Recommended Coolant Analysis: Tin
Level 1: After initial 500 hours for new or rebuilt Engines. 500 Main and rod bearings
hours after refilling cooling system. Also, as determined by Camshaft bearings
customer requirements and operating conditions. Water pump bearings
Level 2: After initial 1000 hours for new or rebuilt engines, and
annually thereafter. Also, as indicated by Level1 analysis.
Engine Oil Cooler: Water Aluminum
Cooling System: 568 Liters (150 Gal.) Main and rod bearings
3SJ, 1HL, 4GZ - 568 liters (150 Gal.) Timing gear bushings
ATY - 682 Liters (180 Gal.) Piston
Oil Transfer Possibilities: Camshaft bearings
Engine to converter housing, which is hydraulic system oil, Oil pump bushings
through a damaged rear crankshaft seal. Dirt Entry (clay soils)
Anti-seize compounds (no failure)
Air compressor bearings
Notes: Rear cluster gear bearings
1. Recommend Caterpillar Diesel Engine Oil (DEO).
2. Fuel injectors are under valve cover. Leakage could Silicon
show as fuel dilution in the oil sample. Dirt entry
Silicon grease (no failure)
Oil additives (no failure)
WEAR ELEMENT SOURCES Condensation

Copper Molybdenum
Oil cooler core leaching (no failure oil side) Top piston ring plasma coated
Rocker arm bushings
Wrist pin bushings
Governor drive and bushings Sodium
Timing gear thrust bearings Water or coolant entry
Turbocharger bearings Oil additives (no failure)
Camshaft lifter roller pins Condensation
Air compressor bearings
Rear cluster gear bearings
Scavenge pump screen (earlier models)
Oil additives (no failure)
Anti-seize compounds (no failure)
Cooling system leaks from oil cooler, gaskets or after-cooler

Iron
Crankshaft
Camshaft
Valves, valve seat, guides and push rods
Cylinder liners
Timing gears
Oil pump shafts, gears and body
Air Compressor

3 Printed in U.S.A. 04/15/02

TRANSMISSION
Machine Models: 793, 793B and 793C
Serial No. Range: 793: 3SJ; 793B: 1HL and 793C: ATY, 4GZ
Tin
Roller bearings
Type: 6 Speed Electronically controlled Automatic Planetary
Pump bearings
Power Shift
Speeds: 6F - 1R
Oil Change Interval: 1000 Hrs.
Filter Change Interval: 500 Hrs. Aluminum
Oil Sampling Interval: 500 hours Anti-seize compounds (no failure)
Capacity: Dirt entry (clay soils)
Transmission Reservoir: 102 Liters (27 Gal)
Total System: 227 Liters (60 Gal.)
Transmission Pump Type: 3 Section Gear Silicon
Oil Cooler Type: Water Dirt entry
Disc Material: Bronze and Cellulose Fiber Silicon grease (no failure)
Common Sump With: Separate Oil additives (no failure)
Oil Transfer Possibilities:
1. Transmission oil can transfer to final drive/differential
through damaged pinion shaft seal. Sodium
Oil additives (no failure)
2. Transmission oil to hydraulics through damaged pump Water or coolant entry
seal. Condensation
Additional Information:
First forward and reverse are torque converter drive with lockup
clutch engaging in upper speed range of first gear. Gears two
through six are direct drive.

Notes:
1. Recommend Caterpillar Transmission / Drive Train Oil
(TDTO).

WEAR ELEMENT SOURCES

Copper
Brass pump parts
Cooler core leaching (no failure)
Oil additives (no failure)
Anti-seize compounds (no failure)
Bronze clutch discs - transmission

Iron
Gears
Roller bearings
Pump bearings
Clutch plates
Splines
Shafts
Pump housing

Chromium
Roller bearings
Pump bearings

Lead
Friction bonding agent (early models)

4 Printed in U.S.A. 04/15/02

 Pump wear
TORQUE CONVERTER, BRAKES AND Brake hub
HOIST HYDRAULICS Brake plates
Machine Models: 793, 793B and 793C
Serial No. Range: 793: 3SJ; 793B: 1HL and 793C: ATY, 4GZ
Oil Change Interval: 2000 Hrs. Chromium
Filter Change Interval: 250 Hrs. Roller bearings
Capacities: Pump bearings
Reservoir: 580 Liters (153 Gal.) Cylinder rods
Total System: 1137 Liter (300 Gal.)
Oil Sampling Interval: 500 hours
Oil Cooler Type: Water Lead
Pump Type(s): Friction bonding agent (early models)
Gear Pump controls flow to: Main Hydraulics
Gear Pump controls flow to: Brake Cooling
Gear Pump controls flow to: Converter Cooling Tin
Gear Pump controls flow to: Converter Scavenge Roller bearings
Common Sump: Hoist hydraulics, torque converter and brakes Pump bearings
share a common sump.
Brakes:
Front and Rear - Wet Multiple Disc Aluminum
Disc Friction Material: Torque converter impeller
Lockup Clutch: Sintered Bronze Torque converter turbine
Front and Rear Brakes: Cellulose Fiber and Cork Dirt entry (clay soils)
Oil Transfer Possibilities: Isolation plate (gear pump)
1. Oil can transfer between engine and converter housing Pump body wear (gear pump)
at rear crankshaft seal. Anti-seize compounds (no failure)
2. Steering system oil can transfer to the hydraulic oil at
the pump drive housing by passing through a
damaged steering pump shaft seal. Silicon
Dirt entry
Silicon grease (no failure)
Oil additives (no failure)
Notes:
1. Recommend Caterpillar Hydraulic Oil (HYDO).
2. Brake discs are non-metallic and will not show in wear Sodium
metal analysis. Wear particles can be seen in filters, Coolant leak
and will be noted in particle count. Condensation
Water entry
Oil additives (no failure)
WEAR ELEMENT SOURCES

Copper
Brass pump parts
Oil additives (no failure)
Anti-seize compounds (no failure)
Cooler core leaching (no failure)
Lockup clutch discs
Torque converter bushings

Iron
Pump housing
Gears
Roller bearings
Pump bearings
Clutch plates
Splines
Shafts
Cylinder wear

5 Printed in U.S.A. 04/15/02

STEERING HYDRAULICS
Machine Models: 793, 793B and 793C
Serial No. Range: 793: 3SJ; 793B: 1HL and 793C: ATY, 4GZ
Silicon
Dirt entry
Oil Change Interval: 2000 Hrs.
Silicon grease (no failure)
Filter Change Interval: 500 Hrs.
Oil additives (no failure)
Capacities:
Reservoir: 129 Liters (34 Gal.)
Total System: 190 Liters (50 Gal.)
Oil Sampling Interval: 500 hours Sodium
Oil Cooler Type: None Coolant leak
Pump Type(s): Condensation
Steer Metering Pump: Valves Water entry
Axial Piston Pump: Steer Valves Oil additives (no failure)
Common Sump: Separate
Oil Transfer Possibilities:
Steering oil to main hydraulic oil at the oil pump drive for
steering and hoist pumps through steer pump shaft seal
Additional Information:
Used with nitrogen charged, bladder-type accumulators

Notes:
1. Recommend Caterpillar Hydraulic Oil (HYDO).

WEAR ELEMENT SOURCES

Copper
Brass pump parts
Oil additives (no failure)
Anti-seize compounds (no failure)
Cooler core leaching (no failure)

Iron
Pump housing
Gears
Bearings
Cylinder wear
Pump wear
Brake discs

Chromium
Pump bearings
Cylinder rods

Tin
Pump bearings

Aluminum
Dirt entry (clay soils)
Pump body wear (gear pump)
Anti-seize compounds (no failure)

6 Printed in U.S.A. 04/15/02

 Sleeve bearings – Differential
DIFFERENTIAL AND FINAL DRIVES Sleeve bearings - Final drive gears
Machine Models: 793, 793B and 793C
Serial No. Range: 793: 3SJ; 793B: 1HL and 793C: ATY, 4GZ
Oil Change Interval: 2000 Hrs.
Capacities:
Iron
Gears
Differential 663 Liters (175 Gal.)
Roller bearings
Final Drive (each): 114 Liters (30 Gal.)
Splines
Total Common Sump: 891 Liters (235 Gal.)
Carriers
Oil Sampling Interval: 500 hours
Shafts
Final Drive Type: Double Reduction Planetary
Carriers
Common Sump: Differential, bevel gear and final drives share
Differential thrust button
a common sump.
Axle thrust button
Oil Transfer Possibilities:
1. If brake hydraulic oil (10W) transfers into the
differential/final drive sump through a failed Duo-Cone Chromium
seal, the lighter weight oil can cause a final drive Roller bearings
failure. Recommend that a viscosity test be performed
on transmission/final drive samples. If maintenance
staff detect overfull final drives they should be alert for Tin
hydraulic oil transfer. Roller bearings
2. Oil can transfer between the transmission and
differential/final drive through a damaged bevel pinion
shaft seal. Oil transfer could occur in either direction.
Aluminum
Dirt entry (clay soils)
Anti-seize compounds (no failure)

Notes:
1. Recommend Caterpillar Transmission / Drive Train Oil Silicon
(TDTO). Dirt entry
2. When operating in water, check for water and/or silicon Silicon grease (no failure)
Oil additives (no failure)
entry.
3. Wheel spin is controlled by automatic electronic
traction aid, which modulates brake action on spinning Sodium
wheel. Excessive tire spin causes differential and tire Water entry
wear. 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.

WEAR ELEMENT SOURCES

Copper
Oil additives (no failure)
Anti-seize compounds (no failure)
Differential thrust washers
Final drive thrust washers

7 Printed in U.S.A. 04/15/02

FRONT WHEELS
Machine Models: 793, 793B and 793C
Serial No. Range: 793: 3SJ; 793B: 1HL and 793C: ATY, 4GZ
Oil Change Interval: 1000 Hrs.
Pump Type: Gear
Sump Capacity: Each 23 Liters (6 Gal.)
Oil Sampling Interval: 500 hours
Common Sump: Separate
Oil Transfer Possibilities: Brake cooling oil (10W Hydraulic
Oil) may transfer to front wheel bearing compartment through a
defective inner Duo-Cone seal. This will reduce the viscosity of
the front wheel bearings oil and could lead to failure.

Notes:
1. Recommend Caterpillar Transmission/Drive Train Oil
(TDTO).

WEAR ELEMENT SOURCES

Copper
Oil additives (no failure)
Thrust washers
Anti-seize compounds (no failure)

Iron
Roller bearings
Shaft

Chromium
Roller bearings

Tin
Roller bearings
Pump bearings

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)

8 Printed in U.S.A. 04/15/02