File Under Construction and Mining

FLUID ANALYSIS GUIDE

Machine Profiles
793, 793B and 793C Construction 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
793C: ATY, 4GZ

O&MM
SEBU6333
01-97
SEBU6519
06-98
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:

1. If the machine is under a Customer Support

Agreement (CSA).
2. If the machine application is more severe than normal.
3. If the machine is under a close follow to monitor wear
levels to ascertain whether a failure mode is in
progress.
4. If an oil change interval has been altered from the
interval recommended in the Operation & Maintenance
Guide.

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This document contains unpublished confidential proprietary,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.

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
Engine Model: 3516 TA
Horsepower Rating: 2057 FWHP
793C: 1615kW/2166 FWHP
Oil Change Interval: 250 Hrs.
Filter Change Interval: 250 Hrs.
Sump Capacity: 212 Liters (56 Gal.)
793C: 291 liters (77 Gal.)
Recommended Coolant Analysis:
Level 1: After initial 500 hours for new or rebuilt Engines. 500
hours after refilling cooling system. Also, as determined by
customer requirements and operating conditions.
Level 2: After initial 1000 hours for new or rebuilt engines, and
annually thereafter. Also, as indicated by Level1 analysis.
Engine Oil Cooler: Water
Cooling System: 568 Liters (150 Gal.)
3SJ, 1HL, 4GZ - 568 liters (150 Gal.)
ATY - 682 Liters (180 Gal.)
Oil Transfer Possibilities:
Engine to converter housing, which is hydraulic system oil,
through a damaged rear crankshaft seal.

Chromium
Piston rings

Lead
Main and rod bearings

Tin
Main and rod bearings
Camshaft bearings
Water pump bearings

Aluminum
Main and rod bearings
Timing gear bushings
Piston
Camshaft bearings
Oil pump bushings
Dirt Entry (clay soils)
Anti-seize compounds (no failure)
Air compressor bearings
Rear cluster gear bearings

Notes:
1. Recommend Caterpillar Diesel Engine Oil (DEO).
2. Fuel injectors are under valve cover. Leakage could
show as fuel dilution in the oil sample.

Silicon

WEAR ELEMENT SOURCES

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

Copper

Molybdenum

Oil cooler core leaching (no failure oil side)

Rocker arm bushings
Wrist pin bushings
Governor drive and bushings
Timing gear thrust bearings
Turbocharger bearings
Camshaft lifter roller pins
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

Top piston ring plasma coated

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

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

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
Type: 6 Speed Electronically controlled Automatic Planetary
Power Shift
Speeds: 6F - 1R
Oil Change Interval: 1000 Hrs.
Filter Change Interval: 500 Hrs.
Oil Sampling Interval: 500 hours
Capacity:
Transmission Reservoir: 102 Liters (27 Gal)
Total System: 227 Liters (60 Gal.)
Transmission Pump Type: 3 Section Gear
Oil Cooler Type: Water
Disc Material: Bronze and Cellulose Fiber
Common Sump With: Separate
Oil Transfer Possibilities:

Tin

1. Transmission oil can transfer to final drive/differential

through damaged pinion shaft seal.
2. Transmission oil to hydraulics through damaged pump
seal.

Sodium

Roller bearings
Pump bearings

Aluminum
Anti-seize compounds (no failure)
Dirt entry (clay soils)

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

Oil additives (no failure)

Water or coolant entry
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)

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

Pump wear
Brake hub
Brake plates

TORQUE CONVERTER, BRAKES AND

HOIST HYDRAULICS
Machine Models: 793, 793B and 793C
Serial No. Range: 793: 3SJ; 793B: 1HL and 793C: ATY, 4GZ
Oil Change Interval: 2000 Hrs.
Filter Change Interval: 250 Hrs.
Capacities:
Reservoir: 580 Liters (153 Gal.)
Total System: 1137 Liter (300 Gal.)
Oil Sampling Interval: 500 hours
Oil Cooler Type: Water
Pump Type(s):
Gear Pump controls flow to: Main Hydraulics
Gear Pump controls flow to: Brake Cooling
Gear Pump controls flow to: Converter Cooling
Gear Pump controls flow to: Converter Scavenge
Common Sump: Hoist hydraulics, torque converter and brakes
share a common sump.
Brakes:
Front and Rear - Wet Multiple Disc
Disc Friction Material:
Lockup Clutch: Sintered Bronze
Front and Rear Brakes: Cellulose Fiber and Cork
Oil Transfer Possibilities:

Chromium
Roller bearings
Pump bearings
Cylinder rods

Lead
Friction bonding agent (early models)

Tin
Roller bearings
Pump bearings

Aluminum
Torque converter impeller
Torque converter turbine
Dirt entry (clay soils)
Isolation plate (gear pump)
Pump body wear (gear pump)
Anti-seize compounds (no failure)

1. Oil can transfer between engine and converter housing

at rear crankshaft seal.
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
metal analysis. Wear particles can be seen in filters,
and will be noted in particle count.

Sodium
Coolant leak
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

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
Oil Change Interval: 2000 Hrs.
Filter Change Interval: 500 Hrs.
Capacities:
Reservoir: 129 Liters (34 Gal.)
Total System: 190 Liters (50 Gal.)
Oil Sampling Interval: 500 hours
Oil Cooler Type: None
Pump Type(s):
Steer Metering Pump: Valves
Axial Piston Pump: Steer Valves
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

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

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

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)

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

Sleeve bearings Differential

Sleeve bearings - Final drive gears

DIFFERENTIAL AND FINAL DRIVES

Machine Models: 793, 793B and 793C
Serial No. Range: 793: 3SJ; 793B: 1HL and 793C: ATY, 4GZ
Oil Change Interval: 2000 Hrs.
Capacities:
Differential 663 Liters (175 Gal.)
Final Drive (each): 114 Liters (30 Gal.)
Total Common Sump: 891 Liters (235 Gal.)
Oil Sampling Interval: 500 hours
Final Drive Type: Double Reduction Planetary
Common Sump: Differential, bevel gear and final drives share
a common sump.
Oil Transfer Possibilities:

Iron
Gears
Roller bearings
Splines
Carriers
Shafts
Carriers
Differential thrust button
Axle thrust button

1. If brake hydraulic oil (10W) transfers into the

differential/final drive sump through a failed Duo-Cone
seal, the lighter weight oil can cause a final drive
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
hydraulic oil transfer.
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.

Chromium
Roller bearings

Tin
Roller bearings

Aluminum
Dirt entry (clay soils)
Anti-seize compounds (no failure)

Notes:

Silicon

1. Recommend Caterpillar Transmission / Drive Train Oil

(TDTO).
2. When operating in water, check for water and/or silicon
entry.
3. Wheel spin is controlled by automatic electronic
traction aid, which modulates brake action on spinning
wheel. Excessive tire spin causes differential and tire
wear.
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.

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

Sodium
Water entry
Oil additives (no failure)

WEAR ELEMENT SOURCES

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

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)

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