Description

The 785B Models are construction and mining

trucks with a dump body capacity of 150 tons. The
784B tractor models have a yoke to pull wagons
instead of a dump body. The drive trains on the
machines are identical.
Serial Number Range
784B: 5RK
785B: 6HK
Lubrication Recommendations
For complete information concerning lubrication
recommendations, refer to Caterpillar Machine
Lubricant Recommendations. Form SEBU6250.
Oil Sampling Procedures
Early production of these machines were not
equipped with oil sampling valves. Valves were
added to pressurized compartments in later
production. Please refer to Special Instruction
SEHS9043 for the location of valves on later
machines and installation instructions for earlier
production machines.
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 and the
contents observed. 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This document contains unpublished confidential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. (3/97)
784B Construction and Mining Tractors
785B Construction and Mining Trucks

Bulletin No. 4.2

File Under Off Highway Trucks
FLUID ANALYSIS GUIDE
Machine Profiles
ENGINE
Serial No. Range: 784B: 5RK and 785B: 6HK
Engine Model: 3512 TA
Horsepower Rating: 1290 FWHP
Oil Change Interval: 250 Hrs.
Filter Change Interval: 250 Hrs.
Recommended Oil Sampling Interval: 250 hours
Recommended Level I Coolant Analysis
Sampling: 250 Hours or at Oil Change
Sump Capacity: 133 Liters (29 Gal.)
Engine Oil Cooler: Water
Cooling System: 379 Liters (100 Gal.)
Oil Transfer Possibilities:
1. Oil may transfer between the engine and torque
converter/hydraulic compartments through a
damaged rear crankshaft seal.
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.
WEAR ELEMENT SOURCES
Copper
Governor drive
Front and rear idler gear thrust bearing
Oil cooler core tubes
Wrist pin bushings
Timing gear thrust washers
Oil pump drive thrust washer
Governor bushings
Service meter drive gear
Fuel transfer pump bushings
Turbocharger bearings
Camshaft lifter roller pins
Air compressor bearings
Oil additives (no failure)
Anti-seize compounds (no failure)
Iron
Crankshaft
Camshaft
Valves
Valve seats, guides, liners and cylinder walls
Timing gears
Oil pump
Air compressor
Chromium
Piston rings
Lead
Main and rod bearings
Camshaft bearings
Tin
Main and rod bearings
Camshaft bearings
Water pump bearings
Aluminum
Main and rod bearings
Timing gear bushings
Timing gear cover
Crankshaft thrust bearing
Pistons
Rocker arms
Dirt entry (clay soils)
Anti-seize compounds (no failure)
Silicon
Dirt entry
Silicon grease (no failure)
Silicon additives (no failure)
Sodium
Water or coolant entry
Oil additives (no failure)
Condensation
Molybdenum
Top piston ring
2
Printed in U.S.A. (9/96)
TRANSMISSION
Serial No. Range: 784B: 5RK and 785B: 6HK
Type: 6 Speed Electronically Controlled Automatic
Planetary
Speeds: 6F, 1R
Oil Change Interval: 1000 Hrs.
Filter Change Interval: 500 Hrs.
Recommended Oil Sampling Interval: 250 hours
Capacities:
Transmission System: 248 Liters (66 Gal.)
Transmission Tank: 83 Liters (22 Gal.)
Transmission Pump Type:
3 Section Caterpillar Gear Pump
Oil Cooler Type: Water
Disc Friction Material:
Speed Clutches: Rayflex
Directional Clutches: Rayflex
Lockup Clutch: Rayflex
Common Sump: Separate
Oil Transfer Possibilities:
1. Transmission oil could transfer to the
differential/final drive compartment through a
damaged seal. (Transmission mounts to the
differential case).
2. Transmission oil to hydraulic through a damaged
pump seal.
3. Hydraulic oil (10W) may transfer to the
differential/final drives through a damaged Duo-
Cone seal.
Notes:
Recommend Caterpillar Transmission / Drive Train
Oil (TDTO).
Additional Information:
First gear forward and reverse are torque converter
drive with lockup in first. Gears two through six are
direct drive.
Lockup clutch and brakes are common with the
hydraulic compartment.
WEAR ELEMENT SOURCES
Copper
Brass pump parts
Cooler core leaching (no failure)
Oil additives (no failure)
Anti-seize compounds (no failure)
Iron
Gears
Roller bearings
Pump bearings
Clutch plates
Splines
Shafts
Pump wear
Pump housing
Chromium
Roller bearings
Pump bearings
Tin
Roller bearings
Pump bearings
Aluminum
Dirt entry (clay soils)
Pump body wear (gear pump)
Isolation plate (gear pump)
Anti-seize compounds (no failure)
Silicon
Dirt entry
Silicon grease (no failure)
Silicon additives (no failure)
Sodium
Coolant leak
Condensation
Water entry
Oil additives (no failure)
3
Printed in U.S.A. (9/96)
HOIST, CONVERTER
AND BRAKES HYDRAULICS
Serial No. Range: 784B: 5RK and 785B: 6HK
Oil Change Interval: 2000 Hrs.
Filter Change Interval: 500 Hrs.
Recommended Oil Sampling Interval: 250 hours
Capacities:
Hydraulic System: 641 Liters (169 Gal.)
Hydraulic Tank: 337 Liters (89 Gal.)
Oil Cooler Type:
Torque Converter - Water
Brakes - Water
Hoist - Water
Pump Type(s)
3 Section Caterpillar Gear: Torque Converter
Charge and Scavenge.
2 Section Tyrone Gear: Hoist
Common Sump: Torque converter, brakes, hoist
hydraulics share a common sump.
Brakes: Wet Multiple Disc (Front and Rear)
Disc Friction Material:
Lockup Clutch: Sintered Bronze (early models)
Cellulose fiber (later models)
Brakes: Cellulose fiber and cork
Oil Transfer Possibilities:
1. Oil may transfer between the engine and
hydraulic compartments through a damaged rear
crankshaft seal.
2. Steering oil could transfer to the hydraulic
compartment through a damaged steering pump
seal.
3. 784B hydraulic oil may become comtaminated
from dirt entry or failure of the wagon door
hydraulic cylinders.
Notes:
Recommend Caterpillar Hydraulic Oil (HYDO).
WEAR ELEMENT SOURCES
Copper
Brass pump parts
Cooler core leaching (no failure)
Oil additives (no failure)
Lockup clutch discs (early models)
Torque converter bushings
Anti-seize compounds (no failure)
Iron
Pump housing
Gears
Roller bearings
Pump bearings
Clutch plates
Splines
Shafts
Cylinder wear
Pump wear
Brake hubs
Brake plates
Chromium
Roller bearings
Pump bearings
Cylinder rods
Lead
Friction bonding agent (early models)
Tin
Roller bearings
Pump bearings
Friction bonding agent
Aluminum
Torque converter impeller
Torque converter turbine
Dirt entry (clay soils)
Pump body wear (gear pump)
Isolation plate (gear pump)
Anti-seize compounds (no failure)
Silicon
Dirt entry
Silicon grease (no failure)
Silicon additives (no failure)
Sodium
Coolant leak
Condensation
Water entry
Oil additives (no failure)
4
Printed in U.S.A. (9/96)
STEERING HYDRAULICS
Serial No. Range: 784B: 5RK and 785B: 6HK
Oil Change Interval: 2000 Hrs.
Filter Change Interval: 500 Hrs.
Recommended Oil Sampling Interval: 250 hours
Capacities:
Hydraulic System: 117 Liters (31 Gal.)
Hydraulic Tank: 91 Liters (26 Gal.)
Oil Cooler Type: None
Pump Type(s):
Cessna Piston: Steering
Common Sump: Separate Sump
Oil Transfer Possibilities:
1. Oil may transfer between the hydraulic and
steering compartments. If the steering pump
shaft seal leaks, steering oil will flow to the pump
drive case which is lubricated by hydraulic oil.
Notes:
1. Recommend Caterpillar Hydraulic Oil (HYDO).
WEAR ELEMENT SOURCES
Copper
Brass pump parts
Oil additives (no failure)
Anti-seize compounds (no failure)
Iron
Pump housing
Cylinder wear
Splines
Cylinder wear
Pump bearings
Chromium
Cylinder rods
Pump bearings
Tin
Pump bearings
Aluminum
Dirt entry (clay soils)
Anti-seize compounds (no failure)
Silicon
Dirt entry
Silicon grease (no failure)
Silicon additives (no failure)
Sodium
Condensation
Water entry
Oil additives (no failure)
5
Printed in U.S.A. (9/96)
DIFFERENTIAL AND FINAL DRIVES
Serial No. Range: 784B: 5RK and 785B: 6HK
Oil Change Interval: 2000 Hrs.
Recommended Oil Sampling Interval: 250 hours
Filter Change Interval: 784B: One Time Only at
50 Hrs
785B: One Time Only at 50
784B: 500 Hrs
785B: 500 Hrs
Capacities: Differential: 379 Liters (100 Gal.)
Final Drive (each): 74 Liters (19.5 Gal.)
Pump Type: Single Section Gear Pump (Later
Models)
Total Common Sump: 527 Liters (139 Gal.)
Final Drive Type: Double Reduction Planetary
Common Sump: Differential, bevel gear and final
drives share a common sump.
Oil Transfer Possibilities:
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.
3. Effective with 785B, S/N 6HK523 a gear pump
and 40 micron filter were added to provide
positive oil filtration and lubrication.
Notes:
1. Recommend Caterpillar Transmission / Drive
Train Oil (TDTO).
2. When operating in water, check for water/silicon.
3. Wheel spin is controlled by an 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.
WEAR ELEMENT SOURCES
Copper
Oil additives (no failure)
Thrust washers
Anti-seize compounds (no failure)
Differential thrust washers
Final drive thrust washers
Sleeve bearing-Differential
Sleeve bearings-Final drive gears
Iron
Gears
Roller bearings
Splines
Final drive housing
Shafts
Carriers
Differential thrust button
Axle thrust button
Chromium
Roller bearings
Tin
Roller 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)
6
Printed in U.S.A. (9/96)
FRONT WHEELS
Serial No. Range: 784B: 5RK and 785B: 6HK
Oil Change Interval: 1000 Hrs.
Recommended Oil Sampling Interval: 250 hours
Pump Type: Gear
Sump Capacity: (Each) 14 Liters (4 Gal.)
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 vicosity of the front wheel
bearing oil and could lead to bearing 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
Shafts
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)
7
Printed in U.S.A. (9/96)