Cat® Product Information

Salesgram
May 2020

Cat® 794 AC
PM Optimization

Caterpillar and Cat® dealers continue to improve the Cat 794 AC

Mining Truck through extensive validation testing and a variety
of product improvement projects. We are pleased to announce
significant extensions to wet and mechanical/electrical PM
intervals/checks and reductions in PM labor hours, thanks
to significant testing and evaluations. These updates provide
additional functionality, efficiency, and reduce the Total Cost
of Ownership (TCO) across the entire 794 AC platform.

Caterpillar continues to evaluate and test 794 AC systems and

components through various continuous improvement projects
to deliver a lower TCO and Cost Per Hour (CPH) to our
customers. The improvements featured in this Salesgram have
been shown to offer a combined $2.90 labor hour reduction
(assuming a $120/hr labor cost) in TCO per hour over
70,000 hours of machine life, depending on site application.
Additional projects are in process to further extend PM intervals,
reduce PM labor hours, and increase PM efficiency.

For Caterpillar and Dealer Personnel Only

Project Summaries Wet PM Activity Extensions (Non-Engine Related)
Oil and filter PM intervals have been significantly increased
after validation testing showed that oil life and filtration
capability remained and could be extended. In total, wet PM
activity extensions have been shown to provide a benefit of an
approximately $2.00/hr labor reduction in TCO, depending on
site application. Hydraulic hoist and brake cooling oil drain
intervals were extended from 2,000 hours to 4,000 hours, after
extensive testing shows minimal changes in oil oxidation over
time, which is a measure of oil health. Final Drive oil showed
similar results, extending the drain interval from 3,000 hours
to 6,000 hours (using synthetic oil). Additionally, front wheel
bearing oil drain intervals were increased from 500 hours to
1,000 hours, after testing showed oxidation trends as being
almost flat, indicating the oil was not thermally stressed in
the location.

Various filter and breather change intervals were also increased,

with the most significant change interval being the hydraulic
tank fill filter change interval increasing from 500 hours to
6,000 hours. There was also the addition of an initial 50 hour
high pressure oil filter change for all four filters. Please see the
table below for a summary of wet PM activity changes.

PM Activity Previous Interval New Interval

Final Drive Oil Drain 3,000 hours 6,000 hours (synthetic oil)
Hydraulic Hoist and 2,000 hours 6,000 hours (synthetic oil)
Brake Cooling Drain
Front Wheel Bearing Oil Drain 500 hours 1,000 hours
Filters: Hoist, Steering, Fan, 500 hours 1,000 hours
Final Drive, Front Hub
Hydraulic Tank Filter 500 hours 6,000 hours
Breathers: Hydraulic Tank, Fuel Tank, 500 hours 1,000 hours
Final Drive, Front Hub
All Four High Pressure Oil Filters — Replace after initial 50 hours

2
 Mechanical and Electrical PM Activity Extensions
Following significant validation testing, various mechanical and
electrical PM activities now have extended intervals. In total,
mechanical PM activity extensions have been shown to provide
the benefit of an approximately $0.63/hr labor hour reduction
in TCO, and electrical PM activity extensions have been shown
to provide the benefit of an approximately $0.27/labor hour
reduction in TCO depending on site application. Among the
most significant of the mechanical PM activity extensions is the
increase from 2,000 hours to 6,000 hours for the PAS electric
drive pump oil level check, and the lubrication oil pump change.
Other significant improvements include an extension of the
lubricant pump oil level check from 750 hours to 2,000 hours,
and various lubrication and oil check extended from 500 hours
to 2,000 hours. Multiple electrical PM activities were extended
from 500 hours to 1,000 and 2,000 hours, such as the electrical
cable check and inverter cabinet check/cleaning. The high
voltage cabinet component check at 500 hours is no longer
needed, as it is duplicated in the extended electrical PM activities.
Please see the table below for a summary of mechanical PM
activity extensions, additions, and removals.

PM Activity Previous Interval New Interval

Adapter Bearing (Blower Fan) Lubrication, 500 hours/3 months 2,000 hours
Brake Accumulator Check, Electric Drive
Pump (Power Staircase) Oil Level Check,
Platform (Power Staircase) Lubrication
Lubrication Pump Oil Level Check 750 hours 2,000 hours
(and replacement as needed)
Seat Suspension Inspection/Lubrication 1,000 hours/6 months When Required
Electric Drive Pump (Powered Staircase) 2,000 hours/1 year 6,000 hours
Oil Change, Lubrication Pump Oil Change
24V Alternator and Cab Air Conditioning 4,000 hours Not needed
Compressor Belt Inspect/Replace (Tier 2 only) (duplicated, maintain
every 500 hours)
High Voltage Cabinet Component Check, 500 hours Not needed
Cover (Coupler Adapter)
Cleaning/Inspection (duplicated)
Electrical Cable Check, Electrical Ground 500 hours/3 months 1,000 hours
Stud Inspection/Cleaning/Tighten
Electric Retarder Inlet Screen Cleaning, 500 hours/3 months 2,000 hours
Inverter Cabinet Check/Cleaning,
Retarding Contactor Inspection/Replacement
Retarding Contactor Tip Replacement 2,000 hours/1 year Not needed
(duplicated)

3
 Wheel Hub Enhancements
The wheel hubs on the 794 AC have been modified and
enhanced to improve reliability and decrease PM time
and costs. The ductile iron casting of the wheel hub was
modified to increase web thickness, increasing fatigue life and
improving performance in high severity turning applications.
To accommodate additional features for PM improvement,
there are now three drain ports (compared to one on previous
models) with larger drain openings to accommodate self-sealing
Original Design magnetic plugs. The additional drain plugs eliminate the need
to reposition the truck to get the port above oil level during
front wheel oil changes and inspections, greatly improving
PM time. Additionally, the new magnetic plug assembly allows
the magnetic probe to be removed from the plug body and
inspected without the need to drain fluids from the wheel,
easing service.

New Design

Blower Fan Remote Grease Lines

Remote grease lines were added to the blower fan group to
provide easier access to greasing points on the blower fan
bearing. The new service ports are located on the rubber cover
at the front of the blower fan module and provide service for the
center and output cavities. The blower fan remote grease lines
are available as a retrofit kit for machines already in the field
with serial numbers MN51-56, MT51-167, and HRT1-106, and
are now included from the factory on all machines thereafter.

(A) Remote grease lines

(B) Grease zerk (center cavity)
(C) Grease zerk (output cavity)

4
 Enhanced Engine Oil Filtration (EEOF) Package
The EEOF package adds two key technologies to the proven
Cat C175-16 mining engine, the Self-Cleaning Oil Filter (SCF)
and the Centrifugal Oil Filer (COF). The SCF is a full-flow
filter that removes particles as small as 40 microns, and back-
flushes contaminants to the COF which further remove smaller
contaminants from the oil measuring 1 to 25 microns. The SCF
requires no maintenance over the life of the engine and the
COF is serviced by replacing the paper liner. The enhanced oil
filtration system helps reduce maintenance costs by eliminating
labor, filter, and filter disposal costs. The system also improves
equipment availability by providing an opportunity to extend
oil change intervals based on S·O·SSM oil analysis and reducing
the risk of contaminant exposure. The C175-16 engine with
the EEOF package is standard on all new 794 AC machines
SCF COF from the factory, and COF/SCF retrofit kits are available for
machines already in the field. Please see salesgram TEKQ1487,
marketing bulletin PEHJ0263, and data sheet PEHJ0663 for
more information about the EEOF package.

Availability The following PM interval extensions are now updated in

the 794 AC Operation and Maintenance Manual (OMM)
(SEBU9099). The hub redesign and enhancements are effective
beginning serial numbers HRT00103 and MT500145.

Please contact your local Caterpillar Mining Representative

for more details.

Materials and specifications are subject to change without notice. Featured machines in photos may include additional equipment. TEKQ1542
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