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November 2002
NEW FOR 793B MINING TRUCKS, 3516B HIGH DISPLACEMENT
(HD) ENGINE UPGRADE
Caterpillar is pleased to announce the new 3516B High Displacement (HD)
engine designed specifically for retrofit to 793B mining trucks. The
3516B HD improves efficiency by lowering fuel consumption, improving
engine performance, extending component life, and reducing operating
costs.
The engine is a 2160 hp replacement for the original 3516 and is based
on the current 793C HD platform. The retrofit package incorporates the
original engine oil coolers and auxiliary gear group to enable
installation without requiring significant changes to chassis or
hydraulics.
Features
13% more displacement
New turbos
Extended Repair & Maintenance Intervals
Customer Benefits
improved fuel consumption
Approximately 25% longer life
Better response
Lower Repair & Maintenance costs
Lower cost/ton
Evolution for Improved Performance - 3516B HD Engine Changes
The 3516B HD (sometimes referred to as the "Long Stroke") has been
standard in all 793C low altitude mining trucks since October, 2000.
Improved performance of the HD engine is achieved by increasing
displacement by approximately 13 % (78 liters in the 3516B HD vs. 69
liters in the short stroke 3516B). This increased displacement has been
accomplished through lengthening piston stroke by 25.4 mm (12.7 mm on
each throw) and making associated changes to the crankshaft, connecting
rods, pistons, turbochargers and control software. The increase in
stroke adds about one half of a liter of displacement per cylinder. The
connecting rods are longer and feature a more robust piston pin end that
adds durability to the design. The new pistons are shorter, but feature
the same two-piece design proven in other 3500B engines. A steel crown
with an aluminum skirt assures the best combination of high strength and
low weight.
To optimize the performance of the 3516B HD engine, a new turbocharger
arrangement was also developed. This new, more efficient turbocharger
arrangement features four identical single stage turbochargers providing
improved fuel to air mixtures and a more efficient fuel burn. The 3516B
HD design eliminates both the wastegate and the series turbocharging
design of previous 3516 engines in the 793B. This simpler design offers
improved serviceability and lower operating costs.
This upgraded engine comes with special software that allows it to work
with existing machine control modules. The 3516B HD engine requires
installation of VIMS monitoring system which uses the latest 9.62
version of VIMS configurations.
The 3516B HD is capable of operating at altitudes up to 3700m (12,000
ft.) without performance deration. For high altitude sites where fuel
economy is a top priority the 3516B HD will provide fuel efficiency with
a derate of 0.8% per kpa (390ft) of altitude starting at 3700m (12,000
ft.).
3516B HD Delivers Lower Operating Cost-Per-Ton
3516B HD Engine Operation
The 3516B HD engine combustion system provides real fuel efficiency
improvements for 793B users. On a full load comparison Brake Specific
Fuel Consumption (BSFC) is reduced from 218 to 199, an improvement of
approximately 9 % over the short stroke engine. Lower BSFC contributes
to longer engine life. Elimination of the turbocharger wastegate and
series turbocharging also contributes to reduced fuel consumption, lower
maintenance costs, and extended engine life. The new design increases
engine displacement by 13% which lowers Brake Mean Effective Pressure (BMEP),
effectively reducing thermal, pressure and vibration stresses on the
engine. Lower BMEP is critical to extended component life and longer
overall engine life.
Recommended oil and oil filter change intervals have been extended from
250 to 500 hours. The 3516B HD engine provides the option for Oil
Renewal System (ORS).
The following chart illustrates the engine life a customer can expect
with a 3516B HD engine in relation to the life they previously
experienced with the 3516 engine under a given load factor. On the
average, because of the improvements made with the 3516B HD, about
100,000 more gallons of fuel can be burned over the life of the engine
thus equating to more life between overhauls.
3516B HD Machine Intelligence
With the 3516B HD upgrade, on-board engine and machine diagnostics are
required. A reprogrammable (flashable) ECM with expanded diagnostic
memory capacity increases software utilization for optimum engine
management. Enhanced self-protection features which contribute to longer
engine life include exhaust temperature deration, engine oil level
monitoring, oil filter restriction sensing, acceleration delay, and
engine crankcase pressure monitoring. Additional sensors have been
added, together with the new engine control module, new wiring harness
and wiring plugs. There is also facility for control of associated
optional systems: pre-lube, fans (Rockford), radiator shutters.
3516B HD Engine Upgrade Option for 793B Mining Trucks
Owners of 793B mining trucks (S/N 1HL) can upgrade to the HD engine via
a Reman option, when customers purchase a HD Reman engine and the truck
conversion parts list and return their old 3516 short stroke core
The HD engine upgrade option is summarized below:
Engine
? The Reman option to upgrade a standard stroke engine to a high
displacement engine (10R0946), will be available for order to users with
the return of a 3516B standard stroke core. There will only be a
?Distribution? Reman engine option available for this upgrade program.
There will not be a Made As Order (MAO) Reman engine option available at
this time.
? For subsequent rebuilds customers can either choose a Reman
replacement (part number to be announced later) or a Caterpillar? dealer
rebuild of their HD engines. Discussion with their servicing dealer
should occur to determine the best option for their mine equipment.
? Service Instructions will be available for rebuilding the 3516B HD
engine.
Reman Engine Order Process
? Dealers are strongly encouraged to place orders for the Reman engine
and chassis conversion parts through the Future Dated Order (FDO) order
routines. In order to reduce confusion and establish a common policy
between Major Components and 3500 engines, the MAO option and the
associated discounts will not apply to this upgrade. The use of the FDO
order system will be critical in enabling Caterpillar to provide the
Reman engine required at the time it will be needed on site. It is
anticipated that customers who choose this upgrade option will also plan
to have the upgrade completed during a scheduled engine Planned
Component Replacement (PCR).
? For planning purposes, FDO component orders lead time, from date of
order to ex-factory shipment, is 90 days.
? Caterpillar will maintain a level of inventory on hand to enable a
quick response to short term engine upgrade opportunities. Dealers are
encouraged to check on availability prior to making commitments.
? Communication will be important to make sure Caterpillar and Dealers
will be able to meet the product availability needs of customers who
want to upgrade to the 3516HD engine. Questions on product availability
should be directed to Jamie Gerstenkorn, Caterpillar Reman Products
Division (309) 636-5839.
Truck
? To complete the initial 793B retrofit, truck hardware conversion parts
(lines, hoses, brackets, etc.) are required. The truck conversion
hardware will be available in November, 2002 and can be ordered directly
using the parts list in the Special Instructions (REHS1371-00). All
3516B HD Reman options come standard with a TF750 air compressor. Trucks
equipped with a TF1000 air compressor must also convert the air
compressor lines and air drier group to accept TF750. Refer to Special
Instruction REHS 0521-01.
? Machines must be equipped with the latest VIMS? 9.62 Software. Refer
to Special Instruction (SEHS9829).
Financials
The following charts provide estimated information on repair options,
allow comparison between standard stroke/HD engine options.
Availability improvement should be considered in addition to this
analysis.
All prices are U.S. Suggested Consumers Price. Prices are subject
to change without notice.
Assumptions:
- 40% Load Factor
- Annual Operating Hours: 7,000 hours
- Cost of Fuel: $0.80/Gallon
- Cost of Oil: $1.40/Liter
Questions
Any questions can be directed to:
? Mining Truck Service Support in Decatur, IL - (217) 475-4934
? LEC Service Support Center in Lafayette, IN ? (765) 448-2200
? Cat Global Mining ? (309) 675-4439
? Engine Parts Business Unit ? (309) 578-7304
? Reman Business Unit - (309) 636-5839
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