IMPROVED 10R0964 3516B HD ENGINE ARRANGEMENT NOW AVAILABLE FOR 793B MINING TRUCKS Caterpillar

 December 2006

IMPROVED 10R0946 3516B HD ENGINE ARRANGEMENT NOW AVAILABLE FOR 793B MINING TRUCKS

Announcement

Cat Reman announces an improvement to the 10R0946 3516B HD engine for 793B Off-Highway Trucks. The improved arrangement includes the faster spinning 793D turbos and different software designed to improve engine performance. The changes will help to eliminate engine derates that were triggered by excessive exhaust temperatures within certain RPM ranges. In the validation testing conducted, the new turbo and software modifications have significantly reduced exhaust temperatures and have delivered a 50% quicker acceleration to torque converter stall. Overall improvements in cycle times were measured as the new turbo and software modifications improved acceleration away from the shovel.

The engine remains a 2160 hp replacement for the original 3516 and is based on the 793C HD platform with the exception of the turbos. The retrofit package incorporates the original engine oil coolers and auxiliary gear group to enable installation without requiring significant changes to chassis or hydraulics.

Though offering benefits as shown in the table below, the new arrangement does require a reduction in the altitude capability of the HD engine from 12,000 ft to 10,000 ft to keep turbo speeds within design limits. Also, the fuel consumption as measured in the lab has increased from where it was with the original turbo but is still about 4% better than the original 793B standard stroke engine. Fuel consumption is also very dependent on application and payloads and some sites have reported improvements in fuel consumption from the original design.
 

3516 HD Continues to Deliver Lower Operating Cost-Per-Ton

The 3516B HD engine combustion system provides fuel efficiency improvements for 793B users. On a full load comparison of Brake Specific Fuel Consumption (BSFC), BSFC is reduced from 218 to 209, an improvement of just over 4% 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 both the 3516 standard stroke and the original 3516B HD engine under a given load factor. On the average, because of the improvements made with the 3516B HD, about 50,000 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 duration, 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 such as Prelube, Rockford Fans, and 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 or a Caterpillar? dealer rebuild of their HD engine. 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 (for SS to HD conversions) 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.

Questions on product availability should be directed to Clint Pincock, Caterpillar Reman Products (309) 494-4730.

Truck

• To complete the initial 793B retrofit, truck hardware conversion parts (lines, hoses, brackets, etc.) are required. The truck conversion hardware is available and can be ordered directly using the parts list in the Special Instructions (REHS1371). 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 Instructions REHS0521.
• Machines must be equipped with the latest VIMS? 9.62 Software. Refer to Special Instructions SEHS9829.

Core Acceptance

There is no part number change to the upper level arrangement and the previous design is still acceptable core when ordering the new arrangement. The following Core Acceptance Criteria is available to support this product. All the latest core acceptance criteria guidelines can be found on the Reman Dealer Extranet at http://intranet.reman.na.cat.com/web/main/index_dealerextranet14.html.

SELD0164-08      3500 Engines

Warranty

Please consult the appropriate warranty statement for your area.

Core Management

Please refer to the Caterpillar? Core Management Information System (CMIS 2) Parts Information application describing all reman part/CAF and related information. Also refer to other CMIS 2 inquiry applications such as Customer Profiles, Inspection Reason Codes, Inspection Line Inquiry, Add Charge Information, Entitlement Activity, Entitlement Inquiry, CCR Inquiry, CCR Entry, Shipment Processing; Process Packaging Grief; and Reporting to properly manage core returns and monitor inspection performance. This information will be available to all dealers worldwide after your CMIS 2 conversion date.

For the latest updates of Reman Policies and Core Management (SELD0122), Core Management Systems & Operations Procedures (SELD0040), and Shipping Instructions (SELD0039), go to the Reman website at https://reman.cat.com and click on Procedures and Policies (listed under Reman Program Information).

If you have any questions regarding core return processing, feel free to call your Corinth Dealer Service Representative toll free at (800) 537-2928 or use our e-mail address -- reman_core_operations@cat.com. For assistance with technical questions, call the Peoria Reman Customer Satisfaction Hot Line also toll free at (888) 88-REMAN or use our e-mail address --Reman_Help@cat.com.

Core Management

Any questions can be directed to:

• Mining Truck Service Support in Decatur, IL - 217 475 4020