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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 (RE