CAT 3516E Engine Upgrade for Mining Haul Trucks in Remote Open-Pit Operation

Project Overview

In 2024, a mining contractor operating a remote open-pit site required a reliable power upgrade for its heavy-duty haul truck fleet. The mine runs in high-temperature, high-dust, continuous-duty conditions, with loaded uphill haul cycles placing significant stress on the engine.
To resolve repeated performance issues and improve production stability, the operator selected the CAT 3516E diesel engine as the replacement power unit for its large-capacity haul trucks.

Operational Challenges

Before engine replacement, the haul truck fleet experienced:

• Insufficient torque during loaded uphill haul cycles
• Frequent overheating under high ambient temperature
• Rising unplanned downtime due to power loss
• Reduced payload consistency
• Engine derate events in dusty environments
These issues directly affected ore movement capacity and overall production output.

ZEB POWER Solution – CAT 3516E Engine Upgrade

After technical evaluation, ZEB POWER supplied a CAT 3516E diesel engine configured for mining duty.

The engine delivers higher torque, improved cooling performance, and long-term durability for heavy-load continuous operation.

Actions Implemented:
• Delivered complete CAT 3516E power module
• Matched engine configuration to truck duty cycle and gradient profile
• Optimized cooling and air filtration for high-dust environments
• Performed pre-delivery testing and export packing
• Coordinated transportation to remote mine site

Performance Results After Deployment

After integration and commissioning, the mining operator reported:
• Higher and more stable torque under full payload
• Improved uphill hauling performance
• Significant reduction in overheating incidents
• Increased truck availability and reduced downtime
• More consistent cycle times and production output
The CAT 3516E upgrade restored operational confidence and delivered a measurable improvement in daily tonnage moved.

Why the CAT 3516E Fits Mining Haul Trucks

The CAT 3516E is built for demanding mining conditions:

• V16 heavy-duty platform engineered for continuous operation
• High torque at low RPM for loaded incline hauls
• Proven durability in high-temperature sites
• Efficient cooling and advanced air handling
• Strong global service and parts availability

This engine is widely used in:
• Large mining dump trucks
• High-tonnage haulage systems
• Operations requiring 24/7 reliability

ZEB POWER Support for Mining Operations

ZEB POWER provides:

• CAT mining engines (C18 / C32 / 3512E / 3516E)
• Engine replacement and upgrade solutions
• Technical matching based on truck model and duty cycle
• Testing, inspection, and export packing services
• Global logistics for remote mine delivery

Contact Us

If your mining fleet is experiencing power loss, overheating, or reduced haulage performance, ZEB POWER can support your operation with reliable CAT engine solutions.
Share your truck model, operating conditions, and power requirements for a fast technical evaluation and quotation.