Mining equipment runs the largest turbochargers in the world on the longest duty cycles in the hardest conditions. Boost Lab, Inc. rebuilds the turbochargers on Caterpillar 3500-series powered haul trucks and loaders, Komatsu 930E and 830E with Cummins QSK78 and QSK60 power, Hitachi EH series, underground LHDs and trucks, and the drill rigs and support equipment that keep a mine running. These are massive turbos with massive rebuild economics against OEM assemblies. Fleet and dealer programs available. Nationwide ship-in service.
From 100-ton loaders to 400-ton haul trucks, the turbo hardware is familiar: Garrett, BorgWarner, Holset, scaled up.
The Cat 797F runs a 3516 HD making 4,000 hp through four turbochargers. The 793 and 785 run 3512 and C32 power with two or more turbos each. These are the same 3500-series Garrett and BorgWarner families that serve gensets and marine, scaled to mine-site ratings. Complete assemblies through Cat channels cost five figures per unit; rebuilding is the economic reality on equipment this expensive to idle.
Komatsu ultra-class haul trucks run Cummins QSK power with Holset turbochargers: the 930E-5 uses the QSK78 at over 2,500 hp. These are the largest Holset frames in production, and they rebuild on the same bench as every other Holset unit we service. Core banking for mine fleet operators is available through our dealer program.
The largest wheel loaders share powertrains with their haul truck stablemates: Cat 3512/3516 and Cummins QSK. Same turbos, same rebuild, same fleet economics.
Underground mining equipment runs smaller Cat C7 through C15 and Cummins QSB/QSC power with Garrett, BorgWarner and Holset turbos that are standard across our catalog. Underground heat and ventilation constraints make turbo reliability even more critical: a failure underground is an evacuation-grade event.
Support equipment runs the same Cat and Cummins engine families as the primary fleet, with the same turbo hardware. Our dealer program covers the whole mine site, not just the big iron.
A 797F sitting for a turbo swap costs the mine tens of thousands of dollars per day in lost production. OEM assemblies for 3516 turbos list over $8,000 each, and the truck needs four. Rebuilding cores at a fraction of the assembly cost, with priority turnaround and core banking, is the economic answer for every mine fleet.
Our dealer program banks rebuilt cores so a ready unit is on the shelf before your truck is in the bay. One dead turbo on a haul truck is a repair; a fleet of haul trucks is a pipeline. Core banking, wholesale rebuild pricing, and priority turnaround keep your trucks loaded and moving. Email sales@theboostlab.com to set up a mine fleet account.
Mining turbos identify by engine serial and power rating. The turbo families are familiar; the scale is not. Search by any term.
| Turbo PN | Model | OEM PN | Application | Notes |
|---|---|---|---|---|
| Serial-specific, multiple per engine | Garrett / BorgWarner | Cat 3516 channel | Cat 797F, 994K (3516 HD, 4,000 hp) | Four turbos per engine; five-figure assemblies |
| Serial-specific, multiple per engine | Garrett / BorgWarner | Cat 3512 channel | Cat 793, 785, 993K (3512 power) | Two or more per engine by rating |
| Serial-specific | Holset HE / HX ultra-class | Cummins QSK channel | Komatsu 930E (QSK78), 830E (QSK60) | Largest Holset frames in production |
| Serial-specific | Garrett / BorgWarner | Cat C27/C32 channel | Cat 990K, 775 and support equipment | C-series industrial at mine ratings |
| See construction reference | Various | Various | Underground LHDs, trucks, drills (C7-C15, QSB/QSC) | Standard catalog hardware at smaller scale |
Extreme loads, extreme dust, extreme hours: the patterns are predictable.
Open-pit mining generates airborne particulate that exceeds even construction and agriculture. Multi-stage air filtration systems are the turbo's lifeline, and a breach in the intake system sandblasts compressor wheels in hours, not days.
Haul trucks and loaders run at or near full load for entire shifts. The turbo never cools down, and oil passages never get a break from heat. Sensible oil intervals and proper shutdown procedures are the only protection.
Mines operate from sea level to over 15,000 feet and from Arctic cold to equatorial heat. Altitude reduces air density and makes the turbo work harder; temperature extremes accelerate seal and bearing wear. Altitude-specific calibrations matter.
Haul roads transmit severe vibration through the chassis to every engine component, and turbo bearings absorb cumulative fatigue over thousands of hours. VSR balancing on every rebuild ensures the turbo is not adding its own vibration.
Loaded climb, dump, immediate shutdown for shift change. The heat soak cokes the center section on every turbo in the engine. An idle-down protocol costs a few minutes per shift and saves turbos.
High-hour mining engines on stretched oil intervals push soot-loaded oil through the turbo bearings. The turbo wears to the oil quality, not to its design life.
Yes. Our dealer program banks rebuilt cores, provides wholesale pricing, and prioritizes mine fleet turnaround. Email sales@theboostlab.com with your fleet size and engine family.
Yes, we rebuild all four as a matched set, balanced and documented together, for a fraction of four Cat assemblies.
Band to a pallet, drain all oil passages, cap openings, and ship freight to Boost Lab, Inc., 37833 Pineapple Ave, Unit A, Dade City, FL 33523. Start the paperwork at repair.theboostlab.com before shipping.
Yes. We coordinate with onsite maintenance operations and mine service contractors. The turbo work happens at our shop; the coordination happens by phone, email, and our repair management system.
Yes. Underground LHDs, trucks, and drills run Cat C-series and Cummins QSB/QSC power with standard catalog turbo hardware that we rebuild daily.