Haul trucks, loaders and underground: turbo rebuild service

Cat 793, 797, 785 (3512 / 3516 power)

Haul Trucks

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 930E, 830E (Cummins QSK78, QSK60)

Haul Trucks

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.

Cat 993K, 994K, Komatsu WA1200 (3516, QSK power)

Wheel Loaders

The largest wheel loaders share powertrains with their haul truck stablemates: Cat 3512/3516 and Cummins QSK. Same turbos, same rebuild, same fleet economics.

LHDs, trucks, drills (Cat C-Series, Cummins QSB/QSC)

Underground

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.

Blast hole drills, graders, water trucks

Drill Rigs + Support

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.

Why mines rebuild

Mine Site Economics

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 $8000 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.

Dust loading beyond any other application

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.

Constant full-load duty cycles

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.

Altitude and temperature extremes

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.

Vibration from haul road conditions

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.

Hot shutdown after loaded hauls

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.

Contaminated oil at extended intervals

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.