R1600G verses R1600H Ferreyros Peru.

William Edwards Alexander Urdaneta Feb Mar 2013

NPI Program: R1600H Upgrade

Program Description:
This program is a repower project driven by the phase out of the 3176C engine. Primary objective of the program was is to install the C11 engine. Additional updates have been included within the program timeline.

New Content: ~ 9.6%

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R1600H Changes from R1600G Overview

3176C tier II engine to C11 tier III or VR Ventilation reduction engine package with
lower vent rate option available in lieu of Tier III engine. Upgraded exhaust to reduce noise. Altitude rating engine.

Cooling System upgrade R1700G SBR type cooling package with axle cooling in
radiator package. Note system will only flow through cooling package once pre-determined oil temp has been reached to avoid coolant heating oil.

Front Axle Housing Updates Front axle cooling suction port raised to protect lines.
Brake wear check point repositioned to allow wear check without draining oil.

Operator Presence System R1700G SBR R2900G JLK Operator Presence system
installed to improve safety of machine & operators.

Operator Station Improvements

Improved ergonomic layout of cab. Cat EMS replaced with display screen. Toggle switches replaced with touch button modules. Mechanical lock out to activate STIC Steer lock out lever.

Steering System Upgrade Main Steer Valve replaced with more modern & serviceable
valve group. Steering Release valve updated & to be standard with tow release option.

Rear Frame Updates Replaceable & serviceable rear wear plates. Rear upper ROPS
mount removable to assist in Transmission installation.

Hydraulic Updates Low hydraulic level warning.

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Engine
3176C Engine replaced with C11.
Updated exhaust to improve noise levels in 100-120 Hz range .
3176C Engine

C11 Engine

Ventilation reduction engine package with lower vent rate option available in lieu of Tier III engine. Altitude capability targeted to operate at 4,500 mtrs.
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Engine

15 ppm = 0.0015 % 500 ppm = 0.05 %

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C11 Engine installed into R1600H

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C11 Engine installed into R1600H

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C11 Engine installed into R1600H

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C11 Engine installed into R1600H

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C11 Engine installed into R1600H

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Muffler Changes

New muffler with changes to mounting, insulation, perforation and sound attenuation. Exhaust inlet modified for new design. Installation is now safer and less complex due to lifting points and part reduction.

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Cooling System Upgrade

Axle cooling fans discontinued. Cooling integral part of cooling package. Circuit temp thermostatically controlled oil will only circulate through cooler circuit once operating temp is obtained.

R1600G
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R1600H

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Cooling System Upgrade

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Cooling System Upgrade

R1600G

R1600G Current known field issues of damage to the suction line and guard On the front axle cooling system. Resultant damage can lead to Hose failure and axle draining of oil Suction line guard with subsequent axle failures
Suction hose

R1600H

R1600H Changes Raise the suction line port in the front axle housing reroute hoses and fittings up away from the impact zone

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Cooling System Upgrade

R1600H

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Front Axle Housing Brake Wear Check Port

Additional new location of brake wear check port

Currently Axle oil needs to be drained pump removed, prior to installing tooling for measuring brake wear.

R1600H

Current location of brake wear check port

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Operator Station Improvements

R1600G

Gauges & Displays replaced with more advanced display & diagnostic display module. Fault finding, instructions on faults, system pressures, diagnostics carried out with display. Current language options are English & Spanish. Additional ones to be added.

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R1600H

Operator Station Improvements

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Operator Station Improvements

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Operator Station Improvements

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Operator Station Improvements

Toggle switches replaced by 2 separate push button modules.
R1600H

Additional functions can be added.

R1600H

R1600G
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Operator Station Improvements

Brake pressure gauges replaced by display module. Removes these Hydraulic hoses from the operator station. Dash Diagnostic, Scroll Box functions can be carried out through display monitor.
R1600H R1600G

R1600G
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Operator Station Improvements

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Steering Release Update

Steering release valve moved from main steer valve to hyd tank bay. When not installed manifold replaced by bulkhead so same hoses are used. Steering release standard fit with tow release options.

R1600H
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R1600H

Rear Frame Wear Plates

Replaceable & serviceable rear wear plates. Common part for LH & RH side.
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ROPS Mount
Removable Upper ROPS Mount to allow installation of Transmission easier.

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Options that are now standard on R1600H 9SD model

Following items are now part of standard configuration for base machine. Start Receptacle Brake Gauges (now part of main display module) Transmission Pressure Sensor Radiator Cap manual release type Cab Door Strut when selecting enclosed cab option Remote Mounted Engine Oil Filter Fluid Sample Adaptors (Eng-Tran-Hyd - Coolant) Trans Filter Drain Tap Brake Axle Cooling Electric Fuel Priming Warning, Residual Brake Pressure Light Group Stop Ground level engine shutdowns (x 3) Operator Presence ABA (Automatic Brake Application)
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Start Receptacle

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Front & Rear Brake Pressure Gauges

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Transmission Pressure Sensor

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Manual Release Radiator Cap Door Strut (enclosed cab)

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Remote Mounted Engine Oil Filter

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SOS Fluid Sample Adaptors Transmission Filter Drain

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Brake Axle Oil Cooling

ATAAC

Brake Cooler

Brake Oil Inlet

JW Radiator
Brake Oil outlet
Brake Oil Inlet

Brake Cooler
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Brake Brake Oil Oil outlet outlet

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Brake Axle Oil Cooling

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Electric Fuel Primer

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Residual Brake Pressure Light Group Stop

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Ground Level Engine Shutdown (3 positions)

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Operator Presence System

The System disables the machine if ALL of the following conditions are active for 3 Seconds or more:
Park Brake is in the Off Position Engine Speed is below ~850 rpm Ground Speed is Below 5 km/h (3.1 mph)

Service Brake is Released

The system disables the machine by: Engaging Parking Brake Neutralizing Both the Hoist and Steering Circuits Engine Shutting Down / Idle (ET Configurable)

As an Operator, How do I Benefit from OPS?

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OPS prevents movement of a machine when operator input is not present. When an operators forget the correct stopping and parking procedures, OPS will be engaged for safe shutdown. If an operator exits the cab of a machine without stopping and parking the machine in the correct manner, OPS will disable the machine for safety.

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Operator Presence System

Estrategia de intertraba
Cuando se opera la mquina con el freno de estacionamiento desconectado se debe realizar una de las siguientes acciones antes de que transcurran tres segundos o se conectar el freno de estacionamiento, la transmisin pasar a neutral y el motor se parar. Conecte el freno de servicio Mantenga la velocidad del motor por encima de 850 rpm Mantenga la velocidad de desplazamiento por encima de 5 km/h (3,1 millas/h) Cuando la mquina se para, se debe realizar una de las acciones siguientes antes de que transcurran tres segundos o se conectar el reno de estacionamiento, la transmisin pasar a neutral, las funciones de la direccin se neutralizarn y el motor se parar. Conecte el freno de servicio Mantenga la velocidad del motor por encima de 850 rpm Conecte el freno de estacionamiento Nota: La parada del motor con funcin de intertraba puede configurarse usando la herramienta de servicio Tcnico Electrnico Caterpillar (ET). El motor parar cuando aparezca ENABLED (HABILITADO). El motor no parar cuando aparezca DESACTIVADO.

Adems, para operar las funciones de la direccin y del implemento con el freno de estacionamiento conectado, debe hacer lo siguiente.
Mantenga la velocidad del motor por encima de 1.500 rpm.
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Options that are no longer available

The following items are have been removed from the R1600H 9SD model. EAM Electronic Access Module. Will be replaced by VIMS.
Note VIMS for the R1600H is still being developed & a date when it will be available ex factory is still to be determined. Target is for 9SD00101 & Up.

Hand Held Fire Extinguishers. These options will not be available on the 9SD model from Thailand facility. Guard Gp Axle. No longer available ex factory. Still available through parts distribution system if dealer or customer require them to be installed.

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Questions?

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