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Breathing new life into old machines: 10 steps

Today’s miners continually look for ways to make every dollar count. One way they reduce costs associated with their mining machines is through equipment rebuild programs.

Caterpillar is in the fourth decade of its Cat® Certified Rebuild program, which has grown considerably over the last few years as heavy equipment owners focus on controlling costs. The company has delivered more than 10,000 rebuilds.

A Certified Rebuild is Caterpillar’s most complete rebuild option. The old machine is completely disassembled and all major components are replaced. Rebuilds help miners recover all the performance and productivity of the original machine while incorporating the latest engineering updates, at a fraction of the cost of a new machine.

A Cat Certified Rebuild follows 10 steps:

  1. Inspection / Evaluation
    A machine rebuild includes 350 tests and inspections, while a power train rebuild includes 200 tests and inspections. A customized plan and cost estimate for the rebuild are provided.
  2. Disassembly
    The machine and power train are completely disassembled. A machine rebuild includes the replacement of 7,000 parts, while a power train gets 3,000 new parts.

795F AC rebuild

  1. Reconditioning
    During this step, frames are straightened, welded & reinforced; new linkage pins and shaft bearings are installed; hydraulic systems are restoredl and electronic controls and software are replaced.
  2. Engineering Updates
    Rebuilt machines receive the latest improvements in safety, performance, comfort and maintenance.

engine rebuild

  1. Power Train Tests
    The engine, fuel system, transmission, torque converter, differential, final drives and radiator are reconditioned, updated, tested and reinstalled.
  2. Reassembly
    Critical torques, clearances and pressure settings are maintained and recorded and the engine wiring harnesses are replaced.
  3. Performance Testing
    This step ensures quality control through instrument and operational testing. Contamination control procedures are strictly adhered to during this process.

Cat Certified Rebuild

  1. Repainting
    The rebuilt machine receives new paint, model identity graphics and a Cat Certified Rebuild decal.
  2. New Serial Number or Product Identification Number
    This new number identifies the machine and entitles it to a like-new standard warranty. This step also enables a higher resale value for the machine.
  3. Customer Evaluation
    The rebuild is not officially complete until the owner is satisfied. The machine is put to the test in a working environment, where it is evaluated by the owners and operators.

Choosing the right rebuild option

Local Cat dealers are experts at helping equipment owners select the rebuild option that’s right for their machine and their operation. In addition to a complete Cat Certified Rebuild, other options include:

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