EQUIPMENT MAINTENANCE & MANAGEMENT
REBUILDING REAPS BENEFITS
Today’s expanded rebuild options drive down total cost of ownership and help companies get the most from their equipment By Rick Zettler
M
achine and component rebuilds for heavy construction equipment are part of many contractors’ fleet management plans. Today, contractors target tens-of-thousands of operating hours, multiple service lives and low total cost of ownership (TCO) from a machine by implementing a regimented maintenance plan and multiple machine rebuild strategies. “Service departments consistently following the machine’s suggested maintenance schedule, oil sampling guidelines and monitoring telematics data will typically realize the lowest total ownership costs,” comments Dave Matranga, a Caterpillar market professional for engines and Cat Certified Rebuilds (CCR). “Include a rebuild strategy into the mix, and companies can drive down TCO even further.” Expanded rebuild options weren’t always the industry standard. As recently as the early 1980s, equipment manufacturers didn’t offer certified machine rebuilds. If a contractor wanted a “like-new” piece of equipment, well, buying new was the only option. In response to challenging economic conditions and voice-of-customer requests, Caterpillar was among the first heavy equipment manufacturers to introduce its CCR program in 1984, which gave contractors a “like-new” machine at a lower cost alternative to buying new. The machine was rebuilt from the frame-up – axles to cab – with the goal of getting more than a just few thousand extra hours out of the machine. “The ‘like-new’ product offered a second life for the machine,” comments John Baptiste, project 26
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engineer – Caterpillar Certified Rebuild Products. Matranga adds, “The first units rebuilt through our CCR program were Cat D8K dozers. These dozers offered comparable performance and appearance to their brand-new counterparts with similar extended protection plans and financing rates and options, so they were, indeed, ‘like-new’.” The typical CCR machine rebuild included approximately 7,000 part numbers either replaced or refurbished. Over time, trends showed better maintained and operated equipment resulted in more reusable parts, lowering machine rebuild cost. “A welltrained operator goes a long way in maximizing machine life,” comments Eric Mathewson, senior parts specialist for Caterpillar Undercarriage and Ground Engaging Tools (GET). “Working a side-slope in one direction too long or improper use of the bucket were instances that led to uneven wear and a shorter life for wear items and machine components.” Rebuild programs like CCR were well received by contractors and participation rates remained relatively consistent over the years. However, the extensive program left out companies that wanted targeted system or component rebuilds, so manufacturers responded with options to meet those customers’ needs. “In 2001, we introduced our Certified Power Train rebuild program that upgrades only the systems that move the machine, and participation in our rebuild program tripled,” offers Matranga. “Caterpillar then expanded the program to include Certified Engine Rebuilds, Certified Hydraulic Rebuilds and Certified Machine Component rebuilds over the following years, and program participation rose significantly. Companies realized that reusing components, versus scrapping or landfilling, lowered TCO plus improved sustainability.”
What’s the standard?
Baptiste recommends working with the dealer even before machine purchase to review applications, how long it is anticipated to remain in the fleet and the company’s expectation for uptime availability. This allows the dealer to run a life cycle analysis and have targeted maintenance and rebuild solutions planned. “We have some customers who run their operations 24-7 and demand machine uptime availability in excess of 90 percent,” says Baptiste. “The dealer preschedules downtime for maintenance and rebuilds at prescribed intervals, so the equipment is better able to meet this uptime expectation,” he says. While some may assume that all rebuilds are equal, this is not the case. When it comes to rebuilds, selecting a provider just on initial price-point can sacrifice post-rebuild machine life and productivity. Over the years, manufacturers have developed rebuild standards. Caterpillar, offering more than 35 years of experience with its CCR program, provides its dealers with detailed reuse and salvage guidelines specific to machines like dozers, excavators, trucks and loaders. These documents guide dealers through properly inspecting components for reuse or salvage, based on extensive rebuild history and conservative criteria. This is designed to provide more consistent rebuild results, regardless of where it is performed. Baptiste mentions friction disc replacement and Thermal Spray as examples of where the reuse and salvage guidelines help to lower rebuild costs. “Other companies may overlook the reusability of friction discs or plates and buy new. Caterpillar has an 18page document with pictures to help our dealers identify which items can be reused or reconditioned,” he says. “We also offer Thermal Spray guidelines for components like hydraulic cylinder rods, so they can
