The Cat Certified Rebuild Process

18 May 2020

The Cat® Certified Rebuild Process.

For many Contractors, the aim to reduce the total cost of ownership for heavy construction equipment now includes machine and component rebuilds as part of the fleet management plans.
With a regimented maintenance plan working alongside a dealer, Caterpillar Machine Owners can reduce downtime on machinery and build a second life into their machines.

“When entrusting your machine to a dealer to rebuild, its important for to make sure customers have peace of mind,” Graham Mallet, Service Supervisor at Hastings Deering said.

We dove right in to find out the process and what goes on behind the scenes with Certified Component and Machine Rebuilds at Hastings Deering.

What is involved?

Step 1: Inspection and Evaluations:
Once the machine arrives at the facility, it is thoroughly inspected.

“Our team will look over everything including the SOS Fluid Analysis, attachments and reviewing all prior maintenance, service records and any technology or safety updates to help us understand the machine,” said Mr. Mallet

Step 2: Disassembly:
“With a Cat Certified Machine Rebuild, we disassemble the machine right down to the basic frame, leaving no part or component untouched.”

During the disassembly stage, all parts are inspected and assessed against a Caterpillar Parts Re-usability Guidelines and strict specifications. 

In all rebuilds, parts including hoses, belts, seals, gaskets, bearings, knobs, wiring, switches, and gauges are always replaced with new parts.

“The machine is rebuilt from the ground up to include all Caterpillar Product updates and includes 99% new parts being built in,” he states. “This ensures the same high level of performance and reliability as a new Caterpillar Machine.”

cat engines

Step 3: Reconditioning:
Being used in tough applications, machine frames can suffer damage over time which limits the overall machine performance.

“Frames are examined, straightened, reinforced and welded when it is necessary.”

“At this stage we also replace worn linkage pins, measure and reclaim pin bores, the hydraulic and power train systems are brought back to original levels of performance and reliability,” said Mr Mallet.

Step 4: Engineering Updates:
Caterpillar make engineering improvements and updates to machinery regularly.

By the time a customer machine is due for a component rebuild, there are often updates that have been made since the original manufacture of the machine.

These improvements are reviewed and incorporated into the machine during the reassembly. This ensures that the machine can perform like-new during its second life.

Step 5: Engine and Transmission Tests:
“We don’t just stop at disassembling the machine, during a rebuild the Engine, Transmission and torque converters are also completely disassembled, inspected, reconditioned and updated to the Caterpillar Certified Rebuild Standards.”

Each component then undergoes thorough bench tests before installation in the machine.

Step 6: Reassembly and Performance testing:
Critical clearances and pressure settings are all maintained and recorded.
All critical systems are tested to verify that they meet the stringent rebuild and working performance specifications.

“All oil/fluids must be filtered by using a kidney loop machine to remove any contaminants. This is done until the test reading matches or is better than the ISO standard for that fluid system.”

Step 7: Repainting:
On a Cat Certified Machine Rebuild to ensure that the machines look and feel like new, they undergo a re-paint of the entire machine with all new identifying graphics and Logos applied.

Step 8: New Product Identification Number:
Following a Cat Certified Machine Rebuild, each machine is issued with a Caterpillar Certified Rebuild number to identify the machine and certify that it has completed a Cat Certified Rebuild.

Step 9: Customer Evaluation:
The final step is to allow the customers to evaluate the machines.

“The rebuild process is only complete when the customers are satisfied with the reliability, productivity, and availability of the machine as it operates in their working environment,” Said Mr Mallet.

“When the machine is returned to the customer it will look and perform like new.”

Learn about the Hastings Deering Repair Options here:


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