This vital first step is a thorough process during which we develop a customized rebuild plan and cost estimate. The specific needs of your machine or power train are determined through a comprehensive evaluation, which includes fluid analysis, careful visual inspections and review of maintenance/S-O-S analysis services. Cat Certified Rebuild includes more than 300 tests and inspections. Cat Certified Power Train up to 200.
Once the rebuild plan is established, your machine or power train will be completely disassembled. All hoses, belts, seals, gaskets, bearings, knobs, wiring, switches and gauges will be replaced with new parts. Remaining parts will be inspected and measured against our strict reusability guidelines. Those that do not meet our high standards will either be replaced with new or CAT Reman parts, or reconditioned to meet guideline specifications. Cat Certified Rebuilds include automatic replacement of approximately 7,000 parts; power train rebuilds include approximately 3,000 parts.
This phase of the process addresses equipment needs not typically included in an overhaul. For example, frames are examined and, if necessary, they are straightened, welded and reinforced. Worn linkage pins and shaft bearings are replaced. Hydraulic systems are returned to their original levels of performance, reliability and cleanliness, meeting ISO 18/15. Even electronic control modules and software are replaced.
4. Engineering Updates
During reassembly, critical improvements that have been made to this machine model since original manufacturing will be incorporated into your machine or power train.
5. Power Train Tests
The engine, fuel system, transmission, torque converter, differential, final drives and radiator are also disassembled, inspected, and reconditioned and updated with new or qualified parts. then, before reinstallation, each component is thoroughly bench tested.
All critical torques, clearances and pressure settings will be maintained and recorded during careful reassembly of your machine or power train by our professional technicians. Engine wiring harnesses are always replaced, and all other wiring is replaced on full machine rebuilds only.
7. Performance Testing
Quality control is integral to both rebuild programs. Therefore, rigorous testing is conducted at several stages. Among the tests routinely performed are: turbocharger boost, throttle response, stall speed rpm, transmission and steering clutch response, and hydraulic and pilot relief valve pressures. Contamination control procedures are followed to assure the unit meets total system cleanliness of ISO 18/15. Instrument and operational testing are also conducted to ensure field performance levels match those in the shop.
Your machine will perform like new - and look like new - after a complete paint job and application of new model identity graphics on a full certified rebuild. Finally, a Cat Certified Rebuild decal will be issued.
9. New Serial Number or Product Identification Number
A new serial number or product identification number (Cat Certified Rebuild only) not only identifies your machine, it entitles you to a like-new standard warranty. Because it verifies the exception Caterpillar rebuild process, it dramatically increases your resale value.
10. Customer Evaluation
The rebuild process is not considered complete until your operators are satisfied with the performance of the machine or power train in its working environment.