CAT 775B Rebuild is the business

By deciding to rebuild the 11 year old  Cat 775B off-highway truck used at its Graig Quarry in Mold, Wales, Lafarge gave the rebuild team at Cat dealer Finning its first 775B to rebuild at the specialist Caterpillar Certified Rebuild facility in Winsford, Cheshire. The 60 t machine was completely stripped to its chassis and bare frame. Using knowledge gained from previous equipment rebuilds and following the Caterpillar Certified Rebuild guidelines, specifically written for the 775B model, all parts from the powertrain through to the hydraulic system, cylinders and cab were completely overhauled, refurbished or replaced by the team of engineers.

With the whole process from the receipt of the machine to its delivery back to the Graig Quarry taking only three months and costing less than two thirds of the price of a new machine, Lafarge was able to save tens of thousands of pounds, with little disruption to on-site production. In addition the old machine became a new machine with new serial numbers and a full 12 month warranty.

Finning's dedicated six strong rebuild team took the aged 11 year old truck, that had been working for 20,000 hours under harsh conditions at the quarry face and gave it a complete new lease of life. In addition to upgrading the 775B to the highest specifications available before the range was superseded by the 775D and the latest model, the new 775F, the rebuild team were also able to add a bespoke access platform, at the request of the operator, making it easier to mount and descend from the cab.

Commenting on the decision to rebuild, Lafarge cluster manager, Bill Craggs, says: "We identified the need for serious investment in repair, maintenance or replacement when our contracted maintenance provider, that looks after all of our plant on site, spotted signs of failure in the engine last year. Realising the machine was coming to the end of its useful life, we found ourselves in a situation where we were either facing a much longer wait for a new replacement model, which would have also cost more, or the dilemma of replacing the engine on what was an old machine.

"However, because as a company we have a long standing relationship with Caterpillar and Finning, receiving regular information and presentations on the services they can offer, we were introduced to the concept of the Caterpillar Certified Rebuild. Although we were familiar with the service we had never really considered its benefits in relation to the larger machines on our fleet. Having limited experience of the concept, we took a team including the maintenance contractors and machine operators to Finning's facility in Winsford where we were able to see the team in action, rebuilding and finishing a large D9L Track Type Tractor.

"Seeing images of the old unit when it was first brought in for the rebuild, it looked as if the team had their work cut out, but once the final project was finished it looked magnificent and as good as new. It was only witnessing the transformation first hand that allowed me to really appreciate the work that is put into such a job."

Operating 5 days a week, the 775B (one of two face machines) is loaded at the quarry face by a Cat 365B excavator and then used to transport the 500,000 t of aggregate limestone, road stone and dry stone produced at the Graig Quarry every year.

Keeping the quarry in operation by borrowing alternative equipment from within the Lafarge group, the team at Graig Quarry received their rebuilt 775B at the end of February 2007, putting it straight back to work. Bill: "It is great to see the machine back on site and for our operator Eddie Shone, the newly refurbished cab offers a much more comfortable experience, especially with the improved access. Although I can't talk for the rest of the business, the success of this rebuild project could significantly change our future fleet management strategy, allowing us to move away from the purchase and disposal of equipment after 7-10 years to the use of the rebuild option. From a quarry management and business perspective, having a new piece of equipment allows us to concentrate our maintenance efforts on the other aging machines on-site and our fleet of smaller vehicles."

Rebuilding up to 12 machines a year, the specialist team at Finning has increased capacity at its facility in Winsford due to the rise in demand for this service. Commenting on this and the 775B rebuild, Finning sales representative, Paul Hughes says that designing machines to be rebuilt can double the useful life of a machine though a rebuild programme. From a financial perspective this also changes the lifecycle cost analysis carried out during the initial purchase phase. He says:

"In the case of the 775B Lafarge rebuild, it is also important to recognise the additional benefits this has from an ongoing maintenance point of view. With the site being very remote, Bill and his team rely on maintenance and repair support from a local specialist company. Having serviced the 775B for the last six years, the engineers know the machine inside out. Replacing the unit with the newer 775F range, which has all the latest electronic diagnostics and engine management systems would have also meant a significant investment in training and new diagnostic equipment. Although the rebuild upgrades the machine to the highest specification offered by the 775B range, it does not fundamentally change its mechanical operation, making it easy to maintain."

Caterpillar/ Finning (UK) Ltd
Watling Street
Cannock
Staffordshire
WS11 8LL
UK

T: 0800 028 7778