Modern Mining October 2016

COVER STORY

machines were guaranteed by Barloworld for another 30 000 hours, but they went on to achieve 56 000 each. Machine models Cat machines are designed with a built-in sec- ond life that makes good economic sense for customers who have practised sound first life equipment management. Cat Certified Rebuilds also receive better resale value. Rebuilds are offered across all mining machines including trucks from 777 up to 793, as well as the Cat drill rigs and hydraulic shovels included in the former Bucyrus range of products that joined the Cat stable on the acquisition of Bucyrus by Caterpillar. A Cat Certified Rebuild of a Cat 834 wheel loader has recently been completed by the Barloworld Equipment Polokwane facility for a platinum mine in Limpopo, while two D11 track type tractors and a 16M grader are cur- rently undergoing CCRs at the Middelburg facility. To rebuild or not The durability of the machine is key when mak- ing a decision to rebuild. “We ask questions such as ‘Is the machine designed for a second life?’, ‘Will it still be as durable as new follow- ing the rebuild?’, ‘Will parts still be available through the second life?’, ‘Is the rebuild eco- nomically viable compared to buying a new machine?’. Of course the service history of the machine is also important,” says Parsons. “To help us make this decision we have tools specifically developed by Caterpillar such as condition appraisals and technical analysis. Fluid analysis, visual inspections and review maintenance/SOS analysis services are used to develop a customised rebuild plan and cost estimate. “All Barloworld Equipment’s main service facilities across Southern Africa are accredited to carry out Cat Certified Rebuilds, partner- ing with the company’s specialist component rebuild facilities in Johannesburg, South Africa (Barloworld Rebuild Centre), and Kitwe, Zambia,” he adds. “The remanufacturing programmes run by these facilities ensure that Barloworld Equipment can offer off-the-shelf availability of all major components for Core 15 mining machines as well as other key machines, with the major benefit of quicker turnaround for the machine rebuild.” Caterpillar stipulates which parts must be fitted to the rebuilt machines and Barloworld Equipment’s well equipped parts stores on all

sites also help to speed up turnaround times. Importantly, CCR machines are not only returned to original as-new condition, but also upgraded to include improvements introduced after the original date of manufacture. “Barloworld Equipment has had robust development plans for artisans in place for many years, providing a stable platform of skills to offer this type of solution to the market,” says Parsons. “Every rebuilt machine undergoes a battery of performance tests prior to delivery.” Role of the BRC The Barloworld Rebuild Centre (BRC) opened its doors in Boksburg in 2012 to offer custom- ers off-the-shelf remanufactured components for Cat mining and other key machines. The BRC specialises in the Big 5 components (engine, torque converter, transmission, differ- ential and wheel station) and can rebuild all Cat hydraulic cylinders and pumps. The BRC is the biggest, most advanced facility of its kind in Southern Africa and all major components of the largest machines Caterpillar produces today can be rebuilt and tested here. Willie Coetzee, General Manager of the BRC since May 2015, and his team have taken some bold steps to ensure this facility is able to assist mining customers with remanufactured components as a quick and cost efficient way of keeping their fleets healthy and productive during the commodities downturn. “Processes have been refreshed, our cus- tomer service has improved, we are confident that our remanufactured components are world class, and our turnaround times have reduced by almost 20 % in the past year,” says Coetzee. “All customers can expect 24-hour updates on the progress of components.” In addition to a Cat Certified Rebuild of the entire machine, Barloworld Equipment offers mining and other customers certified rebuilds for power train, hydraulic system, engines and/or transmission/torque converter combi- nations. 

The Barloworld Rebuild Centre (BRC) offers custom- ers off-the-shelf remanu- factured components for Cat mining and other key machines, specialising in engines, torque converters, transmissions, differentials and wheel stations.

“Every rebuilt machine undergoes a battery of performance tests prior to delivery.”

October 2016  MODERN MINING  21