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CATERPILLAR CERTIFIED REBUILDSHastings Deering. The difference counts.

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This document is intended to present a complete overview of the Caterpillar Certified Rebuild Program and all of the features and benefits for Hastings Deering customers.

A. The History

The Caterpillar Certified Rebuild (CCR) Program

began in 1985. The programs first focus was on

large machines, primarily mining equipment. The

models at the beginning were 988 wheel loader

and up, D8 track type tractor and up, and off

highway trucks. The program held this primary

focus until 2001 when the Certified Powertrain

(CPT) program came into effect. This remained

the status quo until 2007 when the Certified

Hydraulic Rebuild (CHR) program was released. In

2009 the Certified Machine Component Rebuild

(CMCR) program was added.

B. The Philosophy

The main focus of the CCR program is to promote

the second life that is built into Cat equipment

and components. By following recommended

service intervals and equipment operating

guidelines, multiple lives are achievable

from components and frames. When many

competitive models would require replacement,

Cat equipment can be rebuilt to deliver a cost

effective “second life.”

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C. The Customer

CCR programs are not designed to be a single solution for all of Hastings Deering’s customers or all of their machines.

The customers that are most likely to reap the benefits and take advantage of these programs are those that demand high

productivity and high utilisation of their equipment.

D. Customer Benefits

Full utilisation of “second life” providing a greater return on investment.•

Ensure maximum productivity through improved reliability and availability.•

Provides like-new parts warranty with extended service coverage available to control costs and minimise risks.•

Budget flexibility due to options of capital or maintenance expenditure options due to the issue of a new serial •number (CCR only).

Can assist in increased resale value.•

E. The Environmental Impact

In many parts of the world recycling is becoming a

common practice. Many large cities throughout the

world have mandatory recycling requirements for paper,

plastic, glass, and steel products. Many countries

have proposed laws for “mandatory buy-backs” of the

machine core at the end of its useful life. During the

CCR process of a full machine, approximately 7000 parts

are repaired, replaced or reconditioned. Even with this level of

new parts content approximately 60-70% of the machine is recycled. This

saves the machine from being scrapped and it also saves the energy required to make

new steel.

F. Dealer Quality and Differentiation

One of the biggest “value added” parts of the CCR program for the end user is the “Required Product Updates”. These

updates are compiled from Caterpillar technical literature. These updates address common product problems and normal

engineering updates that have been released since the machine was new. The inclusion of these updates has a dramatic

impact on increasing the availability of the machine or component, and reducing downtime. The final product from the

CCR program is “as good” or better than the last machine ever produced. No other “rebuilder” has a product offering like a

CCR. The CCR program differentiates the product support services available from Hastings Deering compared to any other

competitor.

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Overview of the Certified Rebuild Programs

1. Caterpillar Certified Rebuild (CCR)

This program involves the complete disassembly of the

machine. All components and machine systems are

inspected, repaired and overhauled. Required product

updates are carried out and the machine is provided with

a new serial number. The new serial number has the same

prefix with a 77_ _ _ _ number depicting the machine

has completed a CCR. Only one CCR can be completed per

machine.

NB – There is a provision for major powertrain components to be excluded from a CCR if recently overhauled. This

exclusion applies to mining machines only.

2. Certified Powertrain (CPT)

The CPT program involves the complete disassembly of the

machine powertrain. The powertrain involves all components

from the radiator through to the final drive or wheel group.

All components are inspected, repaired and overhauled and

the required product updates are carried out. Multiple CPT’s

can be carried out on the same machine and there are no

restrictions on what other work can be carried out at the same

time.

NB – There is no provision that allows for major powertrain

components to be excluded from a CPT if recently overhauled.

3. Certified Hydraulic Rebuild (CHR)

The CHR program is a full system approach which restores

complete hydraulic and hydrostatic drive systems to like-

new performance, reliability and durability – all at the same

time. This program is similar to the other offerings from the

CCR program in that the excavator’s hydraulic components

are completely disassembled, inspected and all critical

engineering updates are incorporated.

NB – The engine can be included as a CMCR if required.

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4. Certifi ed Machine Component Rebuild (CMCR)

The CMCR Program is for serialised components such as engines and/or transmission/torque

converter combinations on any Cat machine which would qualify for a CCR. The

program excludes differentials, fi nal drives and hydraulic components. This

program is similar to the other offerings from the CCR program in that

the machine components are completely disassembled and all

critical engineering updates are incorporated.

SUMMARy

CCR = Cat Certifi ed Machine Rebuild (Complete machine rebuild)

CPT = Cat Certifi ed Machine Powertrain Rebuild (Complete machine powertrain rebuild)

CHR = Cat Certifi ed Hydraulic Rebuild (Complete hydraulic system rebuild for hydraulic excavators only)

CMCR = Cat Certifi ed Machine Component Rebuild (Rebuild of components of CCR/CPT eligible Cat machines only)

REBUILD SCOPE CCR CPT CHR CMCR

Complete Machine √ √ √

Machine Powertrain √ √

Hydraulic System (Excavators Only) √

Engine, Torque Converter/Transmission √

4. Certifi ed Machine Component Rebuild (CMCR)

The CMCR Program is for serialised components such as engines and/or transmission/torque

converter combinations on any Cat machine which would qualify for a CCR. The

program excludes differentials, fi nal drives and hydraulic components. This

program is similar to the other offerings from the CCR program in that

the machine components are completely disassembled and all

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THE 10-STEP CERTIFIED REBUILD PROCESS

1. Inspection/Evaluation

This vital first step is a thorough process during which we develop a customised rebuild plan and cost estimate.

The specific needs of your rebuild, whether machine, powertrain, component or hydraulic, are determined through a

comprehensive evaluation, which can include fluid analysis, visual inspections, and reviews of maintenance/SOS services

2. Disassembly

Once your machine enters a Hastings Deering workshop it receives the undivided attention of our service technicians.

The machine is comprehensively cleaned to comply with strict Caterpillar Contamination Control guidelines before

being disassembled according to the established rebuild plan. All parts will be inspected and measured against our

strict reusability guidelines. Those that do not meet our high standards will either be reconditioned to meet guideline

specifications or replaced with new or Cat Reman parts.

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3. Reconditioning

Hastings Deering recognises that reconditioning of parts often provides better value than replacement and we have

established comprehensive procedures to provide the highest quality repair of worn or damaged parts. This phase of

the process can address equipment needs not typically included in an overhaul. For example, during a CCR, frames are

examined and if necessary, they are straightened, welded, and reinforced. For a CPT, the axle housing may be modified and

for a CMCR the transmission case may be strengthened.

4. Engineering Updates

During reassembly, critical technological/engineering improvements that have been made since original manufacturing

will be incorporated into your machine or powertrain. Optional upgrades* can also be discussed for inclusion in the rebuild

plan.

* Please refer to Page 13 for examples of optional upgrades.

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5. Reassembly

All critical torques, clearances and settings will be measured, tested and recorded during careful reassembly of your

machine or powertrain by our service technicians. Hose assemblies and machine wiring harnesses are all replaced as part

of a CCR. Only the engine wiring harness is replaced during a CPT with all other harnesses and hoses subject to the rebuild

plan.

6. Performance Testing

Quality control is integral to both rebuild programs. Therefore rigorous testing is conducted at several stages. Instrument

and operational testings are also conducted to ensure field performance levels match those in the shop.

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7. Repainting

After a CCR your machine will perform like new - and look like new - with a complete refurbishment, refinish and

application of new model identity graphics. This finish is optional on CPT rebuilds. Finally, CCR or CPT decals are displayed

on the machine to signify that the machine has undergone the certified rebuild process.

8. New Machine P.I.N. Plates

For CCR’s only, a new serial number is issued. This identifies that the machine has undergone a full machine rebuild and

the standard of the rebuild is equal to or better than the last machine that rolled off the assembly line for that model run.

For CPT’S the new plate contains the serial numbers and arrangement numbers of the components installed. Because

these plates verify the CCR process, they can assist in increasing your resale value.

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9. Customer Evaluation

The rebuild process is not considered complete until you are satisfied with the performance of the machine or powertrain

in its working environment.

10. Warranty

Because the CCR rebuild process is so comprehensive it entitles you to a like-new standard warranty of 12 months from

date of delivery covering the entire machine. For CPT rebuilds, all powertrain components are covered for 12 months from

date of delivery.

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CATERPILLAR CERTIFIED REBUILD WARRANTy OPTIONS

1. Standard Warranty – Caterpillar Certified Rebuild (CCR) Warranty Period:

The warranty period is twelve months starting from date of delivery to the first user.

This warranty applies to:

Basic machine including operator’s compartment and integrated hydraulic systems.•Any attachments specifically included as part of a written agreement covering the Caterpillar Certified Rebuild. •

This warranty does not apply to:Certain ground engaging tools.•Any item or attachment warranted directly to the user by its manufacturer or other repairer.•Mobil track belts. •

Transferability: The warranty may be transferred to another user upon receiving written permission from Hastings Deering.

2. Standard Warranty – Caterpillar Certified Powertrain (CPT) Warranty Period:

The warranty period is twelve months starting from date of delivery to the first user.

This warranty applies to:Major powertrain components.•Extra components specifically included as part of a written agreement covering the Caterpillar Certified •Powertrain Rebuild.

This warranty does not apply to:Certain ground engaging tools.•Any item or attachment warranted directly to the user by its manufacturer or other repairer.•Mobil track belts. •

Transferability: The warranty may be transferred to another user upon receiving written permission from Hastings Deering.

3. Equipment Protection Plan (CCR) Powertrain & Hydraulics This coverage is purchased through Caterpillar Insurance.

Warranty Period: The coverage period commences on the first day of the thirteenth month following the date of delivery to the first user and continues for a period of 24/36 months thereafter or until 6000/10,000 hours of machine operation have accumulated from date of delivery to the first user, whichever occurs first, dependant on coverage purchased.

This warranty applies to:Engine (not radiator, alternator, starter compressor or attachments).•Torque converter/divider, flywheel clutch transmission, transfer gears, drives and drive pump.•Drive shaft, universal joint, differential and drive axle.•Transmission pinion, bevel gear, steering clutch and final drive gear train (up to but not including sprockets).•Hydraulic cylinders, accumulators, pumps, motors, valves, lines. •

Transferability: The coverage may be transferred to another user upon receiving written permission from Hastings Deering.

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4. Equipment Protection Plan (CPT) Powertrain This coverage is purchased through Caterpillar Insurance.

Warranty Period: The coverage period commences on the first day of the thirteenth month following the date of delivery to the first user and continues for a period of 24/36 months thereafter or, until 6000/10,000 hours of machine operation have accumulated from date of delivery to the first user, whichever occurs first, dependant on coverage purchased.

This warranty applies to:Major powertrain components.•Extra components specifically included as part of a written agreement covering the Caterpillar Certified •Powertrain Rebuild.

Transferability: The coverage may be transferred to another user upon receiving written permission from Hastings Deering.

5. Equipment Protection Plan (CMCR) – Engines & Torque Converters/Transmissions This coverage is purchased through Caterpillar Insurance.

Warranty Period: The coverage period commences on the first day of the thirteenth month following the date of delivery to the first user and continues for a period of 24/36 months thereafter or, until 6000/10,000 hours of machine operation have accumulated from date of delivery to the first user, whichever occurs first, dependant on coverage purchased.

This warranty applies to:Only machines with serial numbers that are included in the Cat Certified Rebuild Program are eligible. The torque converter and transmission share an oil supply and must be rebuilt or replaced and enrolled at the same time. If the engine is rebuilt or replaced a separate enrolment for the engine is processed.

This warranty does not apply to: Parts that are not covered include: external hoses and lines, the engine radiator and engine attachments (i.e. alternator, starter, air compressor and airconditioner compressor).

Caterpillar Certified Rebuild Warranty Options

Warranty Coverage (Parts and Labour)

Standard Warranty (Provided as part of Certified Rebuild)

Equipment Protection Plan (Must be purchased from Cat

Insurance)

0 – 12 Months √

13 – 24/36 Months0 – 6,000/10,000 Hrs

√

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Caterpillar Certified Rebuild Optional Upgrades

A. Engine Emissions Upgrades – Caterpillar emissions solutions offer emission reduction technology for in-use machines and engines.

There are a number of emissions solutions from which to choose. The best option (or mix of options), depends on your equipment, applications, local emissions requirements and more. Recommended solutions may include:

Engine Repower – replacing your existing engine with a newer-technology, lower emissions engine.•Engine Upgrade Group – upgrading an existing engine using newer technology components, providing lower •emissions.Aftertreatment – treating exhaust gases to reduce harmful emissions.•

B. Machine Retrofit Upgrades – MRU’s are enhancements that have been developed after the original time of manufacture but can currently be retrofitted on certain machines. Examples of optional upgrades are;

VIMS 4.0•Extended life brake discs•Transmission filter retrofit•Oil Renewal System (ORS)•LED signal lights•LED gauge and indicator lights•HID lights•Road Analysis Control (RAC)•Cat comfort seat w/ 3 point•Operator restraint•Retrofit cab•Payload monitor system•Turbine pre-cleaners•Electric priming pumps•Radiator upgrades•Axle oil coolers•STIC steer•Ride control•Enhanced filtration•Autolube•OHT rear axle filtration•

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Before & After

A recent Caterpillar Certified Rebuild involved the upgrade of a 789A OHT to a 789C spec machine. The serial number

remained as a 789A to satisfy CCR requirements.

Since 2007 Hastings Deering has completed over 60 CCR and CPT rebuilds for over 30 customers. Let us discuss with you

how the Certified Rebuild Program may be beneficial to your operation.

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For Caterpillar Rebuild Solutions, contact your local Hastings Deering branch on 131 228