Twelve-week transformation gives landfill compactor another life

07 September, 2023

“This was easily one of the most challenging rebuilds I’ve been involved in.” explained Ben Marston. He continued: “The harsh environment that the machine has been operating in has taken its toll on every part of the machine. The transmission was the worst I’ve ever come across, and the cab was falling to pieces when it came in.

“A key part of the inspection process involves identifying which parts can be reconditioned and reused. In this case we were able to restore and reuse seven of the ten radiator cores.

The reassembly phase can take up to nine weeks, depending on the size and complexity of the machine and reconditioning required – and this is where the technical expertise of the engineers really comes into its own.”

A key part of the rebuild process involves upgrading components or systems within the machine to the latest technical update that would have been introduced during the machine’s production life. This machine had a mix of remanufactured and reconditioned components. Once the major elements were refitted and the cab reinstalled, all the electrical elements were reconnected, and the oil and coolant topped up, so the machine was ready to be restarted.

The performance testing is perhaps the most critical phase of a rebuild and where all components are assessed to ensure they are within Caterpillar’s approved specifications. This includes the first full run of the machine which includes bleeding all the systems and testing the electrics. Then the engine, transmission and hydraulic systems are given a thorough work out by performing pressure checks and critical electronic calibrations.

Once the panel work is reinstalled, the fire suppression and reverse camera systems are fitted – a mandatory safety requirement for machines working in landfill environments.

Adam Walker, Engine and Drivetrain Product Manager at Finning is overseeing the project. He explained: “Sustainability is driving a lot of fleet management decisions, especially for those operating in the waste and recycling sector.

“Customer communication is key throughout a rebuild project, and we take a lot of care to ensure we keep the customer informed of progress on a regular basis. This includes a weekly video walk round the machine so the engineers can explain in detail what elements have been worked on and have the opportunity to flag any specific issues.

“During a rebuild, we aim to recover and recycle over 65% of the original machine. In addition, customers choosing a rebuild typically save around 40-50% on the cost compared with buying a new machine. While remanufactured parts, of which there are around 8000+ Cat certified parts available, can be up to 60% less than the cost of a brand new one.”

The rebuilt machine has now been back and operational on site for around three months.

Bill Stone said: “Our mobile plant fleet is key to our operation, so it is essential these assets are managed effectively, and Finning plays a vital part in that. The strong aftermarket support we’ve received over the years provided reassurance and confidence in deciding to have this machine rebuilt.

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