CAT® REBUILDS GIVE NEW LIFE TO THREE MINING TRUCKS

From Scrap Metal
to Like New

Oceanagold Restores Three Mining Trucks From the Ground Up With Cat^® Certified Rebuilds.

machine driving across a dirt road at a worksite

Cat^® Rebuilds Transform Three Trucks To Like New

After sitting on site for nearly a decade, three mining trucks became part of the landscape, weathered by the elements, stripped for parts and even home to nesting birds. Faced with a decision to scrap them for good, OceanaGold chose a different path: to rebuild and restore them to like-new condition with help from their dealer Terra Cat.

Estimated read time: 3 minutes

Want to connect with your dealer?

REQUEST A CONSULTATION

SITTING ON THE SCRAP HEAP

OceanaGold’s Macraes Mine, located on New Zealand’s South Island, is the country’s largest-producing gold mine. A team of about 300 people works on the site, which features a large-scale surface mine, underground mine and adjacent process plant. The machine fleet consists primarily of Cat 789C and 789D mining trucks, D10 dozers and 988 wheel loaders.

Three of those 789C trucks, originally purchased in 2002, were retired in 2015 after accumulating roughly 65,000 to 70,000 hours each.

“Over that time, most of the parts and components had been taken off those trucks to keep the rest of the fleet going,” says Pieter Doelman, mining manager at OceanaGold. “They were essentially sitting in our yard as scrap metal.”

BUILT TO BE REBUILT

Realizing that these parked trucks possessed untapped potential, OceanaGold turned to its Cat dealer, Terra Cat, for advice on what to do next. Terra Cat has supported the Macraes mining operation for more than three decades, and a dealer representative works on site at the mine to manage day-to-day issues.

“The Terra guys work with me very closely to try to get the best bang for our buck,” says Tony Barrett, OceanaGold’s reliability analyst.

Because Cat equipment is designed for multiple lives, Terra Cat recommended sending the three 789C trucks to the dealership’s Cat Component Rebuild Centre (CRC) in Christchurch. This purpose-built facility specializes in rebuilding engine, transmission and hydraulic components for customers across New Zealand — bringing them back to like-new performance for a fraction of the cost of buying new.

At the CRC, each truck was stripped down to its bare frame for a full evaluation. Cat rebuild experts inspected all components to determine which could be reused, then repaired the frames and replaced the torque tube assemblies. They rebuilt the engines, torque converters, transmissions, rear axle housings and other components. The final step was extensive testing to make sure the rebuilt trucks met emissions standards and delivered like-new performance.

DESIGNED TO PERFORM LIKE NEW

The entire Cat Certified Rebuild process was designed to save time, with Terra Cat’s branch service manager Tony Simpson recalling it took around “three to four months for each truck to be rebuilt.” A key factor for quick turnarounds when it comes to Cat rebuilds is the use of Cat Reman parts, ranging from cylinder heads and injectors to drivetrain components and complete engines.

In addition to the fraction-of-new price¹ of these remanufactured parts, “the chief advantage of using Cat Reman parts and components was time,” Doelman says. “We were able to get these trucks rebuilt in a very short timeframe compared with ordering new trucks.” And each rebuilt 789C came with a 12-month, same-as-new Caterpillar Limited Warranty.²

In addition to restoring original performance and like-new productivity levels, the mining truck rebuild process also allowed OceanaGold to make several performance enhancements. The team installed new lightweight truck bodies to improve payload and chose to upgrade from 1900 to 2100 horsepower for a significant boost. To accomplish this, they replaced the powertrain, pumps, suspension cylinders, torque converters and other components with Cat Reman parts. The ability to reuse components also supported OceanaGold’s sustainability goals.³

Today, all three rebuilt trucks are back in production at the gold mine and exceeding expectations. “The primary things we were looking for were that they could get the required payload and achieve speed on grade,” Doelman explains. “Both of those tests were passed with flying colors.”

End-of-life doesn’t mean end of line. Restore your mining trucks, loaders or other trusted machines to like-new condition. Cat rebuilds extend working life and increase the return on your original investment, while also giving you the benefits of new product enhancements. Your Cat dealer will work with you to map out a rebuild plan that fits your mine site’s needs.

^{¹Cat Reman cost savings statements are based on return of core; core conditions apply.

²Warranty can vary by model and application; limitations apply. For complete details about the applicable Caterpillar Limited Warranty, contact an authorized Cat dealer.

³Any Cat Reman sustainability statements represents U.S. environmental impacts of gate-to-gate remanufacturing and remanufacturing processes for Cat engines and components, as defined in the 2018 United Nations Environment Programme report “Redefining Value – The Manufacturing Revolution.” Does not include impacts elsewhere in our value chain.}

GET MORE FROM YOUR EQUIPMENT INVESTMENT

Discover more ways to extend equipment life and reduce downtime with Cat Customer Value Agreements (CVAs), repair options, condition monitoring, and more.

EXPLORE SOLUTIONS

CONNECT WITH YOUR CAT^® DEALER

Find out more about how your dealer can support your mining operation and keep your jobsite moving.

Consult

GET THE LATEST MINING NEWS FROM CATERPILLAR

Sign Up Today

Want even more info to help you keep your mining business running smoothly?
Check out our article page with tips for controlling costs and increasing productivity.

From Scrap Metal
to Like New