Complete overhaul after 9,000 operating hours
At the heart of the project is a Cat 950 wheel loader from 2015 – in continuous use at REMEX in Potsdam, where around 170,000 tonnes of gravel and sand are moved each year. After more than ten years and around 9,000 operating hours, replacing it with a new machine seemed the obvious choice. However, instead of purchasing a new machine, the decision was made to take a step that REMEX had not yet implemented in this form: a Cat Certified Rebuild.
A first for this class of machinery
Until now, Rebuilds have mainly been common in the market for large construction machinery such as dump trucks used in raw material extraction. The fact that a wheel loader of this class is now undergoing a Rebuild for the first time is a pioneering move. The project is being carried out by Zeppelin Baumaschinen GmbH. Two branches in Germany are involved: the chassis and heavy components are being reconditioned in Berlin, whilst the transmission is being overhauled in Frankenthal in the Palatinate. This means that the entire value chain remains within the region – a plus for the local economy and the environment.
Upgrade for hydraulics and powertrain
The project focuses on overhauling the wheel loader’s most heavily used components: the hydraulics and powertrain. These include hydraulic pumps, cylinders, valves and hoses, as well as the gearbox, axles, torque converter and bearings. In addition, the Cat 950 is undergoing technical modifications for future operation. New engine technology will reduce energy consumption and greenhouse gas emissions. The chassis is completely dismantled, carefully refurbished and repainted. This ensures that the machine is restored to a condition that is virtually as good as new, both technically and visually.
“The Rebuild restores the Cat 950 to full performance, extends its service life and optimises the machine’s environmental footprint.”
Marko Gaspar, Sales Manager Corporate Clients Divisionen of Zeppelin Baumaschinen GmbH
Sustainability under real-world conditions
As is standard practice at REMEX, the use of alternative drive technologies was also assessed prior to the start of the project. However, in open-cast mining operations or at landfill sites where machines have to travel long distances, electric-powered machines are currently often neither economically nor technically viable. In some cases, the required output can only be achieved by operating several machines in parallel. Rebuilding offers a realistic and effective alternative for a more sustainable operation, extending the service life, reducing resource consumption and lowering emissions – without compromising on performance and reliability.
Environmental benefits of the Rebuilds
- Lower greenhouse gas emissions thanks to modernised engine technology
- Conservation of resources through the reuse of existing components
- Optimised energy consumption thanks to new components
- Reduced transport distances thanks to refurbishment in the region
“The Rebuild of the Cat 950 wheel loader is another step towards a future-oriented machine strategy and a clear commitment to innovation, efficiency and environmental responsibility.”
Tim Autenrieth, Corporate Technical Officer of REMEX GmbH
Prospects for Rebuild machines
There is currently no established market for the subsequent sale of Rebuild machines of this class. Yet this is precisely where the opportunity lies: the project can serve as a blueprint and pave the way for a reassessment of modernised existing machines. At the same time, this step strengthens REMEX’s public image among customers and partners. The use of low-emission, state-of-the-art technology demonstrates innovative strength, technical expertise and a commitment to developing and implementing sustainable solutions.
From prototype to strategy
The insights gained from the project are to be applied to other machines. The aim is to make Rebuild processes more efficient and, in the long term, to establish them as an integral part of the commercial vehicle sector. Through this joint Rebuild project, Caterpillar and REMEX are demonstrating that sustainability is not just a matter of new technology, but above all a matter of attitude.
Image credits: © Caterpillar
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