Since 2005, Foley Equipment has restored over 300 machines to their original condition through the Cat Certified Rebuild Program.

The Cat Certified Rebuild Program allows machine owners to benefit from the multiple lives designed into their Cat machines and components. This program incorporates the very latest Cat technology and critical engineering updates into machines, giving them a second life for approximately 40 to 60 percent of the cost of a new machine.

On arrival, machines are completely stripped down and all non-metal components are replaced.

“It could be an engine or machine in Kansas City or an engine or machine out of western Kansas,” said Jon Robinson, Vice President of Engine Rebuild and Parts. “If a piece of equipment is sent to one of our locations, we basically strip them down to bare block and go completely through it and rebuild it to ensure it has the right processes and the right quality for the lowest cost to the customer.”

The facility services a variety of Caterpillar machines such as bulldozers, wheel loaders, trash and landfill compactors, off-road mining trucks, motor graders, scrapers, and more.

A Cat Certified Rebuild involves a complete restoration of Cat machinery including:

• Replacement of around 7,000 parts, down to the wiring, gaskets and switches
• Frame inspection, reinforcement, and repair
• Completion of more than 350 tests and inspections to ensure optimal performance
• Reconditioning of critical systems like the engine, hydraulic systems, torque converter, and transmission
• Technology and engineering updates
• Refreshed equipment appearance

Foley offers two main programs for its rebuilds: the Cat Certified Rebuild (CCR) program and the Cat Certified Power Train (CPT) program. In the CCR program the machine is completely disassembled and rebuilt from the ground up to like-new specifications, while in the CPT program, the power train components are disassembled and rebuilt. Cat product and engineering updates are included in both programs.

“The Cat Certified Rebuild is where you strip it down, and it goes from bare frame to machine,” said Scott Tolley, Product Support Sales Manager. Then we have the Certified Power Train Rebuild, where we rebuild the engine, transmission, radiator, and differentials. That allows us a little more flexibility with the customer. Let’s say if it already had some substantial work done on it, we would not necessarily have to do that again.”

The CCR program includes inspection/evaluation, disassembly, reconditioning, engineering updates, engine/transmission tests, reassembly, performance testing, repainting, a new serial number, and customer evaluation. The CPT program includes the rebuild of the basic engine, transmission, torque converter, drive line, differential, transfer gear group, drive axles, final drives, electronic controls and sensors, and radiators and coolers.

Caterpillar backs the warranties for the rebuild programs, so no matter where the customer works in the country, the warranty will still be effective.

“So if a customer normally works in our territory, and they end up working in another state, they won’t have any issues since it’s backed by Caterpillar,” Tolley said. “There are a strict set of guidelines that Caterpillar sets forth of what has to be done as part of the rebuild. It really makes the difference between a dealer rebuild that some of our competitors might do versus a rebuild at Foley.”

During a Cat Certified Rebuild, Foley’s customers have the opportunity to upgrade optional features to current standards. The upgrades can improve equipment safety, productivity, efficiency, comfort, and serviceability at a lower cost than buying a new machine. Some of the upgrades available include:

• For safety: backup cameras, LED or HID lighting, and seat belt reminder systems
• For productivity and efficiency: onboard technology like grade control and payload monitoring
• For comfort: upgraded cabs, Cat Comfort Seats, and ride control
• For serviceability: enhanced filtration, auto-lube systems, turbine pre-cleaners, and electric priming pumps

Technicians at the Foley Equipment have decades of experience, and each technician must complete a minimum of 80 hours per year of training. Foley creates personalized learning plans depending on what each technician needs and how they are assessed both individually and by their manager.

“We also have our own in-house training department with six training instructors,” Robinson said. “We use a lot of virtual classes, even before COVID. Some of it is hands-on as well. We have about 400 technicians at Foley, and we take their training very seriously.”

According to Tom Chegwidden, a Foley Engine Shop Manager, each rebuild that goes through a Foley facility has one point of contact throughout the entire rebuild process to ensure proper communication. The designated contact will take the customer through the entire rebuild process every step of the way.

Depending on the scope of the work and other indicators, the costs of a rebuild with Foley Equipment can vary. However, the company provides customers with a flat rate with no overages and add-ons. Machine shop work, additional parts, and labor are all included upfront on machines that are operational.

“Generally we say most of our machines are built to be rebuilt,” Robinson said. “After you buy that first machine, if you can rebuild it, the rebuild is roughly half the price of a new machine. Sometimes it is 60 percent, sometimes 40 percent, depending on the work that’s done. We say you’re getting two lives of a machine for about one and a half times the cost.”

The Foley Equipment hours are from 8 a.m. to 5 p.m. Monday through Friday. To speak to a representative about a rebuild solution tailored to your business’s needs, call (316) 943-4211 or (888) 970-9574.