Large off-road machinery frames generally last 40,000 to 60,000 hours or more, depending on use and the conditions and materials they deal with on a daily basis. The life of most of their components are typically about half as long, according to Kirby-Smith Machinery Inc. Business Development Manager Kevin Chastain.
“That means a component rebuild is usually done somewhere around 20,000 hours,” said Chastain. “The advantages are that the customer gets a ‘like new’ machine from a components standpoint at a fraction of the cost of actually purchasing a new machine. We recently completed a component rebuild on a Komatsu HD605-7E0 for a quarry customer at our Oklahoma City shop. It was almost at the 20,000-hour mark. As with previous rebuilds we have done, the process started with good planning.”
Personnel from Kirby-Smith and the customer collaborated on what needed replaced. They determined that the engine, torque flow assembly (transmission and torque converter), and all hydraulic pumps should be replaced with Komatsu Reman components. Final drives and differentials received new bearings and seals.
“We gave the customer a menu of items based on all components, including ancillary items such as hoses and wiring harnesses,” Chastain explained. “We also reviewed the truck’s history using Komtrax, oil sample reports and repairs. In addition, we discussed the customer’s budget and expected life after rebuild.”
Lead time for planning
Chastain noted that planning started four months in advance, which is the ideal minimum time needed before starting a rebuild. “That lead time allows us to order the necessary items and stage them by segment prior to the machine’s arrival. It makes the process smooth right from the start and reduces the overall rebuild time. It also lets us use Komatsu’s Firm Future Order program, which guarantees parts availability at a set price, with some conditions, when it’s time for the rebuild. That’s great for budgeting.”
When the truck arrived, Kirby-Smith technicians removed most of its components before thoroughly cleaning the truck, then returned it to the shop for final disassembly. In total, the rebuild took about four weeks. Parts and labor are guaranteed for one year.
“The goal is to maintain reliability and availability as these machines get older,” said Chastain. “Typically, frames are still in great shape at the time we do the component rebuild, so this is a great way to achieve that goal. We encourage anyone looking for a cost-effective way to extend the life of their machines to contact us about any type of rebuild.”
