LEVEL 1, 2 & 3 PARTS
Not all parts have the same life span. LEVEL 1 - Designed to wear & protect other parts • Including: Anti-friction Bearings, Seals, Gaskets, Valve Guides, Exhaust Valves, & Thrust Plates • Replace these regularly and you will maximize the life of Level 2 Parts
LEVEL 2 - Slower wearing parts
PLANNED INDICATORS » S·O·S SM FLUIDS ANALYSIS » MACHINE SERVICE METER UNITS (SMU’S) » SERVICE HISTORY » CUSTOMER EXPERIENCE / HISTORY
WARRANTY - 12 months unlimited hours for Parts and Labor on all parts replaced*** - 3 years / 5,000 hours non-prorated if Foley does remove and install, whichever comes first - 3 years / 3,600 hours prorated if customer does remove and install - Hydraulic Cylinders 18 months ***warranty and included parts are subject to dealer performing removal and installation of component
» FUEL CONSUMPTION » TELEMATICS » INSPECTIONS
PROBLEM INDICATORS
REPAIR OPTIONS
LONGER LIFE | LOWER COST
CONTROLLING OWNING AND OPERATING COSTS » REPAIR BEFORE FAILURE - Failure costs more – 2 times or more - High risk of contingent damage to other parts - 90% of failures are preventable » REPAIR OPTION SELECTION - Lower costs options - Maximize parts reuse
10% Not Preventable 90% Preventable
WHY DOES REPAIR AFTER FAILURE HAPPEN SO OFTEN?
» HESITATION • Including: Pistons, Cylinder Liners, Intake Valves, Cams, Turbo Bearings, Turbo Seals, Discs, Plates, Gears, and Shafts • Need replaced less frequently
LEVEL 3 - Components intended to last the life of the machine
» WHY FIX IF IT’S NOT BROKEN?
» UNUSUAL NOISES
- It will fail at some point – and cost more to repair - Repairing early can save money down the road
» VIBRATION » OVERHEATING » LEAKS
» WE’RE TOO BUSY RIGHT NOW. PRODUCTION DEMANDS REQUIRE US TO KEEP THE MACHINE RUNNING.
» CLUTCH OR TRANSMISSION SLIPPAGE
- Is current production more important than a future breakdown? - Failure down the road could have a negative impact on long-term production
» DEBRIS IN FILTER • Including: Major Castings, Cases, Housings, Crankshaft, Connecting Rods, Main Shafts, Carriers, and Hubs
» BRAKE CHATTER
» TURNAROUND TIME IS TOO LONG. - It will fail at some point – and cost more to repair - Repair after failure often takes a lot longer
• Will last as long as plan and schedule replacements and repairs to Level 1 and 2 parts
» OPERATORS AREN’T RAISING ANY RED FLAGS ABOUT MACHINE PROBLEMS. - Operators might not be aware - Often machine performance degradation is slow and goes unnoticed until it has lost up to 20% of productivity - Might not communicate potential issues to keep producing Price: Customer Name: Contact Phone No.: Date: Model Serial No.: Make/Model No.: Sales Person:
844-FOLEY-EQ \\\ FoleyEQ.com
FOLEY EQ
REPAIR OPTIONS AVAILABLE FOR MANY CAT ® MODELS » C15 ENGINE OUT-OF-FRAME LEVEL 3 RECONDITION
TRANSMISSION / TORQUE CONVERTER GOOD RUNNING CORE
REAR AXLE
HYDRAULIC CYLINDER REPAIR OPTIONS LEVEL 1 CYLINDER RESEAL / LIGHT HONE
» Extends cylinder life » Lowers cost of ownership through » » »
ESTIMATED PRICE
$ _____
$ _____
$ _____
PARTS REPLACED
LEVEL 1
LEVEL 2
LEVEL 3
x
x
x
INSPECT / TEST
» Inspect for applicable updates » Measure all bearing bores » Clutch friction disc and plates inspected
INCLUDES
INSPECT / TEST
PARTS/SERVICES PERFORMED INCLUDES OUT-OF-FRAME LEVEL 1 & 2 RECON PLUS:
» Camshaft
» Liner protrusion & condition
Warranty: 12 Months Parts and Labor
» Crankshaft
» Piston spray jets
Warranty: 3 yrs/5,000 hours, whichever comes first***
» Exhaust & intake manifolds
» Rocker arm assemblies
All bearings and races
x
x
x
» Fan drive, pulleys, belts & belt
» Intake & exhaust
All seals including control valve
x
x
x
» Rocker arm shaft
Retrieve oil sample to verify cleanliness after rebuild
x
x
x
» Unit injector
Paint component
x
x
x
» Vibration damper
All clutch friction discs that do not meet reuse
x
x
»
All sensors and modulation valves/solenoids
x
x
»
Integral wiring harness
x
x
» Internal engine harness » Engine related sensors, switches and fuel primping pump
» Replace engine oil cooler with Reman » Includes recondition or replacement of unknown hard parts (highlighted in red) found during disassembly that do not meet Cat reuse guidelines. Excludes major castings (engine block, crankshaft, front housing and rear housing)
tensioner
» Flywheel & ring gear » Front gear train » Fuel lines » Intake valves, valve seats, valve guides and valve springs
» Install latest Software to Engine ECM
*Firm price for defined scope of work does not include R & I and is valid until December 31st of current year.
**Warranty and included parts are subject to dealer performing removal and installation of component.
x
» » » »
»
compared to Cat reuse guidelines All internal components inspected compared to Cat reuse guidelines Perform additional crack check on Transfer gears and shaft in transmission drop box Visually inspect harness, hoses, test lines and sensors Air check and dye check control valve for leakage and internal cracks Hydraulically bench test control valves to adjust pressures to Cat specifications Dyno-test transmission to ensure clutch actuation pressures and valve modulation are within specification
140H Transmission: Cost Per Hour Sales Model & Component Rebearing & Reseal Overhaul Hours: Cost of Repair: Cost per Hour:
» Bearings (Eye and/or trunnion
» Provides new component life » Guaranteed Price » Reduces Costs » Reduces Downtime
» Gears » Shaft » Carrier » Wheel spindle » Operational test
COST COMPARISON EXAMPLE
INSPECTION POINTS
LEVEL 1 REBEARING /RESEAL
INSPECT
maximized fuel efficiency and improved cycle times Reduces risk for unplanned downtime Repairs internal leaks (cylinder drift) Reduces risk of contaminate entry into the hydraulic system
» All bushings and anti-friction bearings » All seals and gaskets » Thrust washers
»
ESTIMATED PRICE
$ _____
$ _____
PARTS REPLACED
LEVEL 1
LEVEL 3
Warranty: 12 Months Parts and Labor
x
Warranty: 3 yrs/5,000 hours, whichever comes first**
» Duo-Cone™ seal » Miscellaneous hardware (as needed) Magnetic plug (if needed)
INSPECT / TEST
» Inspect for applicable updates » Measure all bearing bores » Brake friction disc and plates inspected
x
compared to Cat reuse guidelines
» All internal components inspected
All bearings and races
x
x
All seals and gaskets
x
x
Includes all seals and bushings for axle oscillation and supports
x
x
Set pinion depth and bearing preload to Cat specifications
x
x
Paint component
x
x
compared to Cat reuse guidelines
» Perform additional crack check on » Spindles » Wheels » Pressure test brakes » Check for rotation and differential lock function if applicable
Maximum re-use of Cat® Parts
Before Failure
bushings) » Rod and rod eye » Interior walls of cylinder » Threads » Piston » Piston nut or bolt(s) » Head
INCLUDES NEW PARTS INSTALLED
10,000 $9,704 $0.97
Overhaul Hours: Cost of Repair: Cost per Hour:
12,000 $12,344 $1.03
After Failure Overhaul Hours: Cost of Repair: Cost per Hour: Extra 2,000 Hours:* Payback Hours:
PART OR SERVICE INCLUDED
» Disassembly of cylinder » Cleaning of cylinder components » Cylinder bore light hone to remove rust, scratches and/ or cylinder distortions » Thorough washing of cylinder tube to remove contaminants generated during light honing
14,000 $19,869 $1.42
Level 2 Parts begin to deteriorate
Minimal opportunity to re-use parts
$3.76 19,290
Breakeven Point: Number of Hours component would need to last for the cost per hour to be equal or below the RBF cost per hour.
$19,869 = $1.03
» Replacement of all cylinder piston and head seals » Properly torque piston rod nut or bolt(s) » Reassemble cylinder » Pressure test cylinder LEVEL 2 (Salvage or Replace) -QUOTED AFTER INSPECTION
ESTIMATED PRICE
Bearings (Eye and/or trunnion bushings)
$
Rod Reconditioning (Re-Rod, Straighten, Chrome, AST, Polish, etc).
$
Rod Assembly (New or Reman)
$
Re-Tube
$
Cylinder Tube Assembly (New or Reman)
$
Piston
$
Piston nut or bolt(s)
$
OTHER ITEMS
» Component Specific » Buckets / GET » UC » Hydraulics » Frames / Articulation » Cab / Operator Environment » Safety » Upgrades and Retrofits » Cooling System
This example is USD and is for discussion purposes only. All repair situations and the costs associated vary depending on a variety of factors. Prices and availability are estimates only and subject to change. Please contact your Cat dealer to assess your equipment and provide an accurate cost estimate.