The component renovation center of Bergerat Monnoyeur in Seine-et-Marne is responsible for overseeing the engines and transmissions of the brand, giving them a new lease on life.
The Component Reconstruction Center (CRC) of Bergerat Monnoyeur is situated in Brie-Comte-Robert (77) and specializes in Caterpillar equipment. With a 4,200 m² workshop and a team of 38 mechanics, the CRC is capable of refurbishing components such as engines and transmissions for all kinds of machines, ranging from the smallest to the largest.
Léopold Bournier, who leads the component reconstruction activities at the CRC, explains that their primary activity is based on the standard exchange where they rebuild and store components to fulfill the quality and availability requirements of their clients. They provide an eighteen-month warranty for their products, and there is no need for transplantation to ensure the same level of performance as a new part. The CRC follows a well-established operational procedure for refurbishing, starting with high-pressure washing of each component. Sometimes, a sanding step is required in the case of significant corrosion, which is carried out by a nearby service provider.
After the cleaning process, a mechanic in either the engine or transmission division of the workshop disassembles the component. This meticulous work is essential for rebuilding as all the parts, which can number between 300 and 400 for an engine, are inspected and sorted according to their condition and suitability for reuse.
700 components rebuilt in 2022
Next, the various parts undergo a stripping process, which involves using a large washing machine or two ultrasonic machines – one for ferrous metals and the other for non-ferrous metals.
“Pollution is a major factor in the deterioration of components, so we take care to reassemble them in the cleanest possible environment. To optimize our reconstruction times and ensure quality, we systematically replace worn parts, such as seals, bearings, solenoid valves, etc., on transmissions,” explains Leopold Bournier.
Leopold Bournier highlights the expertise and parts recovery as the center’s added value. The mechanics proceed with the assembly of the components in another area, reusing the parts that are still viable and supplementing with new ones if needed. Thirteen assembly stations are dedicated to transmissions while twelve are reserved for engines. There is also a specific area designated for leak tests to assess joint tightness.
After the reconstruction, the component undergoes a performance test on a test bench to ensure its functionality. For the hydraulic part, a technician verifies the proper assembly, tightness and records the pressure and flow data at idle and maximum speed. In the engine test bench, the installation simulates the load of the public works machine, while a strain gauge measures the engine’s temperature at constant pressure and flow. Finally, the component undergoes a mandatory paint job before it leaves the workshop for its new life cycle.
The component reconstruction process takes around 55 hours to complete for a transmission and twice that for an engine.
“We plan to give a second life to approximately 700 engines and transmissions this year,” said the site manager.
To achieve this target, the workshop maintains a stock of around 100 components, comprising 50 engines and 50 transmissions. The headquarters of Bergerat Monnoyeur in Seine-Saint-Denis stores converters, cylinders, and particle filters. The CRC, certified ICPE, celebrated its 20th anniversary this year.
