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REBUILDS JANUARY 2017 • E&MJ; 25 www.e-mj.com er circle components and perform struc- tural repairs while they are apart. The company recently rolled out three levels of rebuild services: • Joy Prime offers rebuilds that maximize equipment life for the lowest cost per ton and full machine warranty (with a possible extension for using Joy con- sumable products); • Joy Select offers rebuilds that extend machine life between full Joy Prime ma- chine rebuild intervals at a fraction of the price based on a condensed scope and enhanced reuse of components; and • Joy Base offers repairs that integrate customer input into a repair and return contact, with recommendations lever- aging the Joy Select specification and scope. This flexible repair option keeps components and machines operating longer and extends rebuild intervals, Joy Global said. In rebuilding customers' equipment, Joy Global can offer machine exchange programs, complete original equipment manufacturer (OEM) repair and return rebuilds, market-driven repair and re- turn rebuilds, and underground rebuild services. Machine rebuilds or exchanges can also be bundled through a pre-agreed schedule. According to Dan Spears, general manager for the company's eastern U.S. region, "Through our machine exchange program, Joy will provide a 'seed ma- chine' built to OEM specifications to facilitate rebuilding a customer's fleet. Once the seed machine is provided to the customer, they, in turn, provide a ma- chine to be rebuilt that will be exchanged with another machine in need of rebuild." Other options are for customers to send their equipment to Joy for a com- plete OEM or market-driven rebuild. An OEM-rebuilt machine will be fully rebuilt back to OEM standard, while market-driv- en rebuilds will undertake selective repair as agreed between Joy and the customer. According to Spears, costs for the company's machine exchange programs and complete OEM rebuilds can range from 50% to 70% of a new machine— depending on the equipment type—but the machines exchanged or completely rebuilt will run the same duration as the original equipment before needing their next rebuild. "Market-driven rebuilds cost less than the other rebuild programs and are performed to meet our customers' plans for managing their equipment fleet. The rebuild cycle and number of rebuilds a piece of equipment can undertake are largely based on the mining conditions it works in," Spears added. As an example of the company's ser- vice in action, Joy Global recently part- nered with Contura Coal West through a life cycle management agreement to relocate and rebuild two mining shovels from the eastern U.S. to Contura's opera- tions in the Powder River Basin. Needing new loading capacity there, but without a capital budget to invest in new equip- ment, Contura required the two then- idled shovels to be moved, reassembled, upgraded and operational within eight months. This was achieved, with the ma- chines averaging nearly 90% availability since being recommissioned, Joy Global reported. The superstructure of a mining shovel is jacked above the main frame. Raising and supporting the superstructure provides the opportunity to safely conduct a full inspection of the slew ring, with access for rebuilding if necessary.