New-for-old strategy gaining traction in off-highway sector

Cummins is forging the market for replacement engine solutions in the off-highway sector.

The concept of replacing engines is well established in the on-highway sector, where bus fleet managers have for many years planned it into their operating strategy, understanding the commercial benefits that spring from reduced downtime and increased product longevity. 

Following a marketing initiative across Europe demonstrating the cost-effectiveness of trading a tired or end-of-life Cummins engine for a remanufactured factory-quality solution that is as good as new, the approach is taking hold in the construction, agriculture and industrial segments. 

Rising equipment prices, higher borrowing costs and long lead times for new equipment have created the conditions in which replacement engines are coming to the fore as a practical solution. 

“Where the chassis, hydraulics and undercarriage remain in good condition, customers can avoid the cost and disruption of buying new, extend the life of an existing asset, and preserve cash flow,” said Jack Walker, Aftermarket Business Development Manager for Off Highway in the UK and Ireland. 

“A replacement high-efficiency modern engine can revitalise older chassis and get equipment back to work faster, while allowing operators to retain a machine whose history, attachments and site-fit are already proven.” 

Unlike the on-highway sector, where only a few core engines cover the bulk of the market, the off-highway sector covers a far broader spectrum of applications and power options and calls for, effectively, a bespoke approach from Cummins. 

Even so, all the operator has to do is communicate the engine serial number to Cummins, and on inspection, Cummins will provide the most suitable replacement option for the asset, whether that is ReCon New Exchange (NX) engines, ReCon Remanufactured Exchange (RX) engines, Short or Long Blocks. In some instances, Cummins can even offer New Exchange like-for-like, made-to order specifications. 

With a service exchange engine, the switch-out can be achieved within days – far quicker than having the engine overhauled locally, which might take up several weeks, or waiting for an original factory unit, which may take months. 

All replacement engines and parts are supplied with a full Cummins warranty and are delivered to the closest Cummins depot within a few short weeks. 

Cummins keeps its replacement engine inventory under constant review to ensure it has the best possible spread of base units covering the Tier 3 to Stage V emissions standards range. 

Major efforts have been made in recent months to boost availability and to keep pricing highly competitive, making the decision to replace rather than buy new even more compelling for owners and operators. 

“Our sweet spot is in the area between 4.5 litres and 9 litres,” said Jack, “and the kind of applications we deal with would be excavators, wheel loaders, crushers and screeners, tractors, sprayers and fork lifts – a real breadth of machinery.” 

By way of example of how Cummins works proactively with customers, Jack described a successful arrangement with a group in the south of England which hires out shunting tugs.

“We work closely with them to build a forecasting model that allows us to have the exact spec engines on the shelf ready so the exchange work can be carried out with the greatest efficiency.

Design upgrades integrated into the rigorous remanufacturing process

Cummins remanufacturing follows a rigorous process. Design updates are also added, so every remanufactured product is built to the latest standards. 

Engines and parts are completely disassembled with great care to protect and prepare key components for processing, right down to the last screw, nut, bolt and spring. 

Each part is cleaned using the latest technology to remove debris without removing any metal, including the use of dry ice, enzymes and lasers for specialised cleaning needs. 

If a part doesn’t make the grade, it is scrapped and replaced with a new Genuine Cummins part. Any upgrades or supersessions since the original part was made are included as part of the Cummins remanufacturing process.

THE GIFT OF LONGER LIFE 

The Cummins aftermarket and engineering teams provide a comprehensive package designed to maximise the lifecycle of off-highway fleets. This includes: 

• Integration of the latest Cummins performance specs for optimised fuel use 
• Use of 100% Genuine Cummins parts for maximum durability 
• Rigorous testing of every engine prior to delivery 
• Extended coverage for up to five years, supported by a global service network.

LOOK FOR THE SIGNS THAT IT’S TIME TO REPLACE 

Even with meticulous maintenance, heavy-duty engines in the off-highway sectors eventually reach the end of their peak utility. Recognising these tell-tale signs early can prevent catastrophic on-site failure: 

POWER LOSS 

The machine struggles under load, takes longer to reach operating speed, or fails to maintain pace on inclines.

UNUSUAL NOISE 

Knocking, rattling, or grinding sounds that indicate internal wear, detonation, or damaged bearings.

EXHAUST SMOKE

Blue smoke (worn rings), white smoke (coolant issues), or black smoke (fuel/air imbalance).

FLUID CONSUMPTION 

Frequently topping up oil suggests internal leaks or worn components.

OVERHEATING 

A rising temperature gauge often points to a failing water pump or a clogged radiator If any of these symptoms appear, it is vital to have the equipment inspected immediately. Early intervention ensures your machinery remains a reliable, safe, and productive asset.