Service
Rebuilds, Refurbishment & Overhauls
A hard-worked machine isn't a write-off. Boom rebuilds, undercarriage overhauls, line boring and full refurbishments that bring an asset back to near-new — and add years to its working life for a fraction of replacement cost.
- Standards
- AS 2550 / AS 1418
- Turnaround
- From 6 weeks
- Coverage
- QLD · PNG · Pacific
- Backed by
- Zero Downtime Guarantee
When you need this
You've got an ageing machine that still earns, but the repair bills are creeping up and someone's asking whether it's time to replace it. A new 20-tonne crane runs around $450,000; larger machines go past a million. Before you spend that, it's worth knowing what a proper rebuild would cost — because in a lot of cases, the machine is repairable, not replaceable.
What we rebuild
- Boom rebuilds — full disassembly and rebuild using specialist tooling, every component restored to safe working condition, reinstalled and tested.
- Undercarriage overhauls — bearings, tracks, rollers, idlers and track adjusters.
- Engine and driveline overhauls — full-life rebuilds, transmissions, final drives.
- Line boring of worn bearing bores, on centre articulations and pin joints, to OEM specification.
- Complete harness replacement and electrical rebuilds.
- Structural refurbishment — crack testing, cross-bracing, sandblasting, paint and compliance stickering.
- Full-machine refurbishment — inspection, repair and cosmetic restoration together, so the machine goes back to work looking and running as good as new.
The KDI process
Assessment
We inspect the machine and tell you honestly whether it's worth rebuilding — including oil sampling and lab analysis to find hidden wear before it costs you.
Scope and quote
A clear, itemised scope and a fixed quote, with the replace-versus-rebuild numbers laid out.
Strip and restore
Disassembly, line boring, component rebuilds and replacements, structural repair.
Reassemble and test
Rebuilt, reassembled, load-checked and tested to spec.
Return to service
Back to work with the documentation to prove it.
Restore, or replace? The honest numbers
This is the calculation every fleet owner is making. A comprehensive major inspection plus rebuild typically extends a compliant machine's life by more than a decade — against a six- or seven-figure replacement. And with ADR 80/04 now in force (since 1 November 2024), keeping a well-maintained machine compliant is often the smarter capital decision. We'll give you the real figures for your asset, not a sales pitch.
Real rebuilds
- Comiskey Mining's specialised tyre manipulator — the machine that services their biggest dump trucks — came to us facing replacement. We ran a major inspection then a full refurbishment of both the manipulator and its supporting forklift, and restored it to near-new instead of replacing it, avoiding the capital cost.
- A hard-worked fleet of Terex MAC25 cranes was assessed as repairable, not replaceable: new front suspension mounts, all bearing bores line-bored, complete harnesses replaced, alongside full major inspection scope — returned to work with minimal rework.
- Kwik Lift Demolition, in Bundaberg, needed the boom on their 80-tonne all-terrain crane fully rebuilt for safe return to service; we disassembled and rebuilt it with specialist tooling and put it back to work.
Assets and brands
Mobile and slew cranes, crawler cranes, pick-and-carry cranes, EWPs and travel towers, telehandlers, mining plant and drill rigs, trailers and earthmoving equipment. Across all major brands.
Why KDI for a rebuild
A rebuild is only as good as the trades behind it. We keep fabrication, machining, line boring, hydraulics, electrical and structural work under one roof — so a rebuild isn't stitched together across five subcontractors with five sets of lead times. That's why our rebuilds come back on time, and why the scope holds.
Proof
513 jobs for 390 customers in 2025; machines from 100 to 300 tonnes; the largest crane we've rebuilt-scope inspected in the field was a Liebherr LR1280. We've been extending the life of Proline crane borers for over six years.
Related services
A rebuild usually starts with a major inspection, can involve custom engineered solutions, and sits alongside general heavy diesel and plant repairs.
FAQ
Is my machine worth rebuilding or should I replace it?
Often it's worth rebuilding. We assess it, including oil analysis for hidden wear, and give you the honest replace-versus-rebuild numbers.
What does a rebuild extend the life by?
A properly executed rebuild plus major inspection commonly adds more than a decade of compliant service.
Can you rebuild a boom?
Yes — full disassembly and rebuild with specialist tooling, reinstalled and tested.
What is line boring and why does it matter?
It restores worn bearing bores (e.g. centre articulations) to OEM spec, so the machine handles load safely again.
Do you handle the compliance side too?
Yes — rebuilds are scoped and certified alongside the major inspection, all in-house.
How long does a rebuild take?
It depends on scope, but everything under one roof means no waiting between trades. We'll give you a firm date, backed by the guarantee.
Based on the Sunshine Coast.
On site across Australia.
Sunshine Coast · Brisbane · Gold Coast · Bundaberg · Gladstone · Mackay
Plus remote, interstate and international mobilisation.
We put $500 a day behind the completion date we give you.
Every job is completed on or before the promised date or you receive $500 in service credits for every eligible working day of avoidable delay caused.
We're ready when you are.
We'll scope it, quote it fixed, and give you a date we'll stand behind.
Backed by our Zero Downtime Guarantee.