Diesel Engine Remanufacture
Melton Industries offers remanufacture programs on diesel engines of ALL sizes, covering an extensive list of brands and manufactureres, including: John Deere, Cummins, Caterpillar, Hatz, Isuzu, Yanmar, International, Kohler, Detroit Diesel, Kubota, Lister Petter, Perkins, and many more.
Based upon over 65 years of experience and over 60,000 engine overhauls, our high quality remanufacture process is one that has not only been tried and tested, but continuously improved upon. Such experience creates true expertise, and with that expertise, have developed one of the most thorough and advanced remaufacturing processes in the industry.
Melton Industries specializes in remanufacturing drop-in, fully tested diesel engines.
At Melton Industries, we possess the most advanced remanufacturing machinery and tools available on the market, expertly trained and highly experienced technicians who are masters of their specialties, as well as expansive, state-of-the-art remanufacture facilities.
Receiving & Visual Inspection
Our remanufacture process begins the moment that we receive assets from the customer, beginning with a detailed visual inspection of each individual unit. A customized receiving report is filled out, annotating any missing or visually damaged items. Photographs are also taken.
During this inspection, our technicians look for visible signs of failure on the unit. If found, these problem areas can often foretell of further damages to be found later on in the disassembly process, or which areas of the engine may require special attention. These findings are then recorded with photographs and annotated on each unit’s receiving report.
Disassembly & Detailed Inspection
After being received, assets move into disassembly. Melton Industries’ disassembly processes are designed to efficiently disassemble all engine components while assuring that all parts and components remain with each respective job number.
During disassembly, the technicians continue the visual inspection process to the internals of the engine; recording any damaged or problem areas for further inspection and testing.
All engine accessories included in the remanufacture process.
At Melton Industries, our remanufacture process includes all engine accessories, such as the Water Pump, Oil Pump, Injection Pump, Injectors, Turbos, Oil Coolers, Heat Exchangers, etc. Each of these critical components is individually and fully disassembled, inspected, remanufactured, and individually tested by our highly specialized, uniquely trained technicians.
Cleaning
Melton Industries’ cleaning process utilizes top-of-the-line machines as well as mechanical and chemical technology, to facilitate both an immensely thorough and highly efficient cleaning process on each component of the engine.
The cleaning process, again, extends to all engine accessories; with all peripheral components receiving the same meticulous cleaning procedure.
Inspection & Testing
Next, castings and critical components move to a third inspection phase & stringent testing process.
At this point, assets undergo rigorous quality tests using state-of-the-art technology, machines, tools, and instruments; all performed by highly trained, specialized NDT (Nondestructive Testing) technicians. Each of Melton Industries’ approved NDT technicians are certified to ASNT SNT-TC-1A in NDT (Nondestructive Testing) alone.
Each of Melton Industries’ NDT technicians are qualified and certified to ASNT SNT-TC-1A standards.
At Melton Industries we have developed a highly proprietary testing process, in which we take great pride, as our testing process is integral to the superior output quality of our overall remaufacture process. This testing process includes a numerous variety of individual tests, the objective of which is to verify quality of components. From both Liquid and Powder Magnaflux tests, to vacuum testing, and numerous other varieties of NDT (Non-destructive Testing).
Finally, all core components undergo a severe measurement and verification process using highly premium measurement instruments. These instruments are consistently calibrated for hyper accuracy on a monthly basis.
Our meticulous testing procedures are critical to the superior output quality of our entire remanufacture process.
At Melton Industries, we devote great care and focus to inspection and testing as these steps are highly critical to the final quality level of remanufactured assets. These concentrated processes are integral to our superior product quality and final results.
Machining Process
At the core of our machining processes is cutting-edge, state-of-the-art machinery. All Melton Industries facilities are fully equipped with the latest in Rottler and Sunnen computer operated machining equipment.
All Melton Industries facilities are equipped with state-of-the-art Rottler and Sunnen machining equipment.
Just like each previous step, our machining processes are executed by extensively trained, specially skilled machinist technicians. Melton Industries retains specialized, expert machining technicians for each component of the engine. Block machining operations are performed exclusively by an engine block specialist, cylinder head machining operations are performed exclusively by a cylinder head expert, and so on.
It is the 3-step quality inspection process employed across previous steps which allows us to achieve remarkable quality at the machining phase.
Assembly
The assembly process is performed by highly experienced, master assembly technicians; some of which having assembled over 10,000 engines in their history with Melton Industries.
All parts and components (new and remanufactured) are inspected by the Assembly Technicians once again, to assure measurements are within approved specifications.
During assembly, each component is measured and checked once again using premium, highly-accurate and calibrated measurement instruments, to ensure they either meet or exceed OEM (Original Equipment Manufacturer) specifications.
Testing
Next, each engine unit is subjected to a stringent, 2-hour minimum, dynamometer testing process. Marine engines are dynamometer tested for a minimum of 4-hours. The objective of this test is to verify like-new performance, workmanship, and integrity of every facet of the remanufactured engine.
Each individual unit is subjected to a severe, minimum 2 hour, dynamometer test for quality assurance and performance verification.
This process is thoroughly monitored using advanced equipment and experience to ensure that the finished product meets our high quality standards. If any discrepancies are discovered, the unit is immediately failed and evaluated for further inspection, analysis, and corrective action.
Paint, Packaging, & Shipping
All paint, packaging and shipping procedures are built to suit the customer’s needs. We offer fully custom options in each of these areas.
Melton Industries is fully certified for overseas packaging and shipping, including IPPC ISPM 15 certification for construction of wood packaging material (WPM) used in Government or International Trade.
Core Policy
Customers are charged core charges when remanufactured engines are purchased. The core charge is a deposit that is paid by the customer to assure that the like-for-like engine core is returned. In order to receive the full credit back, there are conditions that must be met. If the core engine does not meet all of these conditions, then deductions from the core credit may apply, up to the full value of the core charge.
- The engine core must be a like-for-like configuration, meaning the engine core must be the same configuration as the purchased replacement engine.
- Engine core must be returned assembled complete with no missing parts or catastrophic damage, internal or external.
- Engine core must be returned on the same engine stand as the replacement engine.
- All fluids are to be drained prior to shipping.
- The core engine must be returned within 30-days of receiving replacement engine.
- Any core credit will be paid back to the customer within 30-60 days of receiving the customer’s core back for evaluation.
Remanufactured Diesel Engine Limited Warranty
Melton Industries, herein referred to as “Manufacturer,” warrants most remanufactured or overhauled item sold by the Manufacturer to be free from defects in materials and workmanship in normal service for a period stated below from date of purchase, provided that the engine is operated and maintained in accordance with the OEM instructions and manuals. This standard warranty applies to any remanufactured diesel engine, unless otherwise noted at the time of sale
Diesel Engines: 12 Months / 1,000 hours
Electrical Components: 3 Months
The starting time for the warranty period will be the invoice date. For purposes of calculating hours if no hour meter is installed as original equipment, then eight (8) hours of use per day and five (5) days per week will be used to calculate hours used.
The Manufacturer will replace or repair any component or assembly which shall appear, upon complete inspection, to have been defective in material or workmanship. If a component or assembly is determined to be defective in material or workmanship, and the customer complies with the Warranty Claim Procedures herein, then the Manufacturer will bear all transportation charges in connection with replacement of the defective component or assembly. Any deviation from these Warranty Claim Procedures shall void this warranty.
WARRANTY CLAIM PROCEDURES
If the customer believes a defect in material or workmanship is the responsibility of the Manufacturer, then the following procedures shall be complied with in the following order:
1] Customer to notify Manufacturer via verbal communication or electronic transmission. Manufacturer will evaluate customer complaint and offer verbal or electronic technical assistance. If the customer is unable to resolve problem after communication, then proceed to step two (2).
2] Customer to request component replacement, if applicable. Customer shall purchase the required component and the Manufacturer will send customer new or remanufactured replacement component. Upon customer receipt, customer to replace defective component and return to Manufacturer the defective component for evaluation. If upon evaluation, the replaced component is found to be covered as a warranty item, then the Manufacturer will credit the Customer the cost of the component plus all transportation charges in connection with replacement of the defective component. If replacement of a defective component doesn’t solve the problem, then proceed to step three (3).
3] Customer to send Manufacturer engine assembly for diagnostic evaluation. If upon evaluation the engine assembly failure is found to be covered as a warranty item, then the Manufacturer will make the necessary repairs and return the engine assembly back to the customer. If upon evaluation, the engine assembly failure is not found to be covered as a warranty item, then the Manufacturer will provide the customer with an estimate to repair the failed engine assembly.
This Warranty shall not apply to any items which shall have been abused or operated in a manner not recommended by the original equipment manufacturer; nor to any component or assembly in which parts not manufactured or approved by the original equipment manufacturer have been used; nor to any accessories installed where the accessory manufacturer has its own warranty; nor to normal maintenance services or replacement of normal service items.
This Warranty shall not cover damage as a result of damage from transportation, overheating, contamination, lack of lubrication, abuse, misuse, neglect, improper maintenance, or unapproved modifications. Pictures or additional information may be required to assist in the evaluation process.
The Customer is responsible for the proper use and maintenance of the engine in accordance with OEM instructions and manuals. Melton recommends that all receipts and records covering the performance of regular maintenance be retained in case questions arise. If the engine is resold during the warranty period, the maintenance records should be transferred to each subsequent owner.
This Warranty, and the manufacturer’s obligation hereunder, is in lieu of all other warranties, express, implied, or statutory, including any warranties of merchant ability or of fitness for a particular purpose, and all other obligations or liabilities, including special or consequential damages or contingent liabilities arising out of the failure of any engine or part to operate properly. No person is authorized to give any other warranty or to assume any additional obligation on the Manufacturer’s behalf unless made in writing and signed by an officer of the Manufacturer.
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