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, Caterpillar, Cummins & Onan, 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 ISO 9001:2008 compliant remanufacture process is one that has not only been truly tried and tested, but continuously improved upon. Such experience creates true expertise, and with that expertise, we 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.

6.5L Engines Staged

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. Each unit then receives a thorough individual receiving report.
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 and marked on each unit’s receiving report.

Receiving

Disassembly & Detailed Inspection

After being received, assets move into disassembly. Melton Industries’ disassembly processes are executed by specially trained, highly experienced disassembly technicians.
During disassembly, these 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, and Turbos. Each of these critical components is individually, fully disassembled and inspected by our highly specialized, uniquely trained, Water Pump, Oil Pump, Injection Pump, and Turbo technicians.

Disassembly Area
Component Disassembly

Cleaning

Melton Industries’ cleaning process utilizes top-of-the-line machines and 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, assets move to a 3rd, and final, 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 testing technicians. Melton Industries’ specialized testing technicians hold over 1000 training and certification hours in NDT (Nondestructive Testing) alone.

Melton Industries’ specialized training technicians hold over 1000 training & certification hours in NDT.

Inspection Instruments
Block 1

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.

Clyinder Head Boring
Cylinder Boring
Clinder Head Honing

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.

Our assembly technicians have individually performed over 10,000 career engine assemblies with us.

During assembly, each component is measured and checked a second time, again using premium, hyper-accurate measurement instruments, to ensure they either meet or exceed OEM (Original Equipment Manufacturer) specifications.

Power Pack Assembly
Diesel Assembly

Testing

Next, each individual engine unit is subjected to a stringent, 2-hour minimum, dynamometer testing process. The objective of this test is to verify performance and verify the integrity of each component of core unit functionality.

Each individual unit is subjected to a severe, minimum 2 hour, dynamometer test for quality assurance and performance verification.

This process is severely monitored to insure unit quality is absolutely 100%. If any condition should decline to meet minimum standards during this process, the unit is immediately failed and sent for further inspection and re-conditioning.

Dyno Testing Gen Set
John Deere Marine Dyno
Cummins Diesel Dyno Test

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.

Ready John Deere Engines
John Deere Engines
Hatz Engines Ready

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