Diesel Engine Remanufacturing Process

Melton Industries offers remanufacture programs on off-highway diesel engines of ALL sizes, covering an extensive list of brands and manufacturers, including: John Deere, Cummins, Caterpillar, Detroit Diesel, Hatz, Isuzu, Kubota, Navistar / International, Volvo, Yanmar, and many more.

Based upon over 75 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, we have developed one of the most thorough and advanced remanufacturing 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 are 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, components undergo rigorous quality tests using state-of-the-art technology, machines, tools, and instruments; all performed by highly trained, specialized NDT (Nondestructive Testing) technicians, including a Level III NDT inspector on staff. 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 remanufacture process. This testing process includes numerous 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.

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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.