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Services: Repairs / Reconditioning |
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The cost of replacement and defective components such as cylinder covers can be prohibitive, whereas some are virtually irreplaceable. By repairing these components using a procedure established a sound and lasting repair could be performed at a fraction of the new replacement cost.
On receipt at our works, all components are thoroughly cleaned, degreased and identified with a unique reference number to ensure traceability.
The use of up-to-date and conventional inspection techniques such as introsonic examination, non-destructive testing and dimensional checks, often reveal extensive damage and ensure that all defective and worn areas are noted and subsequently corrected where necessary material analyses are taken to ensure welding compatibility.
Once the extend of the defects have been determined, a comprehensive report is forwarded to the client detailing all defects found along with our recommendation for repairs. Defective and worn-out areas are rebuilt with close-grained machineable cast iron, fused perfectly with the parent material.
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| I - Cylinder Heads - Process |
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De-scaling of components is followed by precision re-machining of all critical areas to original limits and tolerances, carried out in our own well-equipped engineering premises.
Cast Iron cylinder covers can be successfully repaired using our proven and tested methods. The same meticulous attention is paid to the repair techniques, subsequent heat treatment and machining operations. |
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All items are hydraulically pressure tested and crack detected after final machining and refitting of ancillary parts such as valve guides and valve seat inserts, using cryogenics, all carried "in house".
Stringent quality control checks are done at various stages during reconditioning independent surveyors Lloyds witness over 80% of repairs. The quality of the work is backed up by a comprehensive computerised records system. All our reconditioned cylinder heads are delivered with a warranty and a certificate from the classification society Lloyds Register |
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II - Exhaust Valves Cages |
We provide a complete reconditioning service for valve cages, spindles and seats. Our repair procedures are strictly controlled to ensure a quality repair every time. The seat and landing end of the water cooled cage is removed, often revealing complete blockage or erosion of the coolant passageways. These passageways are cleared before any necessary internal repairs are carried out and a new crown welded onto the body. |
Upper View
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All our reconditioned exhaust valve cages are delivered with a warranty , and a certificate from classification society.
Material analyses are taken to ensure the correct matching material is used for the new end piece. An etched section through a test piece replica shows the stellited seat and heat affected zones of the T.I.G. welds. Such test pieces are essential to establish the correct welding parameters and pre and post heat treatments; errors can cause cracks through use of incorrect materials, lack of penetration or coolant spaces virtually blocked by weld metal - even when manufactured by the O.E.M. Finish machining is attended to with equal care. Attention to details is essential - in particular, the stellited valve seating and valve cage landing faces leave no margin for error. |
New crown with stellite seat
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Bodies & Crowns ready for reassembly
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Severe damage |
Coolant passageway of the
crown
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The same meticulous attention to detail is applied to the reconditioning of both the upper and lower components of 2 piece valve cages of the cooled and water standard types. Valve spindles and seats are also refurbished thereby extending their working life dramatically.
Stringent and dependable quality control ensures that the end result is a valve cage perfectly restored to standards exceeding that of the original item.
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III - Pistons |
ALL OUR PROCESSES ARE LLOYDS CERTIFIED |
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STATE-OF-THE-ART ALUMINIUM WELDING |
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QUALITY AND EFFICIENCY FOR PART OF THE PRICE |
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| IV - Turbochargers |
Fuji Technical Services Pvt.Ltd is a Specialized Turbocharger service centre for ABB, Niigata-Napier, MAN B&W , Napier ,Niigata MAN B&W,Mitsubishi and KBB. Fuji also supports these makes with Spare parts and trained service engineers. The Fuji Technical Services Pvt.Ltd turbocharger department is fully equipped to handle all types of turbocharger repairs including complete overhauls or standard cleaning and balancing.
All of our senior service personnel have undertaken extensive skills and product knowledge tests in our training suites and this has been complimented having attended turbocharger factories ABB, MAN, Mitsubishi, KBB, PBS Turbo, Niigata-Napier etc. over the past few decades.
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| V - Other Components Repairing |
To compliment Fuji Technical Services’ core activities, we have also diversified our operations to include the following; |
Intake/Exhaust Valves |
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| Fuel Injector Overhaul |
 Fuel Injector Nozzle Reconditioning & Regeneration |
| Fuel Injector Pump Overhaul & Timing |
 Fuel Pump Element Regeneration |
| Governor Overhaul |
| Governor Exchange |
If you have any concerns or quotation requests pertaining to any product/service that are in line with our operations please and our consultants would be at your service. |
