Aluminium radiator repair, core recoring, and aluminium-to-copper-brass core upgrade for all Caterpillar CAT DG set models from 250 KVA to 1200 KVA. C9, C15, C18, C32, C175 engines. Pickup & delivery across Mumbai. 6-month warranty on all work.
All Caterpillar DG sets use aluminium cores from the factory. In Mumbai's coastal, humid climate, aluminium cores develop electrolytic corrosion and pinhole leaks — especially on DG sets running 12+ hours per day in data centres, hospitals, factories, and industrial plants. Once the aluminium core starts leaking, the problem typically keeps recurring every few months.
Ajanta Radiators replaces your CAT aluminium core with a heavy-duty copper-brass core — fitted into your existing CAT radiator frame. Copper-brass is far more corrosion-resistant in humid coastal conditions, significantly easier and cheaper to repair if needed, and gives 2–3× longer service life for continuous-duty CAT DG sets. This is the most cost-effective long-term solution for any Caterpillar DG set running 8+ hours daily in Mumbai. We also repair Caterpillar forklift radiators — see our Caterpillar forklift radiator page →
Caterpillar is the world's leading heavy industrial generator brand, widely used in India for large-capacity prime power and standby DG sets from 250 KVA to 1200 KVA. CAT DG sets are found in data centres, refineries, ports, hospitals, and large manufacturing plants across Mumbai and India. All Caterpillar DG sets use aluminium radiators from the factory — lightweight but susceptible to corrosion in India's coastal climate. Ajanta Radiators repairs and recores CAT aluminium radiators, and offers the unique service of upgrading to copper-brass cores for extended service life.
Alt text: "Caterpillar CAT C15 500 KVA DG set aluminium radiator repair at Ajanta Radiators Worli Mumbai"
| CAT Engine / Model | KVA | Factory Radiator | CB Upgrade | Common Issue | Service |
|---|---|---|---|---|---|
| CAT C9 / DE300 | 250–320 KVA | Aluminium | Available ✓ | Plastic tank cracks, electrolytic corrosion | Repair · Recore · Upgrade · New |
| CAT C15 / DE500 | 400–500 KVA | Aluminium | Available ✓ | Pinhole leaks from 5–7 years, fin damage | Repair · Recore · Upgrade · New |
| CAT C18 / DE600 | 500–625 KVA | Aluminium | Available ✓ | Inlet/outlet fitting corrosion, core blockage | Repair · Recore · Upgrade · New |
| CAT C32 / DE750 | 750–1000 KVA | Aluminium | Available ✓ | Overheating at high load, core damage | Repair · Recore · Upgrade · New |
| CAT C175 / DE1250 | 1000–1200 KVA | Aluminium | Available ✓ | Large core damage, remote radiator leaks | Repair · Recore · Upgrade · New |
| CAT 3306 / 3412 (Older) | 200–500 KVA | Aluminium | Available ✓ | Age-related corrosion, multiple pinholes | Repair · Recore · Upgrade · New |
| CAT 3508 / 3512 (Older) | 500–750 KVA | Aluminium | Available ✓ | Core fatigue, tank joint failures | Repair · Recore · Upgrade · New |
Have a different CAT model? WhatsApp us your CAT model and serial number →
This is the most important decision for CAT DG set operators in Mumbai. Here's our honest guide:
✓ Choose repair when: new set, standby use, minor isolated damage
⭐ Choose upgrade when: 24×7 running, recurring leaks, 5+ year old core
Alt text: "Caterpillar CAT C15 DG set aluminium radiator with electrolytic corrosion pinholes — before copper-brass upgrade at Ajanta Radiators Mumbai"
The most common CAT radiator failure in Mumbai. Dissimilar metals in the coolant circuit create electrolytic corrosion cells. Pinhole leaks develop progressively on the aluminium core. We repair by TIG welding or upgrade to copper-brass for a permanent solution.
CAT radiators on smaller C-series engines often have plastic tanks crimped onto the aluminium core. These tanks crack under thermal cycling and vibration after 5–8 years. We replace plastic tanks with fabricated aluminium or brass tanks for longer life.
The aluminium inlet and outlet fittings on CAT radiators corrode at the hose connection joint — a common leak source on C15 and C18 sets. We replace the fittings or fabricate new aluminium/brass fitting assemblies to eliminate the leak permanently.
CAT C32 and C175 sets running at 80–100% load during summer months hit coolant temperature limits when the core is partially corroded or blocked. We restore full cooling capacity by flushing or recoring — preventing costly engine shutdowns.
Aluminium fins on CAT radiators flatten easily from high-pressure cleaning or debris impact, reducing airflow significantly. We straighten fins or replace damaged fin sections to restore cooling capacity without a full recore.
On 24×7 running CAT DG sets, aluminium cores develop multiple pinhole leaks from 5–7 years onwards. At this stage, repairing individual pinholes leads to more appearing nearby. A full copper-brass recore upgrade is the right solution at this point.
TIG welding and epoxy repair for pinhole leaks and minor cracks on CAT C9, C15, C18, C32 aluminium radiators. Pressure tested to operating pressure after repair. Best suited for sets with light damage and a relatively new core still in good overall condition.
C9 · C15 · C18 · C32 · C175 · 3306 · 3412We remove the corroded aluminium core and fit a new heavy-duty copper-brass core into the existing CAT radiator frame and tanks. Better corrosion resistance, easier repair, longer life — especially for 24×7 running DG sets in data centres and hospitals. Our most recommended service for CAT operators in Mumbai. Core replacement details →
Most Recommended for 24×7 CAT SetsPrefer to keep the original aluminium specification? We recore with a new aluminium tube-fin core fitted into the existing CAT radiator tanks and frame. Pressure tested before delivery. Available for all C-series CAT models.
Keep Original Spec · All CAT KVACracked plastic tanks on CAT radiators replaced with new fabricated aluminium or brass tanks. Tank-only replacement is the most cost-effective solution when the core is still in good condition but the tank has failed. In-house fabrication at our Worli workshop.
In-House Tank Fabrication · FastWe manufacture new copper-brass and aluminium radiators for all CAT DG set models — C9 to C175, 250 KVA to 1200 KVA. Made to original CAT dimensions. New radiator supply details →
250–1200 KVA · Custom BuiltWe collect CAT DG set radiators from anywhere in Mumbai. For large C32 and C175 radiators requiring special handling — WhatsApp us first to confirm. Returned repaired or upgraded with 6-month warranty. Leakage repair →
Pan-Mumbai · 6-Month WarrantyAlt text: "Caterpillar CAT C15 DG set radiator with new copper-brass core upgrade — Ajanta Radiators Worli Mumbai"
Established 1970, Worli Mumbai. Copper-brass and aluminium core manufacturing is our core business — we have the in-house expertise to correctly upgrade CAT aluminium radiators to copper-brass spec.
Very few radiator workshops in Mumbai can properly execute a CAT aluminium-to-copper-brass core upgrade. Ajanta Radiators has done this for hospitals, data centres, and industrial plants across Mumbai for years.
C9 to C175 — every Caterpillar DG set engine series from 250 KVA to 1200 KVA. Older 3306, 3412, 3508, 3512 series also serviced at our Worli workshop.
6-month warranty on every CAT radiator repair, recore, upgrade, and new supply. Fault within 6 months — we fix it free. Every radiator pressure tested before delivery.
Copper-brass cores on continuous-duty CAT DG sets in Mumbai's coastal climate last 2–3× longer than factory aluminium. One upgrade investment saves multiple repair cycles over the DG set's life.
We collect CAT DG set radiators from anywhere in Mumbai. Large radiators (C32, C175) — WhatsApp us first for special handling arrangements. 6-month warranty on all work.
CAT aluminium radiators develop multiple small corrosion pinholes over time — repairing one pinhole often results in another appearing nearby within a few months. This is a sign the aluminium core has reached end-of-life for a continuous-duty DG set. The permanent solution is a full core recore or copper-brass upgrade. For 24×7 running CAT sets in Mumbai, we strongly recommend the copper-brass upgrade at this point — it eliminates the recurring leak problem entirely.
Yes — this is one of our most common and most recommended services for Caterpillar DG set operators. We remove the factory aluminium core from your CAT radiator and fit a new heavy-duty copper-brass core into the existing frame and tanks. The copper-brass core is far more corrosion-resistant in Mumbai's coastal climate, easier to repair by soldering if ever needed again, and gives 2–3× longer service life on continuous-duty DG sets.
For C9 and C15 series radiators (250–500 KVA): copper-brass upgrade or recoring takes 3–5 working days. For C18 and C32 (625–1000 KVA): allow 5–7 working days. C175 and very large radiators: 7–10 working days. We give you a confirmed timeline after receiving and inspecting the radiator at our Worli workshop.
Yes. We handle large CAT radiators including C32 (750–1000 KVA) and C175 (1200 KVA). For C32 and C175 radiators, please WhatsApp us before sending the radiator — these are very large units requiring special handling, and we need to confirm our current workshop schedule and handling capacity before you dispatch.
Yes. We manufacture the copper-brass core to the exact dimensions of your CAT radiator frame — same width, height, and depth as the original aluminium core. The core is custom-built to fit your specific CAT model. The existing frame, tanks, and all mounting points are retained. We have done this upgrade for CAT C9, C15, C18, and C32 models at our Worli workshop and the fit is always precise.
For CAT DG sets running 8+ hours per day in Mumbai — absolutely yes. Copper-brass lasts 2–3× longer than aluminium in coastal humid conditions. On a 24×7 running DG set, you typically avoid 2–3 complete repair or recore cycles over the radiator's life. The upgrade pays for itself within a few years through avoided downtime, repair costs, and coolant loss. For standby DG sets that run rarely, aluminium recoring is the more cost-effective option.
Share your Caterpillar model, engine series, KVA, and radiator photos on WhatsApp — we reply within the hour and advise whether to repair, recore, or upgrade to copper-brass.