New copper-brass and aluminium core replacement for diesel generator radiators from 125 KVA to 1200 KVA. All major brands. Save 30–60% versus buying a new radiator. In-house core manufacturing at Worli, Mumbai. 6-month warranty on all recoring work.
Radiator recoring — also called core replacement — is the process of removing the old, damaged or blocked radiator core and fitting a brand-new core into your existing radiator frame and tanks. The tanks, frame, and all fittings are retained. Only the core — the network of tubes and fins that actually transfers heat — is replaced with a new one.
A new DG set radiator can cost significantly more than a recore — yet 80% of the value in a radiator is in the tanks, frame, and fittings, which are typically still in good condition when the core fails. Recoring replaces only the worn-out part — the core — at 30–60% of the cost of a complete new radiator, while delivering identical cooling performance. For DG sets where new radiators are hard to source (older Cummins, Greaves MWM, imported brands), recoring is often the only practical solution.
Alt text: "DG set radiator core replacement — old corroded core removed and new copper-brass core fitted at Ajanta Radiators Worli Mumbai"
This is the most common question we get. Here is our honest guide based on 55+ years of experience repairing and recoring industrial radiators in Mumbai:
✓ We always try repair first — honest assessment before recommending recore
✓ Recoring at 30–60% of new radiator cost — the smart long-term choice
We manufacture both types of replacement cores at our Worli, Mumbai workshop. Every core is custom-built to the exact dimensions of your DG set radiator — width, height, depth, tube count, and fin density all matched to original specification.
The standard and most recommended core type for Indian DG sets. Copper tubes with brass fins, soldered to brass header plates. Excellent corrosion resistance in Mumbai's coastal climate. Best for continuous-duty DG sets running 8+ hours per day. Repaired by soldering if ever needed again.
Best for Kirloskar · Cummins · KOEL · Ashok Leyland · CAT UpgradeLightweight aluminium tube-fin core for DG sets that require original aluminium specification — such as newer Caterpillar, Cummins QST/KTA, and Perkins models. We supply aluminium cores to exact CAT and Cummins dimensions. For 24×7 running sets in Mumbai, we recommend copper-brass upgrade instead.
Caterpillar · Cummins QST/KTA · Perkins · Original SpecThe smartest option for CAT and newer Cummins DG sets running 24×7 in Mumbai. We build a copper-brass core to the exact dimensions of your original aluminium core — fits perfectly in the same frame and tanks. Eliminates recurring aluminium corrosion problems permanently. More on CAT upgrade →
CAT C9 · C15 · C18 · C32 · Cummins KTA · QSTSend your DG set brand, KVA, and photos of the radiator. We advise repair vs recore and give an estimate.
We arrange pickup from your Mumbai location or you bring it to our Worli workshop directly.
Old damaged or blocked core carefully removed from the existing frame and tanks. Tanks inspected and cleaned.
New copper-brass or aluminium core built in-house at our Worli workshop to exact dimensions of your radiator.
New core soldered into existing tanks. All joints sealed, fittings checked, overflow connection restored.
Complete radiator pressure tested to operating pressure. Zero leaks confirmed before delivery.
Delivered to your Mumbai location with 6-month warranty on the recoring work.
Alt text: "New copper-brass core being fitted and soldered into DG set radiator tanks — Ajanta Radiators Worli Mumbai"
We supply and fit replacement cores for every major DG set brand used in India. Select your brand for brand-specific details:
| KVA Range | Core Type | Core Rows | Typical Brands | Turnaround | Service |
|---|---|---|---|---|---|
| 125–160 KVA | Copper-Brass | 3–4 Row | Kirloskar KG125W, Cummins 6BTA, Leypower, KOEL | 2–3 working days | Recore · CB Upgrade |
| 200–250 KVA | Copper-Brass | 4 Row | Kirloskar KG250W, Cummins QSL9, Leypower 250, KOEL iGreen | 2–4 working days | Recore · CB Upgrade |
| 320–500 KVA | Both Types | 4–6 Row | Kirloskar SL90, Cummins K19, CAT C9/C15, KOEL | 3–5 working days | Recore · CB Upgrade |
| 625–750 KVA | Both Types | 5–6 Row | Kirloskar DV10, Cummins QST30, CAT C18, Perkins | 4–6 working days | Recore · CB Upgrade |
| 1000 KVA | Aluminium / CB | 6+ Row | Cummins KTA38-G5, CAT C32, Perkins 4008 | 5–7 working days | Recore · CB Upgrade |
| 1200 KVA | Aluminium / CB | 6+ Row | Cummins KTA50, CAT C175, MTU Series | 7–10 working days | Recore · CB Upgrade |
Turnaround times are estimates — confirmed after we receive and inspect your radiator. WhatsApp us your DG set details for a confirmed quote →
Established 1970, Worli Mumbai. Core manufacturing is our primary business — copper-brass and aluminium cores made in-house for DG sets, forklifts, cranes, and heavy machinery.
Every replacement core is manufactured at our Worli workshop — not sent to a third party. We control quality at every step, and turnaround is faster because there's no waiting for external suppliers.
Recoring saves you 30–60% compared to buying a brand-new radiator, while delivering identical cooling performance. For most DG sets, recoring is the economically correct decision.
Every core is custom-built to your radiator's exact dimensions — width, height, depth, tube count, fin density. Not a generic replacement — a precise fit for your specific DG set radiator.
6-month warranty on every recore job. If the new core develops a fault within 6 months — we fix it at no charge. Every recore is pressure tested before delivery.
We collect your DG set radiator from anywhere in Mumbai for recoring and return it once the new core is fitted, tested, and ready. WhatsApp us your address.
In a recore, we remove the entire tube-fin core — the network of copper or aluminium tubes and fins that transfers heat from the coolant to the air. The existing radiator tanks (top, bottom), the frame, side members, and all inlet/outlet fittings are retained. A brand-new core is manufactured in-house at our Worli workshop and soldered into your existing tanks. The result is a radiator with new core performance in your original frame — at 30–60% of the cost of a complete new radiator.
Recoring cost depends on the KVA rating, number of core rows, core dimensions, and whether copper-brass or aluminium is required. As a general guide, recoring costs 30–60% less than buying a new radiator for the same DG set. Send us your DG set brand, model, and KVA on WhatsApp — we give you a firm quote within a few hours after assessing the radiator.
Yes — this is our aluminium-to-copper-brass upgrade service and it is one of our most popular recoring options. We build a copper-brass core to the exact dimensions of the original aluminium core and fit it into the existing radiator frame. This is particularly recommended for Caterpillar, newer Cummins (QST, KTA), and Perkins DG sets running 24×7 in Mumbai, where copper-brass gives significantly longer service life and is easier to repair in the future.
Yes — a properly recored radiator with a new core delivers identical cooling performance to a new radiator. The core is the only part that affects heat transfer. Since we manufacture the new core to the original specifications — same tube count, same fin density, same row depth — the thermal performance is equivalent to new. In some cases, where we upgrade from aluminium to copper-brass, the thermal performance can actually be better than the original aluminium core.
Yes — because we manufacture cores in-house to custom dimensions, we can recore virtually any DG set radiator regardless of brand. We have recored radiators for Perkins, MWM (Greaves), MTU, Volvo Penta, Jakson, SDMO, and other brands. Send us the radiator dimensions or photos on WhatsApp and we confirm within the day.
Yes — 6-month warranty on all recoring work. Every recored radiator is pressure tested to operating pressure at our Worli workshop before delivery or pickup. If the new core develops a fault within 6 months of our work, we repair it at no charge.
Send us your DG set brand, model, KVA, and radiator photos on WhatsApp — we confirm whether repair or recoring is right and give you a firm quote within the hour.