Does your existing diesel generator have a leaking radiator or a high-temperature alarm? Compare repair, recoring and complete replacement, see the checks to request before authorising work, and find out which details to send for a quotation in Mumbai. A technician must confirm whether the radiator—or another cooling-system component—is at fault.
Repair may be suitable when a DG set radiator has an isolated, accessible leak and the surrounding core, tanks and mounts remain serviceable. Recoring replaces a damaged, blocked or repeatedly leaking heat-exchange core while reusing sound compatible tanks and fittings. Full replacement is considered when damage is extensive, several components have deteriorated, or the existing assembly cannot be restored to the required cooling and fitment specification.
These are decision points, not a diagnosis from symptoms alone. A qualified technician should investigate the complete cooling system and inspect the radiator before approving a repair. For a commercial estimate in Mumbai, send the generator model, KVA, radiator photographs and symptoms to Ajanta Radiators.
This page is written for the person responsible for keeping a facility's standby or prime power running — not for someone shopping for a new generator. If any of this sounds familiar, the sections below are for you.
A radiator repair or replacement is rarely just a workshop job — for most facilities it also means the standby generator is offline for a window of time. The questions below are worth answering internally before you contact a workshop, so the technical work and the facility's own risk planning happen in parallel rather than one after the other.
Is it your only backup source, or one of several? Is grid power in your area reasonably stable right now, or is this a period where you'd rather not be without standby power at all?
A factory may prefer a weekend or planned shutdown; a hospital or data centre may need to coordinate with a secondary source or a rented DG set for the duration, however short.
Facility manager, maintenance head, safety officer, sometimes a client or tenant SLA. Identifying this early avoids the repair being technically ready while approvals are still pending.
A workshop can only estimate duration once it has seen the radiator or clear photographs — but once given, that estimate is what your internal downtime plan should be built around.
Having these ready before you call or WhatsApp shortens the quotation process considerably.
Facility teams often inherit a generator that was specified and installed years earlier by someone else. That's normal — and it's exactly why photos and the data plate matter more than memory or assumption.
The generator's engine data plate (brand, model, serial number) tells a workshop far more than "it's a Cummins" or "it's about 320 KVA" — it narrows down the likely radiator specification before anyone even sees the unit.
A photo of the radiator from the front, the side, and close up on any tanks, hose necks and mounting brackets tells a workshop more in ten seconds than a phone call can in ten minutes.
Copper-brass and aluminium radiators are repaired and recored differently. If you're unsure which one your DG set has, our copper-brass vs aluminium comparison on the DG Set Hub will help you tell them apart from a photo.
Owners often search for generator radiator leakage repair or DG set radiator replacement after seeing coolant on the floor or a high-temperature alarm. The symptom tells you where to begin checking; it does not identify a failed radiator by itself. Cooling problems can also involve coolant level and condition, hoses, thermostat, water pump, fan drive, airflow, operating load or other engine components. Have your authorised generator technician make the diagnosis; never open a hot, pressurised cooling system.
| What you notice | What it may indicate | Useful information for the radiator workshop |
|---|---|---|
| Coolant dripping from a radiator tank, seam or tube | A localised leak, corrosion or a damaged joint; hoses and connections may also leak. | Photo of the exact wet area, whether it leaks cold or during operation, and any previous repair. |
| High-temperature warning, especially under load | Restricted heat transfer, inadequate airflow or another cooling-system/engine fault. | Alarm history, running load, coolant level history and photos of the core/fan area. |
| Visible fin blockage or damaged core face | Airflow restriction or physical core damage; the internal tube condition still needs assessment. | Front-and-back photos, location of damage and any cleaning or impact history. |
| Repeated leaks after earlier repairs | Widespread ageing, vibration or an underlying pressure/mounting issue may need investigation. | Repair history, locations of past leaks, service notes and engine model. |
| Frequent coolant top-ups or rust-coloured coolant | Possible coolant loss or contamination; the radiator and the wider system both need checking. | How often coolant is added, visible staining and maintenance records. |
Safety: Only trained personnel should isolate the DG set, allow the system to cool and inspect pressurised components. Do not run an overheating generator merely to reproduce a fault; follow the OEM and site safety procedures.
Where the leak is confirmed in the radiator itself, see Ajanta’s DG set radiator hub, including leakage repair. If the core is blocked or deteriorated, the radiator core replacement and recoring page covers that separate service in more depth.
The technical difference between these three options is explained in detail on our DG Set Radiator Hub. What matters for a facility manager is usually less about the radiator and more about the situation around it — how it's failing, how old the asset is, and how much disruption you can absorb.
The radiator has developed a single, identifiable leak or fault, the tanks and frame otherwise look sound, and this is the first time this DG set has had a radiator issue. See leakage repair services on the DG set hub.
Inspection confirms widespread core blockage, corrosion or tube failures, while the tanks and fittings remain suitable for reuse. Brown coolant or overheating alone cannot establish core failure. See core replacement details.
Inspection finds extensive deterioration in the core and tanks, major frame or mounting damage, or an assembly that cannot reliably meet fitment and cooling requirements after repair. See new radiator supply.
These are starting points for your own thinking, not a substitute for inspection — a workshop should always confirm the right path after physically examining the radiator or reviewing clear photographs, since two radiators showing the same symptom can need very different work.
For an existing diesel generator, the cheapest initial quotation is not always the lowest-disruption solution. Compare the scope of the work, condition of the reusable parts and required verification before deciding. The correct choice depends on physical inspection, compatible materials, generator cooling requirements and the facility’s tolerance for downtime.
| Option | Typical scope | When to ask about it | What to confirm |
|---|---|---|---|
| Radiator leak repair | Repair an identified repairable joint, tank or other localised defect, followed by appropriate checks. | One limited defect; core and tanks otherwise pass inspection. | Repair location, cause of failure, test method and the possibility of recurring leaks. |
| Radiator recoring / core replacement | Fit a new, correctly specified heat-exchange core while retaining serviceable compatible tanks and fittings. | Core has widespread damage, leakage or blockage but other components can be reused. | Core measurements, material, tube/fin configuration, compatibility and condition of retained tanks. |
| Complete radiator replacement | Supply a complete new radiator assembly matched to the generator and its installation. | Several major parts are unsound, the assembly is badly damaged, or repair is technically unsuitable. | Drawing/sample match, hose locations, mounting points, fan clearance, lead time and acceptance tests. |
Want to compare specific replacement options? View new DG set radiator supply. For the full brand and KVA overview, visit the DG set radiator repair and manufacturing hub.
An impressive-looking quotation is not enough. Use these questions to compare the actual diagnosis, the proposed work and the checks that will be completed before the radiator returns to your facility.
Ask which part was found defective: tank, seam, tube, core, fitting or mounting. Request photos of the identified defect where practical. If overheating is the only symptom, ask your DG technician to rule out other cooling-system faults.
For recoring, ask how the tanks, headers, fittings and frame were assessed. Reuse is appropriate only when those components are sound and compatible with the proposed replacement core.
Confirm core dimensions and thickness, inlet and outlet positions, mountings, fan clearance, material and required cooling duty against the existing radiator, engine information or approved drawing.
Agree on the appropriate workshop leak or pressure check, any written test record and who will reinstall and commission the DG set. Your authorised maintenance team should check performance under the applicable OEM procedure.
Record the generator and engine model, radiator identification, observed fault, inspection findings, approved scope, parts changed or retained, agreed checks, job date and responsible technician. Attach genuine before-and-after photographs and test documentation if available for that specific job. This is a suggested record format, not a claim that a particular customer job or test has already taken place.
A KVA rating alone cannot identify every radiator. These views help a radiator workshop assess the layout and prepare questions for your quotation. Take photographs only when the generator is safely isolated and the area is accessible.
Show the complete core, tanks and overall shape. Include a side view so the core thickness and fan-side clearance can be understood.
Photograph the leaking seam, crack, damaged tubes or crushed fins. Mark the area in a duplicate photo if it is hard to see.
Where safely available, report core height × width × thickness and note that core measurements exclude the tanks. Share a drawing or OEM part number when available.
Show inlet and outlet locations, mounting brackets and the generator/engine identification plate. Do not publish serial numbers in public reviews or posts.
Ready to request a quote? Send the photographs with your generator brand, engine model, KVA, site area and symptoms. An initial estimate may change after inspection of hidden damage.
Send Radiator Photos for a QuotationThere is no reliable single repair price for every generator radiator. Two radiators on DG sets with similar KVA ratings can differ in construction, dimensions, material and extent of damage. Ask for an itemised quotation after inspection or review of adequate photos and measurements, and confirm which parts and checks are included. Any early estimate may need revision if hidden corrosion or tank damage is found after removal.
For a comparable quote, send: DG set brand, engine model, KVA, core measurements (if known), front/side photographs, the damaged area, facility location and your preferred downtime window.
Request a Radiator QuotationThe workshop quotation and any agreed warranty terms should be checked for your particular job; this guide does not promise a fixed price, repair time or outcome without inspection.
In larger facilities, the person requesting the quotation, the person who approves spend, and the technician who removes the radiator from the DG set are often three different people. A short internal handoff avoids delays that have nothing to do with the actual repair work.
Confirm with your maintenance/electrical team which isolation and safety steps apply to your DG set before the radiator is disconnected, and who is authorised to carry them out.
Keep the generator's data plate details, the photos sent for quotation, and the final quotation together in your facility's maintenance records — useful for future reference even after this job is done.
Nominate one person to communicate with the workshop for this job. Multiple people relaying details independently is a common source of mismatched information on generator brand, KVA or fault description.
Have the radiator reinstalled and the DG set run under load and observed before signing off, so any fitment or performance issue is caught immediately rather than during the next real outage.
Ajanta Radiators is an industrial radiator manufacturer and repair business established in 1970, based in Worli, Mumbai. We handle enquiries for generator radiator repair, copper-brass and aluminium radiator work, core replacement and new radiator manufacturing. Send your installed radiator details for a suitability review and quotation; confirm pickup, delivery, scope and timing for your site before arranging removal.
Facilities enquiring from Mumbai, Navi Mumbai, Thane and nearby industrial areas can share their location and preferred maintenance window. This page is intended for hospitals, factories, warehouses, office buildings, commercial premises and facilities that already own a DG set—not for generator rentals or new-generator sales.
If you have a Cummins, Kirloskar, Caterpillar or Ashok Leyland generator, send the engine and radiator identification as well as the KVA rating. A generator brand alone does not establish the exact radiator dimensions or cooling specification. For model-specific information, browse the Cummins radiator page, Kirloskar radiator page or complete DG set radiator hub.
Ajanta can discuss generator radiator repair in Mumbai, a DG set radiator core replacement and a new radiator quotation from the same set of photographs and identification details. For technical issues such as installation, engine overheating or commissioning, keep your qualified DG maintenance provider involved.
For the technical side — brand-specific pages, KVA capacity coverage, warning signs and our full DG set radiator services — visit the hub below.
Send radiator photos, generator brand, engine model, KVA and the observed fault. Request an inspection-led comparison of repair, recoring or replacement before you approve the work.