Generator Overhauling
Top & Major Industrial Generator Engine & Alternator Overhauling
Complete mechanical and electrical overhauling of diesel and gas generators from 50 kVA to 3000 kVA (Cummins, Perkins, Caterpillar, MTU, Baudouin). Includes cylinder kit renewal, alternator VPI rewinding, and resistive load bank testing.
Key Deliverables & Specifications
OEM Cylinder & Piston Kits
Original factory cylinder liners, pistons, rings, and valve guides.
Alternator Stator & Rotor Rewinding
Class H insulation with vacuum pressure impregnation (VPI) varnishing.
Fuel Injection & Turbo Balancing
Precision Bosch/Cummins pump calibration and dynamic balancing.
Full Step Load Bank Testing
0% to 110% step load certification with calibrated digital power logging.
Engineering Scope & Capabilities
Industrial Diesel & Gas Generator Overhauling
Industrial backup power systems require dependable reliability when the national grid fails. Trafo Engineering provides certified mechanical and electrical generator overhauling for factories, data centers, hospitals, and commercial high-rises across Bangladesh.
Top vs. Major Overhauling Capabilities
- Top Overhauling (5,000–8,000 Hours): Cylinder head servicing, valve lapping, injector calibration, turbocharger de-carbonising, and cooling jacket descaling.
- Major Overhauling (15,000–20,000 Hours): Complete engine teardown, crankshaft journal micropolishing, main & con-rod bearing replacement, piston kit renewal, and alternator vacuum pressure impregnation (VPI).
Step-by-Step Engineering Methodology
Pre-Overhaul Compression & Boroscope Audit
Assessing cylinder wall scoring, valve leakage, and vibration spectrum.
Engine Teardown & Precision Micrometry
Measuring crankshaft deflection, bearing clearance, and liner wear against OEM specs.
Machining, Assembly & Timing Calibration
Installing new piston kits, setting valve clearance, and calibrating fuel timing.
Commissioning & Full Load Verification
Gradual step load testing from 25% to 100% with real-time fuel and temperature monitoring.
Diagnostic & Calibration Instruments
| Testing Instrument / Apparatus | Capability & Standard Compliance |
|---|---|
| Resistive Load Bank | 1.5 MW Step Load Bank (0.8 PF Capable) |
| Crankshaft Deflection Gauge | Starrett Precision Dial Indicator |
| Injector Calibration Bench | Common Rail Digital Test Stand (2500 Bar) |
| Vibration Spectrum Analyzer | Fluke 810 Diagnostic Analyzer |
Frequently Asked Technical Questions
Book Generator Overhauling
Get an on-site engineer dispatched or receive a formal branded quotation.
Available 24 hours a day for factory power outages and emergency substation repairs.