D-check top overhaul
IBM Bangalore
4 × 1010 kVA Cummins sets, campus-critical power
Service · Repair & Overhauls
Overhauls that start with the why
Compression tests, meggering and a written root cause before any spanner turns — then D-checks, alternator overhauls and full stator rewinds, up to 1250 kVA, any major brand.
1250 kVAlargest rewind done
D-checktop overhauls
Multi-brandCummins · Perkins · MTU +
RCA firstwritten cause analysis
Scope of work
The workshop scope most rental companies don't have and most rewinders can't commission. Power Solutions does both ends: diagnose, repair, run it back up on load.
- D-check / top overhauls — heads, injectors, valves, liners
- Alternator overhauling — bearings, diodes, AVRs, end-shields
- Full stator rewinding up to 1250 kVA, Class H/F machines
- Meggering, compression testing, sensor and protection checks
- Root-cause analysis in writing before scope approval
- Load testing and recommissioning after every major job
Done, not claimed
Full stator rewind
Siemens, Verna Goa
1250 kVA MTU alternator — failure investigation, rewind, recommissioning
Alternator overhauls
HSBC Vishakhapatnam
1010 kVA & 2 × 1500 kVA Perkins sets
The rule
No repair without a cause. No cause without a test.
The Siemens Goa rewind started as an alternator failure investigation — insulation weakened by age, proven by meggering, then rewound once. That is cheaper than replacing the machine and far cheaper than rewinding it twice.
Overhauls, answered
Frequently asked questions
What is a D-check on a DG set?
A D-check is the deepest scheduled overhaul in a generator maintenance cycle — a top overhaul of the engine covering cylinder heads, injectors, valves and associated systems, done when running hours demand it. Power Solutions has performed D-check top overhauls on four 1010 kVA Cummins sets at IBM Bangalore.
When should an alternator be rewound rather than replaced?
When insulation resistance is failing due to age but the frame, core and mechanicals are sound, a full stator rewind restores the machine at a fraction of replacement cost — typically decided after meggering and a root-cause investigation. We rewound and recommissioned a 1250 kVA MTU alternator for Siemens at Verna, Goa on exactly this basis.
Which alternator makes do you repair?
Stamford, Crompton, Leroy Somer, Kirloskar and other Class H/F industrial machines — overhauls, bearing and diode work through to full stator rewinding, on alternators up to 1250 kVA and beyond.
Do you investigate the failure or just repair it?
Both — a repair without a root cause is a repeat failure on a timer. Standard practice includes cylinder compression testing, sensor checks, alternator meggering and a written cause analysis, as done for Siemens at Kalwa and Goa before any rewind was approved.
Can you overhaul engines from brands other than Cummins?
Yes — multi-brand is the point. Perkins alternator overhauls for HSBC Vishakhapatnam, MTU work for Siemens, Ashok Leyland engine health checks, plus Cummins, Kirloskar and Mahindra Powerol fleets under AMC.
How is overhaul work priced?
Against a written scope after inspection — never a number over the phone. You get the findings, the recommended scope, itemised commercials with GST, and the option to phase work that can safely wait.
Reply within 4 working hours. Engineered offer within 24 hours.