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When a glass manufacturing plant on Merseyside had their main power source a 700KVA FG Wilson generator break down recently, they called Bellwood Rewinds Limited’s generator division for help. The main stator on the alternator had blown up and they were left with an expensive hire generator in its place costing them £2K per week. They tried many companies but settled on Bellwood Rewinds due to the very competitive price but mainly the 3 week turnaround guarantee.

The generator arrived and underwent an initial inspection, it was in a bit of an uncared for state.

Repairing a Generator on Merseyside

Our engineers got to work straight away and carefully detailed the list of problems the generator had, these included:

  • Alternator main stator and exciter stator blown
  • Both front and rear crank shaft oil seals failed on engine
  • Radiator and intercoolers totally blocked with oil due to above
  • Fuel lift pump weakening

Once the customer had inspected the damage they gave us the green light to proceed, still on the 3 week turnaround time, we got to work.

Firstly the roof came off the canopy and the alternator and radiator/ intercooler unit were removed:

Repairing a Generator on Merseyside

We then dismantled the alternator to find the damage that we have previously noted during static testing, the main stator had blasted to earth:

Repairing a Generator on Merseyside

Repairing a Generator on Merseyside

The radiator core and intercooler were totally blocked with oil due to the failed crank shaft seals:

Repairing a Generator on Merseyside

The alternator underwent a full main stator and exciter stator rewind, the remainder of the alternator was fully overhauled.

Repairing a Generator on Merseyside

Repairing a Generator on Merseyside

The radiator/ intercooler unit was dismantled into its 4 separate components and they were each cleaned in an ultrasonic cleaning bath for 48 hours to release the oil debris. Once they were clean they were all pressure tested and then reassembled:

Repairing a Generator on Merseyside

The crank shaft seals were both replaced:

Repairing a Generator on Merseyside

Then the unit was reassembled, refitting the alternator and radiator. Once all refitted the engine was fully serviced and with a new lift pump fitted was back to perfect working order. We carried out a load test over 4 hours to determine the set up was correct and the customer was advised he could collect the unit, all this work carried out in 2 weeks and 4 days.

Bellwood Generators

I have used Bellwood Rewinds for many years to carry out motor and generator repairs, as well as supplying hire generators. I find them very helpful and most of all on time every time even on matters of an urgent nature. I would have no concern with recommending their services to anybody.
James Simpson
James Simpson
08:56 16 Nov 17
Fantastic company to deal with and great customer service, I would highly recommend!
Mike M
Mike M
08:59 19 Jan 18
Couldn't have asked for a better service from Bellwood Rewinds. Would definitely use again in future, and will most definitely recommend to others within the industry who are looking for quality customer service with a smile.
Lee Harris
Lee Harris
14:01 19 Jan 18
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