Generator Rewinding.
Restored to Factory Specification.

Generator winding failures are caused by thermal stress, moisture ingress, voltage spikes, mechanical vibration, or gradual insulation degradation over years of service. When windings fail, the common assumption is that the entire alternator requires replacement — a significant cost, particularly on larger industrial generator sets. In many cases, professional rewinding restores the alternator to full factory specification at a fraction of that cost.

Generator Solutions provides alternator rewinding services across Gauteng, covering stator windings, rotor windings, and excitation windings across all major alternator brands — Stamford, Leroy Somer, Mecc Alte, Marathon, and others. Before any rewinding work is undertaken, we assess the unit thoroughly to confirm that rewinding is both viable and cost-effective for your specific alternator. Not every winding failure justifies rewinding, and we provide an honest assessment before any cost is committed.

Our rewinding process follows original manufacturer specifications in every respect — wire gauge, insulation class, winding pattern, and connection configuration. Deviation from specification produces an alternator that either underperforms or runs hot, reducing service life. The core is cleaned and inspected for lamination faults and slot damage before new windings are installed, ensuring the foundation is sound before work begins.

Once wound, every unit is vacuum impregnated with varnish and oven-cured. This process fills all voids in the winding and provides long-term protection against moisture ingress, contamination, and thermal stress — the same causes that led to the original failure. Skipping this step leaves rewound windings vulnerable to the same failure modes within a short period.

Testing after rewinding is comprehensive. Insulation resistance, winding resistance, and high-potential testing are completed before the unit is reassembled. After reassembly, a full load test confirms the alternator meets its original rated output specification. The unit is not returned to service until every test is passed.