Manual Book Hydraulic Crawler Drill BARI CD-360 COMPLETO

INSTRUCTION MANUAL
SPARE PARTS CATALOGUE

OF
JRD MODEL CD-360
Hydraulically Operated CRAWLER DRILL
NOTE:- Bari Internacional Company reserves the right to make changes

or add improvement without notice and without incurring any obligation
to make such changes or add such improvements to product sold
previously.
Bari Internacional S.A. de C.V.

Calle 15 #160 por 18 y 20 Fraccionamiento Jardines de
Miraflores, Mérida, Yucatán.
Phones: (999) 9 29-07-30 or (999) 9 40-39-12
web:www.explosivosasturion.com,
email:ecanto@explosivosasturion.com,
ventas@explosivosasturion.com
INSTRUCTIONS
FOR
CARE AND OPERATION OF
CD-360
Hydraulically Operated
CRAWLER DRILL
SELF PROPELLED
DRILL MOUNTING
Bari Internacional S.A. de C.V.

Bari Internacional SA de CV,
Crawler Drill CD-360
CD-360 CRAWLER DRILL SPECIFICATIONS
Mode of Drilling : Down the Hole Air Hammer

Capacity: 90 to 115mm dia
Depth of Hole Vertical: 30.0 mtr under favorable drilling conditions
Depth of Hole Horizontal: 20.0 mtr under favorable drilling conditions
ROTATION UNIT
Heavy Duty Hydraulic Motor directly coupled to spur type gear box
Rotation speed RPM 0-60

Max Torque 1125Nm(10,000 in lbs)
WINCH/FEED UNIT
Heavy Duty Hydraulic Motor directly coupled to spur cum worm drive gear
box
Pull Down Force 0-2200 kgf
Pull Up Force 0-2200 kgf
Max Pull Up Speed 0-15 m/min
HYDRAULIC SYSTEM:
The hydraulic system is designed for fuel efficient and high productive
capacity. All hydraulic elements like Pumps, Motors, Valves and cylinders shall
be of adequate capacity and of reputed make. Fixed displacement Hydraulic
Pumpwith proportional Valve (PVG 32 Make: Sauer Danfoss) are used for
Rotation Unit, Feed Unit (for fast & micro feeding) and divert valves are used
for auxiliary drives like for Tramming, mast and boom raising etc…
All hoses shall withstand high pressure and high temperature. The Hydraulic
oil shall be filtered during suction and return lines with operating pressure
maximum 150bar
HYDRAULIC POWER PACK:
Hydraulic Power pack is driven by Diesel Engine water cooled with Power
36H.P @1500 RPM to drive one main Hydraulic Pump.
Page 1 of 12
DIMENSIONS & WEIGHT
DESCRIPTION METRIC
Overall length 5050mm
Overall Width 2100mm
Height 1700mm
Ground clearance 260 mm
Track Width 260 mm
Track length (Ground contact) 1650 mm
Track Oscillation ±10°
Total Weight 5200 Kg
POSITIONING
Boom Lift above Centre Line 300 up, 300 down
Boom Swing 300 right , 450 left
Drill Guide Tilt 750 (Two position)

0 0
From Vertical -5 to +5
Drill Guide Swing(Horizontal)
from Horizontal
Drill Guide Dump 350mm
TRAMMING
Tramming speed 2.0 km/hr
Climbing ability 250
Draw bar pull 1400 Kg
Page 2 of 12
Operating Instructions for CD-360
Lubrication
All the Gearboxes i.e. Rotation Unit (Gearbox), Feed Unit (Gearbox) , Traction Unit
(Gearbox) to be filled with good quality OIL.
Kindly refer lubrication chart.
Lubricator Adjustment (Air Line Oiler):

The lubricator tank to be filled with good quality of ROCK DRILL OIL, kindly refer Lubrication
Chart .An eight liter airline lubricator assembly is bolted to a bracket at rear side of the main
frame. It supplies the necessary lubrication for the down hole drill (Hammer).The oil level should
be checked and adjusted about every eight hours under normal drilling conditions. To check oil
level remove fill plug and note oil level in airline lubricator. Top up with Rock Drill oil if necessary.
Exercise due care when the lubricator is open to keep rock shavings, mud, water and other
material from contaminating the Oil.
Shut off main valve and disconnect bull hose from Crawler mounting before loosening or
removing lubricator fill cap or before performing any maintenance on lubricator.
Do not operate the machine if lubricator oil is below bottom of dipstick. Damage to
the drill (DTH Hammer) will result as they are operated without proper air lubrication.
The drill must receive adequate lubrication. But must not be over lubricated
To adjust the lubricator first turn the needle valve in clockwise direction until the valve is
completely closed (Finger Tight only). Open the needle valve 1 ¼ to 1 ½ turns. To determine if
the lubricator is properly adjusted, check the discharged air at the drill (Hammer) exhaust port.
Place your hand or a piece of white paper approximately 10cm to 15cm (4” to 6”) from the
exhaust port for 2 to 5 seconds. If a slight amount of oil adheres to your hand or paper, it
indicates that the lubricator is properly adjusted.
Before operating a new drill disconnect the bull hose at the manifold lubricator and pour
approximately half litre of rock drill oil directly into the hose and then the connect the bull hose
to the manifold lubricator.
Page 3 of 12
LUBRICATION CHART
QTY
S.No. DESCRIPTION Oil Grade (Lt.per Castrol Mobil BP
Unit)
1 Rotary Head Gearbox SAE 140 6.5 Gear Oil Grade: SAE 140
2 Feed Unit Gearbox SAE 140 2.5 Gear Oil Grade: SAE 140
Mobilube Energear
EPX
3 Traction Gearboxes SAE 85W/140 8.0 HD Hypo
85W/140 85W/140 85W/140
4 Hydraulic Tank SAE 46 250.0 Hydraulic Oil Grade SAE:46
5 Engine Oil SAE 15W-40 5.0 Lube Oil SAE 15W-40
Line Oiler (Air Line

7 ISO VG100 8.0 Rock Drill Oil Grade : ISO VG100
Lubricator)
Grease Nipples,Tower
Channels,Rod Joints,
8 General Purpose Grease (Good Quality)
Feed Chain & Propel
Chain
Page 4 of 12
PROCEDURE TO CHANGE LOCATION OF CLEVIS PIN:

 Move Crawler Mounting to flat ground
 Remove Rod and hammer from rotary head
 Feed Rotary Head forward to centralizer end guide as shown in the figure
 Move drill guide down until foot piece is planted firmly as shown in the
figure
WARNING
FOOT PIECE MUST BE HELD FIRMLY AGAINST GROUND TO PREVENT GUIDE
FROM SWINGING WHEN BOOM CROSS SHAFT CLEVIS PIN IS REMOVED
 Remove cotter pin and washer and drive pin out, using “SOFT” drive rod
 Extend (or retract) Tilt cylinder to align with alternate hole on Boom Cross
Shaft Clevis (Refer Fig 1.5)
 Insert Clevis pin and Secure with washer and cotter pins.
CD 360
Fig 1.5: RELOCATION OF CHANGE PIN
Page 5 of 12
POSITIONING THE DRILL GUIDE FOR DRILLING:
(A) VERTICAL DRILLING:

a) Turn on main Air, wait for some time till the Air reaches all points in
line
b) Raise the Boom unit to required height
c) Raise the Rotary head to the top of the mast
d) Tilt the mast so that drill is in the vertical plane
e) Operate the swivel assembly to bring the mast to true vertical
position.
f) Extended the Dump cylinder until the foot piece is firmly planted in
the ground and the front of the Crawler mounting is tending to be
raised
(B) TOE-HOLE AND LOW ANGLE DRILLING:

a) Turn on main Air
b) Raise the rotary head to the top of the mast
c) Raise or lower the Boom unit for the desired drilling angle.
d) Tilt and swivel the Mast until it comes to the desired position and
angle
e) Extended the mast extension cylinder until the foot piece is firmly
against the drilling face.
CAUTION
IN THE TOE-HOLE POSITION, THE AIR HOSES TO MAST WILL
REST ON THE GROUND. AVOID FOULTING OR DAMAGING THE
HOSES
Page 6 of 12
PRELIMINARY PROCEDURE FOR DRILLING:
a) Adjust properly Air Line Lubricator.

b) Raise Rotary Head up to the top of the Mast.
c) Place centralizer bushing in centralizer.
d) Insert Drill Rod through centralizer bushing chuck so that the lower
end is resting on the ground through the centralizer.
e) Apply graphite grease on male threads of the Drill rod.
f) Lower rotary head up to top of the drill rod and slowly guide it into
the spindle chuck of rotary head and compress it slightly.
g) Start rotary head on forward rotation and run it slowly until threads
are engaged completely.
h) Raise rotary head along with the drill rod up to the top of the mast
to have the lower end of the drill rod clear of centralizer.
i) Remove centralizer bushing.
j) Insert hammer through the centralizer and support it on the ground.
Place centralizer bushing to hold the hammer in vertical position.
k) Put centralizer bushing on top of the hammer.
l) Slowly lower the rotary head and drill rod till the lower end of the
drill rod comes on top of the hammer.
m) Compress Rod on the unit of hammer slightly.
n) Start the rotary head on forward rotation and run it until threads are
engaged completely.
o) Slowly open the compressed air and examine air passing out of the
bit exhaust holes for traces of oil. Adjust lubricator suitably.
Page 7 of 12
DRILLING PROCEDURES:
a) Start Rotary head in counter clockwise direction and adjust the speed as per rock
conditions by throttling lever for rotation control.
b) Give full blow of air to the hammer.
c) Using slow feed - lower bit and hammer through the centralizer to the ground
level.
d) Adjust feed down pressure until bit just begins to cut.
e) After the hole has been collared, move the drill control to full on position and
increase the feed pressure.
CAUTION
IF THE ABOVE PROCEDURE IS NOT FOLLOWED DURING
COLLARING, BIT MAY DRIFT CAUSING DRILL ROD TO BIND ON
CENTRALISER BUSHING.
f) Keep drilling until the bottom of the first drill rod has passed through centralizer
bushing.
g) Stop rotary head rotation and feed, remove half bushing which are used for hole
collaring only and insert rod bush into the centralizer bushing.
h) Increase feed down pressure for maximum drilling efficiency. The Rotary head must
be adjusted to a slower speed that gives good penetration.
CAUTION
ROTARY HEAD SPEED SHOULD BE OPTIMUM FOR THE HAMMER
FOR MAXIMUM BIT LIFE. DO NOT JAM DRILL DOWN AGAINST
BOTTOM OF HOLE. SEVERE DAMAGE TO DRILL AND BIT MAY
RESULT. ALWAYS FEED DOWN PRESSURE SUITABLY SO AS TO
GET MAXIMUM PENETRATION RATE.
Page 8 of 12
DRILL ROD ADDITION PROCEDURE:
Always use centralizer for chuck and centralizer stops (Provided on mast) to lock the
rods when fastening or unfastening joints.
a) Continue to drill until the flats on top of the drill rod are just above the centralizer
bushing.
b) Stop rotation and blow air.
c) Put fork chuck in the flats of drill rod.
d) Slowly give reverse rotation to Rotary head and raise head very slightly.
e) Ensure that the joint is completely disengaged.
f) Raise rotary head clear of drill rod and apply graphite grease on spindle threads and
then raise the rotary head to the top of the drill guide.
g) Position another rod, in the rod changer, directly under the Rotary Head and the lock
the changer with pins.
h) Lower rotary head and guide the drill-rod-top into spindle chuck.
i) Press rotary head slightly and slowly start forward rotation until all the threads are
engaged.
j) Blow out air so that inside of drill rod is completely cleaned of dirt and rust.
k) Raise the rotary head and swing the rod changer out of the centralizer clear of drill
guide. (Lock the rod changer in the outward position). Lower the rotary head and
engage two rods by forward rotation of rotary head. Remove the centralizer fork chuck
from the lower rod and resume drilling once again as described earlier.
Page 9 of 12
Jupiter Rock Drills (P) Ltd.,
IMPORTANT POINTS FOR DRILLERS:
a) Maintain required air pressure at drill. Operating at lower pressures decreases

efficiency and contributes to shortened bit life.
b) Always note penetration rates of first few feet to determine if there is any reduction
in penetration rate. If the rate has slowed down and the nature of cuttings has not
changed due to variation in rock formation, take out drill and inspect for bit wear.
c) Always use full hole blowing to keep holes free of cutting.
d) Do not run a dull bit.
Following are the indications of a Dull Bit: -

a) Slower penetration rate.
b) Decrease in the volume of cuttings.
c) Binding.
d) Chattering or jerky rotation.
e) If a hole caves in, proceed with extreme care. When a ‘cave-in’ is suspected, keep the
drill running and immediately work it up and down the hole. Increase drill rotation if
necessary until drill is free and hole is blown free of cuttings.
f) Always raise from bottom of hole and blow drill clean before removing drill string.
g) Install thread protectors on rods and drill - when not in use.
h) Handle bits with care to prevent nicking, chipping or fracturing of carbide inserts. Bit
failures result from the following:
i) Improper handling.
ii) Bit running too dull before grinding.
iii) Rotation too fast.
iv) Bit used as a reamer.
Page 10 of 12
PREVENTIVE MAINTENANCE CHART for CD-360

Frequency
Semi-
CHECK Daily Weekly Monthly Quarterly Annually
annually
8 40 160 500 2000
1000
Hours Hours Hours Hours Hrs Hrs
Air Clean the unit. Inspect
feed and drive chain. Clean
the Traction unit.
Check the oil Level in the

lubricator.
Check the Oil in Hydraulic

reservoir. Fill if necessary
Grease all Fitting on the

Boom, Cylinders,Main
Frame, Drill Guide, Power
dump and Swing assembly
Apply Grease to Channel on

Drill Guide
Check the Feed Chain

Tension
Chain & Drive
Hydraulic Reservoir
Drain the Oil
Remove & Clean Suction

Filter
Flush Grit & Slush
Refill
Remove Return Line Filter,

Check and replace element
if necessary
Pressure Wash the Entire

Unit
Page 11 of 12
Frequency
Semi-
CHECK Daily Weekly Monthly Quarterly Annually
annually
8 40 160 500 2000
1000
Hours Hours Hours Hours Hrs Hrs
Clean and inspect Down

Hole Drill
Check Oil Level in Rotary

Head
Check Oil Level in Feed Unit
Check Tightness of Rotary

Head and Feed Gearbox
Fasteners
Check tightness of all other

Fasteners
Inspect Hydraulic and Air

Hoses and fitting
Clean the Feed Chain
Page 12 of 12
BARI BARI INTERNACIONAL SA DE CV
ROTATION GEARBOX FOR CRAWLER DRILL CD-360
PART NO: 9000-4100
ITEM DESCRIPTION QTY DRAWING NO. REMARK
1 Gearbox Body 1 9000-4101
2 Pinion Gear 1 9000-4102
3 Big Gear 1 9000-4103
4 Output Shaft 1 9000-4104
5 Key Output Shaft 2 9000-4105
6 Spacer 1 9000-4106
7 Bearing Cover Lower Output Shaft 1 9000-4107
8 Packing Bearing Cover Lower Output Shaft 1 9000-4108
9 Bearing Cover Upper Output Shaft 1 9000-4109
10 Packing Bearing Cover Upper Output Shaft 1 9000-4110
11 Cover Seal Output Shaft 1 9000-4111
12 Packing Cover Seal Output Shaft 1 9000-4112
13 Hub Air Seal 1 9000-4113
14 Packing Hub Air Seal 1 9000-4114
15 Cover Air Seal 1 9000-4115
16 Spacer Air Seal 1 9000-4116
17 Small Cover 1 9000-4117
18 Packing Small Cover 1 9000-4118
19 Adapator Hydraulic Motor 1 9000-4119
20 Packing Adapator Hydraulic Motor 1 9000-4120
21 Front Cover Gearbox 1 9000-4121
22 Packing Front Cover Gearbox 1 9000-4122
23 Motor Tube Adaptor 1 9000-4123
24 Key Hydraulic Motor 1 9000-4124
25 Hydraulic Motor 1 OMS 200
26 Taper Roller Bearing 2 33117
27 Ball Bearing 1 6211
29 Chevaron Packing (Air Seal) 1 60x80x35
30 Oil Seal 1 72X95X10
31 Oil Seal 2 85X110X13
32 O-Ring Hub Air Seal 1 O-Ring DIA3xID-90
33 Hex Head Screw 8+8 1/2"BSFx1-1/2"L
34 Spring Washer 8+8 DIA-1/2"
35 Allen Screw for Adaptor Hyd Motor 4 1/2"BSFx1-1/4"L
36 Spring Washer 4 DIA-1/2"
37 Allen Screw for Small Cover 6 5/16"x 1"L
39 Allen Screw for Cover Seal 8 5/16"x 1"L
41 Allen Screw for Hub Air Seal 8 5/16"x 1"L
43 Allen Screw for Cover Air Seal 6 5/16"x 1"L
45 Allen Screw for Front Cover Gr.Box 12 5/16"x 1"L
47 Oil Level Gauge 1 1/8" BSP Taper
48 Plug Inlet (oil) 1 1/2" BSP
49 Plug Outlet (oil) 1 1/2" BSP
OMS series 2 and
series 3
Orbital Motors
Service and Parts

Manual
OMS Orbital motor
Service and parts manual
Table of contens, Special versions
Special versions ...................................................................................................................... 3

CONTENTS
Cost-free repairs ..................................................................................................................... 3
Comments .............................................................................................................................. 3
Exploded view OMS series 2 ................................................................................................... 4
Exploded view OMS series 3 ................................................................................................... 5
Spare parts list ........................................................................................................................ 6
Special tools............................................................................................................................ 9
Dismantling ........................................................................................................................... 10
Tacho connection .................................................................................................................. 11
Assembling ........................................................................................................................... 12
© 2003 Sauer-Danfoss. All rights reserved. Printed in Europe

Sauer-Danfoss accepts no responsibility for possible errors in catalogs, brochures and other printed material.
Sauer-Danfoss reserves the right to alter its products without prior notice. This also applies to products
already ordered provided that such alterations aren’t in conflict with agreed specifications. All trademarks in
this material are properties of their respective owners. Sauer-Danfoss and the Sauer-Danfoss logotype are
trademarks of the Sauer-Danfoss Group.
Frontpage: P300083.TIF,
Drawing 151-19.fa
2 DKMH.PS.130.A1.02 • 520L0593 • Rev. A • 05/2003

OMS Orbital motor
Contents
SPECIAL VERSIONS The list of spare parts cannot be used when ordering parts for special OMS versions.
In this respect, please contact the sales organisation for Sauer-Danfoss.
COST-FREE REPAIRS We would point out that cost-free repairs as mentioned in Sauer-Danfoss General Condi-
tions of Sale, are carried out only at Sauer-Danfoss Nordborg or at service shops autho-
rised by Sauer-Danfoss.
COMMENTS a) Only OMS series 2:

After week 41.97 the guide pin has a new location. When repairing motors
manufacturing before week 41.97 it will therefore be necessary to replace end cover,
balance plate, tightening pin and spring washer.
SERIES MARKING
The series number is altering when parts in the motor are changed.
The OMS series marking follows its date marking: XXX-3
OMS SERIES 3
DKMH.PS.130.A1.02 • 520L0593 • Rev. A • 05/2003 3

OMS Orbital motor
Exploded view OMS series 2
EXPLODED VIEW OMS

SERIES 2
Tightening torque: t
Item 13, with item 14: 30 - 60 N.m [ 270 - 530 lbf.in]

Item 34: 75 - 80 N.m [660 - 705 lbf.in]
Item 38: 10 - 15 N.m [90 - 130 lbf.in]
Item 51: 4 - 6 N.m [35 - 55 lbf.in]
4 DKMH.PS.130.A1.02 • 520L0593 • Rev. A • 05/2003

OMS Orbital motor
Exploded view OMS series 3
EXPLODED VIEW OMS

SERIES 3
Tightening torque: t
Item 13, with item 14: 30 - 60 N.m [ 270 - 530 lbf.in]

Item 34: 75 - 80 N.m [660 - 705 lbf.in]
Item 38: 10 - 15 N.m [90 - 130 lbf.in]
Item 51: 4 - 6 N.m [35 - 55 lbf.in]
DKMH.PS.130.A1.02 • 520L0593 • Rev. A • 05/2003 5

OMS Orbital motor
Spare parts list
SPARE PARTS LIST Stock per 100 motors**

Number per motor
Item Spare parts
Series
Code No.
2 3
Dust seal ring 35 • 42 • 3.5 mm [1.38 • 1.65 • 0.14 in] 633B3198 1 1 *
1
(p.t.o. shaft) 40 • 47 • 4.0 mm [1.57 • 1.85 • 0.16 in] 633B3356 1 1 *
2 Bearing housing
OMS Standard flange 151F1534 1 1 2
OMS Standard flange and P.t.o. shaft 151F1549 1 1 2
OMS Special flange 151F1536 1 1 2
OMS A - 2 flange 151F1685 1 1 2
OMS Magneto flange 151F1858 1 1 2
OMS SAE B flange 151F1864 1 1 2
OMSW Metric 151F1535 1 1 2
OMSW SAE 151F1572 1 1 2
3 Shaft seal 35 • 52 • 5 mm [1.38 • 2,05 • 0.20 in] NBR 633B3197 1 1 *
35 • 52 • 5 mm [1.38 • 2,05 • 0.20 in] FPM 633B3196 1 1 *
P.t.o.shaft 40 • 60 • 6 mm [1.57 • 2.36 • 0.24 in] NBR 633B3355 1 1 *
4 Parallel key Metric: A 10 • 8 • 45 mm for 32 mm cyl. shaft 682L8019 1 1 5
Metric: B 6 • 6 • 20 mm for tap. shaft 682L8021 1 1 5
SAE: 5/16 • 5/16 • 1 1⁄4 in for 1 1⁄4 in cyl. and tapered shaft 151-4109 1 1 5
SAE: 1⁄4 • 1⁄4 • 1 1⁄4 in BS 46 for 1 in cylindrical shaft 682L8036 1 1 5
5 Cylindrical shaft Metric: Ø32 mm with bearings incl. item 4 151F0112 1 1 2
SAE Ø1 1⁄4 in with bearings incl. item 4 151F0118 1 1 2
SAE Ø1 in with bearings incl. item 4 151F0127 1 1 2
6 Splined shaft Metric: 1 1⁄4 in with bearings 151F0113 1 1 2
SAE: 1 1⁄4 in with bearings 151F0119 1 1 2
SAE: 1 in with bearings 151F0126 1 1 2
SAE: 0.875 in with bearings 151F0138 1 1 2
7 P.t.o. shaft incl. bearing, DIN 9611 151F0116 1 1 2
8 Washer metric version only 20.5 • 44 • 4 mm 684X2530 1 1 5
9 Castellated nut
Metric: M20 • 1.5 mm 681X8235 1 1 5
SAE: 1 - 20 UNEF 151-4154 1 1 5
10 Tapered shaft
Metric: 35 mm with bearings incl. item 4, (8) and 9 151F0114 1 1 2
SAE: 1 1⁄4 in with bearings incl. item 4 and 9 151F0115 1 1 2
11 Conical seal ring 633B9023 1 1 *
12 O-ring 70 • 2 mm [2.75 • 0.08] NBR 633B1379 1 1 *
13 Drain plug Metric: G 1⁄4 151-1524 1 1 10
SAE: 7/ - 20 UNF 151-5439 1 1 10
16
14 Washer 684X2120 1 1 10
15 Intermediate plate Metric: 151F1811 1 5
Metric: 151F1538 1 5
SAE: 151F1812 1 5
SAE: 151F1553 1 5
16 Mounting flange for OMSS
Metric: 151F1817 1 5
Metric: 151F1486 1 5
SAE: 151F1570 1 5
17 O-ring for OMSS 100 • 3 mm [3.94 • 0.12 in] NBR 151F1033 1 1 10
6 DKMH.PS.130.A1.02 • 520L0593 • Rev. A • 05/2003

OMS Orbital motor
Spare parts list
SPARE PARTS LIST Stock per 100 motors**

Number per motor
Item Spare parts
Series
Code No.
2 3
18 Cardan shaft
OMS/OMSW/OMSS 80 l = 70 mm [2.75 in] 151F1461 1 1 3
OMS/OMSW/OMSS 250 l = 99.5 mm [3.92 in] 151F1770 1 1 3
19 O-ring 82.5 • 2 mm [3.25 • 0.08 in] NBR 633B1431 2 3 *
20 Gearwheel set Series 3
OMS/OMSW/OMSS 80 w = 14 mm [0.55 in] 151F1081 1 5
OMS/OMSW/OMSS 315 w = 55 mm [2.16in] 151F1087 1 5
OMS/OMSW/OMSS 400 w = 68.4 mm [2.69 in] 151F1088 1 5
20 Gearwheel set Series 2
OMS/OMSW/OMSS 315 w = 55 mm [2.16in] 151F1042 1 5
21 Guide pin Ø 4 mm [0.16 in], l = 10 mm [0.39 in] DIN 6325 682L2006 1 5
22 Valve drive 151F1448 1 1 5
151F1821 1 3
23 Channel plate
151F1023 1 3
24 Stop ring (OMSS 200, 250, 315 and 400 only) 151F1542 1 1 3
25 Disc valve 151F1022 1 1 3
26 Balance plate a) 151F1738 1 1 3
27 Guide pin Ø 5 mm [0.20 in], l = 14 mm [0.55 in] ISO 8752 a) 682L9105 1 1 5
28 O-ring 45 • 2 mm [1.77 • 0.08] NBR 633B1429 1 1 *
45 • 2 mm [1.77 • 0.08] FPM 633B1455 1 1 *
29 O-ring 24 • 2 mm [0.94 • 0.08] NBR 633B1428 1 1 *
24 • 2 mm [0.94 • 0.08] FPM 633B1453 1 1 *
30 Spacer 155F1449 1 1 2
31 Spring washer a) 684X0097 1 1 5
32 Valve housing Metric: 151F1801 1 2
Metric: a) 151F1445 1 2
SAE: 151F1805 1 2
a) see comments page 3 SAE: a) 151F1552 1 2
DKMH.PS.130.A1.02 • 520L0593 • Rev. A • 05/2003 7

OMS Orbital motor
Spare parts list
Stock per 100 motors**

Number per motor
Item Spare parts
Series
Code No.
2 3
33 Seal plug 633X0017 2 2 20
34 Screw M10: OMS/OMSW 80 l = 120 mm [4.72 in] 681X1349 4 4 12
OMS/OMSW 100, 125 l = 130 mm [5.12 in] 681X1350 4 4 12
OMS/OMSW 160, 200 l = 140 mm [5.51 in] 681X1352 4 4 12
OMS/OMSW 250 l = 150 mm [5.91 in] 681X1353 4 4 12
OMS/OMSW 315 l = 160 mm [6.30 in] 681X1356 4 4 12
OMS/OMSW 400, 500 l = 180 mm [7.09 in] 681X0038 4 4 12
OMSS 80, 100 l = 100 mm [3.94 in] 681X1347 4 4 12
OMSS 125, 160 l = 110 mm [4.33 in] 681X1348 4 4 12
OMSS 200 l = 120 mm [4.72 in] 681X1349 4 4 12
OMSS 250 l = 130 mm [5.12 in] 681X1350 4 4 12
OMSS 315 l = 140 mm [5.52 in] 681X1352 4 4 12
OMSS 400 l = 150 mm [5.91 in] 681X1353 4 4 12
35 Check valve ball Ø3/16in 689X1005 2 10
Ø1⁄4 in 689X1015 2 10
36 Check valve spring 013-0662 2 10
37 Washer 10.2 • 13.5 • 7 mm [0.40 • 0.53 • 0.27 in] 684X2564 2 10
38 Check valve plug G 1/8 631X2053 2 10
Name plate: Aluminium OMS, OMSW, OMSS 151A0407 1 1 15
39
Brass OMS, OMSW, OMSS 151A0408 1 1 15
43 Tacho valve housing, complete 151F0137 1 2
a) 151F0100 1 2
44 Tacho connection, complete 151F1031 1 1 3
45 Tacho valve drive + guide pin 151F1032 1 1 2
46 Spacer ring 151F1502 1 1 2
47 Tacho valve housing 151F1802 1 1
a) 151F1498 1 1
48 O-ring 40 • 2 mm [1.57 • 0.08 in] 633B1378 1 1 4
49 Bearing housing 151F1499 1 1 1
50 Washer 5.6 • 8.5 • 1 mm [0.22 • 0.33 • 0.04 in] 684X2012 4 4 20
51 Screw M5; l = 15 mm [0.59 in] 681X1880 4 4 16
52 Tacho drive shaft 151F1500 1 1 1
53 Lockin ring UR 6 • 0.7 mm [0.24 • 0.03 in] DIN 6799 682L4922 2 2 4
54 Bearing 8 • 22 • 7 mm [0.31 • 0.87 • 0.28 in] 981X1020 1 1 2
55 Shaft seal 633B3175 1 1 2
56 Locking ring N 22 • 1 mm [0.87 • 0.04 in] DIN 427 682L4008 1 1 2
57 Name plate (Tacho) 151A0410 1 1 4
A Set of seals NBR OMS, OMSW item 1, 3, 11, 12, 19, 28 and 29 151F0111 1 1 10
OMS (p.t.o.) item 1, 3, 11, 12, 19, 28 and 29 151F0117 1 1 10
B Set of seals NBR OMS, OMSW, OMSS item 11, 17, 19, 28 and 29 151F0103 1 1 10
C Set of seals FPM OMS, OMSW, OMSS item 1, 3, 28 and 29 151F0109 1 1 10
D Set of seals NBR OMSS item 11 and 17 151F1033 1 1 10
NBR: Buna N, Perbunan (ISO 1629) FPM: Viton (ISO 1629)
* Contained in spare parts bag A, B, C or D

** The number of spare parts to be held in stock for each 100 motors being in service in your district.
a) see comments page 3
8 DKMH.PS.130.A1.02 • 520L0593 • Rev. A • 05/2003

OMS Orbital motor
Special tools
SPECIAL TOOLS A B C
E F
A. Main holding tool SJ 151-9000-1

B: Holding tool for OMSS SJ 151F9000-1
C : Holding tool for OMSW. Code number: SJ 151B9000-1
D: Mandrel dor fitting shaft seal.
E.: Two guide bolts
F : Mandrel to remove balance plate
D, E and F cannot be bought from Sauer-Danfoss
DKMH.PS.130.A1.02 • 520L0593 • Rev. A • 05/2003 9

OMS Orbital motor
Dismantling
Item Part to remove Comments

DISMANTLING
4 Parallel key Cylindrical or tapered shafts
* 11 Conical seal ring
13, 14 Drain plug and washer
33 Seal plugs (2off) Place the motor in holding tool.
38 Plugs (2 off) Series 2 only Use I 5 mm Allan head spanner
37 Washer (2 off) Series 2 only
36 Springs (2 off) Series 2 only
Tilt motor, springs and balls come out.
35 Ball (2 off) Series 2 only
34 Screw (4 off) Use 17 mm socket spanner.
32 Valve housing Lift off carefully as a unit, holding your fingers
under the channel plate (Item no. 23).
23 Channel plate
19 O-ring Series 3 (2 off ), Series 2 (1off)
24 Stop ring Only on OMSS 200, 250, 315 and 400
25 Disc valve
30 Spacer
26 Balance plate Fill in oil into the spacer hole and use the
ø14.25 mm [0.56 in] mandrel as a piston to press
up the balance plate.
27 Guide pin
28 O-ring
29 O-ring
31 Spring washer
22 Valve drive
21 Guide pin Series 2 only
20 Gearwheel set Hold fingers under the gearwheel set to prevent
the parts from dropping out.
19 O-ring
18 Cardan shaft
15 Intermediate plate
11 Conical seal ring Not on OMSS, is already removed.
12 O-ring
5, 6, Shaft incl. bearings Turn the bearing housing.
7, 10 * *) Press out the shaft/bearing assembly using a
hydraulic press (pressing Force max. 2500 N
[550 lbf ])
Shaft/bearing assembly should not be dismantled.
1**) Dust seal ring

Item no. 1 and 3 to be knocked out by means af
3 **) Shaft seal the special mandrel (“D” on page 9).
* OMSS only
**) OMSS except
10 DKMH.PS.130.A1.02 • 520L0593 • Rev. A • 05/2003

OMS Orbital motor
Dismantling
TACHO CONNECTION
Item Part to remove Comments
51 Screw (4 off)
44 Tacho connection Remove from tacho valve housing
48 O-ring
46 Spacer ring
56 Retaining ring Loosen tacho shaft package (by tapping lightly at
the end of the shaft) and extract the package
from tacho housing.
55 Shaft seal
53 Retaining ring (2 off)
54 Bearing
After dismantling, clean all parts in low aromatic kerosene.

Examine the parts and exchange them if necessary.
Immidiately before assembly, lubricate each part with hydraulic oil and grease rubber
parts with vaseline
DKMH.PS.130.A1.02 • 520L0593 • Rev. A • 05/2003 11

OMS Orbital motor
Assembling
ASSEMBLING Item Part to assemble Comments

3 *) Shaft seal Knock into position in the bearing housing, using
the assembly mandrel. Grease lip with vaseline.
1*) Dust seal ring Use assembly mandrel and plastic hammer.
Grease lip with vaseline.
5, 6, Shaft incl. bearings Use the hydraulic press. (max. 2500 N [550 lbf ])
7, 10 *)
Always press on the bearing outer ring.
15, 12, Intermediate plate, O-ring, conical seal ring Screw the guide bolts into the bearing housing.
11 Fit the O-ring into the bearing housing.
Fit the conical seal ring (biggest diameter facing
the intermediate plate) int the recess in the
intermediate plate. Place the intermediate plate in
position on the bearing housing with the conical
seal ring downwards.
18 Cardan shaft Guide the cardan shaft down into the output shaft
so that the splines engage.
19 O-ring Grease with vaseline.
20, 21 Gearwheel set Hold fingers under the gearwheel set to prevent
parts falling out. Carefully lay the gearwheel set
on the intermediate plate so that the O-ring
groove (OMS series 3) or guide pin hole (OMS
series 2) is upwards.
The through-hole (6 mm [0.24 in]) must line up
with the hole in the intermediate plate. Fit the
guide pin (OMS series 2 only) in the gear rim.
Mark the wheel of the gearwheel set at the point
where the bottom of an internal tooth is opposite
the bottom of an external tooth (see drawing).
22 Valve drive Mark the tip of a spline tooth on the end of the
valve drive with the widest splines. Line up mark
on rotor and valve drive. The end with the widest
splines must point upwards.
Applies to motors with tacho connection:

Pin on valve drive must point upwards.
19 O-ring OMS series 3: 2 off Grease with vaseline. Mount in the gearwheel
OMS series 2: 1 off (only OMS serie 3) and channel plate groove.
12 DKMH.PS.130.A1.02 • 520L0593 • Rev. A • 05/2003

OMS Orbital motor
Assembling
ASSEMBLING Item Part to assemble Comments

23 Channel plate (OMS series 3) Fit the channel plate so that the O-ring groove is
upwards and the check valve holes line up with
the through-hole in the gearwheel set.
Channel plate (OMS series 2) Fit the channel plate so that the guide pin engages
with the hole in the channel plate.
25 Disc valve Align mark on valve drive with a hole in the outer
rim. (A on drawing).
Turn disc valve counter clockwise until splines in
the two parts engage.
31 Spring washer Place into valve housing
28, 29 O-ring Fit the two O-rings (greased with vaseline) in the
balance plate grooves.
27 Guide pin Mount in valve housing.
26 Balance plate Mount in valve housing.
30 Spacer Grease with vaseline to prevent the spacer from
dropping out.
32 Valve housing Mount unit on the rest of the motor. Ports should
face in the same direction as the drain port.
34 Screw (4 off) Lubricate threads and cross tighten screws to
75 - 80 N.m [660 - 705 lbf.in].
36 Spring (2 off) Series 2 only
37 Washer (2 off) Series 2 only
38 Plug (2 off) Series 2 only Tighten to 10 - 15 N.m [90 - 130 lbf.in]
4 Parallel key Secure with plastic ring or tape.
13, 14 Drain plug and washer Fill motor with oil before plugging.
Tighten to 30 - 60 N.m [270 - 530 lbf.in].
11*) Conical seal ring Grease with vaseline to keep in place
*) OMSS only
ASSEMBLING OF TACHO
The tacho connection must be reassembled in reverse order in relation to the procedure
CONNECTION
described under “disassembling the tache connection”.
4 screws (pos. 51) to be tightened to 4 - 6 N.m [35.5 - 53 lbf.in].
DKMH.PS.130.A1.02 • 520L0593 • Rev. A • 05/2003 13

OMS Orbital motor
Notes
14 DKMH.PS.130.A1.02 • 520L0593 • Rev. A • 05/2003

OMS Orbital motor
Notes
DKMH.PS.130.A1.02 • 520L0593 • Rev. A • 05/2003 15

OUR PRODUCTS Sauer-Danfoss Mobile Power and Control Systems
– Market Leaders Worldwide
Hydrostatic transmissions
Sauer-Danfoss is a comprehensive supplier providing complete
Hydraulic power steering
systems to the global mobile market.
Electric power steering
Sauer-Danfoss serves markets such as agriculture, construction, road
Electrohydraulic power steering
building, material handling, municipal, forestry, turf care, and many
Closed and open circuit axial piston others.
pumps and motors
Gear pumps and motors We offer our customers optimum solutions for their needs and
develop new products and systems in close cooperation and
Bent axis motors partnership with them.
Orbital motors
Sauer-Danfoss specializes in integrating a full range of system
Transit mixer drives components to provide vehicle designers with the most advanced
Planetary compact gears total system design.
Proportional valves Sauer-Danfoss provides comprehensive worldwide service for its

Directional spool valves products through an extensive network of Authorized Service
Centers strategically located in all parts of the world.
Cartridge valves
Hydraulic integrated circuits
Hydrostatic transaxles
Integrated systems
Fan drive systems
Electrohydraulics
Microcontrollers and software
Electric motors and inverters Sauer-Danfoss (US) Company
2800 East 13th Street
Digital electronics and software
Ames, IA 50010, USA
Joysticks and control handles Phone: +1 515 239-6000, Fax: +1 515 239 6618
Displays
Sauer-Danfoss (Neumünster) GmbH & Co. OHG
Sensors Postfach 2460, D-24531 Neumünster
Krokamp 35, D-24539 Neumünster, Germany
Phone: +49 4321 871-0, Fax: +49 4321 871 122
Sauer-Danfoss (Nordborg) A/S

DK-6430 Nordborg, Denmark
Phone: +45 7488 4444, Fax: +45 7488 4400
DKMH.PS.130.A1.02 • 520L0593 • Rev. A • 05/2003
www.sauer-danfoss.com
ADAPTOR ASSEMBLY ROTATION & FEED MOTOR FOR CRAWLER DRILL CD-360
PART NO: 9000-4300
1 Adaptor Hydraulic Motor Rotation Unit 1 9000-4301
2 Shaft Adaptor Hydraulic Motor Rot. Unit 1 9000-4302
3 Spacer (Big) for Brg.6010 1 9000-4303
4 Spacer (small) for Brg.6306 1 9000-4304
5 Hydraulic Motor Feed 1 OMP-32
6 Key Hydraulic Motor Feed 1 9000-4305
7 O-Ring 1 DIA2.0xID 82.5mm
10 Circlip (Ext.) 1 DIA 30mm
11 Circlip (Ext.) 1 DIA 50mm
12 Allen Screw 2 1/2" BSF,L=35mm
13 Spring Washer 2 DIA 13.5mm

OMP, OMP C,
OMPW, and
OMPW N
series 7 and 8
Repair Instructions
Orbital Motors OMP, OMP C, and OMPW/N series 7 and 8
Repair Instructions
Table of contents
Revision view Date Page Changed Revision

29 Jun, 2006 all Changed from Danfoss to Sauer Danfoss lay out AA
SAFETY Always consider safety precautions before beginning a service procedure. Protect your-
PRECAUTIONS self and others from injury. Take the following general precautions whenever servicing a
hydraulic system.
Unintended machine movement

Warning
Unintended movement of the machine or mechanism may cause injury to the technican
or bystanders. To protect against uintended movement, secure the machine or disable /
disconnect the mechanism while servicing.
Flammable cleaning solvents

Warning
Some cleaning solvents are flammable. To avoid possible fire, do not use cleaning
solvents in an area where a source of ignition may be present.
Fluid under pressure

Warning
Escaping hydraulic fluid under pressure can have sufficient force to penetrate your skin
causing serious injury and/or infection. This fluid may also be hot enough to cause burns.
Use caution when dealing with hydraulic fluid under pressure. Relieve pressure in the
system before removing hoses, fittings, gauges, or components. Never use your hand
or any other body part to check for leaks in a pressurized line. Seek medical attention
immediately if you are cut by hydraulic fluid.
Personal safety
Warning
Protect yourself from injury. Use proper safety equipment, including safety glasses, at all
times.
Revision view .............................................................................................................2

CONTENTS Safety precautions .....................................................................................................2
Contents.....................................................................................................................2
Special versions .........................................................................................................3
Cost-free repairs ........................................................................................................3
Exploded view OMP, metric version series 8 with integrated spigot flange ...................4
Exploded view for OMP/OMP C metric version, series 7 with separate spigot flange .....5
Exploded view for OMP W, metric version series 7 .....................................................6
Spare part list .............................................................................................................7
Tightening torque .................................................................................................... 11
Tools and dismantling .............................................................................................. 12
Cleaning .................................................................................................................. 13
Assembly ................................................................................................................ 14
© 2006 Sauer-Danfoss. All rights reserved.
Sauer-Danfoss accepts no responsibility for possible errors in catalogs, brochures and other printed material. Sauer-Danfoss
reserves the right to alter its products without prior notice. This also applies to products already ordered provided that such
alterations aren’t in conflict with agreed specifications. All trademarks in this material are properties of their respective owners.
Frontpage: F301213.TIF, F301228 Drawing 151-1837.eps
2 11012811 • Rev A • Okt 2006

Orbital Motors OMP, OMPC, and OMPW/N series 7 and 8
Repair Instructions
Special Versions and Cost-free Repairs
sPeCial veRsions The list of spare parts cannot be used when ordering parts for special OMP versions.
In this respect, please contact the sales organisation for Sauer-Danfoss.
Cost-fRee RePaiRs We would point out that cost-free repairs as mentioned in Sauer-Danfoss General
Conditions of Sale, are carried out only at Sauer-Danfoss Nordborg or at service shops
authorised by Sauer-Danfoss.
oMP seRies 7
Output shaft
with spool valve
Cardan shaft
Output shaft
oMP seRies 8 with spool valve
Cardan shaft
11012811 • Rev A • Okt 2006 3

Repair Instructions
OMP metric version, series 8 with integrated spigot flange
EXPLODED VIEW OMP,
METRIC VERSION
SERIES 8 WITH
INTEGRATED SPIGOT
FLANGE
4 11012811 • Rev A • Okt 2006

Repair Instructions
OMP/OMP C metric version, series 7 with separate spigot flange
EXPLODED VIEW OMP

AND OMP C,
METRIC VERSION
SERIES 7 WITH
SEPARATE SPIGOT FLANGE
11012811 • Rev A • Okt 2006 5

Repair Instructions
OMP W and OMPW N metric version, series 7
EXPLODED VIEW
FOR OMP W, METRIC
VERSION SERIES 7
6 11012811 • Rev A • Okt 2006

Repair Instructions
Spare part list
number per motor

series series 7 with separate spigot flange
8*
oMP oMP oMP C oMP oMP oMPw
item spare Part Dimensions Code no. flange flange flange flange flange oMPw n
a2 a2 a2 a4 C
M6: L = 16 681X1989 6 6 6
1 Screw M5: L = 16 681X1961 6
M6: L = 16 681X0247 6
Dust seal ring
ø25 mm, ø1”,1” spl. shaft (HPS) 35.0 • 27.5 • 2.2 mm 633B0370 1
3
ø28.5 mm tapered shaft 28.56 • 35.0 • 4.0 mm 151-1313 1 1 1 1
ø25 mm shaft 35.0 • 28.5 • 4.0 mm 633B0010 1
ø32 mm shaft 42.0 • 35.0 • 3.5 mm 633B3198 1
Spigot flange
ø25 mm, ø1”,1” spl. shaft (HPS) 151-5588 1 1
ø25 mm, ø1”, 1” spl. shaft 151-5458 1 1
ø25 mm shaft 151-5473 1
4 ø25 mm shaft 151-1827 1
ø25 mm
35 mm tapered shaft 151-1978 1
ø32 mm shaft, (HPS) 151-5589 1
ø32 mm shaft 151-1734 1
Shaft seal
ø25 mm, ø1”,1” spl. shaft (HPS) 39.0 • 28.6 • 4.9 mm, HSN 633B0361 1 1 1
ø25 mm, ø1”, 1” spl.
42.0 • 28.6 • 5.5 mm, NBR 633B3385 1 1 1 1
28.5 mm tapered shaft
5
ø25 mm, ø1”, 1” spl. shaft
42.0 • 28.6 • 5.5 mm, FPM 633B0323 1 1 1 1
ø32 mm shaft, (HPS) 46.0 • 35.0 • 4.6 mm 633B0363 1 1
ø32 mm shaft 48.0 • 35.0 • 5.5 mm 633B3273 1 1 1
O-ring
ø25 mm, ø1”, 1” spl. 1
47.2 •3.5 mm, NBR 633B1191 1 1 1
6 28.5 mm tapered shaft
ø25 mm 48.0 • 2.0 mm, NBR 633B1333 1
ø32 mm shaft 53.0 • 2.0 mm, NBR 633B1528 1
Bearing race
ø25 mm, ø1”, 1” spl. shaft 41.6 •29.0 • 4.0 mm 151-5708 1
7 ø25 mm, ø1”, 1” spl. shaft 47.5 • 29.5 • 3.0 mm 151-1608 1 1 1 1 1
28.5 mm tapered shaft 47.5 • 29.5 • 2.4 mm 151-1931 1
ø32 mm shaft 52.0 • 35.0 • 3.5 mm 981X0095 1
Axial needle bearing
ø25 mm, ø1”, 1” spl. shaft 42.0 • 28.7 • 4.5 mm 151-5709 1
8 ø25 mm, ø1”, 1” spl. shaft 151-1458 1 1 1 1 1
28.5 mm tapered shaft 981X0008 1
ø32 mm shaft 981X3198 1
NBR: (Buna N, Perbunan) FPM: Viton (ISO 1629) HPS: High pressure shaft seal *Series 8 wih integrated spigot flange
11012811 • Rev A • Okt 2006 7

Repair Instructions
Spare part list
number per motor

series series 7 with separate spigot flange
8*
item spare Part Dimensions Code no. flange flange flange flange flange oMPw n
a2 a2 a2 a4 C
Bearing race
9 ø28.5 mm tapered shaft 44.5 • 28.6 • 1.6 mm 151-1940 1
32 mm shaft 52.0 • 35.0 • 3.5 mm 981X0095 1
Castellated nut
10 M20 • 1.5 681X8202 1
11 Washer
44.0 •20.5 • 4.0 mm 684X2530 1
for 28.5 mm tapered shaft
Parallel key
for ø25 mm shaft A8 • 7 • 32 mm, DIN6885 682L8035 1 1 1 1 1
for ø25 mm shaft A8 • 7 • 31 mm 682L9007 1
12 1
for ø1” shaft ¼ • ¼ • 1¼ in, B.S.46 682L8036 1 1 1
for ø32 mm shaft A10 • 8 • 45 mm, DIN6885 682L8019 1
for ø28.5 mm tapered shaft B5 • 5 • 14 mm, DIN6885 682L8016 1
13 Housing + output shaft
Cardan shaft
OMP 25 L = 73.8 mm 151-2690 1
OMP 25 L = 91.2 mm 151-5461 1 1
OMP 32 L = 74.9 mm 151-2691 1
OMP 32 L = 92.3 mm 151-5460 1
OMP 40 L = 76.8 mm 151-2643 1
OMP40 L = 94.0 mm 151-1787 1
OMP 50 L = 94.0 mm 151-1787 1 1 1 1
OMP 50 L = 76.8 mm 151-2643 1 1
OMP 80 L = 98.0 mm 151-1788 1 1 1 1
OMP 80 L = 80.7 mm 151-2644 1 1
OMP 100 L = 100.5 mm 151-1789 1 1 1 1
14 OMP 100 L = 83.3 mm 151-2645 1 1
OMP 125 L = 100.5 mm 151-1789 1 1 1 1
OMP 125 L = 87.1 mm 151-2646 1 1
OMP 160 L = 108.5 mm 151-1790 1 1 1 1
OMP 160 L = 91.2 mm 151-2647 1 1
OMP 200 L = 113.5 mm 151-1791 1 1 1 1
OMP 200 L = 96.4 mm 151-2648 1 1
OMP 250 L = 120.0 mm 151-1861 1 1 1 1
OMP 250 L = 102.9 mm 151-2649 1 1
OMP 315 L = 128.5 mm 151-1792 1 1 1 1
OMP 315 L = 111.4 mm 151-2650 1 1
OMP 400 L = 139.5 mm 151-1793 1 1 1 1
OMP 400 L = 122.6 mm 151-2651 1 1
16 O-ring 75.9 • 1.8 mm, NBR 633B1173 3 3 3 3 3 3
17 Distributor plate 151-1713 1 1 1 1 1 1
8 11012811 • Rev A • Okt 2006

Repair Instructions
Spare part list
number per motor

series 8* series 7 with separate spigot flange
item spare Part Dimensions Code no. flange flange flange flange flange oMPw
a2 a2 a2 a4 C n
Gear wheel set
OMP 25 W = 4.1 mm 151-1180 1 1 1
OMP 32 W = 5.2 mm 151-1181 1 1
OMP 40 W = 6.5 mm 151-1188 1 1
OMP 50 W = 6.5 mm 151-1126 1 1 1 1 1 1
OMP 80 W = 10.4 mm 151-1127 1 1 1 1 1 1
18 OMP 100 W = 13.0 mm 151-1128 1 1 1 1 1 1
OMP 125 W = 16.3 mm 151-1112 1 1 1 1 1 1
OMP 160 W = 20.8 mm 151-1129 1 1 1 1 1 1
OMP 200 W = 26.0 mm 151-1185 1 1 1 1 1 1
OMP 250 W = 32.5 mm 151-1193 1 1 1 1 1 1
OMP 315 W = 40.9 mm 151-1186 1 1 1 1 1 1
OMP 400 W = 52.0 mm 151-1187 1 1 1 1 1 1
End cover
Side port without drain 150-0328 1 1 1
19
Side port motor 151-1459 1 1 1 1
End port motor 151-1832 1 1
Washer
20 Side port motor 15.2 • 8.2 • 1.0 mm 684X0115 7 7 7 7 7
End port motor 15.2 • 8.2 • 1.0 mm 684X0115 5 5
Screw
Side port motor M8 • 1.25
OMP 25 l = 30 mm 681X0238 7 7 7
OMP 32 l = 30 mm 681X0238 7 7
OMP 40 l = 35 mm 681X0179 7 7
OMP 50 l = 35 mm 681X0179 7 7 7 7 7
OMP 80 l = 40 mm 681X0180 7 7 7 7 7
OMP 100 l = 40 mm 681X0180 7 7 7 7 7
OMP 125 l = 45 mm 681X0181 7 7 7 7 7
OMP 160 l = 50 mm 681X0182 7 7 7 7 7
OMP 200 l = 55 mm 681X0183 7 7 7 7 7
OMP 250 l = 60 mm 681X0184 7 7 7 7 7
21 OMP 315 l = 70 mm 681X0186 7 7 7
OMP 400 l = 80 mm 681X0188 7 7 7
End port motor M8 • 1.25

OMP 50 l = 40 mm 681X0180 5 5
OMP 80 l = 45 mm 681X0181 5 5
OMP 100 l = 45 mm 681X0181 5 5
OMP 125 l = 50 mm 681X0182 5 5
OMP 160 l = 55 mm 681X0183 5 5
OMP 200 l = 60 mm 681X0184 5 5
OMP 250 l = 65 mm 681X0185 5 5
OMP 315 l = 75 mm 681X0187 5 5
OMP 400 l = 85 mm 681X0189 5 5
11012811 • Rev A • Okt 2006 9

Repair Instructions
Spare part list
number per motor

series 8* series 7 with separate spigot flange
item spare Part Dimensions Code no. flange flange flange flange flange oMPw
a2 a2 a2 a4 C n
Name plate
Side port motor-aluminium 151A0411 1 1 1 1
22
Side port motor-brass 151A0412 1 1 1
End port motor-aluminium 151A0417 1 1
24 Washer 17.5 • 13.5 • 1.5 mm 684X2120 1 1 1 1 1
25 Drain plug 151-1524 1 1 1 1 1
26 Check valve incl. item 27 151-1076 2 2 2 2 2
Only for OMP motors with
built-in check valves
27 O-ring 5.0 • 1.5 mm, NBR 633B1324 4 4 4 4 4
Plug
Side port motor-plastic plug 633X0074 2 2 2 2 2
28
End port motor-steel plug 631X9706 2 2
End port motor-plastic plug 633X0074 2 2
Spare parts bag for motors
with HPS and ø25 mm, ø1”, 1” 151-1286 1
spl.shaft (Series 8)
3 1 pcs. Dust seal 35 • 27.5 • 2.2 mm NBR 633B0370

5 1 pcs. shaft seal (series 8) 39 • 28.6 • 4.9 mm HSN 633B0361
16 3 pcs. O-ring 75.9 • 1.8 mm NBR 633B1173
16 3 pcs. O-ring 90 • 2.0 mm NBR 633B1301
20 7 pcs. Washer 11.9 • 8.2 • 1 mm 684X0115
24 1 pcs. Washer 17.5 • 13.5 • 1.5 mm 684X2120
Spare parts bag for motors
with standard shaft seal and 151-1275 1 1** 1 1 1
ø25 mm, ø1”, 1” spl.shaft
3 1 pcs. Dust seal 35 • 28.5 • 4.0 mm NBR 151-1313
5 1 pcs. Shaft seal (series 7) 42 • 28.6 • 5.5 mm NBR 633B3385
6 1 pcs. O-ring 47.2 • 3.5 mm NBR 633B1191
6 1 pcs. O-ring 48 • 2.0 mm NBR 633B1333
16 3 pcs. O-ring 75.9 • 1.8 mm NBR 633B1173
20 7 pcs. Washer 11.9 • 8.2 • 1 mm 684X0115
24 1 pcs. Washer 17.5 • 13.5 • 1.5 mm 684X2120
Spare parts bag for motors 1 1 1
ø32 and 35 mm tapered shaft 151-1179
(Series 6/7)
3 1 pcs. Dust seal 42 • 35 • 3.5 mm NBR 633B3198

5 1 pcs. Shaft seal 48 • 3.5 • 5.5 mm NBR 633B3273
6 1 pcs. O-ring 53 • 2.0 mm NBR 633B1528
16 3 pcs. O-ring 75.9 • 1.8 mm NBR 633B1173
20 7 pcs. Washer 11.9 • 8.2 • 1 mm 684X0115
24 1 pcs. Washer 17.5 • 13.5 • 1.5 mm 684X2120
NBR: (Buna N, Perbunan) FPM: Viton (ISO 1629) HPS: High pressure shaft seal *Series 8 wih integrated spigot flange **Excl.dust seal ring 633B0010
10 11012811 • Rev A • Okt 2006

Repair Instructions
Spare part list
TIGHTENING TORQUE item Code number torque n•m torque [lbf•in]

681X1989 5-8 [45 - 70]
1 681X0247 5-8 [45 - 70]
681X1961 5 - 10 [45 - 88]
10 681X8202 90 - 110 [800 - 975]
21 - 30 - 35 [270 - 315]
25 - 38 - 44 [335 - 390]
28 631X9706 20 - 23 [180 - 200]
11012811 • Rev A • Okt 2006 11

Repair Instructions
Special tools
SPECIAL TOOLS
F300131
SJ 151-9000-12.
Fork. For use when fitting OMP

cardan shaft.
Code No.: SJ 151-9000-3.
Main holding tool (horse hole):

Code No.: SJ 151-9000-1.
P300129
SJ 151-9000-14.
Holding tool for motor with

square mounting flange:
Code No.: SJ 151-9000-12.
Holding tool for OMPW N.

Code No.: SJ 151-9000-14.
Mandrel: Mandrel:
Code No.: SJ 151-0414 Code No.:
SJ 151-9000-7 or
SJ 151F9000-7
DISMANTLING item Part to remove Comments

10 Castellated nut
11 Washer
12 Parallel key
Put the motor in a holding tool, with the output shaft downward.
28 Seal plugs
For end port version use 10 mm hexagon socket spanner.
25, 24 Drain plug, washer
Use a 17 mm spanner socket.
(if present)
21, 20 Screws, washers Use a 13 mm spanner socket.
19 End cover Remove end cover sideways.
18, 16 Gear wheel set O-rings Keep fingers under the gearwheel set to prevent the parts from falling
(2 off) out.
14 Cardan shaft
17, 16 Distributor plate O-ring
12 11012811 • Rev A • Okt 2006

Repair Instructions
Dismantling / Cleaning
DISMANTLING item Part to remove Comments

(CONTINUED)
13 Output shaft Motors with integrated spigot flange:
Place the motor housing on the work bench and press the shaft out of the
motor housing.
Shaft and bearings should normally not be removed from OMPW N.
However, if necessary for inspection and cleaning, remove the shaft from
the housing by gently tapping the axle journal with a plastic hammer. The
front bearing can thus remain in the housing.
After this, turn the motor.
1 Screws (6 off) Use Torx-spanner type T30, 9 mm screwdriver or 4 mm hexagon socket
spanner.
2 Washer Only OMPW N
4 Spigot flange
6, 7 O-ring, Motors with integrated spigot flange:
bearing race Remove bearing and bearing race from the motor housing.
Motors with separate spigot flange:

Use a 2 mm screwdriver
8 Needle bearing
5 Shaft seal Motors with integrated spigot flange:
3 Dust seal With mandrel and plastic hammer, carefully knock out the shaft seal.

Knock out the shaft seal / dust seal with a plastic hammer.
Use mandrel SJ 151-9000-7 or SJ 151F9000-7
9 Bearing race Only OMP/OMPW N with ø32 mm/28.5 mm tapered shaft.
Use a 2 mm screwdriver.
26 Check valves (2 off) Only OMP with check valves.
Pull the check valve out with, for example, a ground (shortened) 3.5 mm
screw tap.
CLEANING Cleaning
Clean all parts carefully with low aromatic kerosine.
Inspection and replacement

Check all parts carefully and replace if necessary.
Lubrication
Before assembly, lubricate all parts with hydraulic oil and grease rubber parts with
vaseline.
11012811 • Rev A • Okt 2006 13

Repair Instructions
Assembly
ASSEMBLY item Part to install Comments

Place the motor housing in the holding tool with the flange upwards.
26 Check valves (2 off) Only OMP with check valves
Grease the check valves (fitted with new O-rings) and fit them in their
bores with light blows using plastic hammer.
9 Bearing race Only OMP/OMPW N with ø32 mm / 28.5 mm tapered shaft.
5 Shaft seal Motors with integrated spigot flange:
Lubricate the shaft seal on the outside with hydraulic oil. Fit the shaft seal
correctly onto mandrel SJ 151-0414 and carefully press the shaft seal into
position in the motor housing.

Knock the seal into position in the spigot flange. Check that the seal lies
against the cover recess. Use mandrel SJ 151-9000-7 or SJ 151F9000-7
3 Dust seal ring Place the dust seal ring in the spigot flange and knock it into position with
a plastic hammer and appropriate mandrel.
SJ 151-9000-7 or SJ 151F9000-7
7,6 Bearing race Motors with integrated spigot flange:
O-ring Fit bearing and bearing race onto the shaft and mount together with the
shaft.

Grease the O-ring with vaseline and fit the bearing race and O-ring into the
spigot flange.
8 Needle bearing
4 Spigot flange Turn so that the holes line up.
2 Washer Only OMPW N
Tightening torque
Torx screws M6: 5-8 Nm [45-70 lbf• in]
Slotted screws M6: 5-8 N•m [45-70 lbf •in]
1 Screws (6 off) Hexagon socket screws M5: 5-10 N•m [45-70 lbf• in]
Hexagon socket screws M5: 12-15 N•m [45-70 lbf •in]
After this, turn the motor.
13 Output shaft Grease the journals with hydraulic oil.

The rear shaft end must be marked before fitted. The mark must be
positioned vertically above a commutation slot leading up to the front
annular channel.
For OMPW N, guide the shaft into the motor housing back with the rear
needle bearing fitted on the shaft. Bring the shaft in line with the back of
the motor by gently tapping the shaft with a plastic hammer. Check that
the shaft rotates easily
16 O-ring Grease the O-ring and put it in the O-ring groove of the housing.
17 Distributor plate Turn the distributor plate so that the holes line up.
14 11012811 • Rev A • Okt 2006

Repair Instructions
Assembly
ASSEMBLY item Part to install Comments

14 Cardan shaft Guide the cardan shaft down into the motor housing.
Only OMP 25, 32 and 40

Place the assembly tool under the upper splines of the cardan shaft.
In case of different splines lengths turn the cardan shaft to ensure

the long splines end is fitted in the output shaft.
Transfer marking from output shaft to cardan shaft.
18, 16 Gearwheel set Place the O-rings (greased) in the O-ring grooves of the gearwheel.
In gearwheels with non through splines place the gearwheel

with the recess in the spline hole facing down towards the housing.
Place the gearwheel set on the cardan shaft so that the top of a tooth in
the external teeth of the gearwheel is vertically above the mark on the
cardan shaft.
Turn the gearwheel set counter clockwise until the cardan shaft and the
gearwheel start to mesh (15°). Turn the gearwheel rim so that the holes
made for the screws line up.
19 End cover Turn the end cover so that the holes line up.
20, 21 Washer, screws Use a 13 mm spanner socket
Tightening torque: 30 - 35 N•m [265-310 lbf•in].
24, 25 Washer, drain plug Use a 17 mm spanner socket.
28 Seal plugs End port version:
Threaded plug Screw plastic plugs into end ports.
(if present) Screw in the side port plugs using 10 mm hexagon socket spanner.
Side port version:

Screw in plastic plugs.
12 Parallel key To be secured with tape or plastic ring
11 Washer
10 Castellated nut
11012811 • Rev A • Okt 2006 15

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Joysticks and control handles Sauer-Danfoss (US) Company Sauer-Danfoss ApS
Displays 2800 East 13th Street DK-6430 Nordborg, Denmark
Ames, IA 50010, USA Phone: +45 7488 4444
Sensors Phone: +1 515 239-6000 Fax: +45 7488 4400
Fax: +1 515 239 6618
Sauer-Danfoss GmbH & Co. OHG Sauer-Danfoss-Daikin LTD
Postfach 2460, D-24531 Neumünster Sannomiya Grand Bldg. 8F
Krokamp 35, D-24539 Neumünster, Germany 2-2-21 Isogami-dori, Chuo-ku
Phone: +49 4321 871-0 Kobe, Hyogo 651-0086, Japan
Fax: +49 4321 871 122 Phone: +81 78 231 5001
Fax: +81 78 231 5004
11012811 • Rev A • Okt 2006 www.sauer-danfoss.com
Centrum Tryk 10/2006

BOTTOM ROLLER ASSEMBLY FOR CRAWLER RIG - 4506-1200[E]
1 Shaft - Bottom Roller 1No. 4506-1205

2 Bottom Roller 1No. 4506-1206
3 Middle Spacer 1No. 4506-1207
4 End Spacer 2No. 4506-1208
5 Ball Bearing 2No. 6205Z
6 Hex. Nylock Nut 1No. 7/8" BSF
7 Spring Washer 1No. Ø 7/8"
8 Grease Nipple 1No. 1/8" BSP
BARI INTERNACIONAL S.A. DE C.V.
Calle 15 #160 por 18 y 20 Fraccionamiento Jardines de Miraflores,
Mérida, Yucatán.
TOP SPROCKET ASSLY FOR CRAWLER RIG - 4506-1100[E]
1 Holder - Top Sprocket 1No. 4506-1106
2 Sprocket 1No. 4506-1107
3 Shaft - Top Sprocket 1No. 4506-1108
4 Spacer 2No. 4506-1109
5 Grease Nipple 1No. 1/8" BSP
6 Ball Bearing 2No. 6205
7 Circlip - Internal 2No. Ø50.0mm
8 Adjustable Screw 1No. M24 X 4"L
9 Hex. Nut 1No. M24
10 Hex. Nylock Nut for Shaft-Top Sprocket 1No. 7/8" BSF
11 Spring Washer For Hex. Nylock Nut -7/8"BSF 1No. Ø 7/8"
BONFIGLIOLI RIDUTTORI S.p.A. BONFIGLIOLI RIDUTTORI S.p.A..
Sede Centrale - Head Office Divisione TRASMITAL BONFIGLIOLI
Via Giovanni XXIII, 7/A - 40012 Lippo di Calderara di Reno Bologna (ITALY) Via Enrico Mattei,12 - Z.I. Villa Selva 47100 Forli' (ITALY)
Tel. (++039) 0516473111 Tel. (++039) 0543789111
Fax (++039) 0516473126 Fax (++039) 0543789187 (Uff.Tecn./Tech.Dept.)
web www.bonfiglioli.com - e-mail: bonfiglioli@bonfiglioli.com web www.bonfiglioli.com - e-mail: trasmital@bonfiglioli.com
PRODOTTO TIPO / PRODUCT TYPE
7 05 T 2 L0HB1 B 26 II H1 MH HYDROMATIK A2FE 45

7C 06 3 K A E 79 G050VP40
2T255608050
2T706C3K079003
18/06/2014
06/10/2004
Importante/Important
N°matricola/Serial number MATRICOLA RIDUTTORE (a cura del cliente)
GEARBOX SERIAL NUMBER (at customer care)
No. DE SERIE DU REDUCTEUR (doit ètre indiqué par le client)
GETRIEBE-SERIENNUMMER (muss von kunden angegeben werden)
PER L'IDENTIFICAZIONE DEI RICAMBI E' CONSIGLIATO FORNIRE SEMPRE IL NUMERO DI SERIE DEL RIDUTTORE.
IN ORDER TO IDENTIFY THE SPARE PARTS, IT'S ALWAYS SUGGESTED TO SPECIFY THE GEARBOX SERIAL NUMBER.
POUR L'IDENTIFICATION DES PIECES DE RECHANGE NOUS CONSEILLONS D'INDIQUER LE NUMERO DE SERIE DU REDUCTEUR.
FUER DIE KORREKTE ERMITTLUNG DER ERSATZTEILE BITTEN WIR UM ANGABE DER SERIENNUMMER.
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N O

MOTORIDUTTORE PER TRASLAZIONE
TRACK DRIVE
SERIE / SERIES
700CK
Manuale di installazione uso e manutenzione

Installation and service manual
Drives Service Center

Compilatore/Prepared by:
Approvato da/Approved by:
Emissione/Issue: 02/2011
Revisione/Revision: 0.1
Data/Date 05/09/2011
File: MAN_serie700CK_IS.doc
Indice Index Par.
INFORMAZIONI GENERALI GENERAL INFORMATIONS 1.0

 Scopo del manuale  Manual aim 1.1
 Informazioni sulla sicurezza  Information on safety 1.2
IDENTIFICAZIONE PRODOTTO PRODUCT IDENTIFICATION 2.0

 Designazione prodotto  Product description 2.1
NOTE NOTES 3.0

 Condizioni di fornitura  Delivery conditions 3.1
 Trasporto  Handling / Transport 3.2
 Stoccaggio  Storage 3.3
 Sollevamento e movimentazione  Lifting and handling 3.4
 Peso del riduttore  Track drive weigh 3.5
INFORMAZIONI TECNICHE TECHNICAL INFORMATION 4.0
INSTALLAZIONE INSTALLATION 5.0

 Realizzazione delle flangiature  Construction of the flanges 5.1
 Installazione motoriduttore sulla macchina  Installation of the track drive on the machine 5.2
 Fissaggio ruota motrice  Sprocket fixing 5.3
 Senso di rotazione  Direction of rotation 5.4
 Collegamento dell’impianto oleodinamico  Connection of the hydraulic system 5.5
 Collegamento del freno  Connection of the brake 5.6
LUBRIFICAZIONE LUBRICATION 6.0

 Lubrificazione riduttore  Gearbox lubrication 6.1
 Riempimento olio  Oil filling 6.2
 Scarico e sostituzione olio  Oil draining and replacement 6.3
 Riduttore fornito con olio  Gearbox factory filled with oil 6.4
 Caratteristiche dell’impianto oleodinamico  Characteristics of the Hydraulic System 6.5
MESSA IN ESERCIZIO E RODAGGIO START UP AND RUNNING IN 7.0

 Disinnesto meccanico  Mechanical disengagement 7.1
VARIANTI VARIANTS 8.0
MANUTENZIONE MAINTENANCE 9.0

 Localizzazione guasti  Trouble shootings 9.1
 Dismissione e rottamazione del prodotto  Dismantling and destroying the product 9.2
ALLEGATO ATTACHED
 Disegno di installazione  Installation drawing
REV: 0.0 2 / 35 MAN_serie700CK_IS.doc
1.0 INFORMAZIONI GENERALI 1.0 GENERAL INFORMATION
I prodotti standard devono essere usati alle seguenti The standard products must be used at the following
condizioni: conditions:
 Non possono essere impiegati in ambienti con  Not be used in environments with vapors, fumes or dust
vapori, fumi o polveri corrosivi e/o abrasivi. corrosive and/or abrasive.
 Non possono essere impiegati in ambienti in cui sono  Not be used in environments where potentially
presenti atmosfere potenzialmente esplosive. explosive atmospheres are present.
 Le condizioni limite di temperatura ambiente  The environment temperature limit conditions
ammesse in cui i prodotti possono essere impiegati permitted in which products can be used ranging from
variano da -15°C a +45°C. -15°C to +45°C.
Il prodotto è pregettato e realizzato in modo tale da The product is designed and constructed so as not to
non recare danno all'operatore in caso di injure the operator in case of malfunction or breakage.
malfunzionamento o rottura.
1.1 Scopo del manuale 1.1 Manual aim
i Informazioni Il presente documento è redatto i Information This document is drawn up with

con le "Istruzioni originali" in lingua italiana e the "Original instructions" in Italian and translated
tradotto con "Traduzioni delle istruzioni originali" as "Translation of the original" in English.
in inglese.
This manual has been devised by the Bonfiglioli
Questo manuale è stato realizzato dalla Bonfiglioli Trasmital to give necessary information to those
Trasmital per fornire le informazioni necessarie a authorised to work on this product for example the
coloro che sono autorizzati ad interagire con il design engineers, installers, repair and maintenance
prodotto: dai progettisti, agli installatori, manutentori e technicians.
riparatori. Besides helping one understand the rules of good
Oltre ad adottare le regole della buona tecnica di manufacturing techniques used, the information given
costruzione, le informazioni devono essere lette must be carefully read and strictly applied.
attentamente ed applicate in modo rigoroso. Failure to observe this information may lead to health
La non osservanza di dette informazioni può essere and safety risks to persons as well as economic loss.
causa di rischi per la salute e la sicurezza delle
persone e danni economici. i Information A strict and consistent
compliance with the specifications of this
i Informazioni La completa e costante technical manual ensure the minimum operating
osservanza delle indicazioni contenute nel costs and a longer unit life.
presente manuale tecnico garantisce la migliore Photographic documentation and drawings are
economia di esercizio ed una più lunga durata di supplied for educational purposes, so as to safely and
funzionamento del prodotto. properly carry out maintenance operations.
La documentazione fotografica ed i disegni sono forniti Minor deviations from pictures of this manual may
a scopo esplicativo, in modo da descrivere appear on the actual gearbox. However, these
esaurientemente le operazioni da eseguire sul discrepancies are not relevant to the main parameters,
prodotto. or maintenance functions.
Anche se il riduttore in vostro possesso si discostasse
in parte dalle illustrazioni contenute in questo manuale
tecnico, le caratteristiche e la sequenza delle
operazioni descritte sono sempre garantite.

1.2 Informazioni sulla sicurezza 1.2 Information on safety
Leggere attentamente le istruzioni riportate in questo Carefully read the instructions given in this instruction
manuale e eventualmente quelle applicate manual as well as the ones attached to the product
direttamente sul prodotto, in particolare rispettare and make sure to follow the information concerning
quelle riguardanti la sicurezza. safety.
Il personale che effettua qualsiasi tipo di intervento in Personnel, which perform any type of work on the
tutto l’arco di vita del prodotto, deve possedere precise product during its life span, must possess precise
competenze tecniche, particolari capacità ed technical qualifications as well as recognised skills and
esperienze acquisite e riconosciute nel settore experience gained in the specific sector. Failure to do
specifico. La mancanza di questi requisiti può causare so may lead to health and safety risks to persons.
danni alla sicurezza e alla salute delle persone.
It is recommended that when handling the product
Eseguire la movimentazione del prodotto rispettando attention is paid to the information given in this manual
le informazioni riportate in questo manuale oppure or simply follow the instructions given on the
applicate direttamente sull’imballo (se presenti). packaging (if present).
Utilizzare il prodotto solo per gli usi previsti dal Utilise the product only for the use specified by the
fabbricante. L’impiego del prodotto per usi impropri manufacturer. Improper use of the product could lead
può recare rischi per la sicurezza e la salute delle to health and safety risks to persons as well as
persone e danni economici, nonchè il decadere della economic loss and furthermore will invalidate the
garanzia da parte di Bonfiglioli Trasmital. guarantee given Bonfiglioli Trasmital.
Mantenere il prodotto in condizioni di massima Keep the product in perfect working order by following
efficienza effettuando le operazioni di manutenzione the scheduled maintenance procedure set out by
programmata previste da Bonfiglioli Trasmital. Una Bonfiglioli Trasmital. Good maintenance will ensure
buona manutenzione consentirà di ottenere le migliori the best performances, a longer period of operation
prestazioni, una più lunga durata di esercizio e un and a constant safeguard towards security
mantenimento costante dei requisiti di sicurezza. requirements.
Per eseguire interventi di manutenzione in zone non To undertake maintenance procedures in areas which
facilmente accessibili o pericolose, predisporre are hard to reach or otherwise dangerous it is
adeguate condizioni di sicurezza per sé stessi e per gli important to follow adequate safety conditions for one
altri rispondenti alle leggi vigenti in materia di self and for others in compliance with the rules and
sicurezza sul lavoro. regulations that govern safety in the workplace.
Sostituire i particolari usurati utilizzando i ricambi When replacing worn parts, use original spare parts.
originali. Usare gli oli e i grassi consigliati da Use oils and greases recommended by Bonfiglioli
Bonfiglioli Trasmital. Tutto questo potrà assicurare Trasmital. Doing this, will ensure that the product
la funzionalità del prodotto ed un livello di “sicurezza works properly and that the safety level is
accettabile”. “acceptable”.
i Informazioni Se le superfici raggiungibili del

i Information If the surfaces of the product
prodotto hanno temperature superiori a 65°C è have reached temperatures above 65°C, is
necessario aspettare che si raffreddino prima di necessary to wait for it to cool before running any
eseguire qualsiasi intervento e se necessario, action, and if necessary the operator should wear
l'operatore deve indossare guanti anti calore. anti heat gloves.
Per le operazioni nelle quali è possibile entrare in For actions in which you can get in contact with
contatto con fluidi lubrificanti e grassi devono fluids, lubricants and greases should be followed
essere seguite tutte le avvertenze contenute nelle all the warnings contained in safety data sheets of
schede di sicurezza dei rispettivi fabbricanti e the respective manufacturers and should be used
devono essere utilizzati gli eventuali dispositivi di any personal protective equipment provided
protezione individuale ivi previsti. therein.

2.0 IDENTIFICAZIONE PRODOTTO 2.0 PRODUCT IDENTIFICATION
I dati per l’identificazione del prodotto sono riportati su The identification data of the unit are shown on a name
di una targhetta applicata su di esso. plates applied on it.
i Informazioni i Information
Per la richiesta di informazioni, ricambi, assistenza, For all enquiries regarding general information on
fornire sempre i dati identificativi. the product, spare parts, assitance, always give the
Le targhette vanno mantenute integre per tutta la identification data stamped on the ID plate.
vita del prodotto. The plate must not be removed or damaged during
the life of the product.
L’illustrazione evidenzia la disposizione dei dati su The following illustration shows how the data is set out
targhetta standard. on standard name plate.
Per qualsiasi richiesta di assistenza, rivolgersi For all requests for assistance please contact the
direttamente alla rete di vendita Bonfiglioli Trasmital. Bonfiglioli Trasmital sales network, directly.

2.1 Designazione prodotto (esempio) 2.1 Product description (example)
(Esempio / Example)
7C 05 2 K S001 D B 53 G050VP60 D LA VH BC U10C TS

Ref. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
Par.
1 Serie / Series
2 Grandezza / Size
3 N°stadi riduzione / Reduction stage nos.
4 Forma costruttiva / Product design
5 Specialità / Speciality
6 Livello di revisione / Revision Number
7 Versione / Version
8 Rapporto di riduzione / Reduction ratio
9 Entrata / Input
10 Orientam. flangia motore / Motor adaptor orientation
11 Disinnesto / Disengagement 7.1/7.2
12 Tipo freno / Brake type 5.6
13 Accessori uscita / Output fittings
14 Lubrificazione / Lubrication 3.1/6.0/8.0
15 Verniciatura / Painting 3.1/8.0
16 Bollino identificativo / Identification label 8.0
17 Ulteriori specialità / Further speciality
18 Opzioni / Options

3.0 NOTE 3.0 NOTES
3.1 Condizioni di fornitura 3.1 Delivery conditions
I riduttori vengono forniti dalla BONFIGLIOLI Gearboxes are supplied by BONFIGLIOLI
TRASMITAL nelle seguenti condizioni standard: TRASMITAL at the following standard conditions:
 Predisposti per essere installati nella posizione di  Ready for installation in the mounting position
montaggio come definito in fase di ordine. specified when ordering.
 Le parti interne, per garantirne l'integrità, sono  To guarantee their reliability, the internal parts are
preventivamente lubrificate con un velo d'olio usato properly lubricated with a layer of oil, the same as the
per il collaudo finale del riduttore e compatibile con one used in the final test of the gearbox and
gli olii raccomandati al paragrafo "Lubrificazione compatible with the recommended in section
riduttore". "Gearbox lubrication".
 Senza olio lubrificante (come segnalato da  Without oil (as shows on the appropriate card),
apposito cartellino), ma con tappi di carico, however with filling, draining and level plugs.
scarico e livello.
 Le parti grezze e le superfici di accoppiamento  All unmachined parts and surfaces to be coupled are
vengono opportunamente trattate con antiossidanti. appropiately treated by antioxidants.
 Le superfici esterne sono protette con smalto di fondo  External surfaces are protected with an antioxidant
antiossidante all'acqua di colore grigio, sopra water resistant grey color suitable for finish painting.
verniciabile. La verniciatura finale è a cura del cliente. Finish coat to be applied by the customer.
 Le superfici di accoppiamento non sono verniciate.  Machined surfaces are not painted.
 Il tappo di sfiato se presente, non deve essere  The breather plug must not be painted, if available.
verniciato.  Tested to in-house specifications.
 Collaudati secondo specifiche interne.  Appropriately packaged to facilitate handling,
 Appositamente imballati per agevolarne la transport and storage.
movimentazione, il trasporto e lo stoccaggio.
i Information When the product arrives,
i Informazioni Al ricevimento del prodotto, ensure that it meets the information contained in
accertarsi che corrisponda alle specifiche di the purchase agreement and that there are no
acquisto e che non presenti danni o anomalie. Per damages or irregularities. If there are any
qualsiasi inconveniente rivolgersi direttamente problems contact the Bonfiglioli Trasmital
alla rete di vendita Bonfiglioli Trasmital. manufacturers’ sales network directly.
i Informazioni Oltre alle condizioni di fornitura i Information In addition to the above delivery
sopra citate, i riduttori possono essere forniti dalla conditions, the gearboxes can be supplied by
Bonfiglioli Trasmital nelle seguenti condizioni Bonfiglioli Trasmital at the following conditions as
definite in fase di ordine: specified when ordering:
 Riempiti con olio lubrificante al giusto livello (come  Factory filled with lubricant oil at level (as shown on
segnalato da apposito etichetta adesiva applicata sul the appropriate adhesive label applied on the
prodotto). product).
 Verniciati con smalto a finire  Final painted.
Il tipo di olio e i dati di verniciatura sono riportati nel The oil type and painting data are shown on the
disegno di installazione. installation drawing.
3.2 Trasporto 3.2 Transport

Durante il trasporto è norma trattare i riduttori come We recommend that the box containing gearboxes is
merce delicata per evitare danni. handled carefully in order to avoid damages during
Durante i trasporti interni dei riduttori senza imballo, transport. When removing gearboxes from their
evitare che questi prendano urti per non danneggiare packaging, extra caution should be taken to avoid
le parti delicate. impacts, which may damage sensitive parts.
Le illustrazioni raffigurano i tipi di imballo piu’ frequenti. The illustrations show the more common types of
packaging.

3.3 Stoccaggio 3.3 Storage
Per il corretto stoccaggio del prodotto, osservare le Observe the following instructions to ensure correct
seguenti raccomandazioni: storage of delivered products:
1. Escludere aree all'aperto, zone esposte alle 1. Do not store outdoors, in areas exposed to weather
intemperie o con eccessiva umidità. or with excessive humidity.
2. Interporre sempre tra il pavimento ed i prodotti, 2. Always place boards of wood or other material
pianali lignei o di altra natura, atti ad impedire il between floor and products, to avoid direct contact
diretto contatto col suolo. with the floor.
3. Per periodi di stoccaggio superiori ai 60 giorni, le 3. For storage periods of over 60 days, all machined
superfici interessate agli accoppiamenti quali surfaces such as flanges, shafts and couplings must
flange, alberi e giunti, devono essere protette con be protected with a suitable anti-oxidation product
idoneo prodotto antiossidante (SHELL ENSIS (SHELL ENSIS FLUID SDC or equivalent
FLUID SDC od equivalente). product).
Per periodi di stoccaggio previsti superiori ai 6 mesi, i The following measures must be taken for products
prodotti devono essere oggetto delle seguenti attività: which expected storage period exceeds 6 months:
4. Ricoprire le parti lavorate esterne e quelle di 4. Cover outer machined parts and mating parts with
accoppiamento con grasso atto ad evitare grease to avoid oxidation.
ossidazioni. 5. Fill completely the gearboxes with oil to protect the
5. Riempire i riduttori completamente di olio a internal components. In case of gearboxes
protezione dei componenti interni. Nel caso di complete with hydraulic motor, the motors too
riduttori completi di motore idraulico occorrerà should be filled with oil (ISO VG46) to prevent
riempire con lubrificante idraulico (ISO VG46) oxidation, using metal plugs and washers to close
anche i motori per evitare ossidazioni, chiudendo the motor pilots and drain ports. If the holes are not
opportunamente con tappi metallici e rondelle le sealed, dirt, water or other substances can get
porte di pilotaggio e di drenaggio dei motori. La inside that would undermine correct operation of the
mancata chiusura dei fori potrebbe favorire l'entrata gearbox.
di sporcizia, acqua o altre sostanze dannose che For storage lasting more than 6 months the rotating
comprometterebbero il corretto funzionamento del seals will no longer be efficient. It is recommended that
riduttore.
they be checked periodically by turning all the internal
Per immagazzinamento prolungato oltre i 6 mesi kinematic motion, by temporarily connecting the
decade l’ efficienza per le tenute rotanti. Si consiglia engine connections to a hydraulic gearcase. For a
un controllo periodico facendo ruotare tutto il negative multi-disk brake, it is necessary to release the
cinematismo interno, collegando provvisoriamente gli brake by connecting it to the hydraulic gearcase. It is
attacchi dei motori ad una centralina idraulica. In recommended that the gaskets be replaced when the
presenza di freno lamellare negativo, sbloccare il machine is started.
freno, collegandolo anch’esso alla centralina idraulica.
L’eventuale sostituzione all’atto dell’avviamento delle i Information Before use, the gearboxes
guarnizioni è consigliata. should be filled with the proper amount of
i Informazioni I riduttori, prima del loro utilizzo,

lubricant of the recommended type.
dovranno essere riempiti con la corretta quantità e

tipo di lubrificante previsto.

3.4 Sollevamento e movimentazione 3.4 Lifting and handling
Se la movimentazione avviene quando il prodotto è If the handling occurs when the product is still
imballato, è sufficiente attenersi alle indicazioni packaged, simply follow the instructions given on the
applicate direttamente sull'imballo e/o comunque packaging and/or use normal hoisting means.
utilizzando i normali mezzi di sollevamento.
Attenzione Considerando che la massa e la Warning Considering that the size and form
forma del prodotto non ne consentono lo of the product do not allow manual shifting, in
spostamento a mano, in particolari particular handlings, (e.g. installation) it is
movimentazioni (es: installazione), è necessario necessary to use accessories that guarantee
utilizzare accessori che consentono di garantire la human safety and which also avoid damages to the
sicurezza delle persone ed evitare danni al product, such as eyebolts, hooks, brackets etc. or
prodotto, quali: golfari, ganci, fasce ecc..o special tools supplied by Bonfiglioli Trasmital.
attrezzature speciali fornibili dalla Bonfiglioli To lift and handle the product, after having opened the
Trasmital. packaging, follow the information given below:
Per sollevare e movimentare il prodotto, dopo aver
1. By using a tackle lift and handle with care avoiding
aperto l’imballo, attenersi alle seguenti indicazioni:
impacts.
1. Servendosi di un paranco, movimentare con la
To turn gearboxes up side down it is necessary to use
massima cautela evitando gli urti.
the hanging points provided for lifting operations, and
Per effettuare operazioni di rotazione dei riduttori in accordance with the rules which have been
occorre utilizzare i punti di presa previsti per le previously defined.
operazioni di sollevamento, secondo le modalità Wear ever gloves to provide appropriate mechanical
definite in precedenza. protection to the hands.
Indossare sempre guanti adeguati a fornire una The up side down operations must be carried out by
protezione meccanica alle mani. keeping the gearbox as close as possible to a worktop;
Le operazioni di rotazione devono essere effettuate it is important to pay attention to its center of gravity so
mantenedo i riduttori il piu' possibile vicino ad un piano that its weight does not get unbalanced during this
di appoggio; è essenziale curare la posizione del handling process.
baricentro in modo che il carico non si sbilanci troppo Gearbox hookings must be made so that they do not
durante tutta la fase di rotazione. come out of the hanging points or they cannot move
Gli agganci devono essere realizzati in modo che non and cause risks of falling loads; this is very important
fuoriescano dai punti di sollevamento o si spostino in when the up side down turning operation is carried out
modo da generare pericoli di caduta del carico; ciò è by means of ropes or lifting bands which are more
particolarmente importante in caso la rotazione venga subject to displacement risks from loads hanging
effettuata utilizzando fasce o funi che sono points.
maggiormente soggette a rischi di spostamento dai
punti di presa del carico.
i Informazioni Non togliere in nessun caso il
coperchio in plastica delle porte di alimentazione
del motore idraulico, in modo da evitare
l’introduzione accidentale di corpi estranei, sino al
momento del collegamento dei tubi flessibili.
i Information Under no circumstance remove

the plastic lid from the power supply ports of the
hydraulic motor; this will help avoid the accidental
introduction of foreign bodies into the motor, until
the hoses are assembled.

3.5 Peso del riduttore 3.5 Track drive weigh
La tabella seguente riporta il valore dei pesi indicativi The following table shows the weight values of every
di ogni grandezza di riduttore (il peso del prodotto puo' gearboxes sizes (The product weight can vary
variare in funzione del tipo di motore idraulico depending on the type of the hydraulic motor installed)
installato).
Tipo / Type Peso / Weight (Kg)

7 00 C K 20
7 00/2 C K 25
7 01 C K 25
7 02 C K 35
7 04 C K 60
7 05 C K 70
7 06 C K 80
7 07 C K 140-150
7 09 C K 225
7 10 C K 230
7 13 C K 300
7 15 C K 380
7 18 C K 900
7 20 C K 935

4.0 INFORMAZIONI TECNICHE 4.0 TECHNICAL INFORMATION
I motoriduttori Bonfiglioli Trasmital della serie descritta The Bonfiglioli Trasmital gearmotors of the series
in questo manuale sono stati progettati e costruiti per decribed in this manual are designed and built for
essere applicati su macchine cingolate per il comando application as track drive for crawled machines equipped
della traslazione con azionamento in circuito aperto o with open or closed loop hydraulic circuit depending on
chiuso in funzione dell'applicazione. the application.
L’unità è composta da: The unit includes:
a Riduttore epicicloidale a Planetary gearbox
 Riduttore epicicloidale a corpo rotante a due/tre  2/3 reduction stages planetary gearbox, with
stadi di riduzione. rotating housing
 Flangia di fissaggio al telaio macchina  Connecting flange to the machine frame
 Flangia di fissaggio alla ruota motrice  Connecting flange to the sprocket.
b Motore idraulico b Hydraulic motor

Motore idraulico per circuito chiuso Motor for closed loop hydraulic circuit
Il motore idraulico viene utilizzato in circuiti chiusi per The hydraulic motor is used in closed loop hydraulic
macchine tipo: circuit for machine type
 Caricatore cingolato  Compact track loader
Caratteristiche motore idraulico: Hydraulic motor characteristics:
 a pistoni assiali a cilindrata variabile su 2 punti per  Two speed hydraulic motor (axial piston swash
ottenere una alta ed una bassa velocità di plate type).
traslazione.  Negative multidisc parking brake hydraulically
 Freno statico a dischi in bagno d’olio ad apertura actuated (additional hose is required).
idraulica comandato esternamente dal motore  Two speed control manually operated.
(necessita di comando idraulico indipendente).
 Integrated flushing valve
 Comando cambio cilindrata manuale.
Belove are reported the sketches of the hydraulic
 Valvola di lavaggio circuits most 'commonly used
Di seguito sono riportati gli schemi dei circuiti idraulici
piu’ comunemente utilizzati.
esempio 1: circuito idraulico chiuso example 1: closed loop hydraulic circuit

Motore idraulico per circuito aperto Motor for open loop hydraulic circuit
Il motore idraulico viene utilizzato in circuiti aperti per The hydraulic motor is used open loop hydraulic
macchine tipo: circuit for machine type
 Escavatore e mini escavatore cingolato.  Escavators and mini escavators.
Caratteristiche motore idraulico: Hydraulic motor characteristics:
 a pistoni assiali a cilindrata variabile su 2 punti per  Two speed hydraulic motor (axial piston swash
ottenere una alta ed una bassa velocità di plate type).
traslazione.  Integrated counterbalance valve.
 Valvole di frenatura.  Anticavitation valve (two types).
 Valvola anticavitazione (due tipologie).  Crossover relief valve wich contains a shock
 Valvole di massima pressione con ammortizzatore absorber to smoooth acceleration and stopping.
per prevenire urti in fase di accelerazione e di  Negative multidisc parking brake built-in directly
frenatura. driven from ythe motor oil pressure (no additional
 Freno statico a dischi in bagno d’olio ad apertura hose is required).
idraulica comandato internamente dal motore (non  Two speed control manually or automatic operated
necessita di comando idraulico indipendente). (auto two speed).
 Comando cambio cilindrata manuale o automatico Belove are reported the scketches of the hydraulic
Di seguito sono riportati gli schemi dei circuiti idraulici circuits most 'commonly used.
piu’ comunemente utilizzati.
esempio 1: circuito idraulico aperto example 1: open loop hydraulic circuit


Attenzione Assicurarsi che nell'impianto di Warning Make sure that there is no residual (back)
alimentazione del freno non vi sia pressione residua pressure inside the brake pilot line when the
quando la macchina è ferma. Una eventuale machine has been stopped. A potential presence of
presenza di pressione residua puo' ridurre residual pressure can reduce the efficiency of the
l'efficienza del freno di emergenza. emergency brake.
i Informazioni il valore della pressione massima i Information maximum admissible pressure

ammissibile per il corretto funzionamento del freno value which allows proper brake function is shown
è indicata nel disegno di installazione. on gearbox installation drawing.
Una importante raccomandazione è di progettare “a An important recommendation is “to perfectly” design the
regola d’arte” l’impianto idraulico di comando. main hydraulic system.
Lo schema funzionale ed i valori relativi a pressioni e The functional scheme and the data regarding pressure
portate da utilizzare, sono riportati nel disegno di and flow rate to use, are shown on the installation
installazione. drawing.

5.0 INSTALLAZIONE 5.0 INSTALLATION
5.1 Realizzazione delle flangiature 5.1 Construction of the flanges
La corretta realizzazione delle flange e del corpo Correct construction of the flanged hub and gearbox
riduttore e le relative indicazioni di accoppiamento housing and relative coupling indications are shown
sono riportate di seguito. here follow.
Riduttore / Gearbox Ruota motrice / Sprocket

[mm] [mm]
≤300 d2 H9 [mm]
d2
>300 (d2+0.2) H9 [mm]

5.2 Installazione del motoriduttore su macchina 5.2 Installation of the track drive on the machine
i Informazioni tutte le fasi di installazione i

Information The entire installation process
devono essere considerate, sin dalla realizzazione must be planned as early as the general design
del progetto generale. Colui che è autorizzato ad phase of the machine. The person authorised to do
eseguire queste operazioni, dovrà, se necessario, the work must, if necessary, set out a safety plan
attuare un “piano di sicurezza” per salvaguardare to protect the health and safety of all persons
l’incolumità delle persone direttamente coinvolte directly involved and apply all applicable
ed applicare in modo rigoroso tutte le leggi legislation.
esistenti in materia.
1. Ensure that the structure to wich the gear unit is to
1. Accertarsi che la struttura alla quale si vincola il be mounted is sufficiently robust and rigid to support
riduttore abbia caratteristiche di rigidezza e di its weight and operating stresses.
robustezza sufficienti a supportarne il peso proprio
2. Check that the machine to which the gear unit is to
e le forze generate nel funzionamento.
be installed is switched and cannot be accidentally
2. Verificare che la macchina sulla quale si installa il switched on again.
riduttore sia spenta e che ne sia impedito il riavvio
3. Make sure all mating surfaces are flat.
accidentale.
4. Make sure the shaft/shaft or shaft/bore are perfectly
3. Verificare che le superfici di accoppiamento siano
aligned for coupling.
piane.
5. Fit suitable guards to protect against the gear unit’s
4. verificare il corretto allineamento albero/abero o
external moving parts.
albero/foro.
6. We recommend applying a protective paste to all
5. Predisporre adeguate protezioni di sicurezza in
gear/motor mating surfaces and other parts such as
relazione agli organi rotanti esterni al riduttore.
Klüberpaste 46 MR 401 or Tecnolube WRL 115 or
6. Su tutti gli alberi di accoppiamento tra similar product, to ensure optimal coupling and
riduttore/motore ed altri organi è consigliabile usare protection against fretting corrosion.
una pasta protettiva tipo Klüberpaste 46 MR 401
oppure Tecnolube WRL 115 o prodotto similare,
che favorisce l’accoppiamento ed ostacola
l’ossidazione da contatto.
7. Spostare il motoriduttore nella zona di installazione 7. Move the track drive in the mounting area applying
sollevandolo come indicato nel paragrafo lifting methods shown in section "Lifting and
"Sollevamento e movimentazione ". handling ".
8. Pulire le zone di accoppiamento da protettivi o 8. Clean the mating surfaces from oils or paint and fit
vernice ed installare il motoriduttore sul telaio the track drive on the machine frame (for the correct
macchina (per il corretto orientamento fare orientation refer to the installation drawing).
riferimento al disegno di installazione). 9. Apply LOCTITE 270 or similar product on the thread
9. Applicare LOCTITE 270 o prodotto equivalente screws (A). Fix the gearmotor to the machine frame
sulla filettatura delle viti (A).Fissare il motoriduttore tightening all the screws foreseen
al telaio macchina serrando tutte le viti previste (A) (A) by a torque wrench at a torque shown on the
con una chiave dinamometrica alla coppia indicata following table.
nella tabella seguente.
5.3 Fissaggio ruota motrice 5.3 Sprocket fixing
1. Pulire le zone di accoppiamento da protettivi o 1. Clean the mating surfaces from oils or paint and
vernice ed assemblare la ruota motrice al assemble the sprocket to the gearmotor.
motoriduttore. 2. Apply LOCTITE 270 or similar product on the thread
2. Applicare LOCTITE 270 o prodotto equivalente screws (B). Fix the sprocket to the gearmotor
sulla filettatura delle viti (B). Fissare la ruota motrice tightening all the screws foreseen (B) by a torque
al motoriduttore serrando tutte le viti previste (B) wrench at a torque shown on the following table.
con una chiave dinamometrica alla coppia indicata
nella tabella seguente.

Telaio macchina / Machine frame Ruota motrice / Drive
Coppia max Vite/Screw Vite/Screw
Riduttore
Torque Max. N°/Nos. (Nm) N°/Nos. (Nm)
Gearbox
(Nm) A B
7 00 C K 1200 M10-8.8 8 50 M10-8.8 8 50
7 00/2 C K 1900 M10-10.9 8 70 M10-10.9 8 70
7 01 C K 2500 M12-8.8 9 86 M12-8.8 9 86
7 02 C K 3500 M12-10.9 9 120 M12-8.8 9 86
7 04 C K 5000 M14-8.8 9 140 M14-8.8 9 140
7 05 C K 9000 M14-10.9 12 195 M14-10.9 12 195
7 06 C K 12500 M16-8.8 20 215 M16-8.8 12 215
7 07 C 2 K 18500 M16-10.9 16 300 M16-8.8 20 215
7 07 C 3 K 26000 M16-10.9 16 300 M16-10.9 20 300
7 09 C K 30000 M16-8.8 30 215 M16 30 215
7 10 3 K 36000 M16-10.9 30 300 M20-10.9 16 585
7 13 C K 60000 M24-8.8 18 720 M20-10.9 24 585
7 15 C K 85000 M20-12.9 24 705 M20-10.9 24 585
7 18 C K 180000 M24-12.9 30 1220 M24-10.9 30 1000
7 20 C K 200000 M30-8.8 30 1440 M30-10.9 24 2020

5.4 Senso di rotazione 5.4 Direction of rotation
Al momento dell’installazione e del collegamento dei When assembling the track drive on the machine and
tubi olio, vedere lo schema seguente per il corretto connecting the hoses, follow instructions shown in
senso di rotazione del motoriduttore. below sketch for proper direction of rotation.
Entrata olio Uscita olio Senso di rotazione

Oil inlet port Oil outlet port Direction of rotation
P1 P2 Antiorario / Counteclockwise
P2 P1 Orario / Clockwise

5.5 Collegamento dell’impianto oleodinamico 5.5 Connection of the hydraulic system
1. i Informazioni Procedere sempre alla pulizia 1. i Information Clean hoses thoroughly prior
di tutti i tubi prima del montaggio mediante to connection and remove any internal
decapaggio e rimuovere completamente obstructions.

qualsiasi incrostazione all'interno dei tubi. Prevent any foreign particles from getting into
Evitare l'immissione accidentale di qualsiasi the hoses by removing the plastic caps only at
corpo estraneo nei tubi o nel corpo motore, the time of the assembly.
rimuovendo i tappi di plastica che proteggono After hoses are connected to the motor, flow the
gli attacchi delle apparecchiature solo al hydraulic circuit and filter the oil from all the
momento della installazione. particles that may have contamined it.
Dopo l'assemblaggio delle tubazioni, procedere
ad una accurata filtrazione dell'olio del circuito
idraulico per eliminare tutte le particelle che
possono averlo contaminato.
2. Pulire la superficie di accoppiamento sul motore 2. Clean the surface to be connected on the hydraulic
idraulico. motor.
3. Effettuare i seguenti collegamenti al motore 3. Connect the hoses to the hydraulic motor ports (for
idraulico (per dimensione e tipo fare riferimento al hoses sizes and dimensions refer to the installation
disegno di installazione). drawing).
Motore idraulico per circuito chiuso Motor for closed loop hydraulic circuit
a. Alimentazione motore: porte P1-P2 a. Service ports: P1-P2
b. Drenaggio: porta Dr b. Drain port: Dr
c. Comando cambio cilindrata: porta Ps c. 2 speed control port: Ps
d. Comando freno: porta Pp d. Brake pilot port: Pp
Motore idraulico per circuito aperto Motor for open loop hydraulic circuit
a. Alimentazione motore: porte P1-P2 a. Service ports: P1-P2
b. Drenaggio: porte T1 o T2 b. Drain port: T1 or T2
c. Comando cambio cilindrata: porta Ps c. 2 speed control port: Ps
Porte motore idraulico per circuito chiuso Porte motore idraulico per circuito aperto
Closed loop hydraulic motor ports Open loop hydraulic motor ports

Assicurare che la pressione sul ramo di drenaggio The drain pressure must be lower than the values
rispetti i valori riportati nel disegno di installazione. shown on the installation drawing.
Il ramo di drenaggio olio, deve essere collegato Drain pipe must be directly and independently
direttamente ed indipendentemente al serbatoio e connected to the tank. Drain port must be located on
deve essere posizionato sull'attacco piu’ alto del the upper side of the motor.
motore. If the oil level in the tank is below the motor, connect
Se il livello dell'olio nel serbatoio si trova al di sotto del the drain pipe as shown in the drawing (fig. 1). In case
motore idraulico collegare il ramo di drenaggio come the oil level in the tank is above the motor, it's possible
illustrato nella fig. 1. Nel caso in cui il livello dell'olio to connect the drain pipe also as shown in the drawing
nel serbatoio si trovi al di sopra del motore idraulico, è (fig. 2).
possibile collegare il ramo di drenaggio anche come
illustrato nella fig. 2.

5.6 Collegamento del freno 5.6 Connection of the brake
Il motoriduttore e’ provvisto di un freno negativo a The track drive is supplied with a safety negative disc
disco di sicurezza montato nel motore con sblocco a brake fitted into the motor with hydraulic control release
comando idraulico (freno di stazionamento). (parking brake).
In caso di motore idraulico per circuito aperto In case of motor for open loop hydraulic circuit
l’apertura del freno avviene automaticamente quando parking brake release is automatically operated when
ad uno dei due rami di alimentazione del motore high pressure oil is supplied to one of the two ports of
idraulico arriva olio in pressione. Quindi il freno non the hydraulic motor. For this reason, there is no need
necessita di comando esterno. of brake external pilot.
Per informazioni generali riguardanti le caratteristiche For general information regarding the characteristics of
del freno, fare riferimento al disegno di installazione. the brake refer to the installation drawing.
In caso di motore idraulico per circuito chiuso, In case of motor for closed loop hydraulic circuit,
collegare il tubo di comando freno alla porta comando connect the brake pilot pipe to the brake pilot port
freno "Pp" (vedi schema seguente). "Pp".(see the following sketch)
I valori della pressione alla porta comando freno The pressure value at the brake pilot port “Pp” are
“Pp” sono indicati nel disegno di installazione. shown on the installation drawing.

6.0 LUBRIFICAZIONE 6.0 LUBRICATION
6.1 Lubrificazione riduttore 6.1 Gearbox lubrication
La lubrificazione è separata fra motore e riduttore. The motor and the gearbox have separate
La lubrificazione del riduttore e' a sbattimento in bagno lubrication. The gearbox is lubricated by oil splashing.
d'olio. The recommended oil type has to be
L'olio consigliato e' del tipo per trasmissioni ad EP characteristics according to
ingranaggi, con caratteristiche EP rispondente a: MIL- MIL-L-2105 C & API GL5.
L-2105 C & API GL 5.
For standard working conditions, the recommended
Per utilizzi in condizioni di lavoro standard si oil is:
raccomanda olio tipo:
Olio tipo / Oil type Viscosità / Viscosity

Minerale / Mineral SAE 80W/90
Sintetico / Synthetic SAE 75W/90
Per utilizzi in condizioni gravose, continuative e con For heavy duty working conditions (high loads, high
elevate temperature ambiente, si raccomanda olio duty cycles or high ambient temperatures), the
tipo: recommended oil is:
Olio tipo / Oil type Viscosità / Viscosity

Minerale / Mineral SAE 85W/140
Sintetico / Synthetic SAE 80W/140 - SAE 75W/140
Nella tabella seguente sono riportate le marche piu' In the following table the most common brands of
diffuse di lubrificanti con i tipi di olio consigliati. lubricant and the types recommended are shown.
i Informazioni Durante l'esercizio e solo per i
Information During the operation the oil
brevi momenti l'olio può raggiungere, ma non temperature must not exceed 85-90°C intermittent,
superare, la temperatura di 85-90°C intermittente, if not otherwise indicated on installation drawing.
se non diversamente indicato nel disegno di
installazione.
Attenzione In caso di lubrificazione con oli Warning In case of lubrication with syntetic
sintetici, è consigliato utilizzare solo quelli a base oils, is recommended to use only oils with PAO
Polialfaolefine (PAO) se non definito diversamente base if not otherwise specified when ordering.
in fase d'ordine. Do not mix together oils of different brands or
Non mescolare oli di marca o caratteristiche characteristics.
diverse. Use oils listed in the table or similar products with
Utlilizzare gli oli indicati in tabella o prodotti con equivalent characteristics in order to not modify
caratteristiche equivalenti per non causare the brake performances (if present).
possibili modifiche alla coppia frenante generata
dai dischi a bagno d'olio del freno (se presente).
For information about characteristics of lubricating oils
Per chiarimenti sulle caratteristiche degli oli lubrificanti and their proper use, please consult the lubricant
e sul loro corretto impiego, si consiglia di consultare suppliers directly.
direttamente il proprio fornitore di lubrificanti.

6.2 Riempimento olio 6.2 Oil filling
Attenzione Il riduttore viene fornito privo di olio Warning The gearbox is supplied without oil;
ma predisposto con tappi di carico, scarico e anyway it has filling, draining and oil level plugs.
livello. Prima della messa in funzione occorre fare Before putting the gearbox into operation, it is
il riempimento. necessary to fill it with oil.
Eseguire questa operazione come di seguito indicato: Proceed according to the following instructions:
1. Con l'asse del riduttore in orizzontale, ruotare il 1. Check that the gearbox axis is horizontal. Rotate the
corpo fino a che il tappo di scarico (1A) si trovi in gearbox housing until the drain plug (1A) is on the
basso sull’asse verticale del coperchio di chiusura. bottom of the vertical axis of the end cover.
2. Svitare i tappi di carico e livello olio (1A-1B). 2. Unscrew the fill and level oil plugs (1A-1B).
3. Inserire l’olio lubrificante dal foro (1A) con le 3. Add the lubricating oil from the hole (1A) with the
caratteristiche indicate nel paragrafo features listed in section "Gearbox lubrication"
"Lubrificazione riduttore" fino a che non fuoriesca untill it flows out from the level hole (1B).
dal foro di livello olio (1B). 4. Screw the filling and level oil plugs (1A-1B)
4. Avvitare il tappi di carico e livello olio (1A-1B) 5. Run the gearmotor, after a few minutes, stop and
5. Azionare il motoriduttore; attendere qualche check the oil level.
minuto, poi verificare nuovamente il livello dell'olio. 6. If necessary, refill with lubricant oil.
6. Aggiungere olio se necessario.
For further information see the installation drawing.
Per ulteriori informazioni fare riferimento al disegno di
installazione.
6.3 Scarico e sostituzione olio 6.3 Oil draining and replacement
1. Con l'asse del riduttore in orizzontale, ruotare il 1. Check that the gearbox axis is horizontal. Rotate the
corpo fino a che il tappo di scarico (1B) si trovi in gearbox housing until the drain plug (1B) is on the
basso sull’asse verticale del coperchio di chiusura. bottom of the vertical axis of the end cover.
Attenzione Rimuovere i tappi olio con estrema Warning Remove the oil plugs with extreme
cautela perché una eventuale sovrapressione caution because an overpressure inside the unit
all’interno del riduttore potrebbe espellerli con could strongly expel them.
forza verso l’esterno.
2. Svitare i tappi (1A-1B) e fare defluire l'olio in un 2. Unscrew the plugs (1A-1B) and let the oil flow in a
recipiente sufficientemente capiente; per agevolare large enough container; in order to facilitate the
l'operazione di scarico è bene operare con olio draining must be oil still warm.
caldo.
3. Attendere qualche minuto affinché tutto l'olio sia 3. Wait a few minutes until all the oil is drained and
uscito, quindi avvitare i tappi (1A-1B). then proceed to screw on the plugs (1A-1B).
4. Effettuare il riempimento dell'olio seguendo le 4. Proceed with the oil fill-up according to the following
modalità predefinite nel paragrafo "Riempimento procedures listed in Section "Oil filling".
olio".
Warning Never mix mineral oils with synthetic
Attenzione Si raccomanda di non miscelare oli oils and vice versa.
a base minerale con oli a base sintetica e
Warning Do not dispose of the oil in the natural
viceversa.
environment but be careful to eliminate it in
Attenzione Non disperdere l’ olio nell’ ambiente compliance with the relative rules and regulations
ma smaltirlo rispettando le leggi vigenti in materia. that govern locally.

i Informazioni Verificare l’esatto livello olio iInformation Check the correct oil level after
lubrificante al momento del riempimento tramite filling through the appropriate plug
l’apposito tappo
La quantità di olio lubrificante necessaria al Oil quantity to fill the gearbox is indicated on the
riempimento del riduttore è riportata nella tabella following table or on the product installation drawing
seguente e nel disegno di installazione del prodotto (Indicative values).
(valori indicativi).
Di seguito sono riportati gli schemi piu’ comuni di Belove are reported the standard gearbox oil filling-
riempimento e scarico olio riduttore. draining sketches.
Qt. olio
Posizione tappi olio Carico olio Scarico olio Riduttore
Oil qt.
Oil plugs position Oil filling Oil draining Gearbox
(l±10%)
7 00 C K 0,3
7 00/2 C K 0,4
7 01 C K 0,8
7 02 C K 1
7 04 C K 1,3
7 05 C K 1,3
7 05 C K 1,3
7 13 C K 5
7 15 C K 6,5
7 06 C 2 K 1,3
7 06 C 3 K 1,6
7 07 C K 3,5
7 09 C K 4
7 10 C K 4,5
7 13 C K 5
7 18 C K 20
7 20 C K 25
i Informazioni Le dimensioni dei tappi di i

Information Fill, level and drain oil plug
riempimento livello e scarico olio sono indicate dimensions are indicated on the product
nel disegno di installazione del prodotto. installation drawing.
Per riduttori con carico scarico olio lato mozzo fare, For gearboxes with filling and draining oil hub side,
riferimento al disegno di installazione. refer to the installation drawing.

6.4 Riduttore fornito con olio 6.4 Gearbox factory filled with oil
Qualora il riduttore sia già fornito con olio lubrificante In case the gearbox is factory filled with lubricant oil at
al giusto livello (come definito in fase d'ordine), level (as specified when ordering) ,follow the
attenersi alle istruzioni riportate in dettaglio ai paragrafi procedures given in detail at sections "Oil filling" and
"Riempimento olio" e "Scarico e sostituzione olio" "Oil draining and replacement" only for the oil
solo per i cambi olio successivi alla messa in esercizio. replacements following the start up and running in.
6.5 Caratteristiche dell’impianto oleodinamico 6.5 Characteristics of the Hydraulic System

Il motore idraulico viene lubrificato con l’olio del The hydraulic motor lubrication must reflect the ISO
circuito idraulico che deve rispondere alle VG 46 characteristics. It must be filtered with a
caratteristiche ISO VG 46. Esso deve essere filtrato maximum grade of 10 µm and with a contamination
con grado massimo di 10 µm e con livello di level equal to or inferior to class 9 according to NAS
contaminazione uguale o inferiore alla classe 9 1638 or 22/18/15 according ISO/DIS 4406 (unless
secondo NAS 1638 oppure 22/18/15 secondo otherwise indicated on the product installation
ISO/DIS 4406 (se non diversamente indicato nel drawing).
disegno di installazione del prodotto).
E’ opportuno non mescolare fra loro olii con proprietà Hydraulic fluids with different properties should not be
differenti. mixed.
E’ consigliato usare un filtro con indicatore visivo Use filter with a visual indicator which can detect
d’intasamento visibile dall’esterno, con una valvola clogging from the outside, and with a reliefvalve which
limitatrice che blocchi il flusso dell’olio quando il filtro by-passes the oil when the filter element is clogged.
sia intasato. Should the machine operate at very low temperature
Qualora si dovesse lavorare a basse temperature, (artic climates) it is essential to use specific guidelines
(climi artici) sono necessarie norme specifiche (contact the manufacturer).
(contattare il costruttore). As the temperature of the hydraulic oil may be a critical
Il controllo della temperatura dell’olio idraulico è una factor we recommend that it be checked.
delle costanti più critiche nel sistema idraulico. High operational temperatures will causea corruption
Alte temperature di esercizio, causano un degrado of the oxidation resistance level and will accelerate the
della resistenza all’ ossidazione ed accelerano il deterioration process of the hydraulic oil.
deterioramento dell’olio idraulico. The following precautions should be taken:
Osservare quindi le seguenti precauzioni : 1. The temperature ranges of the hydraulic oil during
1. La temperatura dell’olio idraulico in esercizio operation have to be within 25°C÷90°C.
continuo di lavoro si mantenga in un campo fra i 2. The temperature of oil should reach -20°C prior to
25°C÷90°C. start operation.
2. La temperatura di messa in funzione deve essere 3. During operation the oil temperature can rise to 90°C
possibilmente al di sopra di -20°C. but this temperature is acceptable only for very short
3. Durante l’esercizio, e solo per brevi momenti, l’olio periods of time.
può raggiungere, ma non superare, la temperatura
di 90°C. These temperatues have been set to take into
consideration general degrading in viscosity as well as
Questi valori di temperature sono stabiliti in base a the wear resisting additives used in the oil.
considerazioni generali sul degrado della viscosità e
sugli additivi antiusura dell’olio. The lifetime of motor will be reduced significantly if it
should continuously above 90°C.
La vita del motore subirà una notevole riduzione se la
temperatura di esercizio in continuo sarà superiore
agli 90°C.

7.0 MESSA IN ESERCIZIO E RODAGGIO 7.0 START UP AND RUNNING IN
In questa prima fase, si raccomanda di adottare alcune In this first stage it is advised to follow the measures
precauzioni come di seguito indicato: given below:
1. Controllare che il motoriduttore sia correttamente 1. Check the correct lubrication of the unit.
lubrificato.
2. Riempire il corpo motore con olio idraulico dalla 2. Fill the motor housing with hydraulic oil from the
porta di drenaggio in alto T1 o T2, in caso di motore drain port at the top T1 or T2, in case of motor for
idraulico per circuito aperto; dalla porta di drenaggio open loop hydraulic circuit; from the drain port Dr, in
Dr, in caso di motore idraulico per circuito chiuso case of motor for closed loop hydraulic circuit (see
(vedi disegno seguente). the following sketch).
3. Eliminare eventuale aria residua dal circuito 3. Bleed air from every part of the hyraulic circuit and
idraulico e aggiungere olio nel serbatoio se add oil in the tank if necessary.
necessario.
i Informazioni La presenza di aria residua nel i Information The presence of residual air in the
circuito idraulico si manifesta con la presenza di hydraulic circuit will manifest itself with the
schiuma nel serbatoio e causa un funzionamento a presence of foam in the tank and will lead to a jerking
strappi del motore ed un eccessiva rumorosità del of the motor as well as excessive noise coming from
motore e delle valvole. the motor and the valves.
4. Avviare il motoriduttore a bassa velocità ed 4. Start the gearmotor at a low speed and gradually
incrementare gradualmente, dopo avere verificato increase it after having verified that it functions
che il funzionamento sia corretto, in assenza di correctly without any noises or vibrations.
rumore e vibrazioni.
i Informazioni Non arrivare alla massima i Information Do not reach maximum pressure
pressione sino a quando tutto l’impianto non sia unless the entire system has been filtered to
stato filtrato per l’eliminazione di eventuali eliminate any particles of dirt that may be present.
particelle di impurità.
Durante il rodaggio eseguire le operazioni di seguito During the running-in stage follow the steps given
indicate: below.
5. Controllare che il numero dei giri ed il senso di 5. Check the correct revolution and direction of
rotazione siano corretti. rotation.
6. Controllare che il funzionamento sia regolare ed in 6. Make sure that the functioning is regular and with-
assenza di rumore eccessivo e vibrazioni. out any excessive noises and vibrations.
7. Controllare che la temperatura dell’olio non superi i 7. Make sure that the oil temperature does not exceed
90°. 90°.
Al termine di questo primo rodaggio eseguire le After having terminated this first running-in follow the
operazioni di seguito indicate. steps given below.
8. Controllare che non vi siano perdite olio. In caso 8. Check that there are no oil leakages. If present,
contrario provvedere alla loro eliminazione. proceed to remove them.
9. Controllare il livello dell’olio lubrificante del 9. Check the level of lubricating oil in the gearmotor.
motoriduttore.
10. Durante il primo avviamento, causa l’eventuale 10. It could happen that due to the presence of air,
presenza di aria, l’apertura del freno potrebbe during the first start up, the opening action of the
risultare ritardata. Ripetere alcune volte il comando brake could be slowed down. It is advised to repeat
di apertura e chiusura del freno. the opening and closing function of the brake.
11. Controllare che non vi siano altri problemi. 11. Check that there are no other problems in general.
7.1 Disinnesto meccanico 7.1 Mechanical disengagement

Il riduttore puo’ essere fornito completo di disinnesto The gearbox can be supplied with mechanical
meccanico che lo rende idoneo ad essere trainato con disengagement getting it suitable to be driven both
motore idraulico fermo e con freno di stazionamento with stad still hydraulic motor and with closed static
chiuso. brake.
i Informazioni La velocità massima della ruota i

Information The max wheel speed with
con riduttore disinnestato non deve superare il disengaged gearbox must not overcome the rpm
numero di giri/min (indicati nella tabella seguente) shown in the following table for max continuative
per un tempo max di 1 ora di traino continuo. period of 1 hr.
Attenzione Il disinnesto deve essere inserito o WarningThe disengagement must be
disinserito solo a riduttore fermo su superfice connected or disconnected only when the gearbox
piana. is stopped on flat ground.
Di seguito sono riportati gli schemi piu’ comuni di Belove are reported the standard sketches of gearbox
disinnesto riduttore. disengagement:
Disinnesto riduttore
1. Svitare il tappo disinnesto dal coperchio di chiusura Gearbox disengagement
con chiave esagonale maschio (vedi tabella 1. Unscrew the disengagement plug from the end
seguente). cover by a male hex head wrench (see following
2. Avvitare una vite M6x50-8.8 nel filetto del solare di table).
prima riduzione. 2. Tighten a screw M6x50-8.8 in the thread hole of the
3. Sfilare il solare di prima riduzione dal riduttore. 1st reduction sun gear.
i Informazioni Ripristinare il livello dell'olio se

3. Take out the 1st reduction sun gear from the
gearbox.
necessario.
4. Serrare il tappo disinnesto del coperchio di chiusura i Information If necessary, refill with lubricant
con una chiave dinamometrica esagonale maschio oil.
alla coppia indicata nella tabella seguente. 4. Tighten the disengagement plug of the end cover by
a male hex head torque wrench at a torque shown
on the following table.
Innesto riduttore Gearbox engagement

1. Svitare il tappo disinnesto dal coperchio di chiusura 1. Unscrew the disengagement plug from the end
con chiave esagonale maschio (vedi tabella cover by a male hex head wrench (see the following
seguente). table).
2. Assemblare il solare di prima riduzione nel riduttore. 2. Assemble the 1st reduction sun gear into the
gearbox.
i
Ripristinare il livello dell'olio se
Informazioni
necessario. iInformation If necessary, refill with lubricant
3. Serrare il tappo disinnesto del coperchio di chiusura oil.
con una chiave dinamometrica esagonale maschio 3. Tighten the disengagement plug of the end cover by
alla coppia indicata nella tabella seguente. a male hex head torque wrench at torque shown on
the following table.

Riduttore Disinnesto tipo Ruota/Wheel A (mm)
Nm
Gearbox Disengagement type (max rpm) Chiave/Key
7 05 C K D 100 19 90±10
7 06 C K D 60 22 250
7 07 C K D 40 18 250
7 09 C K D 40 22 250
Funzionamento: Operation:
1. Riduttore innestato: 1. Engaged gearbox:
In questa condizione il moto viene trasmesso dal At this condition the motion is trasmitted from the
motore idraulico al riduttore. hydraulic motor to the gearbox.
2. Riduttore disinnestato: 2. Disengaged gearbox:
Attenzione In questa condizione il motore e Warning At this condition the hydraulic motor
il freno di stazionamento sono disinseriti and static brake are disconnected to the
rispetto al riduttore: la ruota motrice è folle per gearbox: the wheel is idle so the machine can
cui la macchina può muoversi liberamente. move freely.
i Informazioni A seguito di un disinnesto, i

Information Following disengagement,
innestare sempre il riduttore nel momento in cui la always engage the gearbox when the machine is
macchina venga utilizzata normalmente. used normally.
8.0 VARIANTI 8.0 VARIANTS

Su richiesta i riduttori possono essere forniti con varianti If requested the gearboxes can be supplied with variants
preventivamente definite in fase di ordine a seguito di previously specified when ordering after agreement with
accordi con il cliente. the customer.
1. Lubrificazione: I riduttori possono essere forniti 1. Lubrication: The gearboxes can be supplied with
con diversi tipi di olio lubrificante al giusto livello. different types of lubricant oil at level.
2. Verniciatura: Le superfici esterne del riduttore 2. Painting: External surfaces of the unit can be
possono essere verniciate con diversi smalti a painted with different finish paint coats.
finire. 3. Identification labels: Identify visually different
3. Bollino identificativo: Identifica visivamente product configurations.
differenti configurazioni di prodotto. Variants are described on the product installation
Le varianti del riduttore sono descritte nel disegno di drawing attached.
installazione del prodotto allegato.

9.0 MANUTENZIONE 9.0 MAINTENANCE
In caso di normale funzionamento il motoriduttore non Under normal operating circumstances, no routine
necessita di alcuna manutenzione ad eccezione del maintenance is required, except routine oil checks and
controllo e cambio olio. Sono necessari interventi di oil changes. As recommended in this manual, unusual
assistenza solo in seguito ad anomalie di operating characteristics, such as noise or overheat,
funzionamento. Osservare scrupolosamente le should indicate further investigation. Always follow
avvertenze indicate al paragrafo "Informazioni sulla instructions set out in paragraph "Information on
sicurezza" safety"
Eseguire i controlli ed attività secondo la tabella For a proper maintenance of the gearbox, the following
seguente: checks and operations have to be done.
Controllo / Inspection Frequenza / Frequency Azione / Action

Serraggio viti Dopo le prime 50 ore di lavoro del riduttore Verificare serraggio viti
Tightening screws After the first 50 operating hours of the gearbox Screws tightening torque check
Livello olio Ogni 150 ore di lavoro del riduttore Aggiungere olio se necessario
Oil level Every 150 operating hours of the gearbox Refill oil if necessary
Primo cambio olio A 150 ore di lavoro del riduttore Sostituire olio
1st oil change At 150 operating hours of the gearbox Oil replacement
Cambi olio successivi (olio minerale) / Next oil change (mineral oil)
Condizioni standard Ogni 1000 ore di lavoro del riduttore o 12 mesi Sostituire olio
Standard conditions Every 1000 operating hours or 12 mounths Oil replacement
Condizioni gravose Ogni 500 ore di lavoro del riduttore o 12 mesi Sostituire olio
Heavy duty conditions Every 500 operating hours or 12 mounths Oil replacement
Cambi olio successivi (olio sintetico) / Next oil change (sinthetyc oil)
Condizioni standard Ogni 2000 ore di lavoro del riduttore o 24 mesi Sostituire olio
Standard conditions Every 2000 operating hours or 24 mounths Oil replacement
Condizioni gravose Ogni 1000 ore di lavoro del riduttore o 24 mesi Sostituire olio
Heavy duty conditions Every 1000 operating hours or 24 mounths Oil replacement
I valori riportati in tabella si riferiscono a condizioni The values listed on the table above refer to general
generali di utilizzo del riduttore. In caso di manutenzioni working conditions values of the gearbox. In case of
con tempistiche differenti, queste sono oggetto di scelte maintenance with different schedules, they are subject
tecniche effettuate durante la definizione del prodotto. to technical choices made during the product definition.
i
In caso di manutenzioni importanti
Informazioni
e complesse, fare riferimento ai Disegni Esplosi e i Information In case of important and complex
Liste Ricambi fornibili su richiesta ed alle maintenance operations, make reference to The
prescrizioni contenute nel presente manuale Spare Part Lists Exploded View which can be
tecnico. supplied under request or the suggestions of this
Se sono necessarie istruzioni supplementari o se manual.
dovessero nascere problemi particolari, non esitate a Do not hesitate to contatct the gearbox distributor or
contattare il distributore o direttamente il nostro servizio manufacturer if further instructions are necessary or in
tecnico al sito web "www.bonfiglioli.com". case of particular problems, web site
"www.bonfiglioli.com".

9.1 Localizzazione guasti 9.1 Trouble shootings
La seguente tabella è stata realizzata per una The following table is realized to localize troubles in
individuazione dei guasti nei motoriduttori per track drive.
traslazione completi di motore idraulico.
Anomalie / Anomalies Cause / Causes Rimedi / Remedies
Perdita olio esterna / External oil leakage:

Dalla tenuta frontale Tenuta frontale danneggiata Sostituzione tenuta frontale
From the lifetime seal Lifetime damaged Replace lifetime seal
Dal coperchio Guarnizione O-ring danneggiata Sostituzione guarnizioni O-ring

From the end cover O-ring seal damaged Replace O-ring seals
Guarnizione tappo danneggiata Sostituzione guarnizione tappo

Plug seal damaged Replace plug seal
Tappi o viti allentate Serrare tappi/viti

Plugs or screws loose Tighten the plugs/screws
Dai tappi olio
From the oil plugs
Livello olio troppo elevato Verifica livello olio
Oil exceeding max. level Check the oil level
Tappo sfiato ostruito Pulire o sostituire il tappo

Breather plug clogged Clean or replace the plug
Guarnizioni danneggiate Sostituzione guarnizioni

O-Ring seals damaged Replace O-Ring seals
Dal motore idraulico Tappi o viti allentate Serrare tappi/viti

From the hydraulic motor Plugs or screws loose Tighten the plugs/screws
Interno motore danneggiato Verifica motore idraulico

Internal motor parts damaged Check hydraulic motor
Eccessiva rumorosità / Too much noise:
Interno al motore idraulico

Contattare Assistenza Tecnica
(rumore meccanico) Interno motore danneggiato
Bonfiglioli
Inside the hydraulic motor Internal motor damaged
Contact Bonfiglioli Service Dpt.
(Mechanical noise)
Rumore idraulico (in fase di motor speed)

rallentamento velocità motore)
Impianto idraulico malfunzionante
Hydraulic noise
Hydraulic circuit malfunctioning
(during the slowing down of the
Verificare impianto idraulico
Verify hydraulic circuit
Interno al riduttore
(zona ingranaggi) Danneggiamento interno
Bonfiglioli
Inside the gearmotor Internal damage
(reductions)

Anomalie / Anomalies Cause / Causes Rimedi / Remedies
Altro / Other:
Verificare livello olio e aggiungerne
Livello olio scarso se necessario
Insufficient oil level Check the oil level and refill if
necessary
Surriscaldamento Olio idraulico troppo caldo Verificare circuito idraulico
Overheating Hydraulic oil too warm Check the hydraulic circuit
Incompleta apertura freno Verificare pressione apertura freno

Brake not fully released Check brake release pressure
Potenza insufficiente Interno motore danneggiato Contattare Assistenza Tecnica

Insufficient power Internal motor parts damaged Bonfiglioli
Motore alimentato non correttamente Verifica circuito idraulico

Motor feed not correct Check the hydraulic circuit
Velocità insufficiente
Insufficient speed Rendimento volumetrico del motore Contattare Assistenza Tecnica

basso Bonfiglioli
Low volumetric efficiency Contact Bonfiglioli Service Dpt.
Malfunzionamento freno di stazionamento

Parking brake malfunctioning
Coppia frenante insufficiente -Dischi freno usurati Sostituzione dischi freno

Insufficient braking torque -Brake discs worm Replace brake disc pack
-Parti danneggiate Verifica componenti freno

-Damaged parts Check brake components
Motore idraulico bloccato
Bonfiglioli
Hydraulic motor locked
Traslazione cingolo bloccata Freno bloccato Verifica completa apertura freno

Sprocket locked Parking brake locked Check the complete brake release

Componenti meccanici danneggiati
Bonfiglioli
Mechanical components damaged

9.2 Dismissione e rottamazione del prodotto 9.2 Dismantling and destroying the product
La dismissione del motoriduttore va effettuata When dismantling the track drive follow the
rispettando le seguenti indicazioni. indications given below.
1. Smontare il motoriduttore dalla sua sede e svuotare 1. Remove the track drive from the machine frame and
l'olio lubrificante. let the lubricant oil flow.
2. Smontare completamente il motoriduttore e 2. Completely dismount the track drive and remove all oil
rimuovere l'olio e il grasso dai componenti. and grease from its parts.
3. Avviare i materiali pericolosi e/o inquinanti ai rispettivi 3. Send all dangerous and/or polluted parts to the
centri di smaltimento, come richiesto dalle leggi authorised demolishing centres whilst keeping in line
vigenti in materia. with respective local rules and regulations.
Tab. "Valori coppie di serraggio viti / Screws tightening torque values"

8.8 10.9 12.9
(Nm) (ft*lbs) (Nm) (ft*lbs) (Nm) (ft*lbs)
M8 25 18,4 35 25,8 42 31
M10 50 36,9 70 51,6 85 62,7
M12 86 63,4 120 88,5 145 106,9
M14 140 103,2 195 143,8 235 173,3
M16 215 158,6 300 221,2 350 258,1
M18 295 217,6 415 306 495 365
M20 415 306 585 431,4 705 519,9
M22 565 416,7 800 590 960 708
M24 720 531 1000 737,5 1220 899,7
M27 1050 774,3 1500 1106,2 1800 1327,4

M30 1440 1061,9 2020 1489,7 2430 1792

Rev.
Data / Date
05/09/2011
N PARAGRAFO PARAGRAPH 0.1 0.2 0.3 0.4
1.0 INFORMAZIONI GENERALI GENERAL INFORMATIONS
1.1 Scopo del manuale Manual aim
1.2 Informazioni sulla sicurezza Information on safety
2.0 IDENTIFICAZIONE PRODOTTO PRODUCT IDENTIFICATION

2.1 Designazione prodotto Product description
3.0 NOTE NOTES

3.1 Condizioni di fornitura Delivery conditions
3.2 Trasporto Handling / Transport
3.3 Stoccaggio Storage
3.4 Sollevamento e movimentazione Lifting and handling
3.5 Peso del riduttore Gearbox weigh
4.0 INFORMAZIONI TECNICHE TECHNICAL INFORMATION
5.0 INSTALLAZIONE INSTALLATION

5.1 Realizzazione delle flangiature Construction of the flanges
5.2 Installazione del motoriduttore su macchina Installation of the track drive on machine
5.3 Fissaggio ruota motrice Sprocket fixing
5.4 Senso di rotazione Direction of rotation
5.5 Collegamento dell’impianto oleodinamico Connection of the hydraulic system
5.6 Collegamento del freno Connection of the brake
6.0 LUBRIFICAZIONE LUBRICATION

6.1 Lubrificazione riduttore Gearbox lubrication X
6.2 Riempimento olio Oil filling
6.3 Scarico e sostituzione olio Oil draining and replacement
6.4 Riduttore fornito con olio Gearbox factory filled with oil
6.5 Caratteristiche dell’impianto oleodinamico Characteristics of the Hydraulic System
7.0 MESSA IN ESERCIZIO E RODAGGIO START UP AND RUNNING IN

7.1 Disinnesto meccanico Mechanical disengagement
8.0 VARIANTI VARIANTS
9.0 MANUTENZIONE MAINTENANCE

9.1 Localizzazione guasti Trouble shootings X
9.2 Dismissione e rottamazione del prodotto Dismantling and destroying the product
Questa pubblicazione annulla e sostituisce ogni precedente edizione This publication replaces and supersseds any previous issue and
o revisione. la BONFIGLIOLI TRASMITAL si riserva il diritto di revision. BONFIGLIOLI TRASMITAL reserves the right to implement
apportare modifiche senza preavviso. E' vietata la riproduzione anche modifications without notice. This manual cannot be reproduced, even
parziale senza specifica autorizzazione. partially, without prior written consent.

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FOREWORD
Dear Customer,
Congratulations! We welcome you to the family of Ashok Leyland.
This User Guide has been prepared to acquaint you with the operation and maintenance of Industrial, Marine,
Genset and Harvester Engines. Care has been taken to include as much useful information as possible. Operators
are requested to get familiarised with this guide, before operating the engine.
Every reasonable effort has been made to ensure that this manual is accurate. Neither Ashok Leyland nor any of AL
Dealer shall in any circumstances be held liable for any inaccuracy or the consequences thereof.
In accordance with Ashok Leyland Limited (the Company’s) policy of continuous product improvements, the company
reserves the right to change the procedures, material, specifications, dimensions or design referred to in this manual,
at any time and without prior notice.
Operators are strongly advised to get the service and repairs done at the workshops of Ashok Leyland authorised
Dealers/Service Centres and use only Leyparts. This would ensure smooth implementation of warranty supports
extended.
We welcome your suggestions and feed back on the contents of this manual. Should you require any clarifications
concerning the contents of this manual, please write to:
POWER SOLUTIONS BUSINESS

No.1, Sardar Patel Road, Guindy, Chennai - 600 032.
PUB. NO. OM:INDMARGEN:08:2013

CONTENTS
Chapter 1 - Model Coverage Chapter 6 - Maintenance Schedule
Recommended Lubricants
Chapter 2 - Preservation and pre-recommissioning
procedure Filling capacities
Oil change intervals - Genset Engines
Chapter 3 - Gauges and Engine Fail Safe System
Oil change intervals - Industrial and
Chapter 4 - Operating Procedure Marine Engines
Before Starting the Engine Chapter 7 - Marine Engine and Accessories
Frost Precautions
Installation instructions with mechanical
Do’s and Don’ts gear box
Seacock and strainer
Chapter 5 - Maintenance instructions
Marine oil cooler (AL Engine)
Fuel System
Lubrication System Marine heat exchangers
Cooling System Sea water pump

Air Intake System Gear Box (for AL Engine)
Turbocharger Ghatge patil gear box
L Series Integrated Speed Control Screw propeller
(Applicable to 100 - 125 KVA) Marine hydraulic gear box 135A
Warning / Emergency Stop
Chapter 8 - Dealer network
1. Model coverage
MODEL COVERAGE: H4 SERIES - GENSET ENGINE
1 MODEL ALGPWO4DMK1/HA4D AL4DTG3/HA4DT AL4DTIG2/HA4DTI
Rating (KVA) 40/45 50/62.5 82.5
Type Diesel, 4 stroke, 4 cylinder in-line, overhead valve, water cooled
Aspiration Natural Turbocharged Turbocharged,

After cooled.
Engine Max (HP) 54.3 85.2 109.4
Engine rated (HP) 49.4 77.5 103.2
Engine rpm 1500
Bore & Stroke (mm) 104 x 118
Displacement (litres) 4.009
Compression ratio 17.9 : 1
Engine oil capacity - Total (litres) 9.3
Cooling system capacity (litres) 17.5
Electrical system 12 V
Direction of rotation Anti-clockwise from rear
Firing order 1-3-4-2
Battery capacity (AH) 120
1.2 MODEL COVERAGE

MODEL COVERAGE: AL6DTI SERIES - GENSET ENGINE
1
MODEL HAG6DTI2U/AL6DTIG1 HAG6DTI2S/AL6DTIG2
Rating (KVA) 100 125
Aspiration Turbocharged, After cooled
Engine Max (HP) 136.1 170.5
Engine rated (HP) 123.7 155
Engine rpm 1500
Engine oil capacity - Total (litres) 17.5 17.5
Cooling system capacity (litres) 19 22
Electrical system 12V / 24V
Firing order 1-4-2-6-3-5
MODEL COVERAGE 1.3

MODEL COVERAGE: AL6DTI SERIES - GENSET ENGINE
1
MODEL AL6DTIG3 AL6DTIG4
Rating (KVA) 140 160
Aspiration Turbocharged, After cooled
Engine Max (HP) 191.4 218.4
Engine rated (HP) 174 198.5
Engine rpm 1500
Engine oil capacity - Total (litres) 17.5 17.5
Cooling system capacity (litres) 22 22
Electrical system 24V
1.4 MODEL COVERAGE

MODEL COVERAGE: H4 SERIES (NON EMISSION) - INDUSTRIAL / AGRICULTURE ENGINE
1
MODEL ALUWO4D ALUWO4CT
Aspiration Natural Turbocharged
Engine Max (PS) 42.4 - 88 47.4 - 116
Engine rpm 1500 - 2800 1200 - 2600
Bore & Stroke (mm) 104 x 118 104 x 113
Displacement (litres) 4.009 3.84
Engine oil capacity - Sump (litres) 7.5
Electrical system 12 V - 24 V
Firing order 1-3-4-2
MODEL COVERAGE 1.5

MODEL COVERAGE : H4 SERIES (BSIII) - INDUSTRIAL / HARVESTER
1
MODEL ALH4CTIC3 ALHT4CTIC3
Aspiration TCIC TCIC
BHP (Gross) 76 101
RPM 2200 2200
BoreXStroke (mm) Ø104 x 113 Ø104 x 113
Displacement (Lts) 3.84 3.84
Compression Ratio 17.9 : 1 17.9 : 1
Lub oil Sump Capacity (Lts) 7.5 7.5
Starting System Voltage Vdc 12V/24V 12V/24V
Direction of Rotation Anti-clockwise from rear
Firing Order 1-3-4-2
1.6 MODEL COVERAGE

MODEL COVERAGE : HA6DTI SERIES - INDUSTRIAL ENGINE ( NON EMISSION)
1
MODEL ALUW06DTI
Aspiration Turbocharged & Intercooled
BHP (Gross) 169-170 180 181 188
RPM 2100-2200 2400 2500 1800
BoreXStroke (mm) Ø104 x 113
Displacement (Lts) 5.76
Compression Ratio 17.7:1
Lub oil Sump Capacity (Lts) 16
Starting System Voltage Vdc 24V
Firing Order 1-4-2-6-3-5
MODEL COVERAGE 1.7

MODEL COVERAGE : H6ETIC3 SERIES - INDUSTRIAL / HARVESTER ENGINE (BS III)
1
MODEL H6ETIC3RD H6ETIC3RU H6ETIC3RS
BHP (Gross) 101 133 160
RPM 2200 2200-2400 2200-2300
Starting System Voltage Vdc 12V / 24V
1.8 MODEL COVERAGE

MODEL COVERAGE: H4 SERIES - MARINE ENGINE
1
MODEL ALMW04D
Aspiration Natural
Engine Max (PS) 50 62.5 68
Engine rpm 1500 1800 2000
Bore & Stroke (mm) 104 X 118
Displacement (liters) 4.009
Engine oil capacity - Sump (Ltr) 7.5
Firing order Anti-clockwise from rear
1-3-4-2
MODEL COVERAGE 1.9

MODEL COVERAGE: ALM6DTI SERIES - MARINE ENGINE
1
MODEL ALM6DTI
Engine Max (PS) 160 179 190 205
Engine rpm 1500 1800 2000 2500
Bore & Stroke (mm) 104 X 113
Engine oil capacity - Total (ltr) 18
Firing order Anti-clockwise from rear
1-4-2-6-3-5
1.10 MODEL COVERAGE

MODEL COVERAGE : HAM6ETI3 SERIES - MARINE ENGINE
1
MODEL HAM6ETI3K/1 HAM6ETI3U/1
BHP (Gross) 151 172
RPM 2000 2000
Starting System Voltage Vdc 12V / 24V
MODEL COVERAGE 1.11

MODEL COVERAGE - AL 412 TAC3 CEV SERIES - INDUSTRIAL ENGINES
1 GENERAL DATA
Type Diesel 4 stroke cycle, vertical 6 cylinder, inline overhead valve, water cooled,
turbocharged, EGR filtered & EGR cooled
Combustion System Direct injection system
Cylinder bore X stroke 107.18 mm X 120.65 mm
Piston displacement 6.540 Lit
Direction of rotation Anti-clockwise from flywheel side
OUTPUT DATA
Industrial Engines
Maximum output (KW) 128-136
Rated rpm 2200-2400
1.12 MODEL COVERAGE

2. Preservation and
pre-recommissioning procedure
b) Remove the injectors and spray 20 cc 1.1 Clean all external parts thoroughly.
PRESERVATION AND PRE- of engine inhibiting oil (Shell Ensis oil Direct the jet of air to remove all dust.
COMMISSIONING PROCEDURE SAE 10, Castrol storage oil 30, Servo 1.2 Uncover all openings and appropriate
preserve 30) through injector hole. connections should be made.
STORAGE OF ENGINES AT NORMAL
Crank the engine for about 30
AMBIENT TEMPERATURE Remove the tapes from fuel inlet to the
2 seconds. Then fit back the injectors.
feed pump of the fuel injection pump.
Whenever engines are in storage, proper c) Spray liberally anti-corrosive oil over
care should be taken as detailed below: Remove the tape from the outlet of the
rocker levers, push rods, FIP plunger
breather pipe.
If stored for a short period: ( below 6 springs and tappets.
1.3 Remove fuel filters and fit new ones.
months) d) Drain the lubricating system and
Please refer to Service Manual for
replenish the same with engine
(a) The engine should be thoroughly procedure.
inhibiting oils.
washed, to remove any deposits of mud 1.4 Remove injectors and check for correct
which may be salt-laden. e) It is advisable to drain the cooling
opening pressure and refit as follows:
system. A board is to be hung on the
(b) The engine should be stored in a Loosen high pressure pipe
engine indicating that cooling system
covered area, on plain hard surface. connections at pump and injector end
has been drained out to avoid
(c) Disconnect battery terminals. accidental starting of the engine. and remove. Also remove the injector
(d) Once a week the engine should be leak off pipe.
f) It is advisable to drain the fuel tank as
started and run for a few minutes with well as the fuel filters to avoid formation Extract the injector. Plug the inlet and
coolant and lub oil system filled as per of gum deposits and the possibility of leak off opening with protection caps.
recommended lub oil & engine coolant. difficult starting later. Wipe off dirt and loosen carbon from
If stored for longer periods: ( more than injector with a cloth.
g) Completely seal with masking tape the
6 months) engine intake, exhaust tail pipe, Connect the injector to the nozzle tester.
a) The batteries should be removed and breather pipe, fuel feed pump inlet and Operate the hand lever of the tester for
prepared for storage in a dry place. Top the vent hole of the fuel tank. about 10-12 strokes. The nozzle should
up with distilled water and charge fully spray in a well atomized form.
PRE-COMMISSIONING HINTS
before storage. Check and charge at For checking the opening pressure
De-preservation procedure
regular intervals during storage. depress the hand lever until the nozzle
1. De-preserve the engine as per ejects the test oil and the pressure
procedure given below:
2.02 PRESERVATION AND PRE-RECOMMISSIONING PROCEDURE
gauge reading suddenly drops. Note date of re-preservation must be entered Connect the injector to the nozzle tester.
down the reading at this stage. If the in a label attached to the engine. Cancel Connect the pressure gauge to the
reading differs from the prescribed the label showing the first preservation. nozzle tester to the injectors. Operate
value adjust by changing the total This must be repeated every 12 the hand lever of the tester for about
thickness of the shims. months, if the period of storage exceeds 10- 12 strokes. The Nozzle should
While refitting the injector, check and a period of one year. spray in a well atomised form. 2
clean the nozzle bore in the engine. 2.1 The engine must be prepared for re- For checking the opening pressure
Replace the injector sealing washer . preservation. depress the hand lever until the nozzle
Tighten the nozzle clamp to the 2.2 Clean all external parts, thoroughly. ejects the test oil and pressure gauge
recommended torque of 4.20 to 4.80 reading suddenly drops. Note down
Direct the jet of air to remove all dust.
kgm. Flush the high pressure pipes the reading at this stage. If the reading
2.3 Uncover all openings and appropriate differs from the prescribed value adjust
thoroughly and connect to injector.
connections should be made. by changing the total thickness of the
Connect the leak off pipes to the
injector. Remove the tapes from fuel inlet to the shims.
Drain engine inhibiting oil from oil
feed pump of the fuel injector pump and While refitting the injector, check and
outlet of the breather. clean the bore in the engine. Replace
sump and fill with recommended lub
oil. 2.4 Remove fuel filters and fit new ones. the injector sealing washer . Tighten
Please refer to Service Manual for the the nozzle clamp to the recommended
Fill the coolant system with torque of 4.20-4.80 kgm. Flush the high
procedure.
recommended engine coolant. pressure pipes thoroughly and connect
2.5 Remove injectors and check for correct
Flush the diesel tank and remove vent to injector. Connect the leak off pipes
opening pressure and refit.
hole mask. Fill the diesel tank with fuel. to the injector.
Loosen high pressure pipe
Now the engine is ready for installation. 3. Run the engine for 15 minutes with the
connections at pump and injector end, following rust preventive agents:
2. If the engine is stored beyond one year, and remove. Also remove the injector
re-preservation and repacking must be leak off pipe. a) Fill water jacket with water containing
carried out 1% shell bocut cutting compound or
Using special tool, extract the injector. any water soluble cutting compound.
1. If the period of preservation exceeds Plug the inlet and leak off opening with
one year then re-preservation must be b) Connect fuel feed pump to a mixture of
protection caps. Wipe off dirt and
carried out during the 12th month. The diesel and 10% flushing oil such as
loosen carbon from injector with a cloth.
lubrex or equivalent.
PRESERVATION AND PRE-RECOMMISSIONING PROCEDURE 2.03
c) Fill engine sump with Servo Preserve d) Breather (e) Replace the fuel filter elements.
SAE - 40 or equivalent. 3.3 Drain (f) Flush out fuel tank and fill the diesel.
d) After 15 minutes disconnect the fuel a) Coolant from water jacket
line and allow the engine to run so that (g) Check the injectors thoroughly for
b) Oil from FIP. correct spray characteristics and
the fuel in the filter and pump are
2 exhausted. c) Attach a label showing ‘NO OIL & pressure setting.
COOLANT’ and date of preservation.
3.1 Stop engine and remove (h) Check the complete electrical
4. Repacking
a) Air cleaner and cylinder head cover charging circuit. Clean starter solenoid
Cover the engine with polythene sheet point and battery terminals. Also check
b) Injectors
and place inside the packing case.
c) Fuel pump inspection cover starter motor and alternator bushes for
Close the case and keep in an area
Crank engine with starter motor. free of moisture. proper contact with the commutator.
During cranking spray 10 cc of rust 5. To start the engine after a long storage (i) Replace air system and cooling
preventive oil (Servo Preserve SAE - 40) (a) After a long storage the engine must system hoses.
into each injector hole in the cylinder head be checked and gaskets and seals (j) Start the engine and observe for
and 20 cc through the inlet manifold. (removed and fitted back during re- engine noise.
Stop cranking after spraying oil into the preservation) must be replaced.
(k) Monitor engine coolant temp, Oil
cylinders and manifold. (b) Flush the cooling system completely.
pressure .
Refill the cooling system with
Spray oil (Servo Preserve (SAE 40) on
recommended coolant. (l) Check for oil, coolant & air leak and for
a) Rocker assembly any abnormal noise.
(c) Remove masking tapes from the
b) Fuel pump plunger springs and engine intake, the exhaust manifold (m) If everything is alright, put the
tappets and the vent hole of the fuel tank. engine on load and observe engine
3.2 Replace all components and seal all (d) Drain the oil from the engine sump. parameters and performance.
openings:
Fill the sump with the recommended
a) Air cleaner engine oil to the required level and
b) Coolant - inlet and outlet replace lub oil filter.
c) Fuel inlet
2.04 PRESERVATION AND PRE-RECOMMISSIONING PROCEDURE

3. Gauges and Engine Fail Safe System
TEMPERATURE GAUGE AMMETER
GAUGES
Normal operating temperature is reached It indicates the rate at which the battery is
when the needle registers in the 75° - 85° being charged while in operation.
OIL PRESSURE GAUGE of the gauge. If the needle enters into the
Under normal engine operating When the engine is started, it is normal for
over heating range during normal
conditions, the needle registers in the the pointer to go towards the negative side
operation, a fault may be indicated. In the
centre section of the gauge. and when once the engine starts running
case of overheating an indicated fault
at the rated rpm the pointer should normally
should be investigated immediately. Stop
3 Should the indicator move into shift to the positive side and show charging
the engine and allow the engine to cool for
low oil pressure section of the rate. Battery charging indicator lamp on the
several minutes.
gauge, stop immediately and dash board, will also go off when the engine
Look for coolant leaks. If the temperature speed crosses the idling speed.
switch off the engine. After
does not drop, stop the engine. Check
approximately ten minutes (to
drive belt condition and coolant level, if fault RPM AND HOUR METER:
allow the oil settle in the sump)
is not found, do not start the engine. In order to assess the engine performance
check the oil level and top up
Contact your authorised dealer for and for proper maintenance, the RPM and
as required. If the oil level is
rectification. Hour meter have been fitted on the engine.
found to be within maximum/
minimum marks on the dip During normal operation, the cooling The drive is taken from the oil pump drive
system contains very hot coolant under shaft.
sticks, do not run the engine
pressure.
as the cause of the low oil
BATTERY
pressure is other than low-oil-
For topping up use only For battery specification, please refer to
level.
LEYPOWER COOLANT 5000 respective OEM/PEM.
Contact our authorised dealer for pre mixed coolant directly. Do
For specific gravity, please follow the
investigation. not dilute with plain or instructions of respective battery
demineralised water for top up. manufacturer.
3.02 GAUGES AND ENGINE FAIL SAFE SYSTEM

ENGINE FAILSAFE SYSTEM Linkage between Stop 1. Use socket for tightening
Solenoid and FIP Stop Lever is the solenoid terminals and
This system consists of the following items preset at the factory and it lock nut. Do not use
should not be disturbed in the
combination plier.
1. Engine Failsafe Unit field. Improper linkage
2. Wires connected at
adjustment would cause
2. Stop solenoid solenoid burning / solenoid solenoid terminal should
malfunctioning. If the setting is not touch the body.. Bare 3
3. Pressure Switch disturbed, contact our wire end not to be
authorised dealer to correct connected at solenoid
4. Temperature Switch the setting. terminals as it may touch
the solenoid body. Use 5
5. Wiring Harness
mm eyelet end.
While starting the Genset
The Engine Failsafe System is an Engine for the first time for a
electrical system to protect the Genset day, run the engine for few
Engine against low oil pressure and high seconds and switch-off the
coolant temperature. Engine will be Main toggle switch and check
automatically shutdown when the oil whether the engine stops. If
engine stops, it ensures the
pressure decreases below 0.55 ± 0.15 ksc
proper functioning of Engine
or the coolant temperature increases
Failsafe system. If the engine
beyond 98 +2 -1°C (i.e 97 - 100°C).
does not stop, identify the
cause of problem and rectify.
GAUGES AND ENGINE FAIL SAFE SYSTEM 3.03

FLOW CHART – FOR ENGINE FAILSAFE SYSTEM OPERATION

GENERAL/OPERATING INSTRUCTION: 5. If the oil pressure (or) coolant DO’S AND DON’TS – ENGINE FAILSAFE
temperature crosses the set limit, SYSTEM
1. Switch on the Main toggle switch.
while the engine is running, Engine
2. After switching on toggle switch the Do’s
will be shutdown automatically and
“charge indicator” lamp glows. It stops corresponding lamp glows and buzzer 1. Apply specified voltage to the system.
glowing as soon as Engine starts starts alarming till the main toggle is
running and indicates charge 2. If the solenoid connection with FIP stop
switched-off.
3
alternator is functioning. lever is disturbed, please follow
6. For normal stopping of the engine, “Solenoid Assembly Procedure”.
3. Start the Engine within 25 seconds.
switch-off the main toggle switch.
If the Engine is not started within by 3. Terminals of wiring harness should
7. The entire power circuit of Failsafe Unit be intact.
pass time of 25 seconds, solenoid will
is protected by a 30-amp fuse link that
pull and hold the FIP Stop lever for 25
4. Keep the Stop solenoid, temperature
can be rewired easily in the field.
seconds due to which low oil pressure
switch and pressure switches free
lamp glows and buzzer alarms. 8. “Fuse Fail” lamp glows only when fuse from oil / water / dust.
4. Wait till the solenoid releases the FIP wire is cut.
5. Welding, if any, to be carried out only
stop lever. Now switch-off Main toggle
9. Fault condition will be latched and after removal of battery supply in order
and again switch-on the same and
provides audio (by built-in buzzer) to protect the failsafe system.
make an attempt to start the Engine
visual (by glowing lamps) indication.
within 25 seconds, Engine should 6. When solenoid fails to stop the engine
start. If not trace the problem and 10. Initial low oil pressure during starting (or) overheats in normal shutdown
rectify. has been bypassed for 25 seconds. operation, disconnect the electrical

supply and stop the engine manually temperature switch and pressure
by pulling longer arm of solenoid. switch when the engine is running.
7. If fuse blown-out, replace with 6. Don’t keep hand in front of solenoid

specified rated fuse. when it is in operation as it may cause
injury.
Don’ts
3 7. Don’t assemble the wire cable, which

1. Don’t over tighten the terminals of
is connecting solenoid and FIP stop
Engine Failsafe Unit, Stop solenoid,
lever, too tight or too loose.
temperature switch and pressure
switch. 8. Don’t connect solenoid with AC supply.
2. The terminal connections at switches

should not touch each other.
3. The terminal connections at Stop

solenoid should not touch each other.
4. Don’t splash water on Engine Failsafe

Unit, Stop solenoid, temperature
switch and pressure switch.
5. Don’t attempt to connect / disconnect

the wirings of Stop solenoid,

TROUBLE SHOOTING OF ENGINE FAILSAFE SYSTEM
Defects Causes Remedy
Engine stops immediately Wrongly connected Temperature / Correct connection for switches:
after starting. Pressure switch terminals. Temp switch = COM & NO
Pr. Switch = COM & NC
Low oil level & adequate pressure not developed Check and fill oil.
Short-circuited wiring harness. Check and rectify.
3
Solenoid overheats / burns Loose connection at stop solenoid terminals Tighten the terminals.
& sparking at solenoid Wire rope is too tight and not allowing Loosen the lock nut and slightly slacken
terminals. stop solenoid to come to hold mode from the wire rope and tighten the lock nut.
energizing mode.
Wire rope is connected to FIP stop lever Assemble the link plate and connect the
without LINK PLATE. wire rope through link plate.
Loose connection at Engine Failsafe Unit’s Tighten the terminal.
Solenoid terminal.
Engine not stops when Wire rope is too loose. Connect the wire rope properly.
Main Toggle Switch is Loose connection at stop solenoid terminals. Tighten the terminals.
switched-off. Loose lock nut. Tighten the lock nut fully.
Low volt batteries. Connect healthy batteries.
Solenoid electric cables cut. Check and rectify the connecting cables.
Defective Main toggle switch. Rectify / replace.
Solenoid terminal.

TROUBLE SHOOTING OF ENGINE FAILSAFE SYSTEM
Defects Causes Remedy
Solenoid chatters while Wire rope is tight. Connect the wire rope properly.
stopping the engine.
Low volt batteries. Connect healthy batteries.
Loose connection at stop solenoid terminals. Tighten the terminals.

3 Solenoid terminal.
Solenoid fuse often blowing. Loose connection in fuse terminals. Tighten the terminals gently. Do not over
tighten.
Fuse carrier’s plastic base broken. Replace with new spare fuse. (Spare fuses
are provided in the solenoid rubber boot
externally.
Fuse wire touching the body. Keep the fuse wire away from the body/
replace new fuse.
Wire rope too tight. Connect the wire rope properly.
Low rated fuse wire connected. Use 30A fuse.
“Fuse fail” lamp glows in Engine Failsafe unit fuse wire is loose / cut. Rectify / replace with 30A fuse wire.
the Engine Failsafe Unit.
“Charge fail” lamp glowing “IND” wire connection at alternator end or Connect “IND” wire properly at Engine
even after few minutes of Engine Failsafe unit end has come out / failsafe unit. Fully insert the “IND” cable
engine operation. loose terminals. lucar terminal at Alternator end.

4. Operating procedure
The following subjects are discussed in this section
Before starting the engine
Frost precautions
Do’s and don’ts

After draining, place a notice on the engine
BEFORE STARTING THE ENGINE FROST PRECAUTIONS
to the effect that the cooling system is empty
(a) The radiator is full of coolant. If anti-freeze solution is not in use and the and the drain taps are open.
engine has to be left in the open with

(b) There is sufficient fuel in the tank.
temperatures close to freezing point, the
(c) Engine oil level is correct (dipstick) Engine with anti-freeze
cooling system must be completely
mixture in their cooling
drained by opening the two drain points
TOPPING UP THE ENGINE SUMP systems, need not drain the
which are situated as follows:
The engine oil level should be maintained cooling system.
between dipstick’s high and low marks. 1. Drain Plug fitted at the rear right hand
4
While checking the oil level, shut down the ENGINE ANTI-CORROSION OIL
side of the cylinder block.
engine. Wait for few minutes. Withdraw Useful for engines stored for long periods.
the dipstick from its holder, clean and refit. 2. Drain tap fitted on the radiator. (1) Shell Ensis oil, SAE. 10.
Withdraw again and note the level. Top up
as required with the clean recommended Drain tap/plug should be tested at frequent PRECAUTIONS-SUB-ZERO TEMPERATURE
grade of engine oil. intervals by inserting a length of wire to OPERATION
ensure that they are clear. This should be
TO START AND STOP THE ENGINE Cold start aid is not fitted in the engine. It
done as soon as they are opened, so that
Follow the instructions as given in the fail can be made available as optional fitment.
an obstruction freed by the wire may be
safe system (Chapter 3) The following instruction has to be
flushed out by the water,
followed if the engine is subjected to
operate in sub-zero temperatures.
4.02 OPERATING PROCEDURE

1. Upto 0°C the engine does not require 6. Injectors must be maintained in good
DO’S AND DON’TS
any special starting aids. condition.
GENERAL
2. Below 0°C and upto-15°C cold start 7. Engine timing should be as
aid “Thermostart” has to be fitted recommended. Never adjust by - Study this manual carefully and
depending on ambient temperature. advancing or retarding the injection follow the operating procedures.
timing.
0°C to -7°C Excess fuel - Engine life to a great extent depend
upon clean fuel oil. Always use
-7°C to -15°C Thermostart to be
clean diesel. Before filling the
fitted in the intake manifold. 4
diesel to tank filter it with fine cloth.
3. Battery should be kept in fully charged

- Keep the suction pipe at least 1”
condition (Rating to suit the
from the bottom so that water can
temperature).
settle down and can be drained
periodically.
4. Select the oil grade from
recommended lubrication chart to
- Never use kerosene. This will
suit the ambient temperature.
cause permanent wear of FIP
components and injectors and
5. Use the correct grade of fuel as
ultimately result in major
recommended for the prevailing
expenditure of engine over haul.
ambient temperature.
OPERATING PROCEDURE 4.03

- use always correct grade of engine - Periodically clean the hull during - Propellers can be safeguarded by
oil and coolant as per AL dry-dock so that hull surface is free providing zinc anodes.
recommendations. from sea weeds, algae and shell
growth. It is recommended to paint - In case of vibration felt in propeller
- Use always genuine engine oil and outer surface of hull with special and shafting check the conditions
fuel filters and replace them as marine paints. of propeller and stern tube.
recommended.
- It is recommended to have ballast - Check the propeller once in a

- Never use spurious filter elements
tanks, so that stability and month for stone hitting cavitation
especially gauge type filter
seaworthiness of the vessel can be and crack in the blades.
4 elements.
maintained at all weather
conditions by ballasting and - Check that sea cock is in open
Marine Engines
deballasting. position before starting the engine.
- Clean sea cock filter atleast once a

- Always remember that increase in - Check zinc anode condition in oil
week.
other board weights, and increase cooler and heat exchanger and
in length of fishnet always results replace if necessary.
- Check condition of bilge pump and
in increased fuel consumption and
see that bilge water is always
impose excess load on engine,
pumped out periodically.
clutch and gear box.
- Maintain the batteries properly.
4.04 OPERATING PROCEDURE

5. Maintenance instructions
Your engine has been designed to ensure ease of access to mechanical components.
This will enable you to carry out a number of simple maintenance tasks.
Therefore, keep to instructions provided on the following pages and you will be able to
perform the basic maintenance work yourself.
USED ENGINE OILS
WARNING: Prolonged and repeated contact may cause serious skin disorders,
including dermatitis and cancer.
Avoid excessive contact, wash thoroughly after contact.
Keep out of reach of children.

DUAL FUEL FILTER Filter Element Filter Changed Period
FUEL SYSTEM
Every 250 hours of operations.
Fuel additives should not be used. Renew Fuel Filter Element
- Unscrew centre bolt and withdraw the
Use good quality diesel.
bowl and filter insert. Install new
sealing ring and ensure it correctly
Keep fuel clean and prevent water from located.
entering the fuel system.
- Clean the bowl free of sediments.
Replace a genuine filter insert and refit
When filling the fuel tank in the rain or snow
the bowl. Bleed the fuel system.
care should be taken not to allow water in
the fuel tank. Do not forget to close the fuel
tank cap securely.
5
FUEL TANK
Remove the fuel tank. Thoroughly clean
the inside surface and strainer once in
every 6 months.
FEED PUMP Maintenance

Plunger type - mounted on Fuel Injection Filter inserts must be replaced at regular
Pump. Plunger is operated by the integral intervals.
cam as a part of FIP Cam Shaft.
5.2 MAINTENANCE INSTRUCTIONS

Fuel Filter cum Water separator - (Fleet Renewal procedure for Fuel Filter cum - Start the engine and ensure no fuel
guard) Water separator. leakage around the sealing rubber
- Remove old spinon fuelfilter using ring and filter assembly.
appropriate filter wrench and discard.
- Clean filter head base and ensure that
all the unwanted material is
completely removed.
- Check the filter mounting head for
tightness.
- Apply a thin coat of clean engine oil to
the rubber ring surface of the new filter.
Press the rubber ring firmly into the
Fuel filtering system consists of a strainer retaining groove in the filter. Do Not
(Fitted before feed pump) and fuel filter Use Grease.
cum water separator (Fitted on pressure
side before FIP). - Carefully read the installation
instructions printed on the pheriferal 5
For easy identification, fuel inlet and outlet of the filter, before fitment
ports are embossed clearly on the filter-
head. - Pre-fill the new filter with clean fuel.
Further, as a fool proof, the fuel inlet port is - Mark a reference point on the filter and
provided with M14 size and fuel outlet port filter head to identify the point. Ensure
is provided with M12 size threads. that the rubber sealing ring first
makes contact with the sealing surface
Maintenance of the head.
Under normal operating conditions, fuel
filter cum water separator to be replaced - Screw on the filter fully in and rotate 1/
at every 500 hours of operation and mud 2 turn further.
strainer to be replaced at every 1500 hours Renewal of Fuel Filter cum
of operation. water separator
MAINTENANCE INSTRUCTIONS 5.3

Procedure for draining water installation instructions printed on the Bleeding Procedure for Fuel System
Drain water from the unit as per the side of the filter canister. 1. Ensure that diesel is available in the
instructions provided on the component. - Start the engine and check for fuel tank. Arrest leakage if there is any. And
- Rotate the drain cock anti-clockwise leakage around the sealing gasket and ensure there is no blockage in the filter/
(as shown in the instructions printed filter assembly. pipe lines.
on the outside of the filter)
- Never use a spanner for rotating the 2. The suction strainer in fuel tank is
- Drain the water till the fuel starts to flow. drain cock. clean.
- Rotate the drain cock clockwise the 3. Diesel filters and their seals are is good
number of turns as indicated by the Drain water daily. Drain cock condition.
should be hand tightened fully.
Never use any spanner. 4. The filter in the banjo bolt on feed pump
suction pipe is clean
Fuel additives should not be
used. 5. Pump the plunger on lift pump and
ensure that air free diesel flow occurs
Use good quality diesel. Use
at the filter bleeding screw.
always low sulpher diesel fuel
(BS II Fuel) as per IS1460-2000. 6. Crank the engine few times by
5 loosening the high pressure injector
Keep fuel clean and prevent
pipes at the injector end and retighten
water from entering the fuel
after clear delivery takes place.
system.
When filling the fuel tank in the 7. Start the engine
rain or snow care should be 8. Even after priming if diesel does not
taken not to allow water in the appear at the outlet, remove the feed
fuel tank. Do not forget to close pump assembly. Check and rectify the
the fuel tank cap securely. defects.
Since nozzle tip is very
Draining Water sensitive, do not use emery Use always genuine fuel filter
from Water sheet or any hard material to inserts supplied by Ashok
Separator clean the tip of nozzles. Leyland.

LUBRICATION SYSTEM RENEWAL PROCEDURE FOR SPIN
ON OIL FILTER
Engine Oil level Checking
Withdraw the dipstick located on the LH
side of engine. With a clean cloth wipe the
dipstick scale and re insert fully.
3 5
Using suitable spanner loosen centre bolt
of filter bowl and withdraw the bowl
assembly. Discard the used filter element
and sealing 'O' rings at centre bolt and bowl
fitting face. Fit a new oil filter element after Remove old spin on oil filter using
placing the spring and the plate washer in appropriate filter wrench and discard.
position. Fit filter bowl with filter element
Withdraw the dipstick. If oil level is found to be to the filter head by centre bolt. Ensure - Clean filter head base and ensure that 5
between Min. and Max. marking oil level is that oil filter is not fitted in the inverted all the unwanted material is completely
sufficient for running. If oil level is at Min. mark position. removed.
or below topup engine oil to the Max. level
Open oil filler cap. Refill the engine with - Apply a thin coat of clean engine oil to
Engine Oil and filter change (Catrige type) the correct quantity of the specified grade the rubber ring surface of the new filter.
Ensure that the engine is warm. Draining of engine oil. Check the oil level on the Press the rubber ring firmly into the
of oil should be done within 10 minutes, dipstick and run the engine for a short time. retaining groove in the filter. Do not use
from shutdown. Allow 5 - 10 minutes for the oil to settle Grease.
down. This is essential when the oil filter
When the oil is completely - Carefully read the installation
has been changed and engine oil top.
drained install the drain plug instructions printed on the peripheral
with new washers and tighten of the filter, before fitment
securely.

- Pre-fill the new filter with clean lub oil. ENGINE OIL CHANGE (AL SERIES) TO CLEAN CRANK CASE BREATHER (AL
Unscrew drain plug and drain the oil SERIES)
- Mark a reference point on the filter and
filter head to identify the point. Ensure into a suitable container. Clean crankcase breather fixed on the
that the rubber sealing ring first makes Remove oil filter bowl by unscrewing tappet side cover.
contact with the sealing surface of the dome nut provided on filter head. Soak breather in a suitable solvent and
head. Withdraw the oil filter element gently clean it by blowing with compressed air.
and drain out engine oil.
- Screw on the filter fully in and rotate 1/2
turn further. Wash the oil filter bowl with fuel and No need to clean the breather
blow dry. for 6DTI engine. Breather
Start the engine and ensure no lub oil arrangement for 100 KVA is
Replace new filter element and
leakage around the sealing rubber ring different from 125 KVA.
sealing ring.
and filter assembly.
Fill the oil filter bowl with new engine
oil and refit using dome nut.
Open oil filler cap. Refill the engine
with the correct quantity of the
5
specified grade of engine oil. Check
the oil level on the dipstick and run
the engine for a short time. Allow 5 -
10 minutes for the oil to settle down.
This is essential when the oil filter
has been changed and engine oil
top.
Do not forget to fit the conical

spring provided below oil filter
element as this provides
suspension and sealing for the
filter element.

125,140,160 kVA engines are fitted 7. To ensure that the air in the engine
COOLING SYSTEM with coolant filter (Spin on type) in and the piping is properly expelled, set
the cooling system to filter the the engine speed slightly higher than
Charge air cooler and Radiator core impurities present in the system. normal idling speed. Raise the
cleaning and fin repair Replace coolant filter at every 500 coolant temperature above 82°C, then
When mud, debris, etc. are stuck up at hours. continue to idle the engine for another
the front of the radiator or charge air cooler 10 minutes.
Changing Coolant in Radiator
core, the passage of cooling air is
1. Do not loosen the drain plugs while 8. Stop the engine and after the engine
impaired. Hence such matter should be
the engine is still hot. If you do so, hot has cooled down sufficiently, check the
removed completely by washing with
liquid coolant can come out resulting coolant in the radiator. Add coolant to
water. Deformed fins also can impair
in personal injury. make up for any drop in the coolant
cooling and these should be repaired.
level.
2. Stop the engine. Loosen-the radiator
Replace cooling system rubber hoses. drain plug to drain the coolant. Drain
Check hoses for cracks, swelling or will improve if you remove the cap from Recommended Coolant
deterioration and replace if necessary. radiator.
Use LEYPOWER COOLANT 5000 pre
3. Drain the complete system and tighten
Coolant Filter (For 125,140,160 kVA mixed coolant. No need to add water. 5
the radiator drain plug.
Engines only)
4. Slowly feed coolant into the radiator The recommended coolant change interval
through the filler until the radiator is is 5000 Hrs. or 18 months whichever is
full. When supplying coolant from a
pail, pour it slowly to prevent air from earlier. The coolant is available in package
mixing with the coolant. sizes of 5 lts. & 1 lt.
5. When the level of the coolant reaches
the filler neck, squeeze the upper For topping up use only
radiator hose two or three times. This LEYPOWER COOLANT 5000
will cause air inside the hose to be pre mixed coolant directly. Do
expelled, and the level of the coolant
not dilute with plain or
will fall.
6. Properly close the radiator cap. demineralised water for top up.

Radiator stay Rod & Cowl arrangement The presence of the radiator cap prevents Adjustment of the driving belt tension of
Do not run the engine without radiator loss of coolant, entry of foreign particles water pump (Poly V belt arrangement)
cowl. Ensure that the radiator cowl and raises boiling point of coolant. The
mounting and fan blade clearance are in absent can lead to engine overheating and
proper order. reduction in engine life.
Check radiator stay bracket mounting
bolts for tightness. Also check the silent Water Pump (H Series)
block bush in stay rod and replace if found "H" Series engines are fitted with "integral
defective.
shaft and bearing" type water pumps with
Check radiator mounting bracket bolts for prepacked grease. No further greasing
tightness and the condition of the rubber required.
pads and replace if found defective.
Improper radiator mounting WATER PUMP (AL SERIES) Installation Procedure

can result in radiator hose Water circulation is by a centrifugal vane 1. Loosen the necessary fasteners, slacken
failures as well as core type pump. The pump bearings are taper the pulleys & remove the old belt.
5 cracks at dip soldered joints roller type with spacer at the middle. 2. Check pulley grooves for wear / damage
of top and bottom tanks. and replace the pulley if required.
The pump bearing require 3. Clean the pulley grooves for debris and
Radiator Cap lubrication during running as ensure not to apply oil or grease on the
it is having a grease filled cup. pulley grooves at the time of fitment.
Turn ½ to hear a click sound 4. Check alignment of the pulleys.
to feed in grease to water Misalignment of pulleys will
pump bearing. Refill the produce noise and shorten the
grease cup immediately after belt life.
reaching the last possible ½ 5. Mount the belt over pulleys and ensure
turn. that the belt ribs are seated in the
respective pulley grooves.

6. Tension the belt and tighten all the DO’s:
fasteners. Replace the belt if it is frayed
- Check belt tension at regular intervals or pieces of material missing
7. Run the engine for 3 to 5 minutes with and adjust as needed. or longitudinal cracks
the applied tension to allow the belt to intersect with transverse
- Check for any abnormal wear and
seat in the respective pulley grooves cracks.
damage in pulleys / Belt
properly. Reset tension.
- Check for pulley alignment
8. Apply initial belt tension of 700N by REMOVAL AND REFITMENT OF FAN BELT
adjusting the alternator position. - Make belts free of fluffs and dirt\ (COGGED BELT)
9. To ensure the applied tension, measure DON’TS: - Dismount the radiator side stay and
it in the middle of span between water- loosen radiator bottom mounting to
- Don’t over tension the belt
pump pulley and alternator using sway out a little to clear the cowl
electronic type tension gauge. - Don’t apply oil/grease or paint on covering the fan.
pulley grooves
Belt Tension Measurement Procedure - Loosen alternator link bracket and
- Don’t fix the belt improperly aligned loosen the fan belt fully. Inspect the
- Hold the sensing head steadily across
pulleys for damage and wear.
the belt span within 5 -10 mm distance - Don’t use worn out belts 5
above the top surface of the belt. - Replace the new fan belt and redo
- Don’t pry the belt using sharp tools.
- Tap the belt gently near the mid span the above in reverse.
using a rod or with similar tool to cause Visually inspect the belt. - For marine application - PTO to be
the belt span to vibrate. loosened to insert water pump belt.
- Check the required tension display on
the LCD panel on the tension meter. ADJUSTMENT OF THE DRIVING BELT
TENSION OF WATER PUMP
- If a reading is not obtained check that Loosen the alternator link bracket and
the sensing head and ensure that it is swing the alternator away from engine to
positioned properly. increase the fan belt tension. 1" to 1½"
- Repeat the same procedure to deflection on longest side of fan belt is
recheck. the limit.

AIR INTAKE SYSTEM TURBOCHARGER
Poor air cleaner maintenance will result in
INITIAL RUNNING
excess liner wear, high engine oil
Keep the engine at rated rpm for minimum
consumption, excess blow by and poor
2 minutes before applying load and also
pick up / not taking load. The maintenance
before switching of the engine. Do not run
schedule has been recommended to
engine at full load with oil pressure less
ensure adequate checks on air induction
than 1.5 kg/cm².
system, air cleaner element for normal
service requirements. More frequent Check all air ducts and gaskets for leak.
replacement may be required in severe 4) Replace the Secondary / Safety air Repair any leaks before proceeding. Inlet
dust conditions. Consult our authorised cleaner element after 3rd replacement of air compressor must be free from dust
dealer for specific requirements. of Primary air cleaner element or after and contamination.
DRY TYPE AIR CLEANER – SERVICE 2 years of duration whichever is earlier. MAINTENANCE
INSTRUCTION
DO'S
1) Ensure evacuator valve is intact. 1. Turbocharger does not require any
5 It is not the recommended to
2) Make sure Primary and secondary air maintenance.
operate the engine without air
cleaner elements sealing “O” rings for 2. Adhere strictly to recommended
filter, otherwise the dust and
proper adhesion between end plate maintenance schedule.
impurity will lead to early
of the element and the sealing ring and
failure. 3. Use of specified grade of engine oil
seating with air cleaning housing is
and oil filter and periodic change as
even. If “O” ring found damaged /
recommended in maintenance
incorrect sealing with housing, replace
schedule.
the air cleaner element also look for
any damage to air cleaner housing. 4. Replace air filter element as
recommended.
3) Change the Primary air cleaner
element when Red band appears in 5. Check for oil pressure at engine idling
vacuum indicator. condition minimum oil pressure should
be 1 kg/cm².

6. Allow the engine to run for 2 minutes DON'TS
after starting the engine. L SERIES INTEGRATED SPEED
- Don't run the engine with low oil CONTROL (Applicable to 100 - 125
7. Allow the engine to run for 2 minutes pressure. KVA)
before switching off the engine.
- Don't run the engine with leaky,
The Woodward L-Series combines the L-
8. When carrying out maintenance work restricted oil feed and drain pipes.
Series electric actuator with integrated
on the engine, the piping leading from
- Don't run the engine with blocked, speed control software to control the speed
or to the turbocharger must be
punctured, aged, deformed hose / pipe of an engine. The L-Series is a
removed, and the pipe openings on the
connections from the air cleaner to the microprocessor-based control that is
turbocharger to be closed properly.
turbocharger, turbocharger to charge incorporated into the actuator, creating a
9. Regularly check the oil feed and return air cooler and charge air cooler to the single integrated package. This eliminates
pipes for leaks, air intake system pipes inlet manifold. the need for an additional driver box and
and hoses for leakage, blockage and speed control box. The control uses state-
exhaust piping connections for - Don't run the engine with leaky
of-the-art speed sensing and control
leakages, blockage. connections, blocked, deformed
algorithms. The L-Series also performs
connections to the turbocharger turbine
comprehensive diagnostics for easy
10. Prior to fixing turbocharger to the inlet and from turbine outlet.
troubleshooting. It can be configured and 5
engine, fill the central housing with
- Don't tamper the fuel injection system tuned using the L-Series Service Tool. The
clean engine oil and ensure that, all
L-Series provides a building block
pipes are thoroughly cleaned before - Don't dismantle the turbocharger approach to total
connecting to the turbocharger. centre. e n g i n e
11. Check the fuel injection system for its management. The
proper functioning. modular bi-
directional actuator
12. Close all the turbocharger openings
design is attached
with protective plugs when it is not in
to the fuel pump.
use.
The L-Series
13. Contact Ashok Leyland dealer /
speed control
authorised centres for turbocharger
accepts a speed
complaints / service / overhaul.

signal (MPU), compares this to the speed
set point, and drives the 0–60 degree output WARNING / EMERGENCY STOP TRAINED PERSONNEL
shaft to the commanded position based An unsafe condition could
on an internal shaft position sensor. The The L - Series control should not be used occur with improper use of
high efficiency torque motor delivers 0.34 as the primary means of shutting down these software tools. Only
N-m nominally over 60° travel range to the engine. trained personnel should have
operate fuel injection pump. access to these tools.
There are 4 AUX inputs for I/O functions, Setup and tuning features can
configurable as digital inputs, analog be individually password
ACTUATOR SET UP
inputs, or RS-232 Service Tool protected for security
The actuator must be properly
communications. The functions available purposes. If security is
set up using the L-Series
for AUX input configuration are: applied, these features will
Service Tool prior to starting
not be accessible without the
For status purposes, a relay driver output the prime mover.
is available on the L-Series control which password.
changes state whenever a fault or error
condition is experienced by the L-Series All parameters are set at
5 control. If the system so requires, the L- factory. No adjustment /
Series provides a direct position output realignment is required in the
Many applications are
signal in the form of a dc voltage. The field. Do not attempt to rectify
throttle position (TPS) output represents delivered pre-configured,
calibrated, and tuned. For most the problem experienced.
full counterclockwise (ccw) to clockwise Please get in touch with our
(cw) rotation of the actuator shaft, and thus applications, the default gains
do not need to be changed. Min authorised dealer.
gives the operator an external position
indication after installation and while the Position and Fail Direction
unit is operating. should be checked.

INSTRUCTIONS
- Ensure proper fitment of respective
mating connections to the wiring
harness and speed sensor and 12P-
Deutche Connector.
- Ensure the gap between the speed
sensor and the flywheel ring is between
0.25 to 1.05 mm.
- Ensure lubrication of leakage rod end
bearings.
Do's
- Calibration of linkage is mandatory, if
for any reason linkage is loosened or
disturbed.
- Ensure that calibration and/or 5
reflashing of the program is done only
by the Ashok Leyland authorised
service engineer / dealer.
Don'ts
1. Do not dismantle or disturb the
governor linkage assembly.
2. Do not wash engine.
3. 12-Pin connections of the governor
should not be in contact with oil or water
when connector / wiring harness is not
assembled.

6. Maintenance schedule
SCOPE AND PROCEDURES OF REGULAR MAINTENANCE

The operations described here as “Regular Maintenance” involve such service operations
as inspection, lubrication, adjustment, and replacement which should be carried out at
specified intervals. The importance of these regular service operations need not be
emphasised further for they have a close bearing on the performance and service life of
your engine.
The periods under which the various items are listed are intended to apply to engine
engaged on normal operating conditions. More frequent attention will be necessary to
engine working under adverse conditions. The regular maintenance periods, therefore,
should be altered to suit the local conditions.
hours only
250 hours
First 50
Every
CHECK LIST REMARKS
Daily
1. Check level and top up
a) Oil in engine ✓ ✓
b) Coolant level in heat exchanger (for marine application) ✓ ✓
c) Coolant in radiator (for industrial application) ✓ ✓
d) Oil in aircleaner ✓
e) Oil in gear box (for marine application) ✓
f) Electrolite in battery ✓
g) Oil in FIP ✓ ✓
2. Check tightness of
a) Battery terminals & apply petroleum jelly ✓ ✓
b) Fan belt and tighten if necessary ✓ ✓
6
c) Hose connections in cooling systems ✓ ✓
d) Hose clamp of charge air cooler / turbocharger ✓ ✓
e) Connections at seawater pump (for marine application) ✓ ✓
f) Fuel piping connections ✓ ✓
g) Exhaust piping connections ✓ ✓
h) Engine mountings ✓ ✓
6.02 MAINTENANCE SCHEDULE

hours only
250 hours
First 50
Every
CHECK LIST REMARKS
Daily
i) Engine to drive unit coupling ✓ ✓
j) Electrical connections at instrument panel ✓ ✓
k) Radiator mtg, stay & gap between fan and cowl
(for industrial application) ✓ ✓
l) Turbocharger mounting (411/412) ✓ ✓
m) Injection pump mounting ✓ ✓
n) Cylinder head nuts First 250 Hours and
thereafter every 2500
Hours
3. Run the engine, check and record
a) Oil pressure ✓ ✓
b) Battery charging ✓ ✓
6
c) Idling RPM ✓ ✓ ✓
d) Maximum RPM ✓ ✓ ✓
e) Maximum operating temperature ✓ ✓ ✓
4. Check leakage from
a) Fuel piping & injector high pressure lines ✓ ✓
b) Exhaust manifold, flange & connections ✓ ✓
MAINTENANCE SCHEDULE 6.03

hours only
250 hours
First 50
Every
CHECK LIST REMARKS
Daily
c) Engine oil filter and other areas ✓ ✓
d) Coolant hoses ✓ ✓
e) Gear box and PTO (for marine application) ✓ ✓
5. Check proper engagement (for marine application)
a) Gear box ✓ ✓
b) Power Take Off ✓ ✓
6. Check proper routing to avoid any kink formation
a) RPM cable ✓ ✓
b) Capillary tube to temperature gauge ✓ ✓
7. Check condition of
a) Zinc anode (for marine oil cooler application) ✓
6
b) Alignment of engine to driven unit ✓ ✓
c) Check water pump. Recondition if necessary Every 1250 Hours
8. Lubricate
a) Throttle linkages ✓ ✓
b) Water pump bearing (AL series) ✓ ✓
c) Clutch engaging sleeve (for marine application) ✓ ✓

hours only
250 hours
First 50
Every
CHECK LIST REMARKS
Daily
9. Clean
a) Fuel feed pump strainer ✓ ✓
b) Fuel filter bowl, drain till clear fuel appears and then bleed the system ✓
c) Strainer in fuel tank ✓
d) Engine breather Every 1250 Hours
e) Engine sump and oil pump strainer Every 1250 Hours
10. Replace/Fill
a) Replace engine oil and oil filter at scheduled hours Refer page No. 6.07 - 6.15
b) Change oil in oil bath type air cleaner ✓
c) Change gear box oil ✓ 6

d) Fuel filter and seal ring ✓ Refer page No. 6.07 - 6.15
e) Coolant (Refer page 5.07 for recommended coolants) Every 5000 Hours or
24 months
f) Cooling system hoses and rubber pads for radiator mounting and Every 2500 Hours
stay rods

hours only
250 hours
First 50
Every
CHECK LIST REMARKS
Daily
g) Fuel hoses Every 3500 Hours
h) Air filter element - oil bath type, check and replace if necessary -
(Refer Page No. 5.09 for dry type air cleaner) Every 3500 Hours
11. Check & reset
a) Injection pump timing ✓
b) Adjust valve clearance During every oil change
c) Injector opening pressure Every 500 hours.
d) Recalibrate Fuel Injection Pump Every 3500 Hours.
12. Check charge air cooler
a) For any blockage of fins and clean the cooler if necessary ✓
6 b) Hoses for any damage ✓

RECOMMENDED LUB OIL, OIL DRAIN & FILTERS CHANGE INTERVAL
Oil drain & Oil Filter Fuel Filter Change

Application Engine Model Recommended Lub Oil
Change interval interval
Industrial / Harvester H4- Non-Emission Gulf LEYPOWER Diesel Engine Oil
250 hours or 6 months 250 hours or 6 months
Industrial / Harvester ALBSIII Gulf LEYPOWER XLL Diesel Engine Oil
whichever is earlier whichever is earlier
Marine W04D Gulf LEYPOWER Diesel Engine Oil
H4-BSIII CEV (101/76 HP)-
Industrial / Harvester Gulf LEYPOWER LL Diesel Engine Oil
Non-EGR
500 hours (or ) 6 months Industrial / Harvester HA6DTI (Non- Emission) Gulf LEYPOWER LL Diesel Engine Oil 500 hours (or ) 6 months
whichever is earlier Industrial / Harvester H6ETIC3 Gulf LEYPOWER XLL Diesel Engine Oil whichever is earlier
Marine HA6DTI Gulf LEYPOWER XLL Diesel Engine Oil
Marine HA6ETI Gulf LEYPOWER XLL Diesel Engine Oil
750 hours (or ) 6 months 500 hours (or ) 6 months
Genset H4 series - 40 -82.5 KVA Gulf LEYPOWER LL Diesel Engine Oil
whichever is earlier whichever is earlier
1000 hours (or ) 6 months 500 hours (or ) 6 months
Genset H6 series - 100 - 160 KVA Gulf LEYPOWER LL Diesel Engine Oil
whichever is earlier whichever is earlier 6

GENSET ENGINES
W04D / AL4DTG3 / ALDTIG2 ( 40 - 82.5 Kva)

Gulf LEYPOWER LL Diesel Engine Oil
Type of Service Hours Duration
1st Free Service
0 - 50 hours 0 -30 days
( Installation Check)
2nd Free Service 475- 500 Hours Max within 180 days
3rd free Service 725 - 750 Hours Max within 180 days
Paid Service 1475- 1500 Hours Max within 180 days from the Previous oil change
4th Free Service 2225- 2250 Hours Max within 180 days from the Previous oil change
5th Free Service 3725-3750 Hours Max within 180 days from the Previous oil change
6
Important Note: On H4 Engine Fuel filter to be changed at every 500 Hours.
4th & 5th Free Services are subject to availing of intermediate paid services through AL Service Dealer.
Ashok Leyland reserves the right to change the above schedule , procedures at any time and without any prior notice.
Kindly check with authorised AL Dealer/ Company Executives for any clarifications.

GENSET ENGINES
AL6DTIG1 / G2/G3 / G4 ( 100 - 160 Kva)

1st Free Service
0 - 50 hours 0 -30 days
( Installation Check)
2nd Free Service 475- 500 Hours Max within 180 days
3rd free Service 975-1000 Hours Max within 180 days
Paid Service 1975-2000 Hours Max within 180 days from the Previous oil change
4th Free Service 2975-3000 Hours Max within 180 days from the Previous oil change
Paid Service 3975 - 4000 Hours Max within 180 days from the Previous oil change
5th Free Service 4975 - 5000 Hours Max within 180 days from the Previous oil change
Important Note: On H6 Engine Fuel filter to be changed at every 500 Hours

4th & 5th Free Services are subject to availing of intermediate paid services through AL Service Dealer.

INDUSTRIAL / AGRICULTURE ENGINES
H4/Non Emission Engines

Gulf LEYPOWER Diesel Engine Oil
1st Free Service 0 - 50 hours 0 -30 days
2nd Free Service 225 -250 Hours Max within 180 days
3rd free Service 475 - 500 Hours Max within 180 days from the Previous oil change
Paid Service 725 -750 Hours Max within 180 days from the Previous oil change
4th Free Service 975 -1000 Hours Max within 180 days from the Previous oil change
6
Important Note: 4th & 5th Free Services are subject to availing of intermediate paid services thro AL Service Dealer
Kindly check with authorised AL Dealer/ Company Executives for any clarifications

H4 BSIII /H6 Non Emission

3rd free Service 975- 1000 Hours Max within 180 days from the Previous oil change
4th Free Service 1975 -2000 hours Max within 180 days from the Previous oil change
5th Free Service 2975 -3000Hours Max within 180 days from the Previous oil change
6

Industrial / Agriculture -H6ETIC3

Gulf LEYPOWER XLL Diesel Engine Oil
5th Free Service 2975 -3000Hours Max within 180 days from the Previous oil change
6

Industrial/ Agriculture - AL BSIII

6

MARINE ENGINES
W04D
Gulf LEYPOWER Diesel Engine Oil
6

MARINE ENGINES
HA6DTI/HA6ETI
6

7. Marine engine and accessories
■ Installation instructions with mechanical gear box
■ Seacock and strainer
■ Marine oil cooler (AL Engine)
■ Marine heat exchangers
■ Sea water pump
■ Gear box (for AL Engine)
■ Ghatge patil gear box
■ Screw propeller
■ Marine hydraulic gear box 135A

d) While fitting the clutch on to the flywheel, out of the tyre coupling. This hub could be
INSTALLATION INSTRUCTIONS the clutch plate must be held in position used as sleeve, to align the PTO and driving
WITH MECHANICAL GEAR BOX such that, boss which projects out of flange shafts in the manner mentioned
the flinger plate is towards the flywheel earlier.
ALIGNMENT OF GHATGE PATIL GEARBOX/
side.
ASHOK GEARBOX WITH THE ENGINE To remove the tyre coupling for replacing
In case the gear box or adaptor flange is e) Position and tighten the outer member the front belts, (front pulley to sea water
removed for any repairs, during assembly with the clutch plates inside pump) loosen the clamping screws
reassembly the following are to be checked on to the flywheel locating it on the (holding the tyre on to the hub) and pull the
to ensure proper alignment. dowels. The permissible runout of the tyre out. After replacing the belt, the
outer member is 0.076 mm (0.003"). sequence of operation is reversed for
a) The face out of the face plate fitted on reassembly.
the flywheel should not exceed 0.127 ALIGNMENT OF POWER TAKE OFF
mm (0.005"). Whenever the engine or PTO is removed ADJUSTMENT PTO CLUTCH
b) The face out of the adopter flange and for any repairs, the front and driving flange If the clutch does not pull, overheated or
the run out of its bore with respect to shaft and the PTO shaft should be properly operating lever jumps out, the clutch must
the flywheel should not exceed 0.127 aligned before fitting the tyre coupling. In be adjusted. To adjust the clutch, remove
mm (0.005") and. 0.076 mm (0.003") order to ensure that the two shafts are the hand hole plate in the housing and turn
respectively. properly aligned a sleeve could be the clutch until the adjusting lock pin can
fabricated. be replaced. Disengage the adjusting lock
c) Before fitting the clutch on the flywheel pin and turn the adjusting yoke or ring to
check that the dimension between the The PTO is so positioned, if necessary by
the right or clockwise until the operating
outer member face and the pressure inserting packing (metal pieces) between
lever requires a distinct pressure to
plate is 9.728 mm (0.383"). This must the front mounting base and skid of the
engage. A new clutch generally requires
be checked at 3 places 120° apart to engine that the sleeve easily slides from
several adjustments until the friction
ensure that the pressure plate is the driving flange shaft and the PTO shaft.
7 surfaces are worn.
parallel to the outer member face. If Now the PTO is removed. The sleeve is
any scoring is present on the pressure removed and the PTO is replaced on the
ENGINE FOUNDATIONS
plate, it should not be skimmed and position.
The engine is mounted on L section
reused but a new pressure plate is to If the sleeve is not available, one portion of channels and the latter can be bolted on to
be used. the hub of the tyre coupling could be taken the runners of the boat. To ensure that the
7.02 MARINE ENGINE AND ACCESSORIES

gearbox transmission and its bearings are ensure that the fuel is free from the traces a thin layer of petroleum jelly or vaseline to
not subject to severe strain. It is important of water. Periodical cleaning of the diesel insulate the terminals from moisture,
that the propeller shaft flange and the tank to remove impurities is also before tightening. All electrical connections
gearbox flange must be square with each necessary. Care should be taken to see and terminals of electrical unit must be
other. (The rear output flange of the gearbox that the level of the fuel tank Is not less protected from coming into contact with the
is fitted with an adaptor which is to be than 60 mm (2 ft) below the level of the sea water.
machined to suit the prop. shaft.) Before feed pump. The Injector leak off pipe and
PRECAUTIONS BEFORE COMMISSIONING
tightening the two flanges, a 0.508 mm the filter leak off pipe must be taken
THE ENGINE
(0020”) feeler gauge Is inserted to ensure separately to the fuel tank.
that the gap between the two flanges is - Maintenance manual accompanying
AIR INDUCTION SYSTEM the engine to be studied carefully.
uniform around their outer periphery. It is
All the marine engines are fitted with heavy
important that the gap or alignment should - Engine oil level to be checked. Only
duty oil bath type air filter to ensure that the
be checked and rechecked when the boat recommended engine oil to be used.
air intake is absolutely free from any
is lowered into the water as also after the - Oil level in the air filter to be checked.
impurities. It is advisable to ventilate the
boat is in water sometime as there is a
engine cabin so that hot air is not sucked - Engine to be cranked for a couple of
tendency for the hull to distort in water and
through the intake system. minutes with care to ensure oil
cause misalignment. If this is not checked,
circulation in the engine system.
there is every likelihood of damage to the EXHAUST SYSTEM
Cranking to continue till oil seeps out
gearbox bearings and spigot bearings in The back pressure of the engine exhaust
of the rocker assembly which can be
the input shaft due to misalignment of manifold should not be more than 101.6
checked by removing the rocker cover.
these two flanges. The same care must cm of water column for naturally aspirated
be taken to align flanges (if used) in the engine and 50.8 cms for TC engines. The - Fuel system to be bled.
drive line located near the plummer block silencer is to be suitably located and sharp - The gearbox lever should be kept in
(or any pedal bearings.) bends are to be avoided. Care must be neutral position before starting the
taken to see that the rain water does not engine.
FUEL SYSTEM 7
enter the exhaust system. - Always engage or disengage the gear
It Is advisable to fit a water separator and a
1.1 lit. capacity pre-filter between the fuel ELECTRICAL SYSTEM lever when engine is at idling speed.
tank and the feed pump of FIP, to ensure Always keep the battery terminals clean of - Check the alignment of propeller
longer life of the feed pump. Open the drain all dust and foreign matter. Attention shaft after launching the craft
cock of the water separator weekly to should be paid to smear the terminals with preferably in loaded condition.
MARINE ENGINE AND ACCESSORIES 7.03
PRECAUTIONS:
SEACOCK AND STRAINER MARINE OIL COOLER (AL ENGINE)
1 Sea cock with filter arrangement
The sea water being drawn the system should be provided in the sea water INSPECTION ANODE
should be free from sand, as otherwise it system. The Zinc anode when fitted new is 25 mm
may damage the pump etc. of the system. 2. Sea cocks are of metallic type having long. With service a white or yellowish
Similarly steps must be taken to see that small perforated holes. The deposit appears on the surface due to
the sea water flow is not restricted by the perforations should be capable of
sea weeds and other organisms. decomposition of Zinc. This has to be
filtering sand and other minute
scraped off with a pen knife and fresh zinc
In case the sea water pump is removed particles In the seawater.
surface exposed during Inspections. If the
for reconditioning while refitting care 3. The filter in the sea cock must be
should be taken to see that the pulley fitted cleaned everyday. first inspection shows a very slight deposit
on the sea water pump is properly aligned of decomposition of zinc the frequency of
4. The duplex type sea cock is
with driving flange pulley. In case, the advantageous as one filter can be Inspection can be altered accordingly. It is
engine fan belt is to be replaced, the PTO cleaned while the other is working. very important to replace the anode when
is to be removed. the length of active Zinc remaining in the plug
5. To prevent entry of sea weeds etc. into
A sea cock is normally fitted in the suction the sea water inlet a strainer in the form reduces to 3 mm failing which will result In
side of the sea water line. This is fitted of grating may be used on the hull. rapid corrosion of the tubes due to lack of
below the water line in the majority of the 6. This grating must be free from any protection offered by zinc anode. It is also
cases. When the engine is not working deposit of sea weeds. recommended to use zinc anodes supplied
and the boat is not in operation, the sea
7. As soon as the engine is started, sea by the manufacturer.
cock must be closed to prevent the water
water on the delivery side must be
entering the system. Similarly before Cleaning inside of tubes
checked.
7 starting the engine the sea cock must be To ensure efficient transfer of heat from oil
opened. 8. Always there must be a watch on the
delivery of sea water. In case there is to water it Is Imperative that all tubes should
The sea cock inlet is fitted on to the hull. no water coming out of the delivery side be clean, free of scale, deposits etc.
Immediately, thorough check must be
made in the system.

Under no circumstances should steel
MARINE HEAT EXCHANGERS SEA WATER PUMP
wire or sharp edged rods be used as they
are likely to puncture the tubes. OPERATION
INSPECTION:
Sea water pump is of self priming
Cleaning the shell & tube bundle Examine both the interior and exterior centrifugal pump mounted overhung on
assembly oil side condition of all tubes. Remove blockages the bearing pedestal which is belt driven
If any, suing scrapers or rotating wire/nylon and takes drive from engine crankshaft
The engine lubricating oil has been
through pulleys.
changed as per engine manufacturers brush. It Is advisable to clean the tube
bundle and headers once In a month. The pump is self priming type with inbuilt
instructions there will be no necessity to positive suction head and valve. The pump
clean the oil side of the oil cooler. However, has to be filled with liquid once. When it
when sludge has formed the inside of the Avoid removing the blockages has been switched on the air is evacuated
shell may be soaked in kerosene and with any sharp instruments as from the suction line.
flushed with any good brand of flushing these are likely to puncture the The air is evacuated from the suction line
tubes. and the liquid level in this piping rises. Once
oil. Drain plug is to be opened and all
all air has been evacuated ,the pump starts
traces of flushing oil removed by blowing Examine the headers for corrosion and working as a normal centrifugal pump.
air through the oil ports. clean them If found necessary. The The pump has a non- return valve, so the
condition of the Zinc anode will give an suction and discharge lines can not be
Fresh engine lubricating oil may be used
siphoned empty, when the pump has been
to clean out any remaining flushing oil. The indication of the extent of corrosion. The
stopped. The remaining liquid in the pump
drain plug may be refitted with a fresh deposits on the Zinc Anode may be is always sufficient for the next suction phase.
Aluminium washer and the Oil cooler put scraped to expose the parent metal. If the
PIPING CONNECTIONS
back into the oil stream. exposed material Is less than 5 mm a new The following points should be strictly 7
plug with Zinc Anode should be fitted. It is adhered while installing the pipings for the
also recommended to use Zinc Anode seawater pump.
supplied by the manufacturer. * The piping to the suction and delivery
connection must fit exactly and must not
be subjected to stress during operation.

* The passage of the suction pipe must PREPARATION START UP * Ensure that the system pressure and
be amply dimensioned. This pipe * Check the direction of rotation and temperature are maintained with in
should be as short as possible and ensure that it is as indicated in the pump recommendations.
run towards the pump in such a way casings (by an arrow).
that no air pockets can arise. If this is If no sea water is pumped or if
* Before commissioning the pump,
not possible, a venting facility should excessive noise is apparent,
remove any preservatives and flush the
be provided at the highest point of pipe. the pump must be stopped
pump with the hot water.
immediately. Contact
* If the inside diameter of the suction pipe * Check whether the oil seal chamber is Authorised Service Dealers.
is larger than the suction connection of filled with oil. If not, fill with the
the pump, an eccentric reducer should recommended lubricant. Never allow
MAINTENANCE
be applied to prevent air pocket and the seal to run dry.
For smooth and trouble free running of the
whirls. * Check whether the pump shafts turns pump, Maintenance instructions given
freely do this by turning the shaft end a below should be followed strictly.
* It is advisable to install a foot valve when
few times by hand .
a suction line is long one or static lift is * Keep both the surface of the pump and
high. * Fill the pump with water or the liquid to the surroundings as clean as possible.
be handled through the filling plug on
* It is not advisable to have a common the top of the pump until the liquid * Ball bearing are sealed and packed
suction pipe for two or more pumps starts to over flow. with grease for life and no lubrication
and similarly two or more suction lines is necessary.
* Never run the pump dry.
from different sources. * Open the sealing chamber of mechanical
START-UP-PROCEDURE: seal at least every month and top up with
* Select the suction line diameter as
function of its length. It must not be * Check whether driving pulley and belt oil (SAE 15W/40), if necessary.
smaller than the pump suction are free from any obstructions. * Drain off and replace oil once a year or
connection. It should not be too * Start the pump. every 2000 running hours. (SAE 15W/40)
7 oversized for self priming pumps. Foot * During the self priming phase, ensure * In case of long stand-still, the pump
valve is not required unless suction line the air can escape unhindered and must be started or its shaft turned by
is too voluminous or the operating without causing any back pressure in hand at least every week.
conditions are so unfavourable that the discharge pipe. * If there is any danger of freezing, the pump
suction time is longer than * Check if connections and seals are not must be drained and preferably flushed
approximately 8 minutes. leaking. with oil after having been shut down.

MARINE GEAR BOX (FOR AL ENGINE) The user will benefit attending
to the following instructions
Make Ashok Marine Gearbox Ghatge Patil Gear box before commissioning the
Type 3/1 or 411 GPMG6/GPMG7 gear in service.
Ratio 3 : 1, 4 : 1 3 : 1, 4 : 1 a) Fill the same lubricating oil as is used

Twin plate dry type / 11" for the Engine, in the Reverse Gear
Clutch outside dia / Frictional Area Wet type as well as the Reduction Gears. Use
125 Sq. in. oil with viscosity equivalent to S.A.E.
30 for temperate conditions. S.A.E.
Maximum input Torque 325 lb. ft. 325.6 lb. ft
10 for arctic conditions.
Maximum Speed 2400 Rpm. 2400 RPM b) The Special Aft Thrust bearing of the
for 3 : 1 - 165 kg / Reverse Gear of the Gearwheel
Weight (dry) approx. 180 Kg.
for 4 : 1 - 180 kg Bearings of the Reduction Gear should
for 3 : 1 - 3.25 ltrs. / be replaced by a Ball Journal Bearing
Oil Capacity approx. 4.0 litres
for 4 : 1 - 3.5 ltrs. of the same size, if a Thrust Block is
fitted to the shafting between the
Lubricating oil SAE 90 SAE 30/40
Gearbox and the Propeller. Otherwise
Flywheel Housing SAE 2 SAE 1 early failure of the Aft Thrust Bearing or
the Gearwheel Bearings will follow.
ASHOK MARINE GEAR BOX
c) Before starting up an Engine for the
Gear box is available with either 4:1 or 3:1 ratios for ahead drive and with 3:1 ratio for
first time, it is essential to ensure that
astern drive. The running gears are in constant mesh and the selection of the forward both the ahead and the astern 7
and astern gear trains, is by two dry type friction clutches, which is arranged in such a way positions can be fully engaged.
that as the forward clutch engages the astern clutch disengages and vice versa. The
d) Check and make sure that the rotation
forward astern hand operating lever can be fitted on either side of the gear case depending of reverse Gear and Reduction Gear
on requirement. match the rotation of the engine.

e) It should be noted that during the first
100 hours running or so, the Brake
GHATGE PATIL (FOR AL ENGINE)
Band will probably require periodical MARINE POWER TAKE OFF MODEL C - 107
adjustment whilst the lining of the
Band settles down and high spots are Introduction
removed. Ghatge patil C - 107 Marine Power Take-Off is specially designed to suit marine
applications and widely used as front Power take off to drive the winch on fishing boats.
f) A multiple plate Clutch is provided to This power take-off is also suitable for any industrial application where self contained
lock the bevel wheel assembly for and self supporting power takeoff is desired.
ahead drive, A brake band locks bevel
wheel casing to obtain reversal of the Special Features
output shaft-the Aft Shaft to go astern. Self contained & self supporting.
The Gear is mechanically controlled Water tight casing provides protection against corrosion.
either by means of the hand operated
operating Lever or by a suitable Flexible input coupling assures safety to the engine as well as to the power take
remote control mechanism, off against mis-alignments.
incorporating drop arms, rods, drag Out put shaft is provided with a pulley (‘V’ groove, 3 Belts) for drive to the winch
links etc. shaft.
g) The method of lubrication in the
Transmission Capacity
Reverse Gear and the Reduction
Gears is by oil splash. All bearings Normal
are of the Ball/Roller/ Needle type. So Maximum Horse Engaging Strokes of
there is no need for pressure Maximum Power Maximum force with Torque operating lever
7 lubrication. Torque Speed Std. hand operating
(lb. ft.) (RPM) lever (Kgs.)
Light Normal Heavy Kg.
provided Lbs. Angular
Duty Duty Duty cm
(Lbs.)
131 48 38 26 3000 73 33 940 1085 13°

DIAMETER Theoretical Actual
SCREW PROPELLER —
Diameter is twice the distance from the distance distance
A screw propeller is basically an axial flow X 100%
centreline of the propeller hub to tips of the Theoretical distance
pump. blade, or the diameter of the circle scribed
by the tips of the blade. PITCH RATIO
The rotation of the propeller (RPM) and the
Pitch ratio expresses the relation between
angle of the propeller blade, known as PITCH the diameter and the pitch of the propeller.
pitch, combine to form a thrust force on the Pitch is the angle the blade makes in To obtain pitch ratio, divide the pitch by the
propeller shaft. Thrust is transmitted relationship to the centreline of the hub diameter. If a 60” wheel has a pitch ratio of
through the shaft to the thrust bearing, and is normally expressed as the 0.7, it has a pitch of 42” (60” x 0.7) and is
which is the principal point where the distance, in inches, that the blade would known as a 60 x 42 propeller.
forces generated by the propeller rotation advance in one revolution, if the propeller
act upon the hull. were a screw working in a solid It is to be remembered that all propellers
substance. Thus, the theoretical distance are a compromise. However, it is generally
There is no known formula which will
in inches covered in one minute could be good practice to utilize the largest propeller
automatically give the ideal propeller size
measured by RPM X PITCH. However, diameter possible within practical
for a given boat. One can merely
we are not dealing with a solid and it is limitations. These limitations are:
approximate. The only true test is the “trial
here that a loss of forward motion occurs 1. Size of aperture in which propeller is to
and error” method.
known as “slip”. be installed.
The major terms used when discussing
SLIP 2. Type of operation - towboat, crew boat,
propellers are:
Slip is the difference between the pleasure craft, etc.
1. Diameter 7
theoretical distance and actual distance
2. Pitch 3. Shaft angle required for large propeller.
covered in a given period of time. This
3. Slip relationship is usually expressed in a 4. Weight of propeller, shafting and gear
4. Pitch Ratio percentage calculated as follows: boxes relative to boat’s size.

NUMBER OF PROPELLER BLADES All other applications can be shaded CAVITATION
Three-bladed propellers are more efficient between these two statements of When propeller RPM is increased to a point
over a wider range of applications that any extremes. where suction ahead of the propeller
other propeller. Hence most of the reduces the water pressure below its
calculations are based on this type of PROPELLER TIP SPEEDS vapour pressure, vapour pockets form,
wheel. Propeller tip speed is the speed, in MPH, interrupting the solid flow of water to the
travelled by the tips of the propeller blades. propeller. This condition is known as
In theory, the prop with the least number of The greater the tip speed, the more power cavitation.
blades (i.e. two) is the most efficient. consumed in pure turning effort. A 30”
One of the more common causes of
Diameter and technical limitations in most propeller with a tip speed of 60 MPH will
cavitation is excessive tip speed (a
cases, make a greater number of blades absorb about 12 horsepower in pure
propeller turning too fast for water to follow
necessary. Four and sometimes five- turning effort. This in itself, is a horsepower
the blade contour). Cavitation can usually
bladed propellers are used in cases where loss because it contributes nothing to the
be expected to occur at propeller tip speeds
an objectionable vibration peak is forward thrust. Generally propellers
exceeding 130 mph. Cavitation results in
developed within the operating range greater than 30” in diameter should not
a loss of thrust and damaging erosion of
when using a three blade propeller. have a tip speed over 60 MPH. On smaller
the propeller blades.
propellers, under 20”, tip speed should not
All other conditions being equal, the exceed 120 MPH.
PROPELLER OVERHANG
efficiency of a four blade propeller is
D x Shaft RPM x 60 x 3.14 The maximum distance from the stern
approximately 96% that of three blade T = bearing to the propeller should be limited
propeller having the same pitch ratio and 12 x 5280
to no more than one shaft diameter.
blades of the same proportion and shape. Where Propeller shafts are apt to vibrate and
7
An old water front rule of thumb for all produce a whip action if these limits are
T = Tip speed in MPH
propeller selection is: exceeded. This condition is greatly
D = Propeller diameter in inches. accelerated when a propeller is out of
“Tow boats - big wheel, small pitch”
balance due to faulty machining or
“Speed boats - little wheel, big pitch” damage.

MULTIPLE PROPELLERS: Therefore it may be necessary to install PROPELLER SHAFTS
two and sometimes three propellers to The connecting link in a boats propulsion
permit to a proper pitch ratio for efficient package is the propeller shaft. This portion
propulsion. of the drive train serves the dual function of
transmitting engine torque to the propeller
Propeller rotation is determined from
and propeller thrust to the thrust bearing.
behind the vessel, facing forward. The
starboard side is on the right and the port Propeller shafts are classified into two
side on the left. Rotation of the propeller is groups, tail shafts and line shafts. The
determined by the direction of the wheel section or sections of the shafting totally
when the vessel is in forward motion. Thus within the hull are termed line shaft. Tail
a clockwise rotation would describe a right shafts are that portion which is partially or
hand propeller and a counter clockwise totally exposed to water outside the hull.
rotation would be left hand propeller. Because this portion of the shaft is
subjected to such erosive forces as water,
Right hand propellers are more frequently
sand and bending movements due to
used in single screw installations. But twin
propeller over hang, it is generally good
screw vessels are equipped with two
practice to use a tail shaft that is heavier
possible combinations of wheels viz., a)
than the line shaft.
Outboard turning propellers and b) Inboard
turning propellers.
Reduction Gears:
The most efficient method of propelling a A rotating propeller tends to drift sideways Selection of the reduction gear ratio is one
boat is by the use of a single screw. in the direction of rotation. In a single screw of the most important decision to be made
However, there are other factors which vessel this can be partially offset by the 7
in any marine power installation. A range
when taken into consideration, make the design of the stern post an the rudder. In a of reduction ratios is normally provided to
use of a single propeller impossible. twin screw vessel this can be completely assure optimum performance under a
If a boat has to operate in shallow water, eliminated by using counter rotating given set of operating conditions. Factors
the diameter of the propeller is limited. propellers. taken into account while selecting the

reduction gear ratio are anticipated boat This assumes the hull to be a normal changes the original engine and shaft
speed, usage of boat, proper pitch ratio, displacement form with a reasonable alignment.
propeller tip speed, engine horse power. beam to length ratio.
Engine alignment to Propeller shaft
The optimum of V/√(LWL) = 0.9 or 1.1 is The face out of the couplings should be
Specific type of hull for fishing vessels
simply used as a base to establish the checked before the engine is placed in the
Vessels in this classification that fish by
most practical speed of a displacement boat. It is important to align the engine
means of nets drawn through the water
hull. Beyond this point the horsepower per only when the boat is afloat and NOT dry
offer a special problem. For example, a
knot increase becomes economically docked. During this alignment period, it is
shrimp boat may travel as far as 500 miles
unfeasible. Thus, from data taken on a also advisable to fill the fuel tanks and add
or more to the fishing grounds. Owners
large sample of displacement hulls, a any other ballast that will be used when
usually want to cut this travel time as much
general formula for estimating a boat’s the boat is in service.
as possible. However, when fishing, the
“maximum feasible” speed was developed
boat has to tow large doors performance With the engine in position on the engine
where 1.34 times the square root of the
requirements calls for a compromise in bed, arrangement must be made to have
loaded waterline length (in. ft) equals the
the propeller selection and reduction ratio a controlled lifting and lowering of each of
boat’s speed in knots i.e. 1.34√LWL = V,
to obtain the maximum usable power for the four corners of the engine. This can be
where
both operating conditions. These accomplished with jacking screws. In this
“optimum” conditions are as a rule V = Speed in knots, and case a threaded hole is provided in each
achieved when the speed in knots divided LWL = Loaded Waterline Length (in. ft) of the engine mounts. By inserting screws
by the square root of the waterline length in these holes, the engine can be raised
(in feet) equals either 0.9 or 1.0. ALIGNMENT by screwing down or lowered by backing
i.e. V Proper alignment of an engine is critical.... off the desired amount. Steel plates must
7 = 0.9 or 1.1 both during the initial installations and at be inserted under the jacking screws so
√LWL frequent intervals during the life of the boat. that the bolts will not damage the engine
It is rather common for a boat to change its bed. Lifting can also be accomplished by
Where V = speed of boat in knots and
from under various loads and with age. A the use of chain hoists or properly placed
= loaded water line length (in ft)
bend is actually formed in the keel which jacks. Adjustable shims also are available

sides to check the parallel alignment of engine and propeller couplings. This
the coupling edges. The feeler gauge is clearance might be 0.005 to 0.007 while
run completely around the coupling. the top would maintain the standard 0.002.
Then the engine coupling is rotated 90°, During the process of securing final
180° and 270° with the feeler being run alignment, it may be necessary to shift the
around the flange again at each engine many times. When it becomes
successive position. If the alignment is apparent that the alignment is reasonably
correct, the feeler gauge fits snugly with close, the holes for the lag studs are
the same tension all around the coupling. marked and drilled. Then with final
The straight edge should continually show alignment secured, the necessary steel or
and can simplify the whole problem, the edges to be parallel. hard wood shims are made up and the
particularly for future realignment. engine is fastened in place. The
If the alignment varies during rotation then
It will also be necessary to move the engine further alignment is necessary or the shaft alignment is then rechecked, and if
from one side or the other on the bed to couplings should be checked for improper satisfactory, the coupling is bolted together
secure horizontal alignment. This can be face run-out. Face run-out on the engine and rechecked again.
done with a jack placed horizontally coupling can usually be corrected by Although it is not necessary to align a flexible
between the engine and the foundation. repositioning the coupling on its splines. coupling as accurately as a solid coupling,
As the engine then comes to its aligned Shaft coupling run-out is usually due to the closer it is in the initial alignment, the
position, it will be possible to match the inaccuracy of taper fit or key interference. more vibration free it will be. The most
male and female halves of the propeller Some boats are not structurally rigid and accurate method of alignment is to align
coupling and prepare for bolting together. some carry their load in such a way that the shaft on to the engine with flexible
Care should be taken not to burr or mar they will “hog” or go out of normal shape coupling out of the system. This can be
this connection because the fit is very 7
with every loading and unloading. When done with a spacer the same size as the
critical. A 0.002 feeler gauge is inserted this condition exists, it may be necessary coupling but not flexible in nature. Flexible
between the flanges of the coupling at the to make a compromise between the top couplings are used only for noise and
same time a straight edge is laid across and bottom coupling clearance by leaving vibration dampening ... not to correct
the edges of the flanges at the top and a greater clearance at the bottom of the inadequate alignment.

INSTALLATION
MARINE HYDRAULIC GEAR BOX 135A
1. Ensure that the direction of engine
TECHNICAL DETAILS
rotation is identical to that of the gear
Transmission mode : Five helical gears with three shafts box input shaft.
Clutch type : Hydraulic control, wet type multiplate clutch 2. It is necessary to open the side
Type of input coupling : Toothed rubber block coupling inspection door only to observe
Rated speed of the engine : 1000 – 2000 rpm whether the parts surfaces are rusted,
the input and output couplings should
Reduction ratio : 4.11:1
rotate freely by hand.
Rated Trans.capacity : 0.115 KW/(r.min-1) / 0.156KW (HP/r.min-1))
3. Cooling water required for oil cooler
Centre distance : 225mm
should not be less than 2m3/ h, and
Direction of rotation of input shaft the water temperature not grater than
(viewed from output end) : Anti-clockwise 35° C.
Direction of rotation of output shaft
in “Ahead” position (viewed from
output end) : Clockwise
Lubricating oil grade : SAE 30 (SAE 40 in summer)
Lubricating oil capacity : 20 litres
Max. oil temperature : 80° C
7 Permissible angle of inclination : Longitudinal 10°, Transverse 15°
Type of connecting with engine : Bell housing
4. Gearbox should be coupled to engine
Overall dimensions (L x W x H) : 578 x 792 x 830mm
flywheel housing, and firmly fastened.
Net weight : 480 kg
If without bell housing the axial line
COOLER ASSEMBLY: the engine and make it in trail running
1. The cooler is located on the outside at stable speed.
wall of the housing, into which the 2. If the oil pressure gauge shows no
cooling water is led from both ends sign of pressure after running one
with pressure of 4 kgf/cm2. minute, stop the engine to inspect and
2. If the atmosphere temperature is remove any obstructions, for any
below 0°C, the cooling water should running without sufficient oil is not
be drained out completely, when permissible.
gearbox stopped. 3. When the oil pressure is built up,
should be checked so as to make the speed up the engine to its rated speed.
input coupling and engine flywheel 4. After continuous running, for 5- 10
coaxial and the unparallelism of the minutes then operating the control
coupling faces less than 0.25mm valve two or three times at its 50%
rated speed.
5. When the engine running at rated
5. When operating the control valve, the
speed, and the valve at “AHEAD” or time for rising oil pressure should be 2-
“ASTERN” position, the hydraulic oil 5 seconds. The rated hydraulic operating
pressure should be 8-10 kgf/cm2). The pressure should be 8-10 kgf/cm2.
lub. Pressure should be 1-2.5 kg/cm2 3. The output shaft flange of the gearbox 6. After operating the control valve, note
6. After 50 hours of operation, the oil and the companion flange of its tail for any abnormal noise or any leakage
filter should be cleaned. After 100 shaft should be coaxial and the of oil or water.
hours of operation, the oil should be
unparallelism should be less than 7. In case of normal operation, speed 7
0.10 mm. down the engine to about its half
renewed. Later on, it is required to
OPERATION speed, lagging 2-3 sec at stop
keep the conventional rule of
1. After the installation, fill the gearbox position, then operating the control
maintenance.
with clean recommended oil, then start valve to the desired direction.

MAINTENANCE SCHEDULE
NO. ITEMS DAILY 1000 5000 10000
1 Check oil level ✓
2 Clean gearbox external surface ✓
3 Inspect leakage of oil and water ✓
4 Inspect any abnormal noise ✓
5 Clean the filter element ✓
6 Clean hydraulic control system ✓
7 Inspect the inlet sealings ✓
8 Check the clearance of the toothed rubber block and input coupling ✓
9 Check the clearance of connecting bolts and output coupling ✓
10 Remove the inspection cover, turn the couplings by hand and
inspect gears and clutches ✓
11 Inspect the hydraulic oil and lub. hose ✓
12 Change lub.oil. Clean the strainer of the oil pump ✓
13 Inspect the oil pump ✓
14 Inspect and clean the oil cooler ✓
7
15 Dismantle and inspect rubber sealings of input and output shaft ✓
16 Check the friction plates, thrust rings and sealings ✓
17 Disassemble gearbox housing. Inspect the input and output shaft
assemblies and bearings ✓

TROUBLE SHOOTINGS:
NO PROBLEM CAUSE REMEDY
1 Vibration of gearbox Misalignment at Installation Re-adjust it accordingly
Toothed rubber block of input coupling damaged Renew in sets
Loose bolts of couplings and supports of gearbox Tighten
Torsional vibration Avoid resonance speed.
2 Unsteady, low or no oil Pump damaged Repair or replace
pressure Choked filter Clean it
Oil level too low or seating at suction end damaged Fill oil or renew sealing.
Sealing at inlet end damaged Renew sealing.
Oil gauge damaged. Renew gauge.
3 Hydraulic oil failed to Throttling hole in control system obstructed Clean and refit
reach specified value Piston in control system chocked Clean and repair control valve.
4 Clutch slipping Oil pressure too low or fluctuate Refer to No. 2 and 3
Excessive worn of friction plates Renew the plates.
Oil passage chocked or sealings damaged Clean passage or renew sealings.
5 Too large residual torque Friction plates seriously warped Renew
Usage of non-recommended oil Use recommended oil. 7
6 Excessive rise of oil temp. Clutch plates (Friction plates) slipped Refer to No.5
Too high oil level. Lower the oil level.
Choked oil cooler or insufficient coolant Clean cooler or top up coolant.

NO PROBLEM CAUSE REMEDY
Excessive rise of oil temp. Bearings and thrust rings or other moving parts Renew the damaged parts.
damaged
Contaminated oil Renew oil
Broken lub. oil pipe Renew
Too high lub. oil pressure Lower the pressure.
7 Turning in company Incorrect installation of the oil pipe Reinstall it
Warped or stuck friction Renew
Damaged or worn of Piston back spring Renew
Stuck piston Clean and overhaul
Oil viscosity too high Use specified oil
8 Abnormal noise Damaged toothed rubber block of the input coupling Renew
Damaged bearings Renew
Loose screws Tighten
9 Difficult to engage Improper position of remote control device. Adjust the control unit
Stuck friction plates or piston Repair or renew
Too low hydraulic pressure Refer to No.2
7 Incorrect installation of oil pipe Correct
10 Leakage of oil or water Sealing damaged Renew
Sealing surface damaged or dirty Repair and Clean
Bolt loose Tighten the bolt.

8. Dealer network
Ashok Leyland office addresses
Industrial Engine Dealers
Marine Engine Dealers

REGISTERED, CORPORATE AND MARKETING OFFICES
No.1, Sardar Patel Road, Guindy, Chennai - 600 032.
Ph : 044-2220 6000, Fax : 044-2220 6001
REGIONAL OFFICES
NORTH NEW DELHI Ashok Leyland Ltd., Leyland House, 4th Floor, Plot No. 76, Institutional Area, Sector 32, Gurgaon - 122 001. Tel : 0124-4629000
JAIPUR Ashok Leyland Ltd., 601-604, 6th Floor, Brij Anukampa, Ashok Marg,C-Scheme, Jaipur-302 001. Tel : 0141-2361464/2368168
CHANDIGARH Ashok Leyland Ltd, SCO. 812, 2nd Floor, Chandigarh Kalka Road, Manimajra, Chandigarh - 160 101.
Tel : 0172-2739865, 2739869.
LUCKNOW Ashok Leyland Ltd., Second Floor, Shalimar Square, 126/31, B N Road, Lalbagh, Lucknow - 226 001. UP. Tel : 0522-2626286
EAST KOLKATA Ashok Leyland Ltd., First Floor “Motijug House”, 1 Auckland Place, Kolkata - 700 017. Tel : 22400916, 22475043
JAMSHEDPUR Ashok Leyland Ltd., 57 New Baradwari, Sakchi, Jamshedpur - 831 001. Tel : 0657-2440771
WEST MUMBAI Ashok Leyland Ltd., Electric Mansion, Appa Saheb Marathe Marg, Prabhadevi, Mumbai - 400 025. Tel : 24305093, 24305460,
AHMEDABAD Ashok Leyland Ltd, 203, 2nd Floor, “SIGMA -II”, Opp: Sunrise Park, Nr.Himalaya Mall, Off: Drive In Road, Ahmedabad - 380 052.
Tel : 079-40500200
PUNE Ashok Leyland Ltd, PridePortal, Groundfloor, Sr No 103, Bhahiratwadi, Off Senapati Bapat Road, Shivajinagar, Pune-411016.
Tel : 020-25556000
SOUTH CHENNAI Ashok Leyland Ltd., Khivraj Complex II, 6th floor, 477-482 Anna Salai, Nandanam, Chennai - 600 035.
Tel : 24304400, 24341536
BANGALORE Ashok Leyland Ltd, No. 100/1-1, Suraj Manor, 2nd Floor, Bull Temple Road, Basavanagudi, Bangalore - 560 019.
Tel : 26670906, 26671500
SECUNDERABAD Ashok Leyland Ltd, 3rd Floor, Dhraupathi Chambers, 31, Sarojini Devi Road, Next To ITC Agri Marketing Office,
Secunderabad – 500 003. Tel : 040-40662000
CENTRAL NAGPUR Ashok Leyland Ltd., Plot no. 317, IInd floor, Rabindranath Tagore Marg, Civil Lines, Nagpur – 440 001.
(Landmark: Above Bank of India building.) Tel : 2520894/5/7, 2542581
INDORE Ashok Leyland Ltd., 320, Orbit Mall, A B Road, Vijaynagar, Indore - 452 010. Tel : 0731-2529677
8.02 REGIONAL OFFICES

AREA OFFICES
AHMEDABAD Ashok Leyland Ltd, 203, 2nd Floor, “SIGMA -II”, Opp: Sunrise Park, Nr.Himalaya Mall, Off: Drive In Road, Ahmedabad - 380 052.
Tel : 079-40500200
ALLAHABAD Ashok Leyland Ltd., #3/40, Flat -1, 13, P D Tendon Marg, Civil Lines, Allahabad, Pin - 211 001. UP. Tel : 0532-2400696
AURANGABAD Ashok Leyland, F-7, 5th Floor, Aurangabad Business Center, Adalat Road, Aurangabad 431 001. Tel : 0240-2357935.
BANGALORE Ashok Leyland Ltd, No. 100/1-1, Suraj Manor, 2nd Floor, Bull Temple Road, Basavanagudi, Bangalore - 560 019. Tel : 26670906, 26671500.
BHUBANESWAR Ashok Leyland Ltd., Aditya Plaza, 103, Unit-IV, 10, Sachivalaya Marg, Bhubaneswar -751 001. Tel : 0674-2503504
CHANDIGARH Ashok Leyland Ltd, SCO. 812, 2nd Floor, Chandigarh Kalka Road, Manimajra, Chandigarh - 160 101. Tel :0172-2739865, 2739869
CHENNAI Ashok Leyland Ltd., Khivraj Complex II, 6th floor, 477-482 Anna Salai, Nandanam, Chennai - 600 035. Tel :24304400, 24341536
COCHIN Ashok Leyland Ltd., 23 / 500 E, Kallupurakal Centre, Edapally - Pookattupadi Road, Unichira Thykkavu, Changampuzha Nagar PO,
Cochin - 682 033. Tel : 0484 - 2577578 / 2577579
DELHI Ashok Leyland Ltd., Leyland House, 4th Floor, Plot No. 76, Institutional Area, Sector 32, Gurgaon - 122 001. Tel :0124-4629000
GUWAHATI Ashok Leyland Ltd., Aashirwad Bhawan, House no. 34, 2nd Floor, Dr. Rajendra Prasad Road, Last Gate, Dispur, Guwahati. 781006. Assam.
Tel :0361-2235818
HARYANA Ashok Leyland Ltd., Leyland House, 4th Floor, Plot No. 76, Institutional Area, Sector 32, Gurgaon - 122 001. Tel : 0124-4629000
HUBLI Ashok Leyland Ltd., 2nd Floor, SF2, Preeti Ashiana Complex, Sirur Park, Vidya Nagar, Hubli – 580 021. Tel : 0836 – 2270008
INDORE Ashok Leyland Ltd., 320, Orbit Mall, A B Road, Vijaynagar, Indore - 452 010. Tel : 0731-2529677
JABALPUR Ashok Leyland Ltd., 2nd Floor, Sanghi Residency, Block B, Plot 20/A, Wright Town, Jabalpur - 482 002. Madhya Pradesh.
Tel : 0761-4218181/82/83
JAIPUR Ashok Leyland Ltd., 601-604, 6th Floor, Brij Anukampa, Ashok Marg,C-Scheme, Jaipur-302 001. Tel : 0141-2361464 / 2368168 / 3945663
JAMSHEDPUR Ashok Leyland Ltd., 57 New Baradwari, Sakchi, Jamshedpur - 831 001. Tel : 0657-2440771
KARNAL Ashok Leyland Limited, 3rd Floor, SCO - 234, Sec-12, City Centre, Karnal – 132001. Tel : 99922 20064
KOLKATA Ashok Leyland Ltd., First Floor “Motijug House”, 1 Auckland Place, Kolkata - 700 017. Tel : 22400916, 22475043, 22400578.
LUCKNOW Ashok Leyland Ltd., Second Floor, Shalimar Square, 126/31, B N Road, Lalbagh, Lucknow - 226 001. UP. Tel : 0522-2626286
LUDHIANA Ashok Leyland Ltd, 3rd Floor, Sai Tower, Industrial Area-A, Ludhiana – 141003, Punjab. Tel : 0161-5000630
8
MADURAI Ashok Leyland Ltd., TMAK Building, 180 North Veli St, Madurai - 625 001. Tel : 0452-2340998 8
MUMBAI Ashok Leyland Ltd., Electric Mansion, Appa Saheb Marathe Marg, Prabhadevi, Mumbai - 400 025. Tel : 24305093, 24305460, 24300534
AREA OFFICES 8.03

AREA OFFICES
NAGPUR Ashok Leyland Ltd., Plot no. 317, IInd floor, Rabindranath Tagore Marg, Civil Lines, Nagpur – 440 001. (Landmark: Above Bank of India
building). Tel : 2520894/5/7, 2542581
NAVI MUMBAI Ashok Leyland Ltd., Office No. 709, Mayuresh Cosmos, Plot No.37, Sector 11, CBD Belapur, Navi Mumbai - 400 614. Tel : 022-66732991
PATNA Ashok Leyland Ltd., 6th Floor, Bibha Complex, New Dak Bunglow Road, Patna - 800001. Tel : 0612-2214001
PUNE Ashok Leyland Ltd, PridePortal, Groundfloor, Sr No 103, Bhahiratwadi, Off Senapati Bapat Road, Shivajinagar, Pune-411016.
Tel : 020-25556000
RAIPUR Ashok Leyland Ltd., B S Arcade, Trans-Connect & Reliance Building, Near Shivnath Hyundai, G E Road,Tatibandh,Raipur-492099,
Chhattisgarh. Tel : 0771-2573953, 2573001, 2573923
RAJKOT Ashok Leyland Ltd, 308, Sudershan Commercial Centre, Limda Chowk, Rajkot – 360001. Tel : 97277 50579
SECUNDERABAD Ashok Leyland Ltd, 3rd Floor, Dhraupathi Chambers, 31, Sarojini Devi Road, Next To ITC Agri Marketing Office, Secunderabad – 500 003.
Tel : 040-40662000
SURAT Ashok Leyland Ltd., A-703, Shreeji Arcade, Anandma Hal Road, B/H Bhulka Bhavan School, Adajan, Surat - 395 009. Tel : 98251 46917
UDAIPUR Ashok Leyland Ltd., 601-604, 6th Floor, Brij Anukampa, Ashok Marg,C-Scheme, Jaipur-302 001. Tel : 0141-2361464 / 2368168 / 3945663
VIJAYAWADA Ashok Leyland Ltd., 1st Floor, Sreepra Towers, 40-5-5/1A & 1B, M.G. Road, Adjacent to Sweet Magic, Vijayawada – 520010.
Tel : 0866 – 2493451/2
8.04 AREA OFFICES

INDUSTRIAL ENGINE DEALERS
LOCATION DDEALER NAME AND ADDRESS AND CONTACT NUMBERS
ANDAMAN Pandian Enterprises, P.O.Box No : 88, MB-72, Supply Line, Aberdeen Bazaar, Port Blair-744101.
Tel : 03192 – 233808 / 9933251712
ANDHRA PRADESH Andhra Power Services, Plot No : A-30, APIE, Bala Nagar, Hyderabad-500 037.
Tel : 040-23775675, 23775676 23775620 (F) / 9866074552
ANDHRA PRADESH Andhra Power Services, #38,22-90/1, Industrial Estate, Vishakapatnam-530007.
Tel : 0891-2553209 / 2531967
ANDHRA PRADESH Professional Services, 54-9-7,Between II & III Cross, 100 Feet Road, Jawahar Autonagar, Vijaywada-520 007.
Tel : 0866-2544925, 5531206, 2540443 (F) / 9885189081 / 91
ANDHRA PRADESH Professional Services, Beside RTC Bus stand, Shop No.1, Main Road, Chimakurthy–523226, Prakasham Dist.
Tel : 08592-273578 / 98851 89085
ANDHRA PRADESH Rayalaseema Power Solutions,No. 2/395 Nagarajapeta, Opp. Zion College,Kadapa - 516001
Tel : 09493629384
ASSAM S.P.Motors, Opp.Sakshi Motors, Chirwapatty Road, Tinsukia-786125
Tel : 0374-2342589, 2350418 (F) / 94351 35247
ASSAM Engineers Net work, S.H.B.Road, Ambieapatty, Silchar-Cachar, Assam-788004
Tel : 03842-264357 / 94350264357
ASSAM Annapurna Enterprises, AT Road, Jorhat, Assam 785001
Tel : 37623220177 / 9435052777
ASSAM Dee Gee Tech, Mangal Ram Tower, AT Road, Opp Police Reserve, Guwahati 781001
Tel : 0361-2510607 / 9435732022
ASSAM Radiant Engineers, R.Dutta Market, A T Road, Dist Kamrud, Assam, Guwahati 781001
Tel : 0361-25133040361-2733557(Fax) / 9864034828
ASSAM Mechfield Trade & Industries Pvt Ltd, Lahkar Commercial Complex, Opp Police Reserve, AT Road, Guwahati 781001
Tel : 0361-2541329 (Fax) / 9435040374
ASSAM Green Power Solutions, Baridua, 8th mail G.S.Road, Meghalaya 793 101 8
Tel : 0361-2355036 / 9435045740 / 8486078158
DEALER NETWORK 8.5

LOCATION DEALER NAME AND ADDRESS AND CONTACT NUMBERS
BIHAR Narayana Sales & Services, GF-1 Friend’s Regency Apartment, Harishankar Verma Lane, Boaring Patliputra road, Patna -13
Tel : 0612-3202354 / 9931617205
BIHAR DVM Electricals Co, Devi Sthan, Jankpur, Sumitrasadan, Mourva Nagar, Manpur, Gaya Bihar 823 003
Tel : 0631-6990063 / 9934660144
BIHAR Rai Industrial Power (P)Ltd, 2/29 Sri Krishna Nagar, Patna (Bihar) Pin code 800001
Tel : 0612-2522050011-43582765 / 9308257577
BIHAR Care Power Solutions, No. 203, Jayanthi Nilayam Appartment, Opposite to Roxo Convent School, Noth Patel Nagar, PATNA - 800024
Tel : 0612-6449000 / 9934912346 / 9234666660
CHANDIGARH P.K Enterprises, SCF 435, IST Floor , Motor market , Manimanjra, Chandigarh - 160101
Tel : 09417002521
CHATTISGARH Power Tek Engineering, Sales & Service, OPP Ayyappa Mandir, Ring Road No-2T, Atibandh, Raipur 492001, Chhattisgarh
Tel : 0771-42630250771-69915090771-4263025 ( F) / 9827113728
GUJARAT M.M Industrial Services, Ward No:12 A, Plot no:04, 9-Krishna Shopping Center, Gandhidham-370201.
Tel : 02836-324511, 222885 (F) / 9377324511
GUJARAT M.M Industrial Services, 1st Floor Gayatri Complex, Near-Jaynath Petrol Pump, Gondal Road, Rajkot-360002.
Tel : 0281-3292797, 2388784 (F) / 9377574833
GUJARAT Raj Kamal Automobiles, Suzuki Showroom, Opp. Pramukh Enclave, State Highway, Mehsana-384002.
Tel : 02762 – 258888 (F) / 9825471007
GUJARAT Excellent Power Generators, Plot No.201/12.G.I.D.C. Estate, Road No.2, Opp Evertex, Panoli-394116.
Tel : 02646-272311, 272725, 272725 (F) / 9825027889
GUJARAT Excellent Power Generators, A1, Mahendra Complex, Puna Kumbharia Road, Opp Bank of Baroda, Surat.
Tel : 0261-2330893 (F)
GUJARAT Suyash Enterprises, 215, 2nd Floor, Shiv Chambers, Opp. IDBI Bank, NH 8, Vapi, Gujarat-396195.
Tel : 0260-6544258, 9824158765
8 GOA V.K.Enterprises, Leoniza Gomes Mansion, Rua De Saudade, Pajifond, Margao, Goa-403601.
Tel : 0832-2714567, 2732715, 2863533, 2863534 (F) / 9822103819
8.6 DEALER NETWORK

HARYANA Rahul Power and Trans, Opp: Transportnagar, Near Lashkari Mal Petrol Pump, G T Road, Panipat-132104.
Tel : 0180-2669425 (TF) / 9813100001
HARYANA Amrit Power & Compressor Care, Opp Sec -4, Sohna Road, Dharuhera, Rewari - 123016, Haryana
Tel : 01493-230242 / 9812024630
HARYANA Generator Aids, E-142-144, Sanjay Colony, Sec 23, Faridabad, Haryana -121005
Tel : 0129-2233512 / 9810123810
HARYANA Power Supply & Solutions, Dyanand Colony, Delh- - Chandigarh - Highway, NH-1, Model Town, Karnal - 132001
Tel : 0184-4030714 / 9416032773
HIMACHAL PRADESH P.K Enterprises, SCF 435, IST Floor , Motor market , Manimanjra, Chandigarh - 160101
Tel : 09417002521
JAMMU & KASHMIR Amco Automobiles, 2nd Floor, Auqaf Building, Zero Bridge, Srinagar-190001
Tel : 0194-2470162/3 / 9906070720
JAMMU & KASHMIR Tawi Engineering, D-89 Sainik Colony, Jammu J & K180 011
Tel : 0191-2468163
JHARKAND JK Services Katras Road, Dhanbad, Jharkand-826001.
Tel : 0326-6451186 / 9431124509, Fax 0326-2304398
KARNATAKA Amruta Engineers, No.9, J162, 3rd Floor, JC Road, Auto Towers, Bangalore-560002.
Tel : 080-23654565 / 9448514552
KARNATAKA Sri Sai Engineering ,D-109 ,2nd Gate Industrial Estate, Gokul Road, Hubli-580020.
Tel : 0836-6450214, 2355730, 2352308, 9449357499
KARNATAKA Akash Power Gensets No.34,1st Main, SBM Colony,Opp Vidyavahini College, Anandnagar, Bangalore -560024
Tel : 080-23638493, 23337347, 9845204711
KARNATAKA United Diesels, No 18,1st Floor, 8th Main, 19th Cross, Malleshwaram, Bangalore 560 055
Tel : 080-23348233,23347759 / 9243034901
KARNATAKA RA Power Engineers Pvt. Ltd., HO # 17, 100 Feet Road, Ashoka Pillar Circle, 1st Bloock, Jayanagar, Bangalore 560011 8
Tel : 080-26564522, 9845510142
DEALER NETWORK 8.7

KERALA Associated Industrial Engineering (P) Ltd, Kairali Plaza, Karamana-P.O, Trivandrum, Kerala.
Tel : 0471-3131801/ 9388831957
KERALA Associated Industrial Engineering, Leyland Auto Centre, Kadappakada, Kollam-691008.
Tel : 0474-2747117 2768186 (F) / 9447559783
KERALA Cinzac Sales & Services Pvt Ltd, Chitoor Road, Panchalam, Cochin-682012.
Tel : 0484-2395911, 2395912, 9995439511
KERALA Paramount Trade Links,No. 17/550(10) K.T.V Towers,West Fort Road,Palakkad - 678 001Kerala
Tel : 0491-2505722, 0491-2505723
MADHYA PRADESH Gerry Diesels, 34/1, Kundan Villa, Bholaram, Ustad Marg, Opp. Sun India School, Brahmapuri Colony, Indore-452018.
Tel : 0731-4092177 / 5048164 / 5048314 / 9826083977
MADHYA PRADESH Elite Engineer,NH-7, Near Daily M.P Press, Kuthla Katni, Madya Pradesh 483501
Tel : 07622-409485 / 9424708892
MADHYA PRADESH Tushar Enterprises, S-46 Sanjay Complex, Jayendraganj, LashkarGwalior 474009
Tel : 0751-2440956 / 9425109901
MADHYA PRADESH L.K.Engineering Services,132 S.R Compound, Dewas naka, Lasudiya moriIndore 452 001
Tel : 9425312366
MADHYA PRADESH Naresh Mechanical Services, No 8, Shristi Complex, Statium Road, Opp Maruti Show Room, TP Nagar, Korba 495679
Tel : 07759-645148 / 9425532767
MADHYA PRADESH Chhabra Marine Spares, 38,Maugal Udyog Nagar, Near Choti Lakhani, CoIndore
Tel : 9407478880
MAHARASHTRA Kabra Engineering, Plot No B-11, Co Op Industrial Estate, Mul Road, Chandrapur-442401.
Tel : 07172-251782 / 9423115817
MAHARASHTRA Synergy Engineering Services, Nargessic, First Floor, Near UCO bank, 47, Mukund Nagar, Pune-411037.
Tel : 020-24272372 / 9444045712
8 MAHARASHTRA Synergy Engineering Services, 34/11-8, Behind BP Petrol Pump, Dhapodi, Pune-411012.
Tel : Worshop Address
8.8 DEALER NETWORK

MAHARASHTRA Synergy Engineering Services, Ground Floor -7,Aswini -B, Akashganga Housings Complex, Thane(W)-400601.
Tel : 022-25392870
MAHARASHTRA D.B.Automobiles, 1325/36,Shivaji Udyamnagar, Kolhapur-416008.
Tel : 0231-2656410, 2666275 (F) / 9823178637
MAHARASHTRA Gopal Industries, NH-3, Chalisgaon Crossing, Autonagar, Mohadi-424 311, Dhule.
Tel : 02562 – 230074 (F) / 9422296261
MAHARASHTRA Green Power Solutions, Plot No 39 -1C Sector 24, Turbhe, Navy Mumbai 400 705
Tel : 022-27836559022-27832879 (F ) / 9821014453
MAHARASHTRA Maharashtra Boring Works, Goankar Industrial Estate, Near Meena Crane Services, Panchapakhadi, Thane, Maharashtra 400 602
Tel : 022-25431401 / 9821668281
MAHARASHTRA United Engineers Co, Plot No : H5/10, MIDC, Chilkalthana, Aurangabad-431 210.
Tel : 0240-2326566, 2487998, 2321812 (F) / 9822504179
MAHARASHTRA Ramsons Castings Pvt Ltd.A 301Neeti gaurar apptCentral Bazar RoadRamdaspethNagpur 440 010
Tel : 07122435903- 707122435908
NEW DELHI Premnath Auto P Ltd, 42-43, Scindia House, New Delhi-110001.
Tel : 011-23755168, 23329408, 9871090170
NEW DELHI Premier Power Equipments, 171/1, Main IGNOU Road, Neb Sarai, New Delhi-110068.
Tel : 011 – 65654220, 29535370 (F) / 9810032289
ORISSA Shree Jagannath Motors, Nirmal Market Complex, Power House Road, Rourkela-769001.
Tel : 0661-2504959, 2507959, 2503515 (F) / 9437047959
ORISSA Shree Jagannath Motors, AT-Gopapali, NH-23,Vedvyas, Rourkela-769041.
Tel : 0661-2661197 / 9437043799
ORISSA Nigam Enterprisers, Plot No 250, Bomikhal, Bhubaneswar, Orissa 751 010
Tel : 0674-69413510674-25834209338215192
ORISSA Diamond Engineering, 142,Cuttack -Puri Road, Bhubaneswar-751006, Orissa 8
Tel : 0674-25724509431121674
DEALER NETWORK 8.9

PUNJAB K.K.Trading Corporation, 3479/6, Shivaji Nagar, Opp: Transport Nagar, Link Road, Ludhiana 141010
Tel : 98884-60000
PUNJAB Rahul & Company, Adjoining Heera Palace, Patiala Road, Nabha-147201.
Tel : 01765-522511 / 9813100001
PUNJAB Yashodha Motors, Lower Mall, Patiala, Punjab 147 001
Tel : 0175-5001574,5011394 (F) 9872424004
PUNJAB P.K Enterprises, SCF 435, IST Floor , Motor market , Manimanjra, Chandigarh - 160101
Tel : 09417002521
RAJASTHAN Pranay Generators, S-16, State Woolen Mill, Opp Police Motor Driving School, Sr Ganga Nagar Road, Bikaner-334006.
Tel : 0151-2251388 / 9414143888
RAJASTHAN Rajasthan Diesel Motor Workshop, 1-2, Gotewalon Ki Bagichi, Transportnagar, Agra Road, Jaipur-302003.
Tel : 0141-2643596, 9414073561
RAJASTHAN Rajasthan Diesel Motor Workshop, C-II-8, Automobile Nagar, Delhi Road, Jaipur-302003.
Tel : 0141-2643596 / 9414071561
RAJASTHAN AR Power Solutions, Shop No 2, Firoz Complex, Jhalwar Road, Anantpura Circle, Kota -324005, Rajasthan
Tel : 0744-24316550744-2360963 / 9352621696
RAJASTHAN SPS Tech Services, 34 Kamal Vihar, 200 Feet Gopalpura Bye Pass Road, Near Bhank Rota Pullia, Jaipur 302026
Tel : 0141- 3230529 / 9351367822
RAJASTHAN Kartikeya Technocrats63 Bank ColonyRaika Bag Jaipur RoadJodhpur 342 001
Tel : 9414023716
RAJASTHAN Vedant Engineering Service 44-52 Amber TowerSanchar Chandra Road Jaipur 302001
Tel : 0141-2341332/141328313
RAJASTHAN Sarthak Equipment Solutions,No. 42A, Panchwati,Udaipur,Rajasthan - 313001.
Tel : 9950788875
8 RAJASTHAN Gayatri Diesels,No. E - 59, Azad Nagar,Near Kumbha Circle,Bhilwara,Rajasthan - 311001

Tel : 01482 - 244127
8.10 DEALER NETWORK

TAMIL NADU M.S. Engineers, PB No 54085-B,Thiruvalluvar Street, Ramakrishna Nagar, Kaundampalayam, Coimbatore-641030.
Tel : 0422-2441943, 2448151 (F) / 9443149920
TAMIL NADU M.S. Engineers North Street, Back side of Select Steel, Suramangalam Road, Leigh Bazaar Road, Salem-636009.
Tel : 0427-2449886, 2331908 (F) / 9364169037
TAMIL NADU M S Engineers, 73B, VS Reddy Complex, Old Bangalore Road, Hosur-635109.
Tel : 9344169027
TAMIL NADU M.S. Engineers, No.182, Amma Towers, Behind Guruvayuranppan Temple, Vallipalayam Road, Tirupur-641601.
Tel : 0421-2202778 / 9344469017
TAMIL NADU Sri Meenakshi Gen Power Agency, 45/19, Workshop Road, Madurai-625 001.
Tel : 0452-2347640, 2347641, 9843233433
TAMIL NADU Four Stroke Diesel Sales & Service, No 2 Sai Amritha Flats, No 10 Gopal Street, Annai Indira Nagar, Velacherry,Chennai 42
Tel : 044-22435987 / 9841048446
TAMIL NADU Chakkrapaani Engineering Works, No.51,(New No134), Moore street, Chennai-600 001.
TAMIL NADU Chakkrapaani Engineering Works,No. 95, Plot No 3A, Kathivakam High Road Korukupettai, Chennai 21.
TAMIL NADU Chakkrapaani Engineering Works,No. 11, B Nethaji Road, Shenbakkam, Vellore-632008.
TAMIL NADU M/s.Chakkrapaani Engg Works, Plot No: 18,Paranjothi Nagar, Arappanan Cherry, Konnerikuppam Panchayat, Kancheepuram
Tel : 9940014233
TAMIL NADU Venus Energy,No. 5 New No. 3/C, CD Complex,Annagrammam, Gandhi Nagar,Panruti (T.K), Cuddalore : 607308.
Tel : 04142 - 268178
TAMIL NADU SIME PROGRAMME,No. 19/4, LKM Complex,Near BG Naidu Sweets,Melapudur,Trichy – 620001.
TAMIL NADU Maruthi Diesel, G/7-A, Rajaganapathy Plaza, Near ATC Depot, New Bus Stand, Salem - 636009
Tel : 95855 44636, 95855 44637 / 0427-2448212
TAMIL NADU M.S Engineers, D. No – 66/1, Thondikaradu, Street No -1, Thiruchencode Tk, Namakkal –Dt Pin code – 637211
Tel : 9381169017 / 8012033325
TAMIL NADU S.R Gen Power, 48E/6-1, Bye Pass Road, ST. XAVIER’S COLONY, Melapalayam Post,Tirunelveli - 627005 8
Tel : 0462 - 3244111 / 9543521571 /9543521572
DEALER NETWORK 8.11

UTTAR PRADESH Premier Power Equipments, 13, V N Marg, (Nr Luxmi Hotel), Allahabad.
Tel : 011 – 55654220, 05322400046, 9335025396
UTTAR PRADESH Oshonic Motors & Traders, 658,S Block, Vinoba Nagar,Juhi Depot, Kanpur-208014 (U.P)
Tel : 0510-2321584, 9918185839
UTTAR PRADESH Oshonic Motors & Traders, Sudama Building, Opp Bundelkhand Universty, Kanpur Road, Jhansi-284001.
Tel : 0512-2604513 / 9918185839
UTTAR PRADESH Vidhan Enterprises, Dharmashala Bazaar, Opp. Police Chauki, Gorakhpur-273001.
Tel : 0551-2203445 / 9506031003
UTTAR PRADESH Ruhelkhand Diesels,G-1 Pallav Puram-1Phase 1, Meerut, UttarPradesh
Tel : 0581-3241752 / 9719115575
UTTAR PRADESH Sri Balaji Enterprises, Niyawan Machhali Mandi, Faizabad 224001
Tel : 05278 - 212937 / 9889801223
UTTAR PRADESH Global Power Solutions, M-1145, Sec 1, LDA Colony, Kanpur Road, Lucknow, Uttar Pradesh 226012
Tel : 0522-402902, 99453139456
UTTAR PRADESH Parmeet Techno Crats,D35/66-5 ,Jangamwadi, Varanasi 221001
Tel : 0522-3255230 / 9839279661
UTTAR PRADESH Power Diesel, 1/573 Sector-17,Jankipuram, Lucknow, UP226021
Tel : 98392352209756702030
UTTAR PRADESH MK Enterprises, 77 1st Floor, Dushyant Nagar, Bodla-Sikendra Road, Agra UP282007
Tel : 0562-6453340 / 9719841000
UTTAR PRADESH AP Diesels, C-15/74, C-10, Sudhipur, By Pass Road,Shivpur, Varanasi-221003.
Tel : 0542-228209508085587428 / 07869138053
UTTAR PRADESH Power Diesel, Plot No. 733, Indra Nagar Colony, Seemadwar, Dehradun - 248006.
Tel : 8958999925
8 UTTRANCHAL Puri Automobiles, Tickonia Shopping Centre, Haldwani-263139.
Tel : 05496-227262, 222806 / 9837039614
8.12 DEALER NETWORK

WEST BENGAL Mitose Diesel Sales & Service, 22 Chittaranjan Avenue, Kolkata-700072.
Tel : (033) 22126132, 22126427, 9831118273
WEST BENGAL Mitose Diesel Sales & Service Fulbarihat, Baikuntapur, Bhaktinagar-734034.
Tel : 9832031909
WEST BENGAL Mitose Diesel Sales & Service, Pratap Market, 2nd Mile, Sevoke Road, Siliguri-734401.
Tel : 0353 – 2546245 (F) / 9434497117
WEST BENGAL Mitose Diesel Sales & Service, Bye-pass Road, Near Mecheda Road, Contai-721401.
Tel : 032-20256425 (F) / 9434180226
WEST BENGAL Mitose Diesel Sales & Service, Susamaly, Near Doly lodge, Burnpur Road, Asansol-713304.
Tel : 9830168740
WEST BENGAL Mitose Diesel Sales & Service, Vivekananda College Road, Barddhaman-713103.
Tel : 034 -22543724 (F) / 9434255419
WEST BENGAL Mitose Diesel Sales & Service, Baikunthapur, PO-Phulbari Hut Dist-Jalpaiguri.
Tel : 0353 – 2568910 / 9832334153
DEALER NETWORK 8.13

MARINE ENGINE DEALERS
GOA Jayashri Marine Services P Ltd, 1/2, Al Ameen, Panaji margao Highway, Cujira Santa cruz, Goa-403 005
Tel : 0832 -2445034 Fax 238915
GUJARAT Gujarat Fisheries Centarl Co-operative Assn Ltd, GIDC Estate, Patan Road, Veraval Post, Junagadh
Tel : 079-6583054,Fax 6583054 / 9427340004
GUJARAT Gujarat Fisheries Central Co-operative Assn Ltd, Boat Building Yard, Bhidiya Plot, Veraval - 362267
Tel : 231331, 9427340006
GUJARAT Kalpana Marine Agencies, Plot No.B/3 Somnath Road, Near Bhidiya Circle, Veraval - 362267
Tel : 02876-231288,Fax 231544, 9825221688
KARNATAKA Sundaram Motors, 17-6-1312/9, Nandigudda Road, Shankar Vittal Motor Compound, Attavar, Mangalor-575001
Tel : 0824-2446110/2446556/24473-42/ 9448386326
KERALA TVS & Sons Ltd, National Highway,Kaloor, Kochi - 682017
Tel : 0484 - 2536277/2537843 / 9847014506
KERALA TVS & Sons Ltd, XII/646, National Highway, Near Chungam, Feroke, Kozhikode - 637631
Tel : 0495-2481563/2484986
KERALA T.V. Sindaram Iyengar , Kollam, Door No 8 /337, Musaliar Complex, Randam Kutty .Kilikolloor Kollam -Pin 691004
Tel : 0474 2732331
MAHARASHTRA Jayashri Marine Services (P) Ltd,10, Bagkar House, Sasoon Dock, Colaba, Mumbai - 400005
Tel : 022-22186119,22186135,Fax 22186119
ORISSA TVS & Sons Ltd, Plot No: 785/1911(Near Suraj Hotel) Sahadevkhunta-P.O., Balasore - 756001
Tel : 06782-240679 / 9861086325
TAMILNADU TVS & Sons Ltd, 2/14B, II & III, Madurai Bye Pass Road, Madathur-PO, Tuticorin - 628008
Tel : 0461-2341516/ 9443143028
TAMILNADU Sundaram Motors, Bye pass Road, Poonamallee, Chennai - 600056
Tel : 044-26492180/88/26272151
TAMIL NADU T.V.Sundaram Iyengar & Sons Ltd No:52, Madhavaram Red Hills High Road, Vadaperumbakkam, Chennai - 600060.
8 Tel : 044 26591461, 26591462, 26591463
8.014 DEALER NETWORK

MARINE ENGINE DEALERS
WEST BENGAL Mitose Diesel Sales & Service, 22, Chittranjan Avenue, Kolkatta - 700072
Tel : (033) 22126132,22126427, 9831118273
WEST BENGAL Mitose Diesel Sales & Service, Pratap Market, 2nd Mile,Sevoke Road, Siliguri - 734401
Tel : 0353-2546245 / 9434497117
DEALER NETWORK 8.015

40 KVA GENSET ENGINE - ALGPW4DE/14
S.NO SPEC DESCRIPTION SPECIFICATION REMARKS
1 Engine Cylinder Head Assembly ALECH42
2 Engine Cylinder Block Assembly ALECB7
3 Engine Main Bearing ALEMB350
4 Engine Piston And Rings HAEPR2
5 Engine Connecting Rod Assembly ALECN350
6 Engine Crank Shaft Assembly ALECS43
7 Engine Camshaft Assembly HAECM1
8 Engine Fly Wheel ALEFW350/8
9 Engine Flywheel Housing ALEFH19
10 Engine Timing Gear Assembly ALETG300
11 Engine Timing Case Assembly ALETC119
12 Engine Sump ALES24
13 Engine Oil Strainer HAEOS3
14 Engine Oil Pump ALEOP350
15 Engine Valve System ALEVL350
16 Engine Intake Manifold ALEIM350/4
17 Engine Exhaust Manifold ALEEM8
18 Engine Oil Cooler ALEOC7
19 Engine Thermostat Assembly HAETH11
20 Engine Breather Hose ALEBH300
21 Fuel Injection Equipment Assembly ALFIE56
22 Engine Nozzle Holder HAFNH5
23 Engine Water Pump Assembly HAEWP19
24 Oil Level Guage Assembly ALOLG3
25 Starter Motor Assembly-12V ALSM41
26 Dynamo Drive Assembly-12V ALDD149
27 Radiator Assembly FD000900
28 Air Cleaner Assembly 10004867
29 Upfit Kit 10005062

CYLINDER HEAD - ALECH42
SL.NO ILL.NO PART NO DESCRIPTION QTY REMARK
1 B3C03001 S/A OF ENGINE CYLINDER HEAD ( With stud) - 1

2 1 B3C03002 S/A OF ENGINE CYLINDER HEAD (wihout stud) consits of items marked with $ 1
3 F0X01922 $ CYLINDER HEAD 1 NSS
4 2 X1701113 MLS GASKET 1
5 3 F0531522 $ BUSHING, VALVE GUIDE INTAKE 8
6 4 X0900216 $ SEAT,VALVE INTAKE 4
7 5 X0900116 $ SEAT,VALVE-EXHAUST 4
8 6 X3510415 BOLT, CYLINDER HEAD 13
9 7 X3510815 BOLT, CYLINDER HEAD 5
10 8 F1135842 COVER CYL HEAD 1
11 9 F1762100 GASKET C/HEAD COVER 1
12 10 F1100160 OIL FILLER CAP 1
13 11 F4832510 $ BALL STEEL 4
14 12 X3716515 STUD (REF. IVECO PART NO. 98458149W) 8
15 13 X3504211 STUD,EMF 4
16 X3716315 STUD - M8X1.25 2
17 14 F3145315 $ PLUG EXPANSION 30DIA 4
18 15 F3144915 $ PLUG EXPANSION 4
19 18 F3145215 $ PLUG EXPANSION -26 DIA 4
21 F3144715 $ PLUG 1
22 F3145415 $ PLUG EXPANSION 1
23 L4010800 $ WASHER 8 DIA PLATED 6
24 F4922100 $ WASHER 18 OD X 12.2 ID X 1 t 1
25 L1011008 HEX BOLT M10x1.5x40 8.8 GR 4
26 L4111000 SC WASHER 10 DIA PLATED 4
CYLINDER HEAD - ALECH42
27 L2010835 SCREW M8 X 35 X 1.25 CP PLATED 6
29 L4011000 WASHER 10 DIA PLATED 4
CYLINDER BLOCK FOR AESTHETICALLY IMPROVED H4D GENSET - ALECB7
SL.No ILL.No PART NO DESCRIPTION QTY REMARK
1 1 B3B01902 S/A OF CYLINDER BLOCK ( consits of items marked with $) 1
2 F0X02022 $ CYLINDER BLOCK 1 NSS
3 2 X3404222 $ CYLINDER LINER "W" AR
4 2 X3404322 $ CYLINDER LINER "X" AR
5 2 X3404422 $ CYLINDER LINER "Y" AR
6 2 X3404522 $ CYLINDER LINER "Z" AR
7 3 F2702150 O RING CAM AND SEAL 1
8 4 X3511115 $ BOLT, MAIN BEARING CAP 10
9 5,6,7 P0976551 $ BEARING C/SHAFT NO 1 1
10 8 F0536230 $ BUSHING BODY O/PUMP 1
11 9 F7647314 SEAL, PLATE 1
12 X1406714 FLANGE 1
13 10 F0954415 PIN STRAIGHT 2
14 11 F0954515 PIN STRAIGHT (8X16) 2
15 12 F0954615 PIN STRAIGHT (5X10) 1
16 13 F0954715 PIN REAR 2
19 16 F3146615 $ EXPANSION PLUG 3
23 X3108815 PLUG 2
24 F4832610 $ BALL STEEL 2
25 X1710800 GASKET OIL OUTLET 1
CYLINDER BLOCK FOR AESTHETICALLY IMPROVED H4D GENSET - ALECB7
28 L9010818 FLANGED SCREW - M8x1.25x18L 2
29 F1Z01314 LIFTING EYE 1
MAIN BEARING - ALEMB350
MAIN BEARING - ALEMB350
SL. ILL. PART
NO. NO. NO. DESCRIPTION QTY REMARKS
1 9,10 P0990951 THRUST WASHER-STD AR
2 P0994551 THRUST WASHER-S1 AR
3 11,12,
P0928851 CRANK SHAFT MAIN BEARING SET -STD AR
13,14
4 P0928951 CRANK SHAFT MAIN BEARING SET - 0.25 U/S AR
CONNECTING ROD - ALECN350
CONNECTING ROD - ALECN350
SL. ILL. PART
1 1 B7014001 S/A OF CONNECTING ROD 4
2 2 F0536630 CON ROD BUSH 4
3 3 F3585615 BOLT, CON ROD 8
4 4 P0920851 CON ROD BEARING KIT - STD 1
5 4 P0929151 CON ROD BEARING KIT - 0.25 MM U/S 1
6 4 P0929251 CON ROD BEARING KIT - 0.50 MM U/S 1
ENGINE CRANKSHAFT - ALECS43
ENGINE CRANKSHAFT - ALECS4
SL. ILL. PART
1 1 F3438615 COLLAR 1
2 2 X3308411 CRANKSHAFT 1
3 3 F0954915 KEY FOR GEAR CRANKSHAFT 1
4 4 X1602711 GEAR CRANKSHAFT 1
5 5 X1504522 S/A PULLEY CRANKSHAFT POLY V 1
6 6 F2702650 O RING 1
7 7 F1200210 SPACER 1
8 8 F3568715 NUT 1
2
FLYWHEEL HOUSING - ALEFH19
1 1 F7M00922 FLYWHEEL HOUSING 1
2 2 F3769515 STUD-STARTER MOTOR MOUNTING M10 3
3 3 X2705100 H-Series C/S REAR END PTFE OILSEAL 1
4 4 L9011440 FLANGED SCREW - M14x2x40L 8
5 5 L9010832 FLANGED SCREW M8 x 1.25 x 32 6
6 6 L9010812 FLANGED SCREW - M8x1.25x12L 4
7 X1102513 F/H, DUST COVER 2
TIMING GEARS - ALETG300
TIMING GEARS - ALETG300
SL. ILL. PART
1 1 F3585715 BOLT FOR THRUST PLATE SETTING 1
2 2 F7661814 PLATE, IDLE GEAR THRUST 1
3 3 F0955015 PIN, STRAIGHT 2
4 4 F3347211 SHAFT, IDLE GEAR 1
5 5 B7014502 S/A OF SHAFT, IDLER GEAR 1
6 6 F0536530 BUSING FOR GEAR IDLER 1
7 7 F1655411 GEAR, IDLE 1
8 8 B7014501 S/A OF GEAR, IDLER 1
9 9 F7661714 PLATE, IDLE GEAR THRUST 1
ASSY OF ENGINE TIMING GEAR CASE - ALETC119
1 1 L9510819 FLANGED BOLT - M8x1.25x95L 2
2 2 L9510815 FLANGED BOLT M8x1.25x75 8.8 1
3 3 F7647414 SEAL PLATE 1
4 5 F1721600 JOINT-POWERSTEERINGPUMP DUMMY PLATE 1
7 8 X2706700 OIL SEAL, FRONT (PTFE) 1
8 9 F3502400 BOLT 1
9 10 F1761500 GASKET FRT END PLATE 1
11 12 X7200113 TIMING BACK PLATE 1
12 B4M02401 S/A OF TIMING GEAR CASE ( comprises items marked witH $) 1
13 14 F3145915 $ PLUG EXPANSION 32DIA 1
14 15 FK400522 $ TIMING GEAR CASE 1
16 B4M02901 S/A OF BEARING HOLDER ( comprises of items marked with #) 1
17 19 F8L00122 # CASE - BEARING HOLDER 1
18 20 F0245310 # BEARING,BALL 1
19 21 F0743410 # RETAINER RING 1
23 F7909414 SEAL PLATE 1
24 F2749200 O Ring 81.2 x 3.3 1
ASSY OF SUCTION STRAINER - HAEOS3
1 1 F2702750 O RING FLANGE SEAL 1
2 2 L9010822 Flanged screw - M8x1.25x22L 2
3 3 B9255801 S/A OF SUCTION STAINER ( comprioses of itesm marke dwith $) 1
4 4 X4000142 $ STRAINER WITH TREPANNING 1
5 5 F4000310 $ SCREEN OIL STRAINER 1
6 6 F0743510 $ SNAP RING 1
ASSY OF ENGINE OIL PUMP H-Series - ALEOP350
ASSY OF ENGINE OIL PUMP H-Series - ALEOP350
Sl. Ill. PART
no. no. no. DESCRIPTION QTY remarks
1 1 B8729901 S/A OIL PUMP-4CTI-E2 1
2 2 F1761200 GASKET O P COVER 1
3
6 5A F3502400 BOLT 2
7 B8729902 S/A OIL PUMP COVER ( consists of item marked with $) 1
8 6 F1600326 $ OIL PUMP GEAR 1
9 7 F3356215 $ SHAFT OIL PUMP DRIVE 1
10 8 F1661311 $ GEAR, OIL PUMP DRIVE 1
11 9,10 B7018703 S/A OF GEAR OIL PUMP 1
12 10 F0536230 BUSHING BODY O/PUMP 1
13 11,12 B8255003 $ S/A OIL PUMP COVER 1
14 11 X1101122 $ COVER,OIL PUMP 1
15 12 F0536430 $ BUSHING,BODY OIL PUM 1
16 13 F3356315 $ SHAFT OIL PUMP DRIVEN 1
ENGINE VALVE SYSTEM ASSEMBLY - ALEVL 350
1 1 B7015004 S/A VALVE PUSH ROD 8
2 2 F4231511 INLET VALVE 4
3 3 F4231611 EXH VALVE 4
4 3A X1100615 VALVE CAP 8
5 4 X2706400 VALVE STEM SEAL (DOUBLE LIP) 8
6 5 X3607310 SPRING, VALVE 8
7 6 X0900911 SEAT,VALVESPRING-UPPER 8
8 7 X0901011 SEAT-VALVE SPRING LOWER 8
9 8 F4330722 LIFTER VALVE 8
10 9 F3586015 SCREW VALVE ADJUSTG 8
11 10 F3210322 ROCKER ARM.INLET 4
12 11 F3210422 ROCKER ARM.EXH. 4
13 12 B7018802 S/A SHAFT VALVE ROCKER WO4D 1
14 12A F3146015 SPHERICAL PLUG 2
15 13 F7104522 ROCKER BRACKET 1
18 16 F3438515 LOCK VALVE SPG RET 16
19 17 F3438415 COLLAR 4
20 18 F3586215 NUT - HEX M8 X 1 FP X 6 LONG X 0 8
21 19 L9510812 Flanged bolt -M8x1.25x60L 5
22 20 F4945910 WASHER 2
23 21 F3576711 SCREW - HEX M5 X 0.8 CP X 8 LONG X 0 2
ASSY OF ENGINE INLET MANIFOLD - ALEIM350/4
1 1 F1842642 MANIFOLD INTAKE 1

2 2 F1762500 GASKET - I/MANIFOLD 1
3 3 F1934142 PIPE INTAKE 1
4 4 L9510810 Flanged bolt - M8x1.25x50L 3
6 6 L9510818 FLANGED BOLT- M8 X 1.25 X 90L 4
7 7 F3769215 STUD 4
8 8 F3769615 STUD M6X1 3
9 F3136215 PLUG 1
10 F4930240 WASHER 30 OD X 22.5 ID X 1.5 t 1
ENGINE EXHAUST MANIFOLD - ALEEM 8
EXHAUST MANIFOLD - ALEEM8
1 1 F1856722 EXHAUST MANIFOLD 1

2 2 X1700111 SPECIAL GASKET FOR EXHAUST MANIFOLD-CYLINDER HEAD 4
3 3 F1200410 SPACER 2
4 4 F7F00115 HEX NUT FLANGED, M10x1.25 8
5 X1203515 SPACER, LONG (For EMF mounting Long Stud) 6
6 FN000322 EXHAUST PIPE 1
7 F3756815 M10 -STUD 3
8 F1760200 GASKET 1
ASSY. OF OIL COOLER WITH SPIN-ON FILTER - ALEOC7
ASSY. OF OIL COOLER WITH SPIN-ON FILTER - ALEOC7
Sl. Ill. PART
1 1 F4M00142 CASE OIL COOLER 1
2 2 F0B01015 ADAPTOR, OIL FILTER 1
3 3 F4231711 VALVE FILTER SAFETY 3
4 4 F3639410 SPRING OIL VALVE 2
5 5 F3639510 SPRING OIL VALVE 1
6 6 F3147115 PLUG VALVE SPRING 5
7 7 F2749700 O RING 17.6 x 2.6 5
8 8 F7A01500 OIL FILTER - FLEETGUARD PART NO - LF16238 1
9 9 F2702550 O RING 19 x 3 4
10 10 x1707700 OIL COOLER GASKET 1
11 11 F4935530 WASHER SOFT-H-SERIES 3
12 12 F1986715 CONNECTOR PIPE 1
13 13 F3587011 DOUBLE BANJO BOLT-H-SERIES 1
15 15 L9510808 FLA BOLT M8x1.25x40 8.8 GR 3
17 17 L9510821 FLANGED BOLT M8x1.25x105 2
18 18 L9120818 FLANGED NUT - M8x1 4
19 19 X F7824800 S/A OF ELEMENT OIL COOLER 1
ASSY OF ENGINE THERMOSTAT - HAETH11
1 1 F5J01022 COVER THERMOSTAT 1
2 2 X7468900 THERMOSTAT ASSY. 1
3 3 F1761400 GASKET THERMOSTAT 1
5 5 B4L01501 S/A OF THERMOSTAT CASE (comprises of items marked with $) 1
6 F1985515 $ PIPE VENT 1
7 FS300322 $ CASE_THERMOSTAT 1
8 X0148515 ADAPTOR 1
10 7 F2701550 O Ring 31.2 x 3.5 2
11 8 L9010822 Flanged screw - M8x1.25x22L 3
12 X7491300 TEMPERATURE SENSOR 1
engine breather hose - alebh300
engine breather hose - alebh300
Sl. Ill. PART
1 1 F0837710 CLAMP 1
2 2 B7015701 BREATHER HOSE WITH INNER SPRING 1
3 4 X1407414 FLANGE VENT HOSE 1
4 X0807610 CLIP SPRING BAND ( 25X12X1) 1
FUEL PUMP - ALFIE56
1 1 F3585115 BOLT DRIVE GEAR SET 4

2 2 X1608211 GEAR, INJ. PUMP DRIVE 1
3 3 F1437211 FLYWHEEL COUPLING 1
4 4 F2702450 O Ring 142.5 x 3 1
5 5 F5J01422 COVER TIMER 1
6 7 F3575411 BOLT TIMER COVER SET 1
7 7 F3574011 BOLT 3
8 F4945710 WASHER 22 OD X 8.5 ID X 2 t 1
9 8 F3769515 STUD-STARTER MOTOR MOUNTING M10 4
10 F4935430 WASHER 30 OD X 22.5 ID X 1.5 t 1
11 9 F3146415 PLUG TIMING HOLE 1
12 10 B7015802 PIPE OIL- WO6D 1
13 11 F4932940 WASHER 8
14 12 F3575511 BOLT W/DOUBLE HOLE 1
15 13 F7V00900 FUEL INJECTION PUMP 1
16 14 F3147415 BANJO BOLT 1
17 15 B7015817 CLIP S/A THRU FEED 1
18 B7015810 S/A OF CLIP 6
19 B8709806 S/A OF CLAMP INJR. PIPE 1
20 B8709807 S/A OF CLAMP INJR. PIPES 1
21 F3575711 NUT - HEX M6 X 1 CP X 5 LONG X 0 2
22 16 B8709802 S/A OF PIPE INJR. NO.1 1
24 18 B8709804 S/A OF PIPE INJR. NO. 3 1
26 20 X1936510 PIPE SUB ASSY (NOZZLE LEAKAGE) 1
FUEL PUMP - ALFIE56
27 21 F0838610 CLIP 2
28 22 F1939660 HOSE FUEL 1
29 23 B7019409 S/A OF PIPE 1
30 F3574311 BOLT 2
31 X3509410 FLANGED BOLT - M8X1.25 CP X21.05 1
32 F3575611 BANJO BOLT - OIL INLET-COMP 1
33 F4922900 PLAIN WASHER M6.6 2
34 F4946210 WASHER 20.74 OD X 11.22 ID X 2 t 4
35 L2010630 SCREW M6 X 30 X 1 CP PLATED 2
36 B9210801 CLIP FOR LUB OIL PIPE MOUNTING 1
37 X3965600 STRAINER ASSY. 1
38 L3021018 NUT M10 X PC 8 X 1 FP PLATED 4
39 F4930430 WASHER 17.9 OD X 14.2 ID X 1.5 t 2
ASSY OF ENGINE COOLANT PUMP WITH POLY-V - HAEWP19
1 1 L1010811 HEX BOLT M8x1.25x55 8.8 GR 4
2 F1202742 FAN ADAPTOR 1
5 2 FC801722 WATER PUMP PULLEY 1
8 5 B4T01701 SUB ASSEMBLY OF COOLANT PUMP 1
ASSY OF ENGINE OIL LEVEL GAUGE - ALOLG3
1 B8733002 S/A FOR DIPSTICK AND GUIDE AS A PAIR ( Consits of ill No 1 & 2) 1
2 1 B8733001 S/A OIL LEVEL GAUGE 1
3 2 B8250107 S/A OF DIPSTICK GUIDE 1
4 3 F2702050 O RING HOLDER SEAL 1
Starter Motor Assembly - ALSM41
1 2
ASSY OF STARTER MOTOR - ALSM41
1 1 X7479300 M14 PREENGAGED TYPE STARTER MOTOR OF LTVS MAKE 1

2 2 L9121018 Flanged Nut - M10x1.25 3
ASSY OF DYNO DRIVE WITH POLY-V PULLEY - ALDD149
1 F0130711 ADAPTOR 1
2 F2701650 O Ring 43.7 x 3.5 2
3 F3583015 SPECIAL SCREW 1
4 L1011025 HEX BOLT M10x1.5x125 8.8 GR 1
5 L3611018 NYLOC NUT M10 X PC 8 X 1.5 CP PLATED 1
7 L9110818 FLANGED NUT - M8x1.25 1
8 L9511015 FLANGED BOLT - M10x1.5x75L 2
9 FR100822 BRACKET - ALTERNATOR 1
10 X7490100 12 V 65 AMPS ALTERNATOR FROM LTVS (POLY V) 1
11 X0301650 BELT, 8PK 1250 (FENNER) 1
12 L9111018 FLANGED NUT - M10x1.5 1
13 L9011027 FLANGED SCREW - M10x1.5x27L" 4
15 L3011218 NUT M12 X PC 8 X 1.75 CP PLATED 2
16 F4A00610 GUIDE,SLEEVE 1
17 F3570911 LINK BOLT 1
18 F0536115 SPLIT BUSH 1
19 B2F03601 COOLANT ELBOW, VALVE AND O-RING 1
20 FB501022 PIPE COOLANT PUMP 1
21 F2701850 O Ring 13.8 x 2.4 1
22 X4202111 VALVE (Coolant Elbow) 1
RADIATOR ASSEMBLY - FD000900
1 1 FD000900 RADIATOR (make - Tata Toyo ) 1
2 2 F7199414 Bracket - Engine Mtg. - Front 2
3 3 L2011230 SCREW M12 X 30 X 1.75 CP PLATED 8
4 4 L4111200 SC WASHER 12 DIA PLATED 8
5 5 F2V03614 BRACKET - RADIATOR MTG. 1
6 6 F2V03714 BRACKET - RADIATOR MTG. 1
7 7 L2011235 BOLT M12 X 35 X 1.75 CP PLATED 4
9 9 L3011218 NUT M12 X PC 8 X 1.75 CP PLATED 4
10 10 L1021616 BOLT M16 X 80 X 1.75 FP PLATED 2
11 11 F4931410 WASHER 2.25 OD X 41/64 ID X 0.187 t 6
12 12 F0501850 RUBBER BUSH 4
13 13 F1235415 DISTANCE PIECE 2
15 15 L3021618 NUT M16 X PC 8 X 1.75 FP PLATED 2
16 16 F2V03414 RADIATOR STAY - RH 1
17 17 F2V03514 RADIATOR STAY - LH 1
18 18 F8990814 BRACKET TOP STAY 1
21 21 L4010800 PLAIN WASHER M8 2
22 22 F2602158 RADIATOR BUFFER WITH NUTS 2
23 23 F8P06650 HOSE -DIFFUSER 1
24 24 F8638610 STEEL PIPE 1
25 25 F8P13358 STRAIGHT HOSE - RADIATOR PIPING 1
26 26 F0803400 WORM DRIVE CLIP 4
27 27 F1970750 L-HOSE 1
28 28 10004395 PIPE (Radiator Inlet Pipe) 1
29 29 F8P06750 HOSE 1
30 30 X0148515 ADAPTOR 1
31 31 F1990450 STRAIGHT HOSE - FOR RADIATOR PIPING 1
RADIATOR ASSEMBLY - FD000900
32 32 F8200110 JUPITOR HOSE CLAMP 2
33 33 PJ100018 TEMP SWITCH MVD 1
34 X0802410 C-CLAMP 1
35 F9027214 PLATE 1
39 10003405 18.5 INCH 10 BLADE PLASTIC PUSHER FAN 1
40 L2021025 SCREW M10 X 25 X 1 FP PLATED (Fan mounting) 4
41 L4111000 SC WASHER 10 DIA PLATED (Fan mounting) 4
42 L4011000 PLAIN WASHER 10 DIA PLATED ( Fan mounting) 4
AIR CLEANER ASSEMBLY - 10004867
AIR CLEANER KIT ASSEMBLY - 10004867
1 F7A01800 AIR INTAKE KIT 40KVA EXPORT 1
2 1 P7B00017 AIR CLEANER ELEMENT 1
3 2 F3517400 NUT, WING 1
4 3 F8P02900 HOSE REDUCER ELBOW 1
5 4 F8318300 HOSE CALMP 1
6 5 F8206410 HOSE CALMP 1
7 6 FB504100 PIPE ASSY 1
8 7 F8W00300 RESTRICTION INDICATOR 1
9 8 F8M00500 RAIN HOOD , METAL 1
10 9 F1E01314 BRACKET - AIR FILTER MOUNTING 1
11 10 F1E01414 BRACKET - AIR FILTER MOUNTING 1
UPFIT KIT - 10005062 ( FUEL SYSTEM )
UPFIT KIT 10005062 ( Fuel System )
SL.No ILL.NO PART NO DESCRIPTION QTY REMARK
1 1 F8928114 FUEL FILTER MOUNTING BRACKET (1.1) 4CTI 1
4 4 L4011000 PLAIN WASHER 10MM 2
5 5 B4461901 S/A OF FUEL FILTER ( Consits of itmes marked with $ ) 1
6 5b F8835100 $ FUEL FILTER CUM WATER SEPARATOR 1
7 5a F8835200 $ FUEL FILTER HEAD ASSY 1
8 6 L2021240 SCREW M12 X 40 X 1.5 FP PLATED 2
11 F8474714 STRAINER BRACKET 1
12 F8824500 FUEL STRAINER 1
13 F0804814 C-CLAMP 1
14 L2010615 SCREW M6 X 15 X 1 CP PLATED 2
15 L3010618 NUT M6 X PC 8 X 1 CP PLATED 2
17 B3J00501 HOSE - FEED PUMP TO WATER SEPERATOR 1
18 B4461903 HOSE ASSY - STRAINER TO FEED PUMP 1
19 F8200110 JUPITOR HOSE CLAMP 2
20 B3J00502 HOSE - FUEL FILTER TO FIP 1
21 B3J00503 FUEL TANK TO STRAINER 1
22 F3131415 BANJO CONNECTION 1
23 F4930430 WASHER 17.9 OD X 14.2 ID X 1.5 t 2
24 F3590715 BANJO BOLT 1
25 F4922100 WASHER 18 OD X 12.2 ID X 1 t 2
UPFIT KIT - 10005062 ( EXHAUST BELLOW )
UPFIT KIT 10005062 ( Exhaust Bellow )
1 F0S00500 EXPANSION BELLOW 1
2 F1761100 GASKET EXHAUST PIPE 1
3 L1011009 BOLT M10X1.5X45 3
4 L4111000 S C WASHER M10 11
6 F7D00522 EXHAUST FLANGE 1
8 FN000322 EXHAUST ELBOW 1
UPFIT KIT 10005062
1 F2008500 FAIL SAFE UNIT 1
2 F4922300 WASHER 18 OD X 12.2 ID X 1 t 2
3 X0139115 ADAPTOR (OIL SENSOR) 1
4 X7809300 OIL PRESSURE SENSOR 1
5 L1011230 BOLT M12 X 35 X 1.75 CP PLATED 4
7 F3G00614 BRACKET - RELAY MOUNTING 1
9 F7888900 RELAY STARTER 12V - 4D PP 1
13 L1050614 BOLT 3/8 X 1 3/4 BSF PLATED 3
14 L3050611 NUT 3/8 X PCP BSF PLATED 3
15 L4100600 SC WASHER 3/8 DIA INCH PLATED 3
17 PJ200003 FIP MOUNTED SOLENOID WITH RPM LEVER 1
18 L1050814 Hex Bolt M14 2
19 L4100800 SC WASHER 4
20 L3050811 NUT M14 2
23 FB506400 CONNECTOR PIPE 1
24 F0831310 ZERO CLIP 2
25 F8P04550 BREATHER HOSE 1
26 10004430 LUBE OIL DRAIN KIT 1
UPFIT KIT 10005062
27 F7888100 AMMETER 1
28 F7888300 TEMPERATURE GAUGE 1
29 F7888500 OIL PRESSURE GAUGE 1
30 F7Z01800 RPM HOUR METER 1
31 10004886 WIRING HARNESS 1
32 F2230500 STARTER SWITCH 1
33 F7420400 TOGGLE TYPE SWITCH 2
34 F2801610 PANEL 1
35 F1135060 HOOD 1
36 F0837710 CLAMP (WIRING) 1
37 F4930000 FIBHER WASHER 6
38 L2040306 SET SCREW M5 6
39 L3040311 NUT M5 6
40 L4110500 SC WASHER M5 6
41 L3010618 M6 NUT 4
42 L4110600 SC WASHER M6 4
43 L4010600 PLAIN WASHER M6 4
44 L2010515 SET SCREW M6 4
45 L5080811 M14 BOLT 2
46 L2011235 BOLT M12 X 35 X 1.75 CP PLATED 4
47 F1747800 JOINT FOR INTAKE PIPE 1
48 F3769215 STUD 4
49 L3610818 NYLOCK NUT 4
50 F0803400 WORM DRIVE CLIP 4

Manual Book Hydraulic Crawler Drill BARI CD-360 COMPLETO

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Manual Book Hydraulic Crawler Drill BARI CD-360 COMPLETO

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INSTRUCTION MANUAL

SPARE PARTS CATALOGUE

NOTE:- Bari Internacional Company reserves the right to make changes

Bari Internacional S.A. de C.V.

Bari Internacional S.A. de C.V.

CD-360 CRAWLER DRILL SPECIFICATIONS

Mode of Drilling : Down the Hole Air Hammer

Rotation speed RPM 0-60

HYDRAULIC POWER PACK:

DIMENSIONS & WEIGHT

Overall length 5050mm

Overall Width 2100mm

Ground clearance 260 mm

Track Width 260 mm

Track length (Ground contact) 1650 mm

Track Oscillation ±10°

Total Weight 5200 Kg

Boom Lift above Centre Line 300 up, 300 down

Boom Swing 300 right , 450 left

Drill Guide Tilt 750 (Two position)

Tramming speed 2.0 km/hr

Climbing ability 250

Draw bar pull 1400 Kg

Operating Instructions for CD-360

Kindly refer lubrication chart.

Lubricator Adjustment (Air Line Oiler):

4 Hydraulic Tank SAE 46 250.0 Hydraulic Oil Grade SAE:46

5 Engine Oil SAE 15W-40 5.0 Lube Oil SAE 15W-40

Line Oiler (Air Line

PROCEDURE TO CHANGE LOCATION OF CLEVIS PIN:

Fig 1.5: RELOCATION OF CHANGE PIN

POSITIONING THE DRILL GUIDE FOR DRILLING:

(A) VERTICAL DRILLING:

(B) TOE-HOLE AND LOW ANGLE DRILLING:

PRELIMINARY PROCEDURE FOR DRILLING:

a) Adjust properly Air Line Lubricator.

DRILL ROD ADDITION PROCEDURE:

IMPORTANT POINTS FOR DRILLERS:

a) Maintain required air pressure at drill. Operating at lower pressures decreases

Following are the indications of a Dull Bit: -

PREVENTIVE MAINTENANCE CHART for CD-360

Check the oil Level in the

Check the Oil in Hydraulic

Grease all Fitting on the

Apply Grease to Channel on

Check the Feed Chain

Chain & Drive

Remove & Clean Suction

Flush Grit & Slush

Remove Return Line Filter,

Pressure Wash the Entire

Clean and inspect Down

Check Oil Level in Rotary

Check Oil Level in Feed Unit

Check Tightness of Rotary

Check tightness of all other

Inspect Hydraulic and Air

Clean the Feed Chain

Service and Parts

Special versions ...................................................................................................................... 3

© 2003 Sauer-Danfoss. All rights reserved. Printed in Europe

2 DKMH.PS.130.A1.02 • 520L0593 • Rev. A • 05/2003

COMMENTS a) Only OMS series 2:

DKMH.PS.130.A1.02 • 520L0593 • Rev. A • 05/2003 3