Copper-brass radiator repair, core recoring, and new radiator supply for all Ashok Leyland Leypower DG set models from 125 KVA to 250 KVA. H-Series 4-cylinder and 6-cylinder engines. Pickup & delivery across Mumbai. 6-month warranty on all work.
Ashok Leyland is one of India's most trusted commercial vehicle and engine manufacturers. Their DG sets — sold under the Leypower brand — are widely used in factories, warehouses, commercial buildings, educational institutions, and hospitals across India. Ashok Leyland DG sets from 125 KVA to 250 KVA all use copper-brass radiators, making them straightforward to repair and recore at our Worli, Mumbai workshop. We also repair Ashok Leyland truck and bus radiators — see our Ashok Leyland vehicle radiator page →
Alt text: "Ashok Leyland Leypower 160 KVA DG set radiator repair at Ajanta Radiators Worli Mumbai"
Because all Leypower DG sets use copper-brass radiators, repair and recoring is simpler, faster, and more cost-effective compared to aluminium radiators. Copper-brass is repaired by soldering — a skill Ajanta Radiators has mastered over 55+ years of in-house manufacturing at Worli, Mumbai. Most Leypower radiator repairs are completed in 1–3 working days, and recoring in 2–4 working days. We also repair Ashok Leyland truck and commercial vehicle radiators — so we are thoroughly familiar with AL engine cooling systems across all product lines.
| Leypower Model | KVA | Engine Type | Radiator Type | Common Problem | Service |
|---|---|---|---|---|---|
| Leypower 125 KVA | 125 KVA | AL 4-Cyl H-Series | Copper-Brass | Top tank solder joint failure | Repair · Recore · New |
| Leypower 140 KVA | 140 KVA | AL 4-Cyl H-Series | Copper-Brass | Fin corrosion, tube scale buildup | Repair · Recore · New |
| Leypower 160 KVA | 160 KVA | AL 6-Cyl H-Series | Copper-Brass | Coolant overflow, hose joint leaks | Repair · Recore · New |
| Leypower 180 KVA | 180 KVA | AL 6-Cyl H-Series | Copper-Brass | Header joint fatigue cracks | Repair · Recore · New |
| Leypower 200 KVA | 200 KVA | AL 6-Cyl H-Series | Copper-Brass | Core tube failure on older sets | Repair · Recore · New |
| Leypower 250 KVA | 250 KVA | AL 6-Cyl H-Series | Copper-Brass | Internal scale, core blockage | Repair · Recore · New |
| ALG Series (Older) | Various | AL Engine (older) | Copper-Brass | Brittle brass tanks, scale | Repair · Recore · New |
Have an older Ashok Leyland ALG series DG set? WhatsApp us your model details →
The most common Leypower DG set radiator failure — the solder joint between the brass top tank and the copper tube header plate cracks after years of thermal cycling. We re-solder and pressure test to fully restore the joint. Common on 125–160 KVA Leypower sets.
Leypower DG sets used in factories, construction sites, and warehouses show fin corrosion from dust, chemicals, and poor air quality around the radiator. Corroded fins reduce cooling efficiency significantly. We replace fins or recore as needed.
Coolant overflow from the overflow tank is often misdiagnosed as a radiator leak. The actual cause is a failed pressure cap or a small head gasket leak raising system pressure. We diagnose and fix the root cause — not just the symptom.
Leypower sets running in factories and warehouses with untreated or old coolant develop calcium and rust scale inside the copper tubes over 4–6 years. This reduces coolant flow and cooling capacity noticeably. We flush and descale to restore full performance.
Leypower DG sets in Mumbai sometimes overheat during monsoon when airflow through the radiator is restricted by debris, mud, or water ingress. We clean, inspect, and repair the full cooling system for reliable monsoon-season operation.
Bottom tanks on Leypower radiators crack from accidental impact during maintenance or rough coolant draining. We fabricate replacement brass bottom tanks in-house at our Worli workshop — matched exactly to original Ashok Leyland dimensions.
Alt text: "Ashok Leyland Leypower 160 KVA DG set radiator before and after repair — Ajanta Radiators Mumbai"
Pressure testing, leak detection, and soldering repair for all Ashok Leyland Leypower copper-brass radiators. Top tank joint cracks, tube failures, hose nipple leaks, bottom tank cracks — all repaired in-house at our Worli, Mumbai workshop. See our dedicated leakage repair page →
125–250 KVA · Same Day EstimateWhen the Leypower radiator core is scaled, corroded, or has multiple tube failures, we fit a new copper-brass core into the existing brass tanks. 30–50% cheaper than a new radiator with like-new cooling performance. Core replacement details →
Most Cost-Effective SolutionChemical flush and descaling for Leypower radiators with internal scale buildup — particularly important for 200–250 KVA sets running in factories and warehouses where coolant is rarely changed. Restores full cooling capacity without needing a recore.
Restores Full Cooling CapacityWe manufacture new copper-brass radiators for all Ashok Leyland Leypower models — 125 KVA to 250 KVA. Made to original Leypower specifications. Ready in 2–4 working days for most models. New radiator supply details →
OEM-Spec · Made in Worli, MumbaiCracked or corroded top or bottom tanks replaced individually — saving you the full cost of a new radiator. We fabricate replacement brass tanks in-house at our Worli workshop to exact Leypower dimensions and specifications.
In-House · Fast TurnaroundWe collect Ashok Leyland Leypower DG set radiators from anywhere in Mumbai. Repaired radiator returned to your location with a 6-month warranty on all work carried out. Leakage repair service →
Pan-Mumbai · 6-Month WarrantyEstablished 1970, Worli Mumbai. We repair and manufacture Ashok Leyland radiators across both their commercial vehicle and DG set range — deep familiarity with AL cooling systems.
125 KVA to 250 KVA, Leypower and ALG series — every Ashok Leyland DG set model that uses a copper-brass radiator is serviced at our Worli workshop.
Copper-brass cores manufactured in our Worli workshop — not outsourced. We control quality at every step and can turn around faster than competitors who send cores out.
6-month warranty on every Leypower radiator repair, recore, and new supply. Fault within 6 months — we fix it at no charge, no questions asked.
Every Leypower radiator pressure tested to operating pressure before leaving our workshop. We don't deliver a radiator we are not fully confident about.
We collect from anywhere in Mumbai and return the repaired radiator to your site — Andheri, Thane, Navi Mumbai, BKC, Dharavi, Dombivli, Bhiwandi, Borivali and all areas.
Yes. Ajanta Radiators repairs both Ashok Leyland commercial vehicle (truck and bus) radiators and Ashok Leyland Leypower DG set radiators. Both use copper-brass construction, and we handle both types at our Worli, Mumbai workshop. See our dedicated Ashok Leyland vehicle radiator page for truck and bus radiator details.
The most likely cause is internal scale buildup inside the copper tubes reducing coolant flow, or a failed pressure cap causing coolant loss through the overflow. Both issues cause overheating without a visible external leak. WhatsApp us your Leypower model and we will advise — or bring the radiator to our Worli workshop for a pressure test and flush assessment. We give an honest recommendation after inspection.
For standard Leypower radiators (125–250 KVA), recoring typically takes 2–4 working days at our Worli workshop. Minor leak repairs are completed in 1–2 working days. New radiator supply for Leypower models takes 2–4 working days in most cases. We give you a confirmed timeline after inspecting the radiator.
Yes. We manufacture new copper-brass radiators for all Ashok Leyland Leypower models including the 250 KVA. Send us the Leypower model number or DG set nameplate details on WhatsApp — we confirm the specification and pricing within a few hours and typically have the radiator ready in 2–4 working days.
If the brass tanks are structurally sound, repair or recoring is almost always worth it — 30–50% cheaper than a new radiator and achieves like-new cooling performance after recoring. We recommend a full replacement only when the tanks are cracked at multiple points or severely corroded throughout. We will always give you an honest assessment after inspection — we don't push unnecessary work.
Yes. We arrange pickup from anywhere in Mumbai — including Andheri, Thane, Navi Mumbai, BKC, Worli, Dharavi, Dombivli, Bhiwandi, Vasai, Borivali, Chembur and all surrounding areas. Once the repair or recore is complete, we deliver the radiator back to your location. WhatsApp us your address and we arrange collection at a mutually convenient time.
Share your Leypower model, KVA, and radiator photos on WhatsApp — we reply within the hour with an estimate and timeline.