IE S052ACT ON THE RESULTS OF RESTORATIVE REPAIR · 19.05.2000
Compressors, gearboxes, bearings and a locomotive: restoration without disassembly
Gearbox teeth built up metal, bearing clearances narrowed, current and fuel consumption dropped. 0.9–1.6 mm — gearbox tooth thickness, wear before treatment at least 1.5 mm; 37.5 % — radial clearance of the induced-draught fan bearings; 8.3–29.2 % — current draw of the 305VP30/8 compressors; 15 % — locomotive fuel consumption at idle (2000).
with signatures and stamp
Key results
| EQUIPMENT | CONDITION AT THE START OF WORK | WHAT WAS MEASURED |
|---|---|---|
| 305VP30/8 compressors, sinter plant | in operation, parameters recorded before treatment | filling time, current draw |
| ROF-1, ROF-2, DF-1 gearboxes | tooth working surface wear of at least 1.5 mm, scoring, pitting | tooth thickness, surface condition, no-load current |
| EKG-10 excavator gearbox | tooth wear, scoring, pitting | tooth thickness, surface condition |
| No. 3636 bearings of the induced-draught fan, DF-1 | in operation, clearances recorded before treatment | radial and axial clearances |
| TM2UM-941 locomotive, UZhDT | in operation, parameters recorded before treatment | fuel consumption, oil pressure, compression |
ROF-1, ROF-2, DF-1 and EKG-10 excavator gearboxes
| PARAMETER | REPEAT MEASUREMENT RESULT |
|---|---|
| Tooth thickness of the mating gears | growth of 0.9–1.6 mm |
| Tooth working surface | scoring and pitting disappeared, the surface took on the look of a smooth ground finish; a build-up of the metal layer was recorded in the contact zone |
| No-load current draw | reduction of 3.5–5 % |
| Noise and vibration | reduction recorded by the commission |
The layer builds up in the contact zone — exactly where the wear was: the coating regulates itself according to the load on the assembly.
No. 3636 bearings of the induced-draught fan, DF-1
| PARAMETER | REPEAT MEASUREMENT RESULT |
|---|---|
| Radial clearance | reduction of 37.5 % |
| Axial clearance | reduction of 12.2 % |
Narrowed clearances mean restored geometry of the raceways and rolling elements — that is, a deferred replacement of the bearing assembly.
305VP30/8 compressors, sinter plant
| PARAMETER | REPEAT MEASUREMENT RESULT |
|---|---|
| Capacity (by filling time) | increase of 6.4–13.9 % |
| Current draw | reduction of 8.3–29.2 % |
Filling time is a direct measure of a piston compressor’s capacity: more air in the same time and at a lower current.
Engine of the TM2UM-941 locomotive, UZhDT
| PARAMETER | REPEAT MEASUREMENT RESULT |
|---|---|
| Compression across the cylinders | increase of 2–6 kgf/cm² together with levelling across all cylinders |
| Fuel consumption at idle | reduction of 15 % |
| Oil pressure | increase of 0.1 kgf/cm² |
Higher compression levelled across the cylinders means restored sealing of the cylinder-piston group; hence the lower fuel consumption.
Findings of the OJSC “YuGOK” commission
Current equivalent
- Revitalizant gel for compressors and bearingsCompressors · bearings · spindles
- Revitalizant gel for gearboxesGearboxes · transmissions · gear drives
- Revitalizant gel for diesel enginesDiesel engines
How such units are treated:
About this result:
Limits of this report: The results relate to the listed equipment of the OJSC “YuGOK” workshops — the 305VP30/8 compressors, the gearboxes of the ore-processing plants and of the EKG-10 excavator, the induced-draught fan bearings and the TM2UM-941 locomotive; on other machinery and under other operating conditions the figures may differ.