Locomotive TEM2: engine regained power and cut oil burn-off without teardown

PTP Pavlogradpogruztrans, locomotive depot · approved by the company chief engineer I. V. Bilych, company seal

Pavlograd, Ukraine · work carried out 05.12–24.12.2012 · repeat measurements after 276 h of engine running time

PRODUCTXADO revitalizantsrevitalizant gel for diesel engines · revitalizant gel for injection pumps · VITAFLUSH cleaner · JET 100

TREATED OBJECTPDG-1 diesel engine and fuel equipmentlocomotive TEM2 No. 2941 · six cylinders · oil system, fuel system, injection pump

DOCUMENT TYPECompany report
with signatures and seal

Key results

↑25-36%

compression of the worn cylinders, controller position 5, 22-24 → 30 kgf/cm²

↓35%

monthly oil burn-off in normal service, 200 liters per month

↑50-95%

maximum combustion pressure, cylinders 1, 2 and 6, controller position 5, 22-24 → 36-43 kgf/cm²

EQUIPMENT AND UNIT	CONDITION AT START OF WORK	WHAT WAS MEASURED
Locomotive TEM2 No. 2941, PDG-1 diesel engine	Built in 1975, 37 years in service	Compression and maximum combustion pressure in each of the six cylinders, controller positions 3 and 5
Engine oil system	Only cylinders 3, 4 and 5 ran satisfactorily; oil consumption about 5 % of fuel consumption	Oil pressure at controller positions 3, 5, 7, engine block temperature, monthly oil burn-off
Fuel system and injection pump	Flushing with 5,000 ml of JET 100 in the remaining 3,600 l of fuel, then treatment of the injection pump	Maximum combustion pressure per cylinder

Compression in the engine cylinders

CYLINDER	CONTROLLER POSITION 3, kgf/cm²	CONTROLLER POSITION 5, kgf/cm²
I	22 → 26	22 → 30
II	26 → 28	22 → 30
III	34 → 35	36 → 36
IV	32 → 33	32 → 34
V	22 → 27	24 → 30
VI	20 → 26	22 → 30

Maximum compression pressure, maximeter; measured before treatment and after it at a total engine running time of 276 h.

Maximum combustion pressure per cylinder

CYLINDER	CONTROLLER POSITION 3, kgf/cm²	CONTROLLER POSITION 5, kgf/cm²
I	24 → 30	22 → 43
II	26 → 36	24 → 40
III	38 → 40	40 → 45
IV	40 → 42	42 → 44
V	34 → 44	38 → 46
VI	22 → 28	24 → 36

Before treatment, in cylinders 1, 2 and 6 the combustion pressure was almost the same as the compression pressure — these cylinders were not developing rated power.

Engine oil system

PARAMETER	BEFORE	AFTER
Oil pressure, controller position 3	2.8 kgf/cm²	3.0 kgf/cm²
Oil pressure, controller position 5	3.0 kgf/cm²	3.2 kgf/cm²
Oil pressure, controller position 7	3.0 kgf/cm²	3.3 kgf/cm²
Oil consumption as a share of fuel consumption	about 5 %	3.4 %
Engine block temperature	58 °C	56.7 °C

Oil pressure was measured at the same engine temperature. Monthly oil burn-off in normal service fell by 200 liters.

Conclusions of the company commission

Based on the results of a full cycle of flushing and treatment of the fuel and oil systems of the engine of locomotive TEM2 No. 2941 with XADO revitalizant compounds, and on repeat measurements after a total engine running time of 276 h, it was established that: 1. In all engine cylinders the compression rose by 1-8 kgf/cm², which indicates an increase in engine power. The maximum spread of compression between cylinders was 16 kgf/cm² before treatment and fell to 9 kgf/cm² after treatment. 2. The maximum combustion pressure also rose in all cylinders by 2-21 kgf/cm², and the spread of maximum combustion pressure between cylinders decreased from 20 kgf/cm² to 16 kgf/cm². 3. The oil pressure at the same engine temperature rose by 0.2-0.3 kgf/cm² when running at various positions of the driver's controller. 4. The monthly oil burn-off with the engine operating in normal service fell by 35 % (by 200 liters per month). 5. The actual oil consumption was 3.4 % of the fuel consumption, which meets the established standard figures for this engine.

The results relate to a TEM2 shunting locomotive with a PDG-1 diesel engine at 276 h of running time after treatment; on other engines and duty cycles the figures may differ. The measurements were taken jointly by specialists of the locomotive depot of PTP Pavlogradpogruztrans and XADO LLC, and the report was approved by the company chief engineer. The original report with signatures and seals is published in full and available for download.

Current equivalent

Revitalizant gel for cylinder restorationEngine cylinders, deep wear
Revitalizant gel for diesel enginesDiesel engines

How such units are treated: Cylinder-piston group Diesel engine

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