IE S004TREATMENT CERTIFICATES UNDER XADO TECHNOLOGY · 2003–2005
KT6EL compressors and traction gearboxes: lower current, faster air build-up
Compressor current dropped, the air system filled up faster, treated gearbox teeth gained thickness. 5.5–12.8 % — current drawn by the compressor motor, 10.5–90 → 9.5–80 A; 7–19 % — air system fill time, 17.5–82 → 15–72 s; 0.04–0.09 mm — diameter of worn compressor cylinders at teardown; 0.25–0.55 mm — tooth thickness of treated traction gearboxes (2003–2005).
signed and stamped by the depots
What repeated on every locomotive
| LOCOMOTIVE AND DEPOT | MILEAGE AFTER TREATMENT | WHAT WAS MEASURED | CERTIFICATE DATE |
|---|---|---|---|
| VL-8 No. 979 · Nizhnedneprovsk-Uzel | 128 696 km | Two KT6EL compressors: current, air system fill | 23.05.2003 |
| VL-8 No. 506 · Nizhnedneprovsk-Uzel | 94 834 km | Two KT6EL compressors: current, air system fill | 01.07.2003 |
| VL-8 No. 1297 · Nizhnedneprovsk-Uzel | 92 246 km | Two KT6EL compressors; teeth of treated and control gearboxes | 15.08.2003 |
| VL-80K No. 542 · Kazatin | 294 300 km | Two KT6EL compressors: current, air system fill | 05.12.2003 |
| VL-80K No. 1809 · Kazatin | 299 806 km | Two KT6EL compressors at teardown; gearbox teeth | 05.04.2004 |
| VL-8 No. 979 · Nizhnedneprovsk-Uzel | 362 677 km | Same compressors and gearboxes, teardown at TR-3 overhaul | 12.05.2005 |
KT6EL compressors — output and current draw
| LOCOMOTIVE | COMPRESSOR | AIR SYSTEM FILL, s | CURRENT UNDER LOAD, A |
|---|---|---|---|
| VL-8 No. 1297 | No. 4-31-550 | 46 → 42 · −8.7% | 11 → 10.4 · −5.5% |
| VL-8 No. 1297 | No. 434836 | 82 → 68 · −17.1% | 10.5 → 9.5 · −9.5% |
| VL-8 No. 506 | No. 8-41-122 | 71 → 65 · −8.5% | 12 → 11 · −8.3% |
| VL-8 No. 506 | No. 8-484 | 69 → 58 · −15.9% | — |
| VL-8 No. 979 | No. 1118949 | 71 → 66 · −7.0% | 11 → 10.2 · −7.3% |
| VL-8 No. 979 | No. 5-12655 | 79 → 72 · −8.9% | 10.5 → 9.7 · −7.6% |
| VL-80K No. 1809 | No. 1-21-602 | 18 → 16 · −11.1% | — |
| VL-80K No. 1809 | No. 1-21-006 | 17.5 → 15 · −14.3% | — |
| VL-80K No. 542 | No. 10-80-324 | 19 → 15.5 · −18.4% | 90 → 80 · −11.1% |
| VL-80K No. 542 | No. 10-54-754 | 21 → 17 · −19.0% | 78 → 68 · −12.8% |
Fill time was measured with a stopwatch: on the VL-8 over the 5→8 atm range, on the VL-80K over 0→4 atm; current was read with a clamp meter under working back pressure.
Traction gearboxes — treated wheelsets against control ones
| LOCOMOTIVE | MILEAGE | TREATED TEETH | UNTREATED, SAME MILEAGE |
|---|---|---|---|
| VL-8 No. 1297 | 92 246 km | +0.30–0.55 mm | −0.20–0.35 mm |
| VL-80K No. 1809 | 299 806 km | +0.15–0.70 mm | −0.15–0.75 mm |
| VL-8 No. 979 | 362 677 km | +0.25–0.35 mm | −0.35–0.60 mm |
Tooth thickness was taken at the constant-chord height on the same teeth throughout; the untreated wheelsets ran the same mileage on the same locomotives.
Compressor geometry at teardown
| PARAMETER | VL-8 No. 979 · 362 677 km | VL-80K No. 1809 · 299 806 km |
|---|---|---|
| Bore diameter of LP and HP cylinders | smaller by 0.04–0.08 mm | smaller by 0.06–0.09 mm |
| Cylinder ovality | 0.07–0.15 → 0.03–0.076 mm | 0.05–0.09 → 0.01–0.02 mm |
| Cylinder taper | 0.11–0.194 → 0.04–0.085 mm | 0.07–0.12 → 0.01–0.02 mm |
| Radial clearance in crankshaft bearings | 0.12–0.15 → 0.08–0.10 mm | — |
Measured with micrometers and bore gauges during teardown at scheduled maintenance; score marks and scratches in the cylinders are visible through the layer but cannot be felt.
What the depots recorded
Current equivalent
- Revitalizant gel for gearboxesGearboxes · transmissions · gear drives
- Revitalizant gel for compressors and bearingsCompressors · bearings · spindles
- Revitalizant gel for cylinder restorationEngine cylinders, deep wear
How such units are treated:
About this result:
Limits of this report: The results relate to KT6EL reciprocating compressors and to the traction gearboxes of VL-8 and VL-80K electric locomotives; on open assemblies — axle-box guides, spring and brake joints — the certificates record continuing wear. The treatment was performed by XADO LLC, the measurements were made with the depot’s instruments and signed by its officers.