GAZ-66, ZIL-131, KAvZ, PAZ engines — Tatneft JSC, Almetyevsk TTD-1

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CASE SERIES|OIL & GAS · ROAD TRANSPORT|PETROL ENGINES

TEN TECHNICAL ACTS · MEASUREMENTS 04.09 — 09.11.2001

series of 10 acts

GAZ-66, ZIL-131, KAvZ, PAZ: compression up, fuel use and emissions down

Tatneft JSC, Almetyevneft oil and gas production division, Almetyevsk Technological Transport Department (AUTT-1)  ·  treatment carried out by Al-XADO LLC

Almetyevsk, Republic of Tatarstan  ·  contract No. 15 of 23.08.2001 · measurements 04.09.2001 and 09.11.2001

PRODUCTTreatment by XADO technologywithout engine disassembly, in the fleet's regular service
TEST OBJECTPetrol eight-cylinder enginesGAZ-66 · GAZ-3307 · ZIL-131 · KAvZ-3976 · PAZ-32051
DOCUMENT TYPETen technical acts
and the customer's summary

What repeated on every vehicle

↑10-15%
compression across cylinders, 3.0-11.0 → 6.0-11.7 kgf/cm²
↓6-13%
petrol consumption, measured on a metered 100 g portion of fuel
↓46-67%
HC content in exhaust gases, 300-2000 → 230-780 ppm
VEHICLEMILEAGE AT STARTRUN BETWEEN MEASUREMENTSWHAT WAS MEASURED
GAZ-66, 55-29 TBSh103,156 km7,057 kmcompression, fuel use, oil pressure
GAZ-66, V 483 NO11,292 km9,296 kmcompression, fuel use, oil pressure
GAZ-3307, V 014 OV23,980 km12,911 kmcompression, fuel use, oil pressure, CO and HC
ZIL-131, 69-19 TBV121,566 km5,686 kmcompression, fuel use, oil pressure, CO and HC
ZIL-131, V 951 VKh111,010 km7,811 kmcompression, oil pressure
ZIL-131, V 134 SA17,166 km3,488 kmcompression, oil pressure
KAvZ-3976, V 599 OV52,229 km9,571 kmcompression, fuel use, oil pressure, CO and HC
KAvZ, V 475 VKh72,054 km14,116 kmcompression, fuel use, oil pressure, CO and HC
KAvZ-3976, V 185 OV37,721 km13,697 kmcompression, fuel use, oil pressure, CO and HC
PAZ-32051, V 648 EM29,230 km11,398 kmcompression, fuel use, oil pressure, CO and HC

Customer's summary after treating the fleet

DOCUMENTWHAT THE CUSTOMER RECORDED
Summary of the work“I consider the use of XADO technology for restoring worn mechanisms in regular service to be expedient at an engine life consumption of 25-75 % and with no oil leaks, including operation in severe climatic conditions”
Check disassembly“During the disassembly of a ZMZ engine after 150,000 km, the piston group and the crankshaft were measured. The dimensions comply with GOST”
Observations across the fleet“Significant improvement in engine operation”, “Increase in oil pressure”, “Reduction in oil consumption”, “Easier engine starting in winter”, “Reduction of CO and HC emissions”

The summary was signed by S. A. Brusov, head of automotive operations at AUTT-1 of the Almetyevneft division, on 04.09.2001, contract No. 15 of 23.08.2001. This is the customer's assessment, not our measurement.

Compression: ten vehicles, measured before and after treatment

VEHICLEBEFORE, kgf/cm²AFTER, kgf/cm²GAIN PER THE ACT
GAZ-66, 55-29 TBSh7.8-8.58.6-9.210.5 %
GAZ-66, V 483 NO7.0-10.09.0-11.514.6 %
GAZ-3307, V 014 OV9.5-10.19.5-10.81.5 %
ZIL-131, 69-19 TBV6.1-7.87.0-8.211.5 %
ZIL-131, V 951 VKh3.0-8.76.0-8.810.7 %
ZIL-131, V 134 SA4.5-8.06.0-8.014.3 %
KAvZ-3976, V 599 OV8.5-10.010.0-11.712.5 %
KAvZ, V 475 VKh9.0-10.59.5-11.29.3 %
KAvZ-3976, V 185 OV9.0-10.09.0-10.0no change
PAZ-32051, V 648 EM6.5-11.010.0-10.824.2 %

The percentages come from the “Results” section of each act. Compression rises up to the factory nominal and stops there: the heavier the wear, the larger the gain.

Petrol consumption: check measurement on a metered 100 g portion

VEHICLERUN TIME ON 100 G, BEFOREAFTERCONSUMPTION REDUCTION
GAZ-66, 55-29 TBSh1 min 35 s1 min 41 s5.9 %
GAZ-66, V 483 NO2 min 20 s2 min 32 s7.9 %
GAZ-3307, V 014 OV1 min 50 s2 min 07 s13.4 %
ZIL-131, 69-19 TBV2 min 05 s2 min 17 s8.8 %
KAvZ-3976, V 599 OV1 min 03 s1 min 17 s18.2 %
KAvZ, V 475 VKh3 min 35 s4 min 00 s10.4 %
KAvZ-3976, V 185 OV1 min 55 s1 min 55 sno change
PAZ-32051, V 648 EM1 min 50 s2 min 00 s8.3 %

Metered portion of 100 g: the longer the engine runs on it, the lower the consumption. A reduction was recorded on seven of the eight vehicles where consumption was measured.

Exhaust gas toxicity

VEHICLECO, %HC, ppm
GAZ-3307, V 014 OV2.58 → 0.21790 → 430
ZIL-131, 69-19 TBV0.23 → 0.102000 → 780
KAvZ-3976, V 599 OV2.3 → 0.181660 → 630
KAvZ, V 475 VKh1.2 → 0.482000 → 670
KAvZ-3976, V 185 OV1.81 → 1.70300 → 230
PAZ-32051, V 648 EM0.13 → 0.081960 → 430

Measured with a gas analyser before and after the treatment. A reduction in both CO and HC was recorded on all six vehicles where toxicity was measured.

Oil pressure at an engine temperature of 60 °C

VEHICLEIDLE, kgf/cm²2000 rpm, kgf/cm²
GAZ-66, 55-29 TBSh3.0 → 4.04.0 → 5.0
GAZ-66, V 483 NO1.5 → 1.71.8 → 2.0
GAZ-3307, V 014 OV1.0 → 1.32.0 → 2.5
ZIL-131, 69-19 TBV0.5 → 0.82.5 → 2.7
ZIL-131, V 951 VKh1.5 → 1.53.0 → 3.2
ZIL-131, V 134 SA1.0 → 2.02.5 → 4.0
KAvZ-3976, V 599 OV1.0 → 1.13.0 → 3.1
KAvZ, V 475 VKh1.0 → 1.21.5 → 2.5
KAvZ-3976, V 185 OV0.7 → 0.71.0 → 1.2
PAZ-32051, V 648 EM1.8 → 2.03.0 → 3.0

A rise in pressure means restored clearances in the friction pairs of the lubrication system: the pump holds pressure again. On ZIL-131, 69-19 TBV, the act also noted that an oil leak stopped.

Conclusions of the acts and of the customer

All ten acts of Almetyevsk TTD-1 were drawn up on the same form and end with the same list: higher compression and evening-out across cylinders, lower petrol consumption, lower CO and HC emissions, "complete cleaning of the engine". The worn engines responded most strongly: on the PAZ-32051 the compression spread between cylinders narrowed from 4.5 to 0.8 kgf/cm², on a ZIL-131 the weakest cylinder rose from 3.0 to 6.0 kgf/cm². Where an engine ran evenly, the gain is smaller: compression rises up to the factory nominal and stops there. On a KAvZ bus the act recorded separately: "In the first cylinder of the left bank the ring must be replaced urgently, as evidenced by the drop in compression" — the treatment did not hide a mechanical defect but revealed it. Following the work, the customer found the technology expedient to use at an engine life consumption of 25-75 %.

The results relate to the petrol eight-cylinder engines of GAZ-66, GAZ-3307 and ZIL-131 trucks and KAvZ-3976, PAZ-32051 buses of Almetyevsk TTD-1, treated without disassembly in regular service; on other engines and duty cycles the figures may differ. The originals of the ten technical acts and of the customer's summary, with signatures and stamps, are published in full and available for download.

Current equivalent

How such units are treated: Internal combustion engineCylinder-piston group

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