Industrial diesel engines
Restorative repair and wear protection of serviceable industrial-purpose diesel engines with an oil system capacity of more than 30 l by introducing the revitalizant gel into the standard oil in stages without disassembling the engine. Treatment of the fuel system in parallel is recommended.
Units covered by the method
20Method
What is treated
- Serviceable industrial-purpose diesel internal combustion engines (tractor, locomotive, marine, diesel-generator, etc.) with an oil system capacity of more than 30 l.
- Including turbocharged engines.
- Engines having no parts with 100% wear or mechanical damage.
- Engines with oil change intervals of less than 400 engine hours are treated after an oil change in accordance with clauses 20.4.2-20.4.5; subsequent scheduled oil changes are to be performed according to the engine's technical operation rules (note 7).
When treatment is not performed
- Engines with parts having 100% wear or mechanical damage are not subject to treatment — worn or destroyed parts must be replaced.
- Additional (non-standard) filtering devices in the engine lubrication system may reduce the effectiveness of revitalization (note 4).
- Additional (non-standard) filtering devices may reduce the effectiveness of fuel system revitalization (clause 20.9.5).
- To achieve maximum effectiveness, the residual life of the oil must be sufficient for the period of the full engine treatment cycle, i.e. for at least 450 engine hours (note 3).
Preparation
- Eliminate leaks and the causes of increased oil consumption due to burn-off (recommended).
- Before starting engine treatment, centrifugal oil filters must be cleaned and flushed without fail.
- It is recommended to flush the oil system with the “VitaFlush*” oil system cleaner (see the consumption rates below), operate the engine in normal mode for 15–25 hours, drain the old oil, replace the fine filter or flush the centrifugal oil filter, and fill with fresh oil.
- For complete removal of varnish deposits on the pistons and piston rings, it is recommended, before the oil change and the start of treatment, to decarbonize the cylinder-piston group with the VERYLUBE “Antikoks” product; the application procedure is as per the instructions on the package.
- In case of significant cylinder wear (approaching the limit) or damage to the working surface deeper than 0.15 mm — preliminary cylinder treatment: partial disassembly of the engine to gain access to the cylinder working surface, washing the surfaces free of contaminants and wiping dry, applying the “XADO revitalizant gel for cylinder restoration” by spraying from an aerosol can, reassembling the engine, reciprocating piston movement for 10–15 min at idle, then operation for 4–6 hours in normal mode.
- For the high-pressure fuel pump: before treating the fuel system it is recommended to flush it with the “Verylube JET 100** complex fuel system cleaner for diesel engines” or with the “DIESEL-LUX” product; treatment of the high-pressure fuel pump is carried out after the diesel fuel containing the cleaner has been used up.
- Warm up the engine to operating temperature.
- Introduce the fuel system gel into the fuel tank with a minimum amount of fuel, then fill the tank with fuel.
What is measured before and after
| Parameter | Instrument | How and when |
|---|---|---|
| Compression value in each cylinder | Compression gauge or compression recorder | Before the start of treatment and after completion of the full treatment cycle. The measurement procedure is given in appendix No. 4. |
| Maximum combustion pressure in each cylinder (for locomotive and marine engines) | Maximeter (valve device of the KU type, model 55201, or of other types) | Before the start of treatment and after completion of the full treatment cycle. The measurement procedure is given in appendix No. 5. |
| Volume of fuel consumed at idle or at fixed operating modes per unit of time | Determination of the difference in fuel volumes (or weight) | Over a fixed period of engine operation. It is permissible to measure the engine operating time at fixed modes on an identical amount of fuel. |
| Oil pressure | — | At a fixed engine temperature at idle or at specified engine speeds. |
| Engine power | Special test bench | Before the start of treatment and after completion of the full treatment cycle. |
| Degree of wear of the cylinder-piston group parts | Pneumatic testing | Where possible — engine diagnostics (note 5). |
What the reports on these components showed
- Increased electric power consumption10 cases · median 14 %, 14 values
- Loss of compression66 cases · median 13 %, 114 values
- Elevated vibration22 cases · median 46 %, 10 values
- Increased fuel consumption30 cases · median 12 %, 20 values
- Increased clearances and backlash17 cases · median 26 %, 2 values
- Elevated operating temperature8 cases · median 14 %, 9 values
- Oil pressure drop20 cases · median 26 %, 8 values
Consolidated register of the evidence base →
Dosage rates
| Compound | Rate | How and when |
|---|---|---|
| XADO revitalizant gel for diesel engines | 0.9 ml per 1 litre of standard oil | Per one treatment stage; introduced into the engine oil filler neck. Three stages in total. |
| XADO revitalizant gel for diesel engines (top-up) | 0.9 ml per 1 litre of top-up oil | During the first 200 hours of engine operation, when topping up oil consumed by burn-off — to maintain a constant concentration of revitalizant in the standard oil (note 1). |
| XADO revitalizant gel for cylinder restoration | 25 ml of gel per 1.0 litre (1000 cm³) of cylinder displacement | Application in a thin, even layer on the working surface of the cylinders by spraying from an aerosol can in case of significant wear or damage deeper than 0.15 mm. |
| “VitaFlush*” oil system cleaner | 100.0 ml per 1 litre of standard oil in the engine | Introduced into the old oil; then operation in normal mode for 15–25 hours, oil draining, filter replacement/flushing. |
| VERYLUBE “Antikoks” product | 4 tubes (of 10.0 ml each) per 1 cylinder | Decarbonization of the cylinder-piston group before the oil change and the start of treatment; the application procedure is as per the instructions on the package. |
| Verylube JET 100** complex fuel system cleaner | 250 ml per 50 l of diesel fuel | Introduced into the fuel tank to flush the fuel system before treating the high-pressure fuel pump. |
| “DIESEL-LUX” complex product for cleaning the engine fuel system | 1 tube of 10 ml per 20 l of diesel fuel | Introduced into the fuel tank to flush the fuel system before treating the high-pressure fuel pump. |
| XADO revitalizant gel for diesel engine fuel equipment | Engine displacement → tubes (9.0 ml) or aerosol cans: up to 5 l — 1; 5–15 l — 2; 15–30 l — 3; 30–75 l — 4; 75–100 l — 5; 100–140 l — 6; 140–175 l — 7; 175–200 l — 8; 200–225 l — 9; 225–260 l — 10; 260–300 l — 11 | Fuel system treatment in one stage, by introduction into the fuel tank with a minimum amount of fuel. In case of heavy wear of the fuel system components (more than 50%), the recommended rate must be doubled. |
Treatment stages
- Warm up the engine to operating temperature. Introduce the required amount of XADO revitalizant gel for diesel engines into the oil filler neck (at the rate of 0.9 ml per 1 litre of standard oil). Start the engine and run it at idle. Continue operating the engine in normal mode without overloads.Idling for at least 2 min, then normal operation
- Second treatment stage in accordance with clauses 20.4.2-20.4.5 (warm-up, gel introduction, idling for at least 2 min, normal operation). The oil is not changed.Interval of 8–12 hours of total operating time after the first stage
- Third treatment stage in accordance with clauses 20.4.2-20.4.5. The oil is not changed.Interval of 8–12 hours of total operating time after the second stage
- Treatment of the fuel system with the “XADO revitalizant gel for diesel engine fuel equipment” in one stage: introduce the amount of gel specified in table 20.1 into the fuel tank with a minimum amount of fuel, fill the tank with fuel, and operate the engine in normal mode.80 engine hours of engine operation or 4000 km of mileage
After treatment
- Engine treatment is considered completed after a total operating time of at least 400 engine hours from the beginning of the first treatment stage.
- After completion of the full treatment cycle, repeat the measurements of the main engine operating parameters (compression, maximum combustion pressure, fuel consumption, oil pressure, power) — to determine the effectiveness of the XADO compounds applied.
- During the first 200 hours of engine operation, top up the oil consumed by burn-off with revitalizant gel added to it at the rate of 0.9 ml per 1 litre of top-up oil.
- After preliminary cylinder treatment: reassemble the engine, provide reciprocating piston movement for 10–15 min at idle, start the engine, run it for 4–6 hours in normal mode, then treat it through the lubrication system in 3 stages and operate it in normal mode for at least 450 hours without overloads.
- Fuel system revitalization is considered completed after 80 engine hours of engine operation or 4000 km of mileage.
- A characteristic sign of the onset of revitalization is an improvement in the operation of the mechanism (reduced noise level, vibrations, exhaust smoke) already after 10 hours of engine operation.
Points to watch
- Before starting engine treatment, centrifugal oil filters must be cleaned and flushed without fail!
- Treatment of diesel engine fuel systems must be carried out with fuel appropriate to the season!
- Operate the engine after treatment in normal mode without overloads.
- For treatment aimed at preventing wear and ensuring ideal running-in of new diesel engines or of engines with minor (up to 10%) wear, two treatment stages are sufficient (note 2).
- In case of heavy wear of the fuel system components (more than 50%), the recommended rate must be doubled.
- If partial disassembly of the engine is not possible, additional treatment of the cylinder surface with the “XADO revitalizant gel for cylinder restoration” is recommended to be carried out by applying the gel to the cylinder walls of a warmed-up engine through the injector (or glow plug) opening using an aerosol can (note 6).
Instruction appendices
Compounds for these units
- Revitalizant gel for diesel enginesIndustrial diesel engines — tractor, locomotive, marine and generator sets.
- Revitalizant gel for petrol enginesFour-stroke petrol engines with an oil system up to 30 l.
- Revitalizant gel for cylinder restorationEngine cylinders with heavy wear or surface damage deeper than 0.15 mm — applied to the bore before the main treatment.
Methods for specific machines
- Marine diesel engineFour-stroke marine diesel up to 750 rpm with a separator and a two-chamber filter. Treated together with the fuel injection equipment.
Reports on this unit
- SE UkrNTC “Energostal” · 2013↑ 2–13% — compression by cylinder of the petrol GAZ-52, 7.1–9.6 → 8.5–9.8 kgf/cm² (single maximum 32 %)
- SE UkrSTC “Energostal”, pilot plant · 2013↑ 35.4% — compression in the fourth cylinder, 6.5 → 8.8 kgf/cm²
- Transservice LLC · 2013↑ 2.5atm — compression across the cylinders, 28–29 → 31 atm
- PJSC Novokramatorsk Machine-Building Works · 2013↑ 0.2bar — compression in the weakest cylinder, 8.0 → 8.2 bar; the other cylinders changed within 0.5 bar
- ChAAP “Promin” · 2012↑ 3.9–8.3% — compression across the cylinders, 28.7–30.5 → 31.0–32.5 kgf/cm²
- PTP Pavlogradpogruztrans · 2012↑ 25–36% — compression of the worn cylinders, controller position 5, 22–24 → 30 kgf/cm²
- * VitaFlush — oil system cleaner; now XADO RED FLUSH
- ** Verylube JET 100 — diesel fuel system flush; now XADO RED CLEANER (diesel)
The XADO product range has changed since the instruction was issued. Check application details and dosage for the current products with a XADO technical specialist.
Source: Instructions for the use of XADO revitalizant gels IE-24.6-25612000-005-2008, pages 53–57.