Diesel engines with up to 30 l of oil
The procedure describes a three-stage treatment of serviceable diesel internal combustion engines with an oil system capacity of up to 30 l using XADO revitalizant gel without changing the oil or disassembly. The purpose is to restore the engine's operating parameters and to protect the friction pairs against further wear under normal operating conditions.
Units covered by the method
21Method
What is treated
- Serviceable diesel engines with an oil system capacity of up to 30 l, including turbocharged ones.
- Engines having no parts with 100% wear and no mechanical damage.
- New engines or engines with wear of up to 10% — treated in a single stage in accordance with table 21.1.
- Engines with significant (close to critical) cylinder wear or with mechanical damage to the cylinder working surface deeper than 0.15 mm — with preliminary additional treatment of the cylinders.
- In parallel with the treatment of the oil system, single-stage treatment of the high-pressure fuel pump (fuel system) is recommended.
When treatment is not performed
- Engines with parts having 100% wear and with mechanical damage are not subject to treatment — worn or destroyed parts must be replaced.
- Treatment of diesel engine fuel systems shall be carried out with fuel corresponding to the season.
Preparation
- Eliminate leaks and the causes of increased oil consumption due to burn-off (recommended).
- Flush the engine oil system with a special oil system cleaner: add the cleaner to the old oil at a rate of 100.0 ml per 1 litre of the standard oil in the engine; operate the engine in normal mode for 15–25 hours; drain the old oil, replace the fine filter or clean the centrifugal oil filter; fill with fresh oil and carry out the treatment with XADO revitalizant compounds.
- For complete removal of varnish deposits on the pistons and piston rings — before changing the oil and starting the treatment, decarbonize the cylinder-piston group with VERYLUBE “Antikoks” at a rate of 2 tubes (10.0 ml each) per 1 cylinder; the application procedure is as specified in the instructions on the packaging.
- In case of significant cylinder wear or damage to their working surface deeper than 0.15 mm — first apply a thin layer of “XADO revitalizant gel for cylinders” to the cylinder walls of a warmed-up engine through the injector opening of non-prechamber engines by any available means, for example using a technical (or medical) syringe with a flexible polyvinyl chloride tube; ensure reciprocating movement of the pistons for 10–15 min by any convenient means (for example, by periodically cranking with the starter); start the engine, run it for 4–6 hours and then treat it through the lubrication system in 3 stages.
- Before treating the fuel system it is recommended to flush it with “VeryLube JET 100 complex fuel system cleaner for diesel engines” or with “DIESEL-LUX”; the high-pressure fuel pump treatment is carried out after the diesel fuel with the cleaner has been used up.
- The residual service life of the oil must be sufficient for the period of the full engine treatment cycle, i.e. for at least 1500 km of run.
What is measured before and after
| Parameter | Instrument | How and when |
|---|---|---|
| Compression value in each cylinder | Compression gauge or compression recorder | Before the start and after the completion of the full treatment cycle; the measurement procedure is set out in appendix No. 4 |
| Volume of fuel consumed at idle or at fixed operating modes per unit of time | — | Determined from the difference in residual fuel volumes over a fixed period of engine operation; it is permissible to measure the engine running time at fixed modes on the same 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 and after the completion of the full treatment cycle |
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 | Oil sump capacity 3–10 l — 3 pcs., stage pattern 1+1+1; 11–20 l — 6 pcs., pattern 2+2+2; 21–30 l — 9 pcs., pattern 3+3+3 (tubes or aerosol cans) | Added into the engine oil filler neck in three stages without changing the oil, table 21.1 |
| XADO revitalizant gel for diesel engines (new engine) | Oil sump capacity 3–10 l — 2 pcs.; 11–20 l — 4 pcs.; 21–30 l — 6 pcs. | New engines or engines with wear of up to 10% are treated in a single stage, table 21.1 |
| XADO revitalizant gel for cylinders | A thin layer on the cylinder working surface | Additional treatment before the main one in case of significant cylinder wear or damage deeper than 0.15 mm |
| Oil system cleaner | 100.0 ml per 1 litre of the standard oil in the engine | Added to the old oil; operation for 15–25 hours, then oil and filter change |
| VERYLUBE “Antikoks” | 2 tubes (10.0 ml each) per 1 cylinder | Decarbonizing of the cylinder-piston group before the oil change and the start of treatment |
| 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 | Added into the fuel tank with a minimum amount of fuel in a single stage; if the fuel system components are worn by more than 50%, the recommended rate should be doubled |
| VeryLube JET 100 complex fuel system cleaner for diesel engines | 250 ml per 50 l of diesel fuel | Flushing of the fuel system before the high-pressure fuel pump treatment; added into the fuel tank |
| “DIESEL-LUX” | 1 tube of 10 ml per 20 l of diesel fuel | Flushing of the fuel system before the high-pressure fuel pump treatment; added into the fuel tank |
Treatment stages
- Warm up the engine to operating temperature
- Add the recommended amount of XADO revitalizant gel into the engine oil filler neck in accordance with table 21.1
- Start the engine and run it at idleat least 2 min
- Continue operating the engine in normal mode without overloads
- Carry out the second and third treatment stages in accordance with clauses 21.4.1.-21.4.4after 150–250 km of run between stages
- Fuel system (high-pressure fuel pump) treatment: prepare the amount of gel according to table 21.2, add it into the fuel tank with a minimum amount of fuel, fill the tank with fuel, operate the engine in the usual mode — in a single stagerevitalization is completed after 80 engine hours of operation or 3500 km of run
After treatment
- The engine treatment is considered completed after a run of at least 1500 km from the start of the first treatment stage.
- After the preliminary treatment of the cylinders and the subsequent treatment through the lubrication system in 3 stages — operate the engine in normal mode for at least 150 hours (or 3000 km) without overloads.
- Revitalization of the fuel system is considered completed after 80 engine hours of operation or 3500 km of run.
- If it is necessary to determine the effectiveness of the treatment, after the completion of the full cycle the main operating parameters of the engine are measured again: compression in each cylinder, fuel consumption, oil pressure, power.
Points to watch
- A characteristic sign of the onset of revitalization is an improvement in the operation of the mechanism (reduced noise level, vibrations, exhaust smokiness) already after 10 hours of engine operation.
- Additional (non-standard) filtering devices in the engine lubrication system may reduce the effectiveness of revitalization.
- Additional (non-standard) filtering devices in the fuel system may reduce the effectiveness of revitalization.
- In case of severe wear of the fuel system components (more than 50%), the recommended rate must be doubled.
- Treatment of diesel engine fuel systems shall be carried out with fuel corresponding to the season.
- To achieve maximum treatment effectiveness, the residual service life of the oil must be sufficient for the period of the full engine treatment cycle, i.e. at least 1500 km of run.
Instruction appendices
Compounds for these units
- Revitalizant gel for compressors and bearingsPiston, screw and centrifugal compressors; rolling and sliding bearings running in an oil bath; machine-tool spindle units and slideways.
- 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.
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
Source: Instruction for the use of XADO revitalizant gels IE-24.6-25612000-005-2008, pages 57–59.