KT-6 Compressor
Two-stage reciprocating compressor of the brake system of TEM-2, TGM-4, TGM-6 and ChME3 diesel locomotives. Treated without removal from the locomotive, through the oil bath of the crankcase.
KT-6 and KT-6El air compressors of diesel locomotives: treatment in service and during assembly at the factory
The class norm is 1.5 ml per litre of the standard oil. For the locomotive compressor the XADO engineer prescribed a different breakdown: not a share per litre, but whole tubes by stage — this is easier on a locomotive, where the bath is not measured but its rated volume is known. Piston compressors →
What is treated
- A serviceable compressor with no parts worn 100% and no significant mechanical damage.
- Oil leaks eliminated, filter elements of the lubrication system flushed or replaced.
- The compressor stays on the locomotive and runs in its normal mode — removal and disassembly are not required.
What is measured before and after
| Parameter | Instrument | How and when |
|---|---|---|
| Output — the time to fill a separate closed receiver up to working pressure | stopwatch, calibrated pressure gauge on the receiver | The measurement is repeated with the shut-off valves in good order, from one and the same initial pressure. |
| Vibration level at fixed points of the frame, in the vertical, horizontal and axial directions | vibrometer | The points are in the area of the main bearings of the crankshaft. |
| Noise level at fixed points | sound level meter | At a fixed distance, with no extraneous noise sources present. |
| Power consumption or current with the compressor unloaded and under load | clamp meter, wattmeter, multimeter | The standard pointer instruments will not do — they lack sensitivity. |
| Oil pressure at a fixed operating temperature | standard calibrated pressure gauge | — |
| Operating temperature of the lubrication system | liquid-filled or non-contact infrared thermometer | — |
Dosage rates
| Compound | Rate | How and when |
|---|---|---|
| XADO revitalizant gel for compressors and bearings — class norm | 1.5 ml per 1 litre of the standard oil per stage | Methodology No. 1 of the instruction, for reciprocating compressors in general. |
| Compressor of the TEM-2 diesel locomotive — 13.8 l bath | 6 tubes of 9 ml: 2 + 2 + 2 | 8–12 hours of compressor running time between stages. |
| Compressor of the TGM-6 diesel locomotive — 11 l bath | 5 tubes of 9 ml: 1 + 2 + 2 | 8–12 hours of running time between stages. |
| Compressor of the TGM-4 diesel locomotive — 8 l bath | 4 tubes of 9 ml: 1 + 1 + 2 | 8–12 hours of running time between stages. |
Treatment stages
- In a separate vessel, dilute the gel in a small amount of the standard oil heated to 50–60 °C, in a proportion of 1 part gel to 5–10 parts oil, stir until fully dissolved and introduce into the crankcase through the oil filler neck. Start the compressor and run it in the normal mode without overloads.Start of the total running time count
- The second stage is done in the same way as the first.After 8–12 hours of total running time
- The third stage is done in the same way as the first.After a further 8–12 hours of running time
After treatment
- The treatment is considered complete after 400 hours of total compressor running time from the beginning of the first stage.
- After the end of the cycle, all the measurements from the table above are repeated and compared with the initial ones — this is the test report itself.
Points to watch
- Cylinder-piston groups with non-metallic piston rings — graphite and flubon (antifriction polymer composite materials) — are not treated.
- A new compressor, or one with wear up to 10%, is treated in two stages rather than three.
- With increased oil consumption, during the first 200 hours the make-up oil is dosed with additional gel — 1.2 ml per litre of make-up oil, otherwise the concentration drops.
Special case: treatment during assembly at the manufacturing plant
A separate XADO methodology for a new compressor on the assembly line. The task here is different — not to restore wear, but to match the parts to one another during run-in.
- Into warm oil (100 ml, 40–50 °C) add 3 tubes of 9 ml of the gel for compressors and bearings — 27 ml per compressor in total, once, without stages.
- XADO revitalizant gel for cylinders is applied in a thin layer to the working surfaces of the cylinders twice: before the valve covers are first fitted and again before final assembly.
- Run-in: 10 minutes cold without the valve covers, then 5 hours fully assembled, then disassembly, inspection and measurement of the geometry of the parts.
- Final run-in — 1 hour under rated load on fresh oil.
- The oil after the final run-in is not drained as waste: at least four more compressors are run in on it.
- Revitalization continues at the customer's site, on fresh oil: the particles of the formulation have anchored on the friction surfaces during the factory run-in.
Where КТ-6 has already been treated
- Dalnevostochnoe Locomotive Repair Depot · 2009↓ 15% — oil clearance of engine connecting-rod bearing shells, 0.14-0.19 → 0.09-0.17 mm
- JSC «Rzhevsky Sakharnik» · 2009↑ 7-17% — diesel cylinder compression, 560 rpm, 23-29 → 26-30 kgf/cm²
- WSRC "Permskie Mashzavody", Kungur · 2007↑ 31% — compressor output, pressure reached in 2 min 28 s → 1 min 53 s
- Stoilensky GOK · 2003↑ 6-25% — cylinder wall hardness, 269-278 → 292-347 HB
- Tbilisi Locomotive Depot · 2003↑ 40% — output, build-up to 7-8 atm (g), 14 → 10 s
- Rogan Company LLC · 2000↑ 15.4% — compressor output, pump-up to 7.9 atm
Source: XADO applied methodology "Methodology for treating KT-6 air compressors" and "Calculation of the quantity of XADO formulations for treating a unit", lead engineer I. N. Sharaikin. Class norm — instruction IE-24.6-25612000-005-2008, methodology No. 1.