General Provisions of the XADO Technology
The introductory section of the factory instruction: the essence of the XADO technology, the purpose and properties of XADO revitalizant gels, the product range under TU U 24.6-25612000-002-2002, and the list of units for which they are recommended. This section is to be read before selecting a treatment procedure for a specific unit.
Section 1. Introduction. General Provisions
General provisions
- The main line of activity of the XADO Chemical Group is the introduction of the energy- and resource-saving, environmentally sound XADO technology® in all branches of industry, at agro-industrial enterprises, in the power industry and in transport.
- The essence of the XADO technology® is that when XADO revitalizant compounds are introduced into the standard oil of mechanism units, physical and chemical processes form a layer of metal-ceramic coating on the working surfaces of the parts, which makes it possible not only to prevent wear, but also to restore the normal operation of a mechanism that has been in service for a long time.
- The ordinary "metal-to-metal" friction pair is thereby replaced by a low-wear "metal-ceramic-to-metal-ceramic" pair with a microhardness of up to 750 kg/mm², a roughness Ra of up to 0.06 µm and high corrosion resistance.
- The uniqueness of the XADO technology® lies in the fact that the restoration of the mechanism and its reliable protection against further wear take place under normal operating conditions.
- The discovery of the revitalization phenomenon is based on unique physical and chemical processes that occur in the friction zone under certain conditions. When a mechanism operates, loads arise in the friction pairs; under excessive loads, surplus energy directed towards destruction is released at the points of local contact between the surfaces.
- If, however, a revitalizant is introduced into the friction zone, conditions are created in the overloaded zone under which a new coating is formed on the friction surfaces instead of the old one being destroyed.
- The products of the XADO technology® are XADO revitalizant compounds, produced in the form of XADO revitalizant gels, XADO greases, XADO lubricating pastes and preparations for flushing the oil systems of internal combustion engines and the transmission units of vehicles.
- XADO revitalizant gels of various designations are produced in accordance with TU U 24.6-25612000-002-2002 "XADO revitalizant compounds", depending on the type of units and mechanisms of process equipment or vehicles.
- XADO revitalizant gels are intended for the restorative repair and effective protection against wear of various units and mechanisms without stopping for repair and without disassembly, by introducing the calculated amount of gel into the standard oil in stages.
| Unit, mechanism, assembly | The treatment achieves |
|---|---|
| Compressors of various types and purposes | reduction of the time to reach working pressure (increase in output) by up to 30%; increase in oil pressure; reduction and stabilization of the working oil temperature; reduction of electric power consumption by up to 36%; reduction of noise and vibration levels; increase in service life by 1.5 — 2.5 times |
| Industrial gearboxes, final drives, central gearboxes and gearboxes of trucks and tractor equipment | restoration of part geometry and protection against wear; compensation of wear on the contact patches of gear wheels by up to 1.6 mm; reduction of the working oil temperature; reduction of electric power consumption by up to 25%; reduction of noise and vibration levels; increase in service life by 1.8 — 3 times |
| Automatic transmissions of vehicles | compensation of wear on the contact patches of gear wheels; reduction of the working oil temperature; reduction of noise and vibration levels; increase in service life by 1.8 — 3 times |
| Hydraulic systems: hydraulic pumps, hydraulic motors and directional control valves of all types, power steering units and hydraulic suspensions of vehicles | restoration of part geometry and protection against wear; increase in hydraulic pump output; elimination of cross-flow in directional control valves; reduction of vibration acceleration; increase in working pressure and efficiency of hydraulic units; reduction of leakage flow in hydraulic motors; increase in the service life of hydraulic units by up to 2.5 times |
| Rolling and plain bearings of all types | elimination of wear on friction surfaces; reduction of radial clearances by up to 0.02 mm; reduction of axial play of rolling bearings by up to 0.01 mm; increase in service life in aggressive media by up to 10 times; reduction of the noise and vibration level of bearing assemblies |
| Metal-cutting machine tools and equipment | restoration of the geometric parameters of parts; increase in machine tool accuracy; improvement of the quality of the machined surface of parts; stabilization of the operation of machine tool hydraulic systems; reduction of electric power consumption by up to 20%; reduction of noise and vibration levels; increase in service life by up to 3 times |
| Forging hammers, presses and dies | increase in compression in the main-motion cylinders of pneumatic hammers; increase in the output of the compressors in pneumatic hammers; reduction of clearances and restoration of the guides of hammers, presses and dies; reduction of electric power consumption during the operation of hammers and presses; reduction of the vibration level; protection against wear and increase in the service life of plain bearings in mechanical presses and dies by up to 2.5 times |
| Smoke exhausters and forced-draught fans | restoration of geometry and protection against wear of bearing supports; reduction of electric power consumption by up to 11%; reduction of the noise and vibration level of bearing supports; increase in service life in an aggressive medium and under exposure to high temperatures (up to 400°C) by up to 5 times |
| Open gear and chain drives | elimination of wear and restoration of the geometry of rubbing parts; increase in service life in an aggressive medium by up to 5 times; reduction of noise and vibration levels |
| Copying (template-follower) systems of various configurations | increase in the microhardness of the surface layer on the working surface of the templates; retention of the specified accuracy of copying systems over a long period; increase in the service life of the parts of copying systems under exposure to aggressive media by up to 2 times; stability of the parameters of copying hydraulic systems |
| Four-stroke and two-stroke internal combustion engines | restoration of and protection against wear of rubbing parts; restoration of part geometry; fuel savings at idle of up to 30%; increase in oil pressure; equalization and increase of compression across the cylinders; bringing engine power up to 100%; reduction of noise and vibration by up to 10 times; the possibility of operating the engine for up to 300 km in the event of an emergency oil leak; reduction of CO and CH content by 2-10 times |
| Cylinder-piston groups of four-stroke and two-stroke internal combustion engines | increase in compression in the cylinder; restoration of cylinder geometry, elimination of scoring; protection of rubbing parts against wear during "cold start"; reduction of noise and vibration; increase in engine power; fuel savings; reduction of CO and CH content in the exhaust gases |
| Fuel systems of diesel and petrol engines | restoration of geometry and protection against wear of the rubbing parts of all types of high-pressure fuel pumps and unit injectors; reliable protection against poor-quality fuel; reduction of fuel consumption by up to 14%; reduction of noise and vibration levels; increase in engine power by 9-22%; reduction of toxic component emissions |
Notes
- XADO revitalizant gels are compatible with all types of oils and fuels, do not enter into chemical reactions with them, and do not change their viscosity or other physical properties.
- XADO revitalizant gels are compatible with any additives, dopes, metal conditioners, remetallizants, etc., irrespective of the order of application.
- The revitalizant gels are certified by the State Committee of Ukraine for Standardization, Metrology and Certification (certificate of conformity in the State Register No. 0A 1.007.0072925-07).
- During revitalization, a metal-ceramic layer is formed on the surfaces of the friction pairs, built on the crystal lattice of the surface layer of the metal. The protective metal-ceramic coating is formed on friction surfaces made of any metals or their alloys.
- XADO revitalizants can be applied to any serviceable mechanism.
- The main characteristics of the resulting metal-ceramic coating: microhardness up to 750 kg/mm²; high corrosion resistance; roughness Ra up to 0.06 µm.
- During the treatment of units and assemblies, a certain concentration of XADO revitalizants in the standard oil is required in order to obtain the maximum effect. For this reason, when developing individual treatment procedures, it is recommended that possible oil losses also be taken into account (leaks, burn-off consumption exceeding 0.5% per hour of the standard oil sump volume or more than 0.4% of the fuel consumption, etc.).
- XADO-Technology LLC produces XADO revitalizant gels under TU U 24.6-25612000-002-2002 in the following range: for petrol engines; for diesel engines; for gearboxes and reduction gears; for gearboxes and reduction gears (industrial); for cylinders; for the fuel equipment of diesel engines; for the fuel equipment of petrol engines; for power steering; for power steering (industrial); for compressors and bearings; for compressors and bearings (industrial); for household equipment and motorcycle equipment; for automatic transmissions; special.
- The units and mechanisms of process equipment and vehicles listed in the table are recommended to be treated with XADO revitalizant gels.
Points to watch
- If the mechanism is in a critical condition (100% wear of parts, the presence of macro-mechanical damage on the surfaces of parts in the form of chips, cracks, deep scratches, scoring, etc.), the worn or destroyed parts must be replaced.
- It is not recommended to increase the concentration of XADO revitalizant gels specified in this instruction at the first stage of treatment.
- The treatment of mechanical systems consisting of several mechanisms differing in purpose and accuracy, with a common lubrication system containing multilayer fine oil filters, is carried out only with the "XADO revitalizant gel for power steering (industrial)".
- It is not recommended to treat mechanisms and assemblies with wick lubrication with XADO revitalizant gels.
- If it is necessary to treat units and mechanisms with XADO revitalizant compounds where oil consumption is increased, an individual treatment procedure is developed, which must be agreed with the technical specialists of the XADO Chemical Group.
Source: Instruction for the use of XADO revitalizant gels IE-24.6-25612000-005-2008.