Application from the plant, treatment by a dealer engineer
Opens the pilotXADO
Carries out the treatment under the methoddealer engineer
Enters the measurements in the protocoldealer or plant employee
XADO pilot treatment: terms and application
Treatment of one unit of the plant under a method of instruction IE-24.6-25612000-005-2008 with measurements before and after; the result is recorded in a test report of the plant commission.
Obligations of the parties
XADO provides
- compounds for the pilot treatment;
- the component method from instruction IE-24.6-25612000-005-2008 with calculation of the compound quantity;
- the report form, a filled example and analysis of the measurement results;
- support by an XADO engineer throughout the cycle — support options.
The plant provides
- a unit that meets the admission requirements;
- access to the equipment for adding the compound and participation of technical staff in the measurements;
- measurements before and after with the same instrument in the same mode, with the running time between them recorded;
- a plant commission to confirm the measurements and sign the test report.
The compounds for the pilot treatment are provided at no charge. The terms of participation are set out in the pilot treatment contract.
Pilot treatment procedure
- Preparation of the lubrication system: elimination of leaks, flushing or replacement of filter elements.
- “Before” measurements according to the list in the component method.
- Adding the compound in stages at running-time intervals set by the component method: periods by component group.
- Normal operation until the end of the full treatment cycle.
- “After” measurements with the same instrument in the same mode.
Support options
In all scenarios the method and the dose are approved by XADO, and the measurements and the test report are confirmed by the plant commission; an XADO engineer supports every pilot. The scenarios differ in who opens the pilot, carries out the treatment and enters the measurements.
Application from a dealer
Opens the pilotdealer
Carries out the treatment under the methoddealer engineer
Enters the measurements in the protocoldealer or plant employee
The plant carries out the treatment itself
Opens the pilotplant
Carries out the treatment under the methodplant engineer
Enters the measurements in the protocolplant employee*
* The measurements are confirmed by the plant commission; the employee who entered the measurements is not a member of it.
Periods and measurements by component group
Values according to the methods of instruction IE-24.6-25612000-005-2008.
| Component group, method | Before treatment | Measurements before and after | Dosing stages | Full treatment cycle |
|---|---|---|---|---|
| Piston compressors Method 1, pp. 8–9 | flushing or replacement of lubrication system filter elements, elimination of oil leaks (cl. 1.3) | capacity, vibration, noise, power or current consumption, oil pressure, temperature (cl. 1.4.1–1.4.6) | 3 stages at intervals of 8–12 h of total operation | 400 h from the start of the first stage (cl. 1.7); topping up with oil containing gel during the first 200 h (note 2) |
| Screw and centrifugal compressors Method 2, Method 3, pp. 9–11 | filters; oil change if the remaining oil life is below 40 % (method 2; a recommendation in method 3); measurements (cl. 3.3) | vibration, power or current consumption, oil pressure | Method 2: 5 stages every 18–24 h; method 3: 8 stages every 12–24 h | 500 h of total running time |
| Reducers, gearboxes, gear and chain drives Method 4, Method 5, Method 11, pp. 11–14, 19–20 | elimination of leaks (cl. 4.2); method 5 — flushing of filters, removal of condensate | tooth thickness and contact patches of marked teeth (cl. 4.3), vibration, noise, power or current, oil temperature (method 11 — measurements under cl. 11.2) | Method 4: 3 stages, method 5: 5 stages — every 8–12 h; method 11: compound in the oil volume for 500 h (cl. 11.3.1) | Method 4: 450 h; methods 5 and 11: 500 h; vehicle gearboxes — according to engine displacement (method 4) |
| Automatic transmissions and power steering Method 6, Method 8, pp. 14, 16–17 | automatic transmission: fluid level (cl. 6.3.1); power steering: diagnostics (cl. 8.2), leaks, reservoir filter, oil level | automatic transmission — fluid level; power steering — pulley alignment, oil level and volume | single addition; power steering — 5–10 min of operation after adding | 50 h of operation or 1500 km |
| Hydraulic systems of industrial equipment Method 7, pp. 14–16 | elimination of working fluid leaks; measurements (cl. 7.3) | pressure, fluid temperature, pump delivery, internal leakage, vibration of hydraulic machines, hydraulic tightness of directional valves | 6 stages every 8–12 h | 550 h of total running time |
| Rolling and plain bearings Method 9, Method 10, pp. 17–19 | elimination of leaks (cl. 9.2); measurements (cl. 9.3); wear below 80 % | radial clearance, axial play, shaft runout, vibration, noise, oil temperature, electric motor current | Method 9: 3 stages; method 10: 6 stages — interval of at least 8–12 h | Method 9: 350 h; method 10: 550 h |
| Metal-cutting machine tools Methods 12–18, pp. 20–50 | oil leaks (cl. 12.1.1) and working fluid leaks (cl. 12.6.1); inspection of slideways, defects deeper than 0.1 mm are eliminated before treatment | spindle runout and play, vibration, current, roughness and taper of the test workpiece, tooth thickness (cl. 12.1.2, 12.2.1); screw-nut play (cl. 12.4.1); flatness of slideways (cl. 12.5.1.2); hydraulic system parameters (cl. 12.6.2.1–12.6.2.8) | for each component: 3–6 stages every 8–12 h; slideways — periodic lubrication with the compound | spindle and gearbox 450 h; bearings and hydraulic system 550 h; slideways 600–700 h; preventive treatment once a year, 200 h |
| Forging hammers, presses, dies Method 19, pp. 50–53 | compressor oil filters and leaks, hydraulic system leaks, inspection of slideways; clean oil in the compressor; if wear of the main motion cylinder is close to the limit or damage is deeper than 0.1 mm, the cylinder is pre-treated with revitalizant gel | compressor vibration and current, oil pressure; hydraulic system pressure, delivery and temperature; flatness of slideways | compressor 3 stages, hydraulic system 6 stages — every 8–12 h; slideways — 20–30 min of idling after adding | compressor 450 h; hydraulic system 550 h; slideways 550–700 h |
| Diesel engines Method 20, Method 21, pp. 53–59 | elimination of leaks and causes of oil burn-off; cleaning of centrifugal filters; flushing of the oil system; remaining oil life sufficient for the whole cycle; if cylinder wear is close to the limit or damage is deeper than 0.15 mm, the cylinders are pre-treated with revitalizant gel | compression by cylinder, peak combustion pressure, fuel consumption at idle, oil pressure, power | 3 stages: method 20 — every 8–12 h, method 21 — every 150–250 km; after adding — idling for at least 2 min | Method 20: 400 engine hours; method 21: 1500 km; fuel system — 80 engine hours or 3500–4000 km |
| Petrol and two-stroke engines Method 22, Method 23, pp. 59–63 | flushing of the oil system (cl. 22.4.1); warming up to operating temperature before each addition; method 22 — if cylinder wear is close to critical or damage is deeper than 0.15 mm, the cylinders are pre-treated with revitalizant gel | Method 22: compression, fuel consumption, oil pressure, power; method 23: running time, mileage, temperature | Method 22: 3 stages every 150–250 km; method 23: sachets into the tank or the oil according to the scheme of the method | Method 22: 1500 km; method 23: 30 h or 1500 km; fuel system — 80 engine hours or 3500 km |
| Engine fuel systems Method 24, pp. 63–65 | flushing of the fuel system with a cleaner; treatment after the fuel with the cleaner has been used up | the method sets no separate measurements; indicator — improved operation after 10 h or 500 km | gel into the fuel tank, number of tubes according to engine displacement | 80 engine hours or 4000 km |
Oil or working fluid temperature for dissolving the gel and the dosing mode by method — in the section “Operating mode during treatment”.
The instruction contains no method for electric motors, friction pairs, joints and linkages or driveshafts; the treatment procedure is agreed with an XADO engineer.
Pilot treatment documents
| Document | Prepared by | Where |
|---|---|---|
| Component method with calculation of the compound quantity and stage plan | XADO — from instruction IE-24.6-25612000-005-2008 | Treatment methods |
| Report form and filled example | XADO; completed by the plant | Form (PDF, RU) · Example (PDF, RU) · Test procedure |
| Measurement protocol “before”, by stage, “after”: instrument, mode, running time | employee of the plant or dealer; confirmed by the commission | sections 5–10 of the form |
| Test report with conclusions and the commission's signatures, with the stamp where available | plant commission | kept by the plant; copy to XADO |
A test report is published in the trial database only by decision of XADO and with the consent of the plant.
Unit admission
- Parts without 100 % wear or mechanical damage; bearings with wear below 80 %; machine tool slideways without working surface defects deeper than 0.1 mm.
- Oil and working fluid leaks eliminated, filter elements flushed or replaced.
- The remaining oil life is sufficient for the full treatment cycle.
- The compound dosing mode is feasible on the unit: oil temperature, adding on running or stopped equipment and load at the first stage — in the section “Operating mode during treatment”.
- Instruments for “before” and “after” measurements are available: vibrometer, sound level meter, clamp meter or wattmeter, pressure gauge, compression gauge, means of measuring clearances and runout — according to the component method.
A unit that does not meet these requirements is not admitted to the pilot treatment.
Economic effect
The effect is calculated from the results of the measurements before and after, the plant's tariffs and running time; before the pilot treatment, cases in the catalogue with the same result serve as a reference.
| Result in test reports | Cases |
|---|---|
| Lower repair costs postponed repair, operation without replacing the component | 22 |
| Energy savings drive current and power before and after | 70 |
| Fuel savings consumption per mode and mileage | 30 |
| Longer service life running time to repair | 28 |
By industry
The calculator estimates electricity savings from the median and the range in the test reports; treatment costs are not included in the calculation.
Savings calculator →Application for pilot treatment
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