1. Pre-Cleaning Preparation (Safety & Working Condition Adaptation)

1.1 Safety Regulations

• Shut down power and disconnect electricity; cool the housing down below 40°C to avoid scalds and electric shock.

• Wear oil-resistant gloves, goggles and dust masks; keep the operation area well ventilated and free of open flames.

• Place an oil drip pan underneath to collect waste oil and wastewater and prevent ground contamination.

1.2 Tools & Consumables

• Tools: Soft bristle brushes, nylon brushes, high-pressure spray gun (0.3–0.8MPa), ultrasonic cleaning machine, compressed air gun, cleaning rags, scraper.

• Consumables: water-based neutral cleaning agent (degreasing & rust-proof, suitable for cast iron / cast aluminum), industrial kerosene, dedicated gearbox cleaner, rust inhibitor, deionized water.

• Prohibited items: Steel wire brushes (scratch housing surface), strong acid & strong alkali (corrode seals and coatings), gasoline (flammable and explosive).

1.3 Working Condition Evaluation

• Routine maintenance (light oil contamination): External wiping + local spraying.

• Periodic maintenance (oil sludge / metal debris): Disassembly cleaning + rinsing & drying.

• Overhaul / heavy contamination (carbon deposit / stubborn oil scale): Ultrasonic cleaning + high-pressure spraying + drying.

2. Cleaning Procedures by Scenario

2.1 External Housing Cleaning (Daily / Weekly)

Purpose: Remove dust, oil contamination and sundries on cooling fins; ensure heat dissipation and anti-corrosion performance.

1. Dry cleaning: Use a soft brush to remove surface dust and sundries in cooling fin gaps; wipe floating oil with rags.

2. Spraying: Dilute water-based cleaning agent at ratio 1:10–1:20; spray the housing evenly under 0.4–0.6MPa, focusing on flanges, oil drain ports and observation ports; stay for 3–5 minutes.

3. Wiping: Wipe off emulsified oil contamination with soft cloth; clean dead corners gently with nylon brushes.

4. Rinsing: Rinse away residual cleaning agent with deionized water; blow dry with compressed air to avoid water stain and rust.

5. Anti-rust protection: Spray a thin layer of rust inhibitor after full drying to protect the coating.

2.2 Internal Housing Cleaning (Oil Change / Every 3–6 Months)

Purpose: Remove oil sludge, metal wear particles and old oil deposits; avoid accelerated wear of gears and bearings.

1. Drain old oil: Unscrew the oil drain plug and drain old oil completely; clean metal debris on the magnetic drain plug.

2. Primary cleaning (without disassembly): Inject dedicated gearbox cleaner (1/3 of cavity volume); rotate the shaft manually for 1–2 minutes to flush the inner wall fully, stand for 10 minutes then drain; repeat 1–2 times for heavy contamination.

3. Disassembly for deep cleaning: Remove top cover, end covers, oil seals and gaskets; mark all parts for correct reassembly; cover open cavities with clean rags to prevent foreign matter falling in.

4. Soaking cleaning: Immerse the housing in 50–60°C neutral cleaning agent or kerosene for 15–30 minutes; thoroughly clean oil sludge and iron debris on inner walls, cavities and oil passages with soft brushes.

5. Rinsing: Conduct secondary rinsing with clean cleaning agent, then rinse residues with deionized water; blow dry cavities and threaded holes thoroughly with compressed air.

6. Drying: Air naturally for 10–20 minutes or dry at 60–80°C; ensure no moisture or cleaning agent residue remains.

7. Reassembly: Replace oil seals and gaskets with new ones; spray rust inhibitor on housing inner walls and assemble as marked.

2.3 Heavy Contamination / Overhaul Grade Cleaning (Carbon Deposit & Stubborn Oil Scale)

Adopt combined process: Ultrasonic Cleaning + High-Pressure Spraying + Drying, suitable for reducer housings with complex cavities.

1. Pre-treatment: Disassemble the housing, scrape off thick oil sludge and carbon deposits; conduct coarse cleaning via high-pressure spraying (0.6–0.8MPa) to remove large particle impurities.

2. Ultrasonic Cleaning:

• Tank solution: Water-based ultrasonic cleaning agent, diluted 1:5–1:10, temperature 50–60°C.

• Parameters: Frequency 40–80kHz, power 2–5W/L, cleaning time 15–25min; ensure liquid level submerges the housing.

• Principle: High-frequency vibration cavitation penetrates cavities and micropores to peel off stubborn oil contamination and iron debris.

3. Rinsing: Rinse with deionized water under 0.4MPa high pressure; fine clean in a pure water ultrasonic tank for 5 minutes to remove residual cleaner.

4. Drying: Hot air circulation drying at 80–100°C for 30–60 minutes; blow dead corners again with compressed air to eliminate water stains and residues completely.

5. Anti-rust protection: Spray rust inhibitor after cooling to prevent re-rusting.