How to clean the ZJY150-25 gearbox after draining the old lubricating oil
1、 Pre security preparationConfirm that the equipment is shut down and powered off, hang a warning sign reading 'Do not close', and lower the temperature of the gearbox casing to below 40 ℃ to prevent scalding from hot oil splashing.
Prepare tools: oil resistant gloves, goggles, fiber free cotton cloth, nylon soft bristled brush, 0.2-0.4MPa clean compressed air gun, dedicated oil drum, 80-120 mesh filter.
The cleaning agent should be kerosene or a specialized gear oil cleaning agent compatible with the original lubricating oil. The use of highly corrosive solvents is strictly prohibited.
2、 Step 1: Initial cleaning of oil outlet and oil pan
1. After the old oil is completely drained, remove the built-in filter in the oil drain port, rinse it clean with cleaning agent, and replace it directly if the filter is damaged.
2. Blow compressed air inward from the oil filling port for 1-2 minutes to blow up the metal debris and oil sludge deposited at the bottom of the oil pan, and completely discharge them from the oil drain port along with the residual oil.
3. Use a soft bristled brush dipped in cleaning agent to clean the stubborn grease around the corners of the oil pan and the oil drain hole, and then wipe it clean with a clean cloth.
3、 Step 2: Internal circulation flushing to remove impurities
1. Inject about 1/10 of the tank capacity of specialized flushing oil into the box, manually rotate the input shaft 10-15 times, and allow the flushing oil to fully infiltrate the gears, bearings, and tooth surface gaps.
2. Short term no-load low-speed operation for 30 seconds (strictly prohibited with load), allowing the flushing oil to wash away residual old oil and impurities from various lubrication parts. Then, open the oil discharge port to completely drain the flushing oil. This step can be repeated 2-3 times.
3. For key parts such as gear meshing surfaces and bearing raceways, gently brush along the tooth direction with a soft bristled brush to thoroughly remove any attached oil sludge and metal abrasive particles.
4、 Step 3: Compressed air deep blowing
1. Use clean and dry compressed air with a pressure of 0.2-0.3MPa to blow inward from the vent cap and refueling nozzle, completely blowing out the residual oil and debris in the oil passage, bearing gaps, and dead corners of the box.
2. Continuously manually rotate the shaft system during blowing, so that every tooth surface of the gear and every raceway of the bearing can be covered by air flow, avoiding local residue.
5、 Step 4: Drying and Cleanliness Verification
1. After the purge is completed, open the fuel and drain ports for natural ventilation for 15-20 minutes to ensure that there is no residual flushing fluid in the tank.
2. Wipe the visible area inside the box with a fiber free clean cloth to confirm that the cloth has no obvious oil stains or impurities attached; Clean dough with new oil can also be used to roll on the inner wall of the box, removing fine sand particles and debris.
3. Finally, inject a small amount of new oil to flush the internal oil circuit. After rotating the shaft system, completely drain it, and then add the specified type of new lubricating oil according to the standard.
After cleaning, it is recommended to run it without load for 5-10 minutes, check for any abnormal noise or oil leakage, confirm that the oil level is at the center line of the sight glass, and the cleaning operation is complete.
