Exciter Gearbox Cleaned, Dried & Wrapped

Business Need

We recently received an enquiry regarding a specialist gearbox from an exciter unit. These units are heavy-duty mechanical machines designed to vibrate and shake equipment such as filters or feeders.

The gearbox is the core component of the exciter unit, housing the shafts and gears that enable its operation. Due to the number of moving parts, these gearboxes rely heavily on grease and lubrication to function smoothly. Over time and throughout the unit’s lifecycle, grease accumulates and thickens at the base of the housing and within internal channels.

The customer required the gearboxes to be thoroughly cleaned, with all grease pools removed, so that they could be returned clean and completely dry, free from lubricants. This would allow the units to be safely stored and transported, wrapped in VCI paper to prevent corrosion prior to refurbishment.

Our Role

The gearboxes measured approximately 900 × 540 × 380 mm and weighed around 400 kg each, making them challenging components to handle and clean.

To remove the bulk of the oil and grease buildup, we began with a high-pressure jet wash. This initial step helped to break down the heavier contamination and thin the grease pools, reducing adhesion to the base and internal surfaces.

Once the worst contamination had been removed, the unit was transferred using a crane, into one of our larger ultrasonic tanks. The gearbox was submerged for several hours under powerful ultrasonic agitation, combined with heat and our in-house degreasing chemical, CB100. This process allowed the ultrasonic energy and chemistry to penetrate internal channels and cavities that would otherwise be inaccessible.

Following ultrasonic cleaning, a thorough rinse was required to remove any residual chemical. Due to the size of the component, this was carried out using a final jet wash. As the unit could not be re-oiled, it was essential that it was dried immediately. We used compressed air to hand-dry the gearbox before promptly wrapping it in VCI paper to prevent corrosion.

The Outcome

The gearbox was returned in a spotless condition and fully dried before any surface corrosion could occur. The customer was extremely pleased with the results and confirmed that the trial was successful.

As a result, the customer has since advised that there are six to eight additional gearboxes requiring the same process. The cleaned units are now ready to be restored, repaired, and fitted with new gears and shafts, extending their service life and reducing replacement costs.