DesignWithAjay’s Recommendations for Lubrication Systems in Heavy-Duty Gearboxes
At Ajay Industries, we design gearboxes that operate under extreme torque, vibration, and thermal loads.
Whether integrated into shredders, SPMs, or automation systems, these machines demand precision lubrication to prevent wear, reduce friction, and extend service life.
This guide outlines our best
practices
for selecting, integrating, and maintaining lubrication systems in
heavy-duty gearboxes—ensuring performance, uptime, and long-term durability.
Why Lubrication Strategy Matters
Poor lubrication leads to:
- Accelerated gear and bearing wear
- Increased heat and energy loss
- Seal failure and contamination ingress
- Unexpected downtime and costly repairs
A well-designed lubrication system is not an accessory—it’s a core mechanical safeguard.
DesignWithAjay’s Lubrication System Recommendations
1. Select the Right Lubricant Type
| Lubricant Type | Best For |
|---|---|
| EP Gear Oil (ISO VG 220–460) | High-load, slow-speed gearboxes |
| Synthetic Oil (PAO-based) | Wide temperature range, extended service life |
| Grease (NLGI 2 with EP additives) | Bearings and enclosed housings under shock loads |
Ajay Tip: For shredder gearboxes, we recommend ISO VG 320 EP oil with anti-foaming and anti-corrosion additives.
2. Use Splash or Forced Circulation Based on RPM
- Splash lubrication for gearboxes under 1000 RPM
- Forced circulation with pumps and filters for high-speed or high-temperature applications
- Include baffles and troughs to direct oil flow across gear meshes
Ajay Tip: Our CAD models include oil path simulations to validate splash coverage and pump flow rates.
3. Integrate Lubrication Ports and Sight Glasses
- Add fill, drain, and inspection ports with threaded plugs
- Use sight glasses or dipsticks to monitor oil level and condition
- Position ports for easy access during maintenance
Ajay Tip: We embed port locations in exploded views and annotate service intervals directly in the CAD drawing.
4. Seal Strategy to Prevent Leakage
- Use double-lip oil seals with spring-loaded edges
- Apply labyrinth seals for high-vibration zones
- Include breather vents to equalize pressure and prevent seal blowout
Ajay Tip: Seal specs are linked to shaft tolerances and housing geometry in our BOM.
5. Plan for Maintenance and Monitoring
- Define lubrication intervals based on load cycles and ambient conditions
- Include sampling ports for oil analysis
- Use automatic lubrication systems for continuous operation
Ajay Tip: We provide lubrication charts with every gearbox file, showing refill volumes, intervals, and compatible brands.
Real-World Example: Gearbox #GXR-75 for Twin-Shaft Shredder
| Feature | Specification |
|---|---|
| Lubricant | ISO VG 320 EP gear oil |
| Lubrication Method | Splash + auxiliary pump |
| Ports | Fill, drain, sight glass, sampling port |
| Seal Type | Double-lip with breather vent |
| Service Interval | Every 250 hours or monthly |
Outcome: 18 months of continuous operation with zero seal failures and consistent gear wear profile
What You Get with Every DesignWithAjay Gearbox File
- Parametric CAD models with lubrication port geometry
- BOM with lubricant specs and seal types
- Exploded views with service annotations
- Lubrication charts and refill volumes
- Revision-controlled documentation and inspection logs
Final Thoughts
Lubrication isn’t just about oil—it’s about engineering longevity. At DesignWithAjay, we integrate lubrication strategy into every gearbox from the first sketch to the final drawing. Whether you’re designing for high torque, high vibration, or continuous duty, our recommendations help you reduce wear, extend service life, and operate with confidence.