Idlers

Key Features

Longer life & reliability

The new roll features a patent-pending lubrication system called Idler PALTM (Positive Automatic Lubrication). A spring-loaded compensator disk allows grease expansion when hot and compresses grease as the bearing cool. Breathing bearings live longer, and are greased for life. Our engineers also designed new assembly processes and techniques to make sure that every steel roll is put together the same way, and with consistent internal tolerances, to maximize bearing life. Our modified-geometry tapered roller bearing retention method positions the bearing while ensuring consistent reproducible end play. In short, these idlers are designed for longer service life.

Triple tested quality

Every Bucyrus roll is triple-tested for rotational torque, total indicated run out and bearing play. Likewise, the data is stored with the unique identifying data and serial number allowing monitoring of roll life. Competitive products are randomly tested and have no identification. Doesn't that say something about the quality you can expect? It certainly says something about how Bucyrus fine-tunes its product engineering.

Easy retrofit to any frame

Retrofitting is a snap. Literally. Easy to replace competitor box frames with Bucyrus frames, as they are dimensionally compatible. Retrofitting rolls is a snap with RETRO-LOCTM.

Steel Rolls

The Bucyrus steel roll design is the result of over two years of design and engineering effort, and represents new technology in idler design. A new shaft-end configuration and a unique retrofit adaptor allow Bucyrus rolls to operate in virtually any competitor's frame.

The end cap (bearing housing) has been redesigned for increased strength and a close fit to the deflector cap. A new automated assembly process is used, which includes an industry first: three separate, metered grease inputs ensuring that every roll has plenty of grease for a lifetime of trouble-free operation. In addition, Idler PAL™ ensures that the grease stays where it is needed - in the bearing!

Another industry first is Bucyrus' Electronic Quality Tracking. Bucyrus is the first idler manufacturer to offer serial numbering of rolls as standard, allowing the life of each roll to be accurately monitored. Bucyrus is also the only idler manufacturer to quality check each roll for rotational torque, total indicated run out (TIR), and bearing end play, as well as testing each roll to ensure complete grease distribution throughout bearings and seals. This quality data is electronically stored under the serial number for each roll to provide traceable information throughout the life of the product.

The steel roll is a further example of Bucyrus' commitment to becoming the world's leading supplier of underground coal-mining equipment. Our customers' perception of the value and quality offered by Bucyrus is the standard by which we measure our success.

EXALON Rolls

EXALON is a high molecular weight polyethylene conveyor roll constructed of a proprietary formulation, which is fully conductive and MSHA approved (MSHA Acceptance Marking "MSHA IC-56/2") for flame resistance to ensure safe use in underground applications. EXALON has been tested against the bulk material handling industry's leading steel conveyor rolls and is proven to last significantly longer, specifically in highly corrosive and/or highly abrasive environments.

EXALON conveyor rolls offer significant operating and cost advantages over traditional steel rolls, such as:

Extended Life - EXALON has been used in the mining industry for several decades and its highly abrasion resistant formulation and extreme wall thickness (3/4") has proven to last at least twice as long as steel rolls, and up to five times as long in highly corrosive and/or abrasive environments.

Decreased Belt Damage - The low coefficient of friction due to the material characteristics found in EXALON allows the belt to slide over the roll to the point of flattening the surface. EXALON rolls do not expose steel cutting edges that could tear or damage conveyor belting.

Weight - EXALON is 20% - 30% lighter than steel rolls

Sound Dampening - significantly reduces noise levels, specifically when used in underground mining applications

Material Accumulation - The natural non-adhesive property of EXALON resists material build-up.

Conductivity - Exalon's proprietary formulation prohibits static buildup in underground applications.

Cost Efficient - Most importantly, EXALON offers advantages in cost savings through extended life and savings on damaged conveyor belting and corresponding production downtime.