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The world of rock crushers is a place where raw power meets rugged terrain, where solid rock is transformed into valuable materials that build our world. Like any machinery, rock crushers face their fair share of challenges, and two common culprits that can disrupt operations are head pulley oil leaks and excessive conveyor returns.

Today, we’re diving into practical solutions for these crusher conveyor maintenance challenges. We’ll explore what causes these issues and, most importantly, the strategies that can help you keep your rock crusher running smoothly. Let’s get into the rock-solid solutions you need!

Head Pulley Oil Leak: Common Causes and Solutions

Why is my motorized Rulmeca head pulley leaking oil?

We’ve seen several cases where the pulley had too much oil. When overfilled, pressure builds up inside the unit and forces oil out through the seals. Proper head pulley maintenance includes checking oil levels regularly to prevent this issue.

How do I remove the excess oil?

Rotate the head pulley until one of the two Allen Head Set Screws, located on one end of the pulley, are positioned at either 4:00 or 8:00 o’clock. When the pulley is in this position, the lower of the two screws should be removed. If the unit is overfilled, excess oil will pour out, leaving you with the proper oil level.

How do I know it’s at the proper level of oil?

The proper level is reached when oil comes to a slow drip out of the lower hole. This is the correct fill point for optimal head pulley maintenance.

How do I change the oil?

The top screw is the opening for adding oil. If the oil appears to have been compromised by excessive heat, the preferred oil is Mobil SHC630 or equivalent. Regular oil changes are an essential part of preventive maintenance.

What should I do if I find oil inside the electrical box?

According to Rulmeca, the manufacturer of the head pulley, a small amount of oil is not an issue. If there’s a significant amount of oil and you’re unsure whether it’s problematic, reach out to us and we’ll help diagnose the head pulley oil leak.

What should I do if I want to replace the whole pulley?

If you’re replacing one of these head pulleys, note that on one end of the shaft there is an arrow stamped into the shaft. This arrow must point toward the direction of the conveyor. If the pulley is installed correctly, the internal motor will be in the oil bath. If not installed properly, the motor will burn up, causing much larger issues.

Crusher Conveyor Maintenance: Reducing Material Returns

Excessive material returning on your conveyor—whether it’s material rolling back down the belt or spillage around the edges—is a common crusher conveyor maintenance challenge. Here’s how to address it.

I’m getting a lot of material returning on my conveyor. How can I minimize that?

The first thing to check is your curtain settings. For example, if you want 1″ minus material, try setting your secondary curtain to 1″ and your primary curtain to 3″.

How do I adjust the curtain?

For secondary curtain adjustment: Hydraulically extend the cylinder until the clevis lines up with the receiving hole in the rear of the bridge. Insert the retaining pin and extend the cylinder until the back set of shims (closest to the rotor) are loose. To close the gap, remove the desired number of shims. Now retract the cylinder and place the removed shims in the front pocket of the shim box.

NOTE: When moving shims, always move an equal number on each side.

For primary curtain adjustment: Start by loosening the dust covers. Under the dust covers and bridge, you’ll find the adjusting nuts. Turn the adjusting nuts clockwise to open the setting, then counterclockwise to close the gap setting.

NOTE: The gap setting is measured from the trailing edge of the blow bar to the bottom edge of the curtain.

I adjusted the curtains, but now material is rolling down the belt. What do I do?

Not a problem! If you have a closed-circuit plant, you can slow down the speed of your return conveyor. Slowing it down prevents rocks from rolling back down the conveyor, which is a common issue with material spillage. If you don’t have a closed-circuit plant, reach out to our service department and we’ll figure it out together.

I have a closed-circuit plant—how do I slow down the return conveyor?

You can slow down the return conveyor by turning the potentiometer down, which is found on the operator control panel. This simple adjustment often solves material rollback issues. If you have any trouble locating or adjusting the potentiometer, give us a call!

Get Expert Crusher Conveyor Maintenance Support

In the demanding world of rock crushers, addressing head pulley oil leaks and conveyor material returns isn’t just an option—it’s essential for uninterrupted operations and profitability. Proper head pulley maintenance and crusher conveyor maintenance keep your equipment running efficiently and prevent costly downtime.

If you’re facing these issues or have additional questions about conveyor troubleshooting, material spillage, or any aspect of crusher maintenance, don’t hesitate to reach out to Â鶹ԭ´´’s experienced service technicians. We’re here to help you keep your crushing operation running smoothly, efficiently, and profitably.