Operation & Maintenance Instructions: Eljay Rollercone Classic Owner/Operator Manual

Operation & Maintenance Instructions
ElJay Rollercone Classic Owner/Operator Manual

Form 21280 LJ0190100
A Terex Company
21280 (3/97)
Operation & Maintenance Manual
A Terex Company
Introduction
To the Owner & Operator: We have tried to provide information which will give you a clear understanding of equipment construction, function, capabilities and requirements. This information is based on the knowledge and experience of highly qualified people at our company and in our field organization. Proper use of this information will promote high efficiency, maximum service life and low maintenance costs. We strongly recommend that all persons directly involved with this equipment be familiar with this manual. The information contained in this manual should not be considered all-inclusive for every application. Questions about specific uses of this equipment should be directed to Cedarapids Inc. Anyone who uses this equipment for any purposes other than its intended use assumes the risk of any danger in doing so. Respectfully, Cedarapids Inc.
Important Notice! Federal, state and local safety regulations must be complied with to prevent possible danger to person(s) or property from accidents or harmful exposure. This equipment must be used in accordance with all operation and maintenance instructions. (1) Read all warning, caution and instruction signs. Know what guards and protective devices are included and see that each is used. Additional guards and protective devices that may be required due to proximity to related equipment must be installed by the user (owner) before operating. Never lubricate or adjust equipment when it is operating! Securely lock out the involved power source before doing maintenance, cleaning, adjusting or repair. Secure the power source lockout to prevent start-up by other persons. Wear a protective mask whenever harmful air pollution exists. Use ear plugs whenever noise level is above established limits.
(2) (3)
(4) (5)
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A Terex Company
Section 1 Introduction This book is an operation manual for the new owner/ operator of a Rollercone Crusher manufactured by Cedarapids Inc. Old hands may find it useful, too. We strongly recommend that anyone operating or maintaining the Rollercone Crusher become familiar with this manual. This manual can help you understand how your crusher works, how to get the most production from it, and how to perform regular maintenance and replace wear parts. Experience has shown that it is to your advantage to have a copy of this manual on site at the crusher where operators can consult it as needed ... and to have a copy on file in your office so that shift leaders or supervisors can conveniently refer to it. Additional copies can be ordered through your Cedarapids Distributor Representative. Cedarapids is proud to manufacture this superior product for your use and profit. The precisely engineered Rollercone is a highly functional, heavy duty machine designed to provide years of excellent service in producing crushed rock to customer specifications. Cedarapids takes pride in the quality of its service and replacement parts. Ongoing improvement of product design may result in future changes to some parts. When ordering replacement parts, please be as exact as possible in describing the part. Use part numbers, model numbers and serial numbers to communicate with your Cedarapids Distributor Representative. When you have a question about your crusher or the operation manual, please consult your Cedarapids Distributor Representative.
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Section 1 Introduction Table of Contents Section 1 Introduction ................................................ 1.1 Table of Contents ........................................ 1.2 Section 2 - Safety Hints and Rules Personal Safety Hints.................................. 2.1 Work Area Safety Hints .............................. 2.2 Equipment and Tools Safety Hints ............. 2.2 Section 3 - Rollercone Description How It Works .............................................. 3.1 Tramp Iron Relief System .......................... 3.1 Differences Between Fine Head and Standard Head Cone Crushers .................... 3.3 Anti-Spin Brake .......................................... 3.5 Section 4 - Rollercone Capacities Characteristics of Rock ............................... 4.1 Rock Abrasion ............................................ 4.1 Rock Compressive Strength ....................... 4.1 Controlling Wear......................................... 4.1 Getting Better Production ........................... 4.2 Preventing Bowl Float ................................ 4.3 What You Should Know about the Rollercone Bearings ................................... 4.4 Section 5 - Lubrication Importance of Oil Flow Pattern in the Rollercone ................................................... 5.1 Proper Oil Types ......................................... 5.3 Oil Properties at Operating Temperature .... 5.3 Acceptable Lubricants ................................ 5.3 Oil Analysis: When to Change Oil ............. 5.3 Lubricating Oil Capacities .......................... 5.4 Section 6 - Transport and Travel Block the Cone Head .................................. 6.1 Setting Up On Site ...................................... 6.2 Section 7 - Installation Clearance and Mounting Directions ........... 7.1 RC66 Installation Drawings ....................... 7.2 RC60 Installation Drawings ....................... 7.4 RC54 Installation Drawings ....................... 7.6 RC45 Installation Drawings ....................... 7.8 RC36 Installation Drawings ..................... 7.10 Feed Speed ................................................ 7.12 Electrical Control System ......................... 7.13 Electrical Control For External Lubrication ................................. 7.13 Cold Weather Oil Circulation Kit ............. 7.13 Flow Switch and Alarm ............................ 7.14 Oil Heater ................................................. 7.17 Weights and Lifting Procedures................ 7.17 Rollercone Component Weights ............... 7.17 Power and Speed Requirements Chart ..... 7.18 Section 8 - Daily Startup and Maintenance Daily Start Up ............................................. 8.1 Cold Weather Start Up ................................ 8.1 Hot Weather Start Up .................................. 8.1 Daily Maintenance ...................................... 8.1 Rollercone Daily Inspection Form ............. 8.3 Section 9 - Changing Closed Side Settings
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Section 1 Introduction Description of the Rollercone Hydraulic Setting Adjustment System......................... 9.1 Rollercones with Hydraulic Adjust............. 9.2 Rollercones with Remote Auto Adjust ....... 9.2 Minimum and Maximum Closed Side Settings ................................... 9.6 Capacity Calculation .................................. 9.6 RC66 Manganese Options .......................... 9.8 RC66 Setting Options ................................. 9.9 RC60 Manganese Options ........................ 9.10 RC60 Setting Options ............................... 9.11 RC54 Manganese Options ........................ 9.12 RC54 Setting Options ............................... 9.13 RC45 Manganese Options ........................ 9.14 RC45 Setting Options ............................... 9.15 RC36 Manganese Options ........................ 9.16 RC36 Setting Options ............................... 9.17 Gradation Chart ........................................ 9.18 Section 10 - Maintenance The Right Way To Check Oil Level In The Crusher ................................ 10.1 Change Lubricating Oil ............................ 10.1 Change Lube Oil Filter Element ............... 10.1 Hydraulic Fluid & Nitrogen Gas Pressures in the Relief System ................. 10.2 Schematic Description of the HydroPneumatic Tramp Iron Relief System ....... 10.3 Relief Accumulator Positions ................... 10.5 Checking Relief System Pressure: 2 Methods ................................................ 10.5 First Method ............................................. 10.6 Alternate Method of Checking Relief System Fluid Pressure .................... 10.7 Checking Nitrogen Gas Precharge Pressure .................................... 10.8 Charging the Tramp Iron Relief System ............................................ 10.9 Bonnet Support ....................................... 10.11 Rotation Stops ........................................ 10.11 Hard-Facing and Wear Components ....... 10.12 Adjusting V-Belt Tension........................ 10.12 Standard Bolt and Nut Torque Specifications ............................. 10.12 Section 11 - Changing Manganese Removing the Upper Assembly ................ 11.1 Removing Upper Assembly by Method A: Adjusting Bolts Remain with Upper Assembly .................. 11.3 Removing Upper Assembly by Method B: Adjusting Bolts Remain with Lower Assembly ................. 11.4 Changing Manganese Bowl Liners on RC36, RC45, and RC54 Models ........ 11.4 Installing Bowl Liners on Models RC36, RC45, RC54 ............................................. 11.5 Changing Bowl Liner on RC66 and RC60 Models .................................... 11.6 Installing Bowl Liner in RC66 & RC60 .......................................... 11.8 Changing Cone Mantle on Standard Head Crushers ......................... 11.10 Changing Cone Mantle On the RC66, RC60, and RC54 Fine Head ........ 11.12 Changing Cone Mantle on RC45, RC36 Fine Head .......................... 11.14 Plastic Backing Quantity Chart .............. 11.16 Installing the Upper Assembly ............... 11.16 Method A: Installing the Upper Assembly with the Adjusting Bolts in the Upper Assembly .................. 11.16 Method B: Installing the Upper Assembly with the Adjusting
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Section 1 Introduction Bolts in the Lower Assembly .................. 11.17 Adjusting Clamp Cylinder Travel ........... 11.18 Converting RC60 from Standard to Fine Head or Fine Head to Standard ............................ 11.20 Section 12 - Troubleshooting Vibrating Too Much .................................. 12.1 Running Too Hot ...................................... 12.1 Bowl Floating ........................................... 12.1 Possible Causes of Bowl Float ................. 12.1 Section 13 - Glossary Commonly Used Words in Processing Rock with the Rollercone ....... 13.1
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Section 2 Safety Hints and Rules Personal Safety Hints Cedarapids equipment is designed with the safety of all personnel in mind. Do not attempt to change, modify, or eliminate accident prevention devices installed at factory. Make sure all personnel who regularly work or who might do work in area of the equipment are familiar with safety precautions. Guards, covers, and shields are installed around moving parts at factory whenever necessary to prevent accidental injury to operators and others working on or near the equipment. Do not remove . Warning: Hazards or unsafe practices which COULD result in death, system loss, severe personal injury, severe occupational illness or severe or major system or environmental damage. Caution: Hazards or unsafe practices which COULD result in minor personal injury, minor occupational illness, or minor system or environmental damage. Cedarapids recommends the following basic safety practices: 1) Read all warning, caution, and instruction signs. 2) Never lubricate equipment when it is in motion. 3) Do not remove any guards, covers, or shields when equipment is running. 4) Replace any guards, covers, or shields after adjustment or maintenance. 5) Always establish a positive lockout of the involved power source before performing maintenance, cleaning, adjusting, or repair. Secure the power source lockout to prevent start-up by other persons. 6) Block parts as necessary to prevent unexpected motion while performing maintenance, adjustments, or repair. 7) Do not attempt to remove jammed product or other blockage from running equipment. Power must be shut off and locked out while doing so.
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8) Always completely depressurize accumulators before attempting any repair or maintenance to them. Malfunctioning valves or poor maintenance practices can result in build up of extremely high hydraulic and/or pneumatic pressures inside the accumulator, which is a pressure-containment vessel. Allow only qualified, experienced personnel with extensive knowledge of hydraulic systems to attempt maintenance or repair of accumulators. 9) Use adequate hearing protection devices whenever noise level is above acceptable limits. 10) Wear an adequate protective breathing mask when dust and fumes are above acceptable limits. 11) Wear adequate eye protection goggles or safety glasses with side shields to prevent flying particles from entering eyes. 12) Hard hats are a good idea in all work sites and required at most. Wear yours. 13) Dressing appropriately for job. Do not wear loose sleeves, flowing hair, long coat tails, wrist watches or bracelets, or pockets full of tools, which could get caught in moving machinery. Thin-soled shoes without tread could cause unexpected falls or foot injury. Wear safe shoes. 14) Always look around equipment before startup to make sure no one is near moving parts, making adjustments, or performing maintenance. Keep alert to where your coworkers are. 15) Report defective machinery and unsafe conditions to your supervisor. 16) Save your back. If load is more than 40 lbs (18kg), get help or use proper lifting procedures. Use leg muscles, not back, for lifting. Keep loads close to body. Avoid twisting motions and overextensions when moving loads.
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Section 2 Safety Hints and Rules 17) Most of all, know your equipment. Understand the machine and the conditions under which it operates. Dont limit playing it safe to only these few general rules. Think and act safely for your specific work environment and your particular equipment. Work Area Safety Hints 1) Keep the work area neat and clean. 2) Keep all warning and caution signs clear and up-to-date. 3) Make certain that all electrical equipment is properly grounded. Wet spots near electric current are dangerous. 4) Store hazardous materials in restricted access areas and mark them clearly. Federal regulations require special labeling of certain materials. 5) Make certain enough ventilation is present to safely run engines. Do not start an engine in an enclosed space without properly vented exhaust. Exhaust fumes from gasoline or diesel can kill! 6) Do not smoke or allow smoking near flammable fuels or solvents. Use nonflammable solvents when possible for cleaning parts and equipment. 7) Avoid electrical and static sparks and any open flame when handling, moving or pouring fuels, battery electrolytes, hydraulic fluids, or coolants. 8) Check for leaks in tanks or tubing with flashlights or other proper equipment. Never use an open flame to check for leaks. 9) Know where fire extinguishers and other fire suppression equipment are located. Learn to use them. 10) Be alert and wary around any pressurized system: hydraulic or air. High pressure gases and oils can be very dangerous. Know your equipment and operate it properly. Equipment and Tools Safety Hints 1) Clean and properly labeled tools are safer tools. Keep your equipment and tools in order. 2) Always use hoisting equipment for heavy loads. Regularly check hooks, cables, shackles, and chains for stretch and wear. Never overload the lifting capacity of hoists, cranes, and lifting devices. 3) Keep V-belts and sheaves in good condition. Frayed belts or cracked sheaves can be dangerous and cause downtime. 4) Keep equipment clean and free of dirt and grease so it can be checked for loose, cracked, or broken parts. Replace defective parts as soon as discovered.
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Section 3 Rollercone Description How It Works The Rollercone crushes by compressing rock in a continuous action between a moving cone-shaped surface and a stationary, inverted bowl-shaped surface in the crushing chamber. The outer surface of the lower cone shape crushes rock against the inner surface of the bowl shape above it. The Rollercone is engineered to move the special alloy crushing surfaces within controlled distances of each other by the oscillating action of a rotating wedge. See Figure 3-1, a descriptive cutaway of a typical Rollercone. The upper portion of the crusher contains the tramp iron relief system. This system is highly pressurized but designed to yield if uncrushable material, like tramp iron, finds its way into the feed. Without any damage to the crusher the upper assembly quickly lifts to pass the tramp iron through the crushing chamber, then returns to the original position, to go on crushing as before. A combined force of pressurized hydraulic fluid and compressed gas pushes steadily downward during normal crushing to keep the bonnet, part of the upper assembly, in place. The bowl liner mounts to the bonnet. The bonnet rests on the bonnet support. Rock to be crushed is fed through the hopper and into the crushing chamber, an area lined with cast manganese alloy. The upper crushing surface is the bowl liner; the lower is the mantle. The mantle rests on the cone, which in turn mounts on the wedge plate. The rotating wedge plate moves under the cone like a cam with an upward thrust to make the oscillating movement of the cone and mantle. As a point on the mantle comes nearer and nearer to the bowl liner, the force that can be generated grows rapidly. The gear-driven wedge plate rotates on large, lowfriction roller bearings. The movement between the mantle and the stationary bowl liner can be thought of as opening and closing the crushing surfaces, but it takes place in a circular area around a conical shape. The closed side setting (css) is the nearest the two crushing surfaces come to each other. 180 across the cone from the closed side, the oscillating movement makes an open side where the rock falls lower in the crushing chamber until it is discharges in a steady flow at the lower edge of the mantle. Under normal choke feed conditions the rock will be caught three to eight times in the crushing action. After passing through the crushing chamber the rock falls out through the base to be removed at a rate at least equal to the feed rate. Very great crushing forces are created which mostly bear on the upper and lower thrust bearings. Proper lubrication of thrust and radial bearings is very important in the Rollercone. A pump, gear-driven directly off the pinion shaft, forces oil through the lubrication system when the pinion shaft is rotating in the proper direction. An electric pre-lube pump, mounted externally, pumps oil to the bearings at switchable intervals. During normal operation a flow-sensing device meters and monitors oil flow. Tramp Iron Relief System Cedarapids Rollercones use a patented HydroPneumatic Tramp Iron Relief System that provides more protection to a crusher than any other known system in use today. If properly maintained, the relief system holds the bonnet down with great force. It also allows a great deal of bonnet travel for passing tramp iron without crusher damage or stoppage.
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Section 3 Rollercone Description
"crushing chamber"
bonnet and bowl liner
relief system manifold tubes
hopper relief cylinder
accumulator
hold down bolt bonnet support adjusting bolt assembly external prelube oil pump
cone with mantle shim stack shim guard clamp ring
oil filter
upper and lower radial bearings
wedge plate
upper and lower thrust bearings
internal oil pump
oil heater
oil fill pipe
pinion shaft
Figure 3-1 General Description
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Section 3 Rollercone Description The system includes hydraulic cylinders mounted in individual support beams. The beams mount over the bonnet support with hold-down bolts to form a pressure ring. Push rods extend from sockets in each piston to sockets in the bonnet. The hydraulic cylinders vent or relieve pressure off to accumulators if uncrushable items enter the crushing chamber. The accumulator bladders are filled with nitrogen gas at 1800 to 2100 pounds per square inch (psi) at 70 Fahrenheit (F). Metric equivalents are 12411 to 14480 kilopascals (kPa) at 21 Centigrade (C). Hydraulic oil is then pumped into the system to compress the nitrogen bladders to 2600 psi (17927kPa). This provides reserve oil in the accumulators to keep the manifold and cylinder under continuous pressure. The accumulator has enough capacity to hold this reserve oil plus the oil that must be displaced through the manifold from the cylinders when tramp iron passes through the crusher. Caution: This system does not tolerate hydraulic or nitrogen gas leaks. Any leaks will soon empty the small reserve of oil in the accumulator. Note that oil leaks can be seen and are easier to detect than gas leaks. Nitrogen leaks arent obvious and are normally found only by periodic gas pressure checks. Caution: If you allow pressure to bleed off from the Tramp Iron Relief System, bowl float will occur. Bowl float voids your warranty. Bowl float is defined as the periodic separation of the bonnet from the bonnet support. See the Glossary and Troubleshooting sections of this manual. See Checking Relief System Pressure in Section 10 of this manual. Differences Between Fine Head and Standard Head Cone Crushers Until recently Cedarapids Rollercones were built in two main model lines, the Standard Head and the Fine Head. This refers to the shapes of the cone heads and corresponding manganese liners. With the introduction of the RC60, a specially designed, convertible cone allows you to switch from standard to fine head configuration (and back) with a simple, bolt-on conversion (Figure 3-2). The Fine Head Rollercone is used to crush finer specification product. Its size reduction ratio is about 4 to 1. The Standard Head crushes a wider range product, including heavier gradations. Its size reduction ratio is about 6 to 1. To get an idea of the percent of product passing certain screen sizes after crushing with your Rollercone, consult the Nominal Product Gradation charts in Section 9 of this manual. Together with the capacity charts, these graphs provide a basis for estimating production rates in either Fine Head or Standard Head crushers at various typical closed side settings. Each type, either Standard or Fine Head, has manganese liners of differing shapes which fit it best for certain crushing jobs. Many operators have found that production problems were solved or greatly reduced by installing liners which were more appropriate for a particular job. The most common manganese liners currently in use are shown in drawings at the end of the section of this manual called Changing Closed Side Settings. Your Cedarapids Distributor or factory representative will be glad to discuss your specific crushing needs.
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Section 3 Rollercone Description

mantle nut cap bolt o-ring mantle nut cap mantle hold down nut mantle hold down bolt standard cone mantle hold down washer sponge rubber manganese mantle convertible cone standard cone adapter
plastic backing mantle hold down bolt
standard head cone
RC60 "convertible" cone in the standard configuration
sponge rubber ring fine head cone
distributor plate o-ring
distributor plate bolt mantle hold down nut manganese mantle mantle bolt
distributor plate convertible cone
plastic backing
fine head cone
RC60 "convertible" cone in the fine head configuration

Figure 3-2 Differences Between Fine and Standard Head Rollercones
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Section 3 Rollercone Description Anti-Spin Brake The anti-spin brake (Figure 3-3), prevents the cone head from spinning when the crusher runs empty. During crushing, the brake allows the cone head to rotate slowly to the right (clockwise), but not to the left (counterclockwise). It provides smoother operation, and eliminates unnecessary manganese wear. A torque bar bolts and is dowelled to the underside of the cone head. The torque bar slips inside the floating plate. A cone brake shaft engages the underside slot in the floating plate and is keyed to the brake shaft. The brake shaft projects down through the base frame spindle into an overrunning clutch, which is attached to a guide ring with bolts. The bolts are intended to shear off before any damage occurs to the shaft or clutch. Rollercones should not be run empty for extended periods of time. If sump oil is warm enough to flow freely, no further warmup is necessary. As soon as the drive sheave is up to speed, crushing can begin. If the cone head turns left (counterclockwise) at start-up, consult a Rollercone Service Manual or qualified Cedarapids Service person for repair procedures.
cone stem
floating plate
torque bar upper key brake bar
brake shaft clutch (one way overrunning) clutch guide ring w/ 5/16" Allen head cap screws grade five shear bolts 5/16" x 3/4"
brake cover plate Figure 3-3 Anti-Spin Brake
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Section 4 Rollercone Capabilities Characteristics of Rock In any rock crushing operation the physical characteristics of the raw material affect the output product you can achieve. The characteristics of rock of most interest in the rock processing industry are abrasion, compressive strength, toughness, and specific gravity. Cedarapids Inc uses several material tests to quantify or compare rocks on the basis of these characteristics. These tests follow American Standards Testing Methods (ASTM) standard procedures. Rock Abrasion Tests for chemicals with known abrasive compounds can determine the abrasion characteristics of specific rocks. Silica dioxide (SiO2), iron oxide (FeO) and aluminum oxide (Al2O3) are commonly found abrasive compounds in rock. Magnesium carbonate (MgCO3) and calcium carbonate (CaCO2) are also associated with abrasive effects. Abrasive test data are needed more for considering impact or grinder crushing, but abrasion is a factor in the wear life of Rollercone manganese. A high abrasive content causes more liner wear. Rock samples can be sent for chemical analysis to Cedarapids Inc through your Cedarapids Distributor. Such samples should weigh only one to two pounds (0.45 to 0.9kg) and must be representative of the quarry to provide reliable information. Check with your Distributor to get details of the sampling process. Rock Compressive Strength Generally rock with compressive strength up to 50,000 psi (344750 kPa) with acceptable hardness and toughness value is considered suitable for reduction in Rollercones. Before attempting to crush rock with greater than 50,000 psi compressive strength, consult the factory. A scale roughly corresponding to that given in more detail in ASTM C170 is shown below for your convenience: 5,000 to 10,000 psi (34475 to 68950kPa) .......................................Soft 10,000 to 20,000 psi (68950 to 137900kPa) .............................. Medium 20,000 to 30,000 psi (137900 to 206850kPa) ................................. Hard 30,000 to 45,000 psi (206850 to 310275kPa) ........................ Very Hard over 45,000 psi (310275kPa)..................................Extremely Hard Some practical testing of hardness you can do in the field is based on the Mohs Scale of Hardness. Talc has a Mohs hardness value of 1 and diamond the value 10. talc gypsum calcite fluorite apatite =1 =2 =3 =4 =5 orthoclase quartz topaz corundum diamond =6 =7 =8 =9 = 10
With this scale a rock that can be scratched with: your fingernail = about 2 copper coin pocket knife window glass steel file = about 3 = over 5 = 5-1/2 = 6-1/2
For more extensive information about types and characteristics of rock, consult your Cedarapids Distributor and the Cedarapids Pocket Reference Guide. Controlling Wear The manganese wear parts in a Rollercone crusher are designed to wear well in the hammering, compressive action created by the oscillation of the mantle against the bowl liner. Manganese wears faster in highly abrasive conditions.
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Section 4 Rollercone Capabilities The strategy for controlling wear is to reduce chances for abrasive action and increase chances for compressive action wherever possible. Here are five ways to effect this strategy: Make sure the crushing chamber is choke fed as often and as much as possible. Provide efficient screening prior to crushing to prevent as much abrasive sand and fines as possible from entering the crushing chamber. Eliminate as much water as possible from entering the crushing chamber. Water mixed with the infeed increases the abrasive characteristics of the rock. Crush across as much surface area of the mantle as possible. Try to make the mantle surface work (and wear) fully from top to bottom, not just at the parallel zone. Use the appropriate manganese configuration for the type of rock and the desired size reduction. A coarse bowl liner is less appropriate for rock crushed to finer grades. Getting Better Production At any equivalent crusher setting and screen opening, Rollercones yield a higher percentage of product than competitive cone crushers. For you this means greater net capacity. To get the most production, it is best to set your Rollercone no tighter than the minimum necessary to get the product size you want. The unique low angle of fall in the crushing chamber and the virtual zero clearance at the bearings allow settings that are very close to the finished product size. Make sure the feed has only a minimum of rock already to size. Minimum closed side setting is just above the point where the bowl will float under maximum allowable pressure on the tramp iron relief system. This setting can vary widely depending on the condition of material being crushed. For example, if a Rollercone is in a closed circuit making 5/8" (16 mm) minus, the screen should have enough capacity so that very few 5/8" or smaller rocks return to the crusher. Too much rock that is near size can cause bowl float, an unacceptable condition that can damage your crusher. With an open circuit many operators find that setting about 1/8" (3mm) tighter will yield a higher percent product passing the sizing screen. It is a good practice to test the efficiency of your closed side setting by sampling the product as it comes out of your under crusher chute. You will need to know what your acceptable recirculating load is. Recirculating loads in the 15% to 20% range are commonly acceptable. Under some conditions, when the setting is too close, pancakes form and the bowl will float. If this condition exists, increase the setting until bowl float stops. See bowl float in the Trouble Shooting section of this manual. To get the most production it is also very important to choke feed your crusher. Uniform choke feeding not only increases the volume going through your crusher but makes a better quality product. Product is more uniformly broken to grade specifications and is more cubical in shape when the crusher is choke fed. Cubical fractures (broken edges with nearly 90 angles; see Glossary) are best for most crushed rock applications because the right angles compact more efficiently and with more stability. Choke feeding helps eliminate any tendency to produce elongated rock particles. Rock pieces that are long and narrow can pass through the crusher without being further reduced in size. This type of rock does not compact as well as cubical rock pieces. Although it is best to choke feed the Rollercone, sometimes providing a high enough feed rate to choke feed it is difficult. In these conditions, build a surge pile or surge bin and run the crusher only when enough material is on hand to choke feed it. Another
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Section 4 Rollercone Capabilities possible action, when the crusher can't be choke fed, is to slow the incoming feed speed with a batter board or other means. See Section 7. If the incoming rock has too much velocity, it could pass so quickly through the crushing chamber that it would not be crushed properly. When the Rollercone is used as a secondary crusher, some operators run the primary crusher for an extra shift so a continuous supply of rock is available to choke feed the Rollercone. Capacity and gradation charts are included in the section on Changing Closed Side Settings. These charts show the average capacity of Rollercones crushing igneous rocks (granite, trap, basalt, etc.) Gradation charts show the average product grades of widely separated tests in open circuit when choke fed. The gradation and capacity charts are offered only to show what is possible with the Rollercone. Your product grades and capacities may differ because different rock content results in different crushing performance. Also, how you operate your crusher will determine its performance. Please carefully study the capacity and gradation charts to make best use of your Rollercone. Your Cedarapids Distributor will be glad to discuss gradations and capacities appropriate to your crushing needs. The feed openings in the charts are based on new manganese and ideal screening conditions. Cedarapids cone mantles and bowl liners are wear parts. Their design gives the best wear-to-production ratio. As each rock is crushed, it gets more cutting edges as it passes through the crushing chamber. The cutting and scraping of the rock wear away the manganese surfaces, causing the closed side setting to gradually increase. The rate of wear depends on the amounts of rock being crushed, the hardness of the rock, the condition and cross-sectional shape of the manganese, moisture content, and other factors. The parallel zone wears down fastest. Adjust the closed side setting as needed to compensate for manganese wear. Authorized Cedarapids cone mantles and bowl liners maintain acceptable feed opening while wearing. Operators commonly find that properly selected Cedarapids mantles and bowl liners that are matched to the work wear out completely and still have adequate feed opening. Usually, you will find a point where you can get better production by changing the manganese instead of continuing to crush with the old. Sometimes a wear pattern called hooking develops in the manganese. When this happens, the manganese needs to be changed. Sooner or later it will be time to change to new manganese. To install the new cone mantle and bowl liner, see Changing Manganese in this manual. Preventing Bowl Float Bowl float is the periodic separation of the bonnet from the bonnet support. See also the Glossary. Caution: Bowl float causes excessive wear and premature failure of some components. Allowing bowl float voids the warranty. Check the crusher for bowl float after making any change in setting, feed material, or feed rate. Bowl float causes pitting, metal transfer, and general wearing away of the bonnet and bonnet support seats. If it goes on too long, bowl float will cause the relief cylinder seals to leak. The end result will be costly repairs and downtime. Bowl float may not be visible without careful observation. You can detect it by looking for movement between the bonnet and bonnet support or between the rotation stop blocks. Even a small but continual movement can develop serious problems. A number of factors can contribute, separately or in combination, to bowl float. See the Trouble Shooting Section of this manual for a discussion of preventing bowl float.
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Section 4 Rollercone Capabilities What You Should Know about the Rollercone Bearings Besides the prime importance of constant, clean oil flow over the bearings, a few other things are important to know about the Rollercone bearing design. The smooth running, low-vibration Rollercone is sensitive to weight imbalances. Listening to and watching carefully for unusual vibrations can give you an early indication of need for maintenance. One source of imbalance is wear to the counterweights, especially the leading counterweight. Dirt or mud buildup in the crusher or motor sheaves can also cause unbalanced running. Check the condition of the counterweights and drive sheave daily and whenever vibration is detected. Normally, with plenty of clean oil and smooth, lowvibration running, the roller bearings will last a long time and help you produce profitable margins. Other factors can reduce the Rollercones performance. The Trouble Shooting Section may help if you are getting lower product rates than expected. See Transport and Travel, Section 6, of this manual for important notes about blocking the cone head to protect the roller bearings. Why Does the Rollercone Use Rollertype Bearings? The roller bearing design of the Rollercone allows no significant variation in the length of the oscillating stroke of the Rollercone cone head, whether running empty or loaded. This virtual zero clearance makes the Rollercone able, under normal conditions, to work at very close settings and at effective ratios of reduction. The Standard Head Rollercone typically crushes at a 6:1 rock size reduction ratio. The Fine Head commonly has a 4:1 rock size reduction ratio. This means balanced, vibration-free running and better sizing. The only things that affect a Rollercones setting are wear of manganese and bowl float or bonnet float. Manganese wear can be controlled and monitored (especially with the Remote Auto-Adjust system available on some Rollercones). Bowl float should never be allowed. See Bowl Float in the Trouble Shooting Section of this manual.
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Section 5 Lubrication Importance of Oil Flow Pattern in the Rollercone The heart of the Rollercone is the roller bearing system, which the lubrication system must protect from friction and contaminant damage. The lubricating oil not only prevents detrimental metalto-metal contact of internal bearing components, it also acts as a coolant to carry bearing-generated heat to oil sump, where it can be safely radiated out of the machine. Note the flow pattern in Figure 5-1.
Figure 5-1 Flow of Lubricating Oil

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A Terex Company
Section 5 Lubrication The bearings can be severely damaged if any of the following oil characteristics are inadequate: viscosity (grade) quantity (flow) cleanliness toughness of lubricant film (Timken load rating) oil pump cast aluminum heater pre-lube pump filter flow monitoring system internal and external lines and passages oil sump The oil heater is specially designed to keep oil flowing freely in cold weather. The large aluminum fins transfer heat to a larger surface area of the oil without burning it. The pre-lube pump circulates oil to the bearings before rotating the cone and can be used together with the oil heater for cold weather conditions. See the Cold Weather Startup section of this manual. The flow monitoring system includes : a flow meter a flow switch a warning horn If a breakdown in oil flow occurs, the flow monitoring system instantly alerts the operator that a malfunction needs to be corrected. As an added safeguard, also wire the switch to shut down the feed to the crusher if the oil flow is interrupted. Caution: Continued operation of the crusher with insufficient oil flow will severely damage the bearings. We urge you to use the flow monitoring system to its full advantage to prevent costly repairs and downtime resulting from insufficient oil flow. The flow monitoring system must be interlocked properly to protect the crusher or the warranty will be voided. To further ensure that only clean oil flows over the roller bearings, each currently manufactured Rollercone is equipped with an external oil filter. The filter is rated to have a high dirt capacity and to filter harmful particles out of the lubricating oil. The filter has a replaceable element. Change the element when the indicator shows a change is needed. It is important to use the proper replacement element in the filter. An element that is too fine plugs quickly. One that is too coarse allows too many particles to pass. Caution: Take precautions to prevent water from getting in oil. Store oil barrels where condensation and rain cannot get in.
Page 5.2 LJ0190100-1
The lubrication system consists of:
These features help ensure that a proper amount of clean oil constantly bathes the roller bearings.
oil sample port warning horn oil guard filter indicator
pump
flow switch & meter
adaptor
pump motor
cannister for filter element
Figure 5-2 Typical External Lube System
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A Terex Company
Section 5 Lubrication Proper Oil Types Rollercones are filled with filtered ISO 150 oil at the factory when they are tested. This oil will protect the gears and bearings to an operating temperature of 185F (85C). This oil minimizes cold weather start-up problems and still supplies adequate viscosity for bearing lubrication. The lubrication specifications follow. Oil Properties at Operating Temperature Minimum Viscosity: 100 SUS (Saybolt Universal Seconds) Minimum Timken OK Load: 55 lbs Minimum Viscosity Index: 90 All oils should have extreme pressure (EP) additives. Cedarapids feels that the Chevron Borate EP additive is superior to the conventional sulfur-phosphorus additive used in other brands and could prolong bearing life. The following oils can be used as long as the above listed specifications are met.
Oil Company Chevron Amoco Exxon Gulf Mobil Shell Texaco Brand Name/Grade Ultra Gear 80W-90 Amogear EP 150 Spartan EP 150 Gulf EP HD 150 Mobilgear 629 Omala 150 Meropa 150
Acceptable Lubricants Cedarapids has found that, for conditions above 0F (-18C) with no wind chill, internal bearing temperature is independent of the outside (ambient) temperature and can reach 180F (82C) in any size crusher. If the oil temperature in your crusher exceeds 185F (85C) with the ISO 150 grade of oil, we recommend installation of ISO 220 or equivalent. This will not make the crusher run any cooler, but the oil will be able to maintain an adequate oil film thickness at the higher operating temperatures. Cedarapids installs the ISO 150 oil in all new Rollercones. Cold weather operation with this grade of oil may necessitate the use of oil heaters to keep the oil fluid and prevent damage to the main lubrication pump. Continuous operation in subzero temperatures may allow use of lighter oils. For example, ISO 68 oil may be used in subzero climates to maintain fluid liquidity as long as oil temperature does not exceed 150F (65C). Above 150F (65C) the ISO 68 thins out below the minimum viscosity of 100 SUS. At this point it should be replaced with heavier oil. However, even the lighter weight oils may require heaters for cold weather start-ups. Before starting the crusher in cold climates, be sure that the oil in the sump and external lines is fluid. Oil Analysis : When to Change Oil Cedarapids recommends that oil be periodically sampled and analyzed in a qualified lab. The data from a proper analysis indicate: the condition of the oil what contaminants are in the oil when it should be changed. Rollercones built in 1989 and after have an oil sampling valve fitted conveniently near the filter. Usually, oil should be changed every 1000 operating hours. You may get longer service from your oil. The best indicator of the oil condition is the Total
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Page 5.3
LJ0190100-1
A Terex Company
Section 5 Lubrication Acid Number, the TAN. It is a measurement of how much the oil has degraded. The TAN rises as the oil degrades. Generally, a 100% increase in TAN indicates that you should change lubricating oil. As the TAN continues to increase, the oil carries more contaminants and the viscosity increases, decreasing the lubricant effectiveness. A good lab analysis shows concentrations of wear metal elements in parts-per-million. The typical concentrations and limits are shown below:
Wear Metal Aluminum Copper Nickel Chrome Lead Iron Silicon (dirt) Typical Concentration 0 - 10 0 - 15 0-5 0-5 0 - 20 30 - 50 10 - 30 Upper Limit 50 10 10 50 150 75
Additive Sodium Boron Zinc Phosphorus
Normal Concentration 90 3900 400 300
Minimum Concentration 45 1950 200 180
Lubricating Oil Capacities

Crusher Model RC66 RC60 RC54 RC45 RC36 U.S. Gallons 35 30 22 18 9 Liters 132.5 113.6 83.3 68.1 34.1
A good oil sample report should show a viscosity number. For example, if you are using an oil with a rating of 140 SUS at 40C (104F) for SAE 80W-90 when it is clean and fresh, a report might show 168 SUS at 40C (104F) for SAE 80W-90. 168 SUS is an increase of 20% in the oils base viscosity level at the same temperature and SAE rating. In this case the report tells you its time to change the oil. Another indication that it is time to change oil is when any of the additives are reduced by 50%. The factory-installed, borate-based oil in the crusher will show the following additives in parts-per-million:
Note: Variations in foundry processes cause the capacity of the oil sump in those Rollercones with cast steel bases to differ among Rollercones of the same model number. Oil capacities shown in the accompanying chart are guidelines only, based on averages. The lubricating oil capacity of your Rollercone may differ from that stated in the chart.
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Page 5.4
LJ0190100-1
A Terex Company
Section 6 Transport and Travel Block the Cone Head The low profile, light weight, and self-contained lubrication system of the Rollercone make it a highly desirable crusher for operations that frequently move from site to site. Transport is so smooth that breakdown, move, and set up can sometimes be done in the same day. One vital step in preparing to move the Rollercone must be emphasized. The cone head must be prevented from lifting or bouncing during travel. When rock is being crushed, the cone head rides smoothly on its roller bearings. When rock is not being crushed, no downward force, except gravity, keeps the cone in contact with the roller bearings. So, a rough road or any other bouncing action (even from the suspension system of the transport vehicle) can lift the cone off the bearings and the cones own weight can beat downward on the bearings. The bearings and races are designed to withstand very heavy rolling forces, but will not withstand this type hammering action. The force of even slight vertical movements of the cone can result in very powerful hammering action. A bounce of the cone in a RC54 of less than 1/16" (1.6mm) is about equal to the force of a ten pound (4.5kg) hammer dropping five feet (1524mm) that would fall directly on the bearings and races. Caution: Always block the cone head before transporting your Rollercone to prevent the cone from bouncing during travel. Serious damage to the vital roller bearings could result if the cone head is not blocked properly. To block the cone head: 1) Lower the shim guard. 2) Using the electric hydraulic adjusting pump, attach line A (top hose) to the clamp cylinder relief valve quick coupler. See the hydraulic adjustment setup in Figure 9-3. Hook up line B (bottom hose) to the adjusting jack manifold quick coupler.
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3) Close the one gallon accumulator relief valve. 4) Open the clamp cylinder relief valve. With the 3-way control valve of the adjusting pump in the B position, pump the adjusting jack system to 10,000 psi (68950kPa). This will raise the upper assembly off the shim stacks. 5) Cut two wedge-shaped wooden blocks. A 12" to 18" (300 to 450 mm) long piece of 4 x 4 (100 x 100 mm) sawed diagonally works (Figure 61). Place these wedge blocks together in the widest part of the opening between the cone mantle and the bowl liner. Then slide them apart until they are about 30 apart. Tap the wedges tight with a hammer.
30
Figure 6-1
Warning: The next step will let the upper assembly down onto the shim stacks. Make sure people are clear. 6) Make sure everyone is clear of the crusher. Move the 3-way control valve on the adjusting pump to the A position. As the upper assembly comes down it will compress the blocks.
LJ0190100-1
A Terex Company
Section 6 Transport and Travel 7) With the control valve on the adjusting pump still in the A position, recharge the clamp cylinder system to 1600 psi (11 032kPa). Open the relief valve on the one gallon accumulator. If the pressure does not stay at 1600 psi, continue to charge the clamp cylinder system until it reaches 1600 psi and stays there. 8) Close the clamp cylinder relief valve. Using a small pry bar, raise any one of the adjusting jack rams at least 2" (50mm). This allows for any thermal expansion in the system. Disconnect the hydraulic hoses from the quick couplers. Replace the dust covers on the couplers. Raise and secure shim guard in place. Setting Up On Site If your Rollercone is not mounted on a plant, make sure the support structure is heavy enough to carry the working load of the crusher. Your Rollercone is well-balanced and will run smoothly, with very little vibration. It is the weight of the crusher plus the live, moving load of rock that must be supported. See the Installation Drawings included in this manual. If you have doubts or questions about the stability of your support structure, call the Cedarapids, Inc. Engineering Department or your area Cedarapids Distributor. If you are constructing your own under crusher hopper or chute, an access area under the crusher will make the daily check for obstructions and material buildup in the crusher easier. Set the under crusher collecting chutes all the way out to the inside diameter of the crusher base. This way the discharge speed will not be slowed by the collecting chutes being too small. Any restriction to the discharge will reduce the capacity of your crusher. If your crusher is mounted on a portable plant, make sure the plant is level in all directions and properly cribbed before starting your crusher. Support the trailer frame adequately with wheels off the ground and/or wheels removed. If the tires are in contact
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with the ground, the vibration of the equipment running may damage the wheel bearings and/or axle assembly. Its a good idea to wrap the brake drums to protect them from dirt and dust. When wiring the crusher starter during installation, the normally open contacts on the flow switch (See the typical crusher wiring schematic, Figure 7-9) are connected to the start/stop circuit for the device feeding the crusher. This interlocks the feed device so it cannot be turned on unless the crusher is running. The pre-lubrication pump timed-relay (TR1 in Figure 7-9) is wired into the crusher start/stop circuit so the crusher cannot be started until the pre-lube pump cycle is completed. It is reset when the crusher stop button is pushed. Caution: It is important that the following items be checked before operating the crusher at start up. Failure to do so may result in damage to the machine. Check that the motor rotation direction on the crusher drive and pre-lubrication pump is correct. Make sure the transportation wedge blocks are removed from the crushing chamber before start up. It is a good idea to store the wedge blocks for use next time you transport your crusher. Make sure the feed to the crusher is interlocked with the lubrication oil flow monitor system. Refer to the Lubrication Section of this manual. Caution: Be sure that the drive pulley on the crusher is turning in the direction indicated by the arrow on the base frame above the pinion shaft. The oil pump will not pump oil to the bearings if the rotation is wrong! After the first shift of operation check the V-belt tension and adjust to V-belt manufacturers specifications. Refer to the Adjusting V-belt section of this manual.
Page 6.2
LJ0190100-1
A Terex Company
Section 7 Installation Clearance and Mounting Directions Refer to the Installation Drawings for illustrations and dimensions. Mount the Rollercone level. This is very important and should be checked carefully in both the eastwest and north-south directions. Caution: Operating the crusher out-of-level could reduce its life and operating effectiveness. Install the Rollercone with enough clearance to allow easy daily service, adjustment, visual inspection, and routine maintenance. Minimum clearance dimensions for maintenance and replacement of major components are shown in the Installation Drawings. Caution: It is absolutely essential that enough overhead clearance be provided to allow for the maximum travel of the feed hopper for tramp iron relief when the crusher is set at its maximum discharge opening.
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Page 7.1
LJ0190100-1
A Terex Company
Section 7 Installation
RC66 installation
installation information: total weight: 62,700 lbs (28 441kg) recommended drive motor: 300 hp (224kw) belt drive (factory design)1200 rpm motor shaft center to center: 41.9" (1064mm) pinion: 693 rpm crusher sheave: 8-8V-30.0 1800 rpm motor shaft center to center: 45.8" (1163mm) pinion: 722 rpm crusher sheave: 10-8V-30.0 oil capacity: approx. 35 gallons (132 liters) 36" (914mm) 59-1/2" (1511mm) 15" (381mm) 46-1/2" (1181mm) keep this area clear for access to auxilary pump motor and oil filter assembly 15" (381mm)
18" (457mm)
this clearance required to remove pinion assembly.
45-7/8" (1165mm) 51" (1295mm) 60-3/8" (1533mm)
top view
fine head adjustable feed control (removable)
vertical envelope for removal of upper assembly 136" (3454mm)
31" (787mm)
keep this area around circumference of crusher clear for access to shim shim stacks, allowing for crusher adjustment.
20" (508mm)
18" (457mm) 46-13/16" (1189mm) 7-1/2" (191mm) 5-1/2" (140mm)
124-3/16" (3154mm) with hopper extension
10" (254mm) 9-7/8" (251mm) 5-1/2" (140mm) 9-1/2" (241mm) 12-7/8" (327mm) 27-1/2" (699mm)
side view
Figure 7-1 RC66, Four Views for Installation
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Page 7.2
LJ0190100-1
A Terex Company
RC66 installation (continued)
oil drain plugs 88" (2235mm) diameter discharge area 13" (330mm)
13-15/16" (354mm) 5" (127mm) 31" (787mm) 12" (305mm) 4-1/2" (114mm) 1" (25,4mm) x 9-1/2" (241mm) keyway
12-1/2" (318mm) 46" (1168mm) 5" (127mm)
69" (1753mm) square pattern
bottom view
Warning:
Tramp iron may cause hopper and bonnet to lift as much as 7-1/2" (191mm) at outside edge. Allow clearance at all times when crusher is in operation.
7-1/2" (191mm)
upper assembly 23,500 lbs (10 660kg)
94-1/2" (2400mm) fine head & standard w/o hopper extension
pinion rotation lower assembly 42,500 lbs (19 278kg). includes cone & wedge plate assemblies. 91-3/4" (2330mm) 102" (2591mm) 26-1/4" (667mm)
Caution:
Do not allow obstructions in discharge area. Material must not be allowed to build up inside crusher lower assembly. Possible damage to crusher may result.
keep area around external oil system clear of obstructions.
front view
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Page 7.3
LJ0190100-1
A Terex Company
Section 7 Installation RC60 installation

installation information: total weight: 53,000 lbs (24 041kg) recommended drive motor: 250 hp (186kw) belt drive (factory design)1200 rpm motor shaft center to center: 38-1/2" (978mm) pinion: 698 rpm crusher sheave: 8-8V-24.8 1800 rpm motor shaft center to center: 40" (1016mm) pinion: 684 rpm crusher sheave: 8-8V-35.5 oil capacity: approx. 30 gallons (114 liters) 12" (305mm) 55-1/8" (1400mm) 46-1/2" (1181mm) clearance
19" (483mm) on circumference
46-1/2" (1181mm) clearance
32" (813mm) diameter hopper feed opening
24" (610mm) diameter fine head removable feed control opening (fine head only)
top view
141-3/8" (3591mm) fine head adjustable feed control (removable) at maximum crusher opening
66" (1676mm) 42-3/4" (1086mm)

anc anc
rotated in this view. this area around circumference of crusher to be kept clear for access to shim stacks to allow for crusher adjustment.
126-1/8" (3204mm) at maximum crusher opening with hopper extension 41-1/4" (1048mm)
27-3/4" (705mm) 14" (356mm) 14-13/16" (376mm) 24-3/8" (619mm) 9-3/4" (248mm)
18" (457mm) min. 32" (813mm)
4" (102mm) 7-1/16" (179mm) 11" (279mm)
side view
this clearance required to remove pinion assembly.
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Page 7.4
LJ0190100-1
A Terex Company
Section 7 Installation RC60 installation (continued)

15-1/8" (384mm) from mounting hole to oil plug 10-1/8" (257mm) from mounting hole to heater magnetic oil plug 4-1/4" (108mm) 57-5/8" (1464mm) (4) 1-7/8" (47,6mm) dia. mounting holes 4" (102mm) C L C L C L
1/8" (3mm) from mounting hole to heater
oil heater
64" (1626mm)
detail view
4-1/2" (114mm) diameter 1" (25,4mm) x 1/2" (12,7mm) keyway
75-1/4" (1911mm) discharge opening
64" (1626mm)
25-5/8" (651mm)
Warning:
bottom view
7-1/2" (191mm) C L
upper assembly weight 18,630 lbs (8450kg)
130-1/4" (3308mm) required clearance for removal of upper assembly when changing manganese 95" (2413mm) maximum shim setting without hopper extension 35-3/16" (894mm)
lower assembly 34,370 lbs (15 590kg). includes cone & wedge plate assemblies.
pinion rotation
Caution:
8-1/4" (210mm) 4-1/2" (114mm)
27-1/2" (699mm) 85-3/4" (2178mm) 90" (2286)
front view
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Page 7.5
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A Terex Company

installation information: total weight: 41,250 lbs (18 711kg) recommended drive motor: 200 hp (149kw) belt drive (factory design)1200 rpm motor shaft center to center: 38-1/2" (978mm) pinion: 698 rpm crusher sheave: 8-8V-24.8 1800 rpm motor shaft center to center: 40" (1016mm) pinion: 684 rpm crusher sheave: 8-8V-35.5 oil capacity: approx. 22 gallons (83 liters) 52-1/4" (1327mm) this clearance required to remove pinion assembly. 15" (381mm) F.H. only 66" (1676mm)
l ce clearance cl l l l l l l l
26" (660mm) on base frame circumference
41" (1041mm) nominal
41" (1041mm) nominal 12" (305mm) 79" (2007mm)
30" (762mm)
28" (711mm) 51-1/8" (1299mm)

ance clearance a a a a a a a
top view
optional hopper extension 25" (635mm) maximum 110-1/4" (2800mm) vertical clearance required to remove upper assembly when changing manganese.
18" (457mm) keep this area around circumference of crusher clear for access to shim stacks, allowing for crusher adjustment.
d clearance nee
20" (508mm) 16" (406mm) 33-1/2" (851mm)

n n n a ed clearance nee e e
18" (457mm)
22" (559mm)
c c c c
4" (102mm)
clearance need
5-1/4" (133mm)
13-1/2" (343mm)
23-3/8" (594mm)
detail
16" (406mm) 6" (152mm)
side view
4-1/2" (114mm)
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Page 7.6
LJ0190100-1
A Terex Company

66" (1676mm) diameter discharge area 1-7/8" (47,6mm) diameter 4 places 9-3/4" (248mm) nominal
59" (127mm)
21-1/2" (546mm) nominal
3-1/2" (89mm) diameter 7/8" (22,2mm) x 7/16" (11,1mm) keyway allow access to oil drain plug
42-1/2" (1080mm) 59" (1499mm)
Warning:
bottom view
7-1/2" (191mm)
18-1/2" (4699mm)
upper assembly 14,500 lbs (6 577kg)
lower assembly weight 26,750 lbs (12 134kg). includes cone & wedge plate assemblies.
clearance cle
81-3/4" (2076mm) std. 80-3/4" (2051mm) F.H. maximum crusher height at maximum discharge setting
36" (914mm)
2-1/4" (57mm) nominal
1" (25,4mm) 4" (102mm) 78" (1981mm) 82" (2083mm)
Caution:
front view
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Page 7.7
LJ0190100-1
A Terex Company
RC45 installation
installation information: total weight: 27,300 lbs (12 383kg) recommended drive motor: 125 hp (93kw) belt drive (factory design)1200 rpm motor shaft center to center: 42-3/4" (1086mm) pinion: 745 rpm crusher sheave: 4-8V-24.8 1800 rpm motor shaft center to center: 45.8" (1163mm) pinion: 722 rpm crusher sheave: 4-8V-30.0 oil capacity: approx. 18 gallons (68 liters)
43-3/4" (1111mm)
41" (1041mm) nominal typical
keep area clear for oil filter/ flow switch access. 41" (1041mm) nominal typical
69" (1753mm)
22" (556mm) 24-1/2" (622mm) on F.H.
27" (686mm)
this clearance required to remove pinion assembly. 13-3/4" (349mm)
42" (1067mm) 14-1/2" (368mm) 7-1/4" (184mm) keep this area clear for access to auxiliary pump/ motor assembly.
top view
fine head adjustable feed control (removable).
98" (2489mm) F.H. adjustable feed control (removable)
rotated in this view 48" (1219mm) 29-1/2" (749mm) keep this area around circumference of crusher clear for access to shim stacks when adjusting crusher opening.
91-5/8" (2327mm) at maximum crusher opening with hopper extension.
24" (610mm)
33-3/4" (857mm)
18" (457mm)
12" (305mm) 9-3/4" (248mm) 4-3/4" (121mm)
side view
13-1/4" (337mm)
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Page 7.8
LJ0190100-1
A Terex Company
65" (1651mm) diameter discharge area
oil drain plug
2-15/16" (74,6mm) diameter with 3/4" (19mm) x 3/8" (9,5mm) keyway 68" (1727mm)
2" (51mm) 25-1/2" (648mm)
bottom view
Warning:
Tramp iron may cause hopper and bonnet to lift as much as 5-3/4" (146mm) at outside edge. Allow clearance at all times when crusher is in operation. 5-3/4" (146mm)
5" (127mm)
10-1/2" (267mm) 11-1/2" (292mm) on F.H. upper assembly 11,000 lbs (4990kg)
76-5/8" (1946mm) maximum crusher height at maximum discharge setting
Caution:
lower assembly 16,300 lbs (7394kg) includes cone & wedge plate assemblies Do not allow obstructions in discharge area. Material must not be allowed to build up inside crusher lower assembly. Possible damage to crusher may result.
front view
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Page 7.9
LJ0190100-1
A Terex Company

38" (965mm) installation information: total weight: 16,500 lbs (7484kg) recommended drive motor: 75 hp (56kw) belt drive (factory design)1200 rpm motor shaft center to center: 52-1/4" (1327mm) 60" pinion: 738 rpm (1524mm) crusher sheave: 5D22 1800 rpm motor shaft center to center: 46-1/4" (1175mm) pinion: 729 rpm crusher sheave: 6C24 oil capacity: approx. 9 gallons (34 liters) 32" (813mm) 32" (813mm)
23-1/4" (591mm) clearance necessary to remove pinion shaft assembly
9-1/4" (235mm) diameter FH. only
40" (1016mm)
top view
16-3/4" (425mm) maximum
fine head crusher adjustable feed control (removable) rotated in this view. keep this area around circumference of crusher clear for access to shim c c nce shim stacks, allowing nce nce for crusher adjustment.
nce nce nce
79-7/8" (2029mm) vertical clearance required to remove upper assembly when changing manganese
18" (457mm)
18" (457mm) 22-1/4" (565mm) 15-3/4" (400mm)
2-5/8" (67mm) 6-7/8" (175mm)
side view
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Page 7.10
LJ0190100-1
A Terex Company
Section 7 Installation RC36 installation (continued)

56-1/2" (1435mm) diameter discharge area
oil drain plug
58-1/2" (1486mm)
2-11/16" (68,3mm) with 5/8" (15,9mm) x 5/16" (7,9mm) keyway 22-1/16" (560mm)
(4) 1-5/8" (41mm) diameter mounting holes
bottom view
Warning:
Tramp iron may cause hopper and bonnet to lift as much as 5" (127mm) at outside edge. Allow clearance at all times when crusher is in operation. 5" (127mm) 4" (102mm) 12-1/2" c (318mm)
c c c
upper assembly 6,700 lbs (3039kg)
62" (1575mm) maximum crusher height (at maximum discharge setting)
Caution:
lower assembly 9,400 lbs (4264kg) Do not allow obstructions in discharge area. Material must not be allowed to build up inside crusher lower assembly. Possible damage to crusher may result. allow clearance for external oil system.
front view
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Page 7.11
LJ0190100-1
A Terex Company
Section 7 Installation Feed Speed Controlling the speed (velocity) of rock feed entering the Rollercone is as important as maintaining clearance for inspection and service. The Rollercone is designed to work while being choke fed. This means that the volume of rock material should be great enough that it backs up into the hopper. The feed hopper should be at least one-third full continuously during crushing. If rock enters the crushing chamber too fast, two undesirable effects can result: 1) Velocity (speed) of the larger rocks, due to excessive drop distance into the crushing chamber when the crusher is not being continuously choke fed, can be so great that impact on the mantle cap can damage it. This is especially true for Standard cones and Fine Head cones with coarse manganese. Either of these configurations are often fed larger size rock. For example, a 12 inch (305mm) round rock falling ten feet (3048mm) will be moving at a speed of over 25 feet per second (7.625m/ sec). At this velocity that rock can strike the mantle cap with over 2600 lbs (11564N) of force. Repeated strikes of this or greater force will eventually damage or destroy the mantle cap, which could lead to even greater damage to the Rollercone. 2) At this velocity rock can pass entirely through the open side of the crushing chamber without being adequately crushed. Under normal crushing conditions rock is caught three to eight times in the crushing action, if the cone is choke fed. Achieving proper gradation of rock product depends in part upon maintaining a high volume of rock mass through the Rollercone while keeping a slower velocity of individual rock pieces. Minimizing feed velocity while keeping feed volumes high generally maximizes product gradation. To help prevent damage to your crusher and to help maintain spec product, it is important to break the fall of rock into the crushing chamber and limit the height of fall to 36 inches (914 mm) or less. A rock box or other flow diversion device mounted above the feed hopper will help reduce the possibility of impact damage to the mantle and help get product that consistently meets your specifications. See Figures 7-6 and 7-7 for examples of designs for controlling feed speeds.
Figure 7-6
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Page 7.12
LJ0190100-1
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Section 7 Installation Electrical Control For External Lubrication The electrical control shown in the Typical Crusher Wiring Schematic is required for any installation. The electrical controls must be connected in this manner for the proper interlocks and sequence of operation. Note: Failure to have the system interlocked as shown will void the warranty. The electrical control shown in the schematic is available in an optional pre-lube/heater/oil flow control panel mounted in a weather-resistant box which includes: circuit breaker fuses pre-lube pump start/stop push button transformer (440 volt to 115 volt) relay timer relay
Cold Weather Oil Circulation Kit

Figure 7-7
Electrical Control System Standard voltage for Rollercone crusher components is 115v (volt), 60hz (hertz). Optional 220v, 60hz, or 220v, 50hz systems can be supplied upon request. All components are wired to the junction box (sometimes called j-box) mounted on the crusher. The junction box also contains a convenient electrical power tool outlet matched to the same voltage as the control circuit. Wires from the flow monitor switch, warning horn, oil heater, thermostat, and prelubrication pump all terminate at the terminal strip in the junction box. A typical crusher wiring schematic is provided in this manual (Figure 7-8). Study it carefully to better understand how your crusher operates.
Another optional control panel is available that contains an additional timer and relay to cycle the pre-lube pump every 15-30 minutes when the crusher is not running. This option is valuable for cold weather operation. After oil has been heated in the sump the pre-lube pump circulates the oil up through the crusher bearings and forces the cold oil back into the sump to be heated. The optional pre-lubrication control circuit has a timer relay. See TR1 on the electrical schematic (Figure 7-8). The timer relay is a variable, 2-180 seconds, relay, set for 45 seconds. When the prelube pump is started, it activates the timed relay. This relay activates relay R2. Contact R2 is normally open. The pre-lube pump motor, M2, runs until TR1 times out, at which time contact R2 is opened again and the pre-lube pump is turned off. When TR1 times out, it closes another set of contacts. This allows the crusher to be started. The crusher cannot start until the pre-lube pump operating
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Section 7 Installation sequence is completed. Contact R1 stays closed until either the pre-lube pump STOP button or the crusher STOP button is pushed. Either one will also stop the crusher. Crusher Drive The crusher drive circuit is designed to start only after the pre-lube pump has completed its cycle. Line seven , shown in the typical crusher wiring schematic, is connected both to a timed-to-close contact and to the crusher start switch. The pre-lube pump is timed to run 45 seconds while delaying completion of the starting circuit for the crusher drive. The crusher cannot be started during this time.
X1
Another timer, (TR2 in Figures 7-8 and 7-9), is shown for the reduced current starting circuit of a partially wound motor. When you push the crusher start button, one starter coil is pulled into the circuit and the timer starts. After a two-second delay, the other starter coil pulls the remaining windings on the crusher motor into the circuit. Flow Switch and Alarm The flow monitor switch, shown in the electrical schematic (Figure 7-10) is a safety device to protect the crusher in the event of lubrication system failure. It is set to trip when the oil flow decreases. The setting for the flow monitor depends on the size of crusher.
Crusher stop 1 2
Lube pump start 3 R1 3 R1 Crusher start 2 T.C. 18 TR1 TR1 3 T.O. TR1 8 1M1 2 seconds 2-180 seconds
X2
Lube pump 2 stop 5 2 5
TR1
4 4
R2
10 10
TR2
10
To flow monitor switch 1M1
8 TR2
T.C. 9
2M1
10
6 6
R2
14
14
M2
Lube pump
14
Red X2
Figure 7-8
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L1 L2 L3 Main breaker Not provided by ElJay
Circuit breaker
Crusher breaker
M1 M1 M1 M2 M2 M2 Transformer X1 F1 F2 F3 F4 X2
Outlet 20 (12 gauge) Crusher stop 1 2 Lube pump stop 2 5 R1 3 T.C. Crusher start 18 T.O. TR1 8 1M1 TR1 2 seconds 10 R2 Lube pump start 3 R1 3 2-180 seconds
TR1
TR2
10
8 1M1 18 N.C. 19 Stop
T.C.
2M1
10
TR2 Start
Horn
Flow switch N.O. 21 18
Not provided by ElJay
Equipment feeding crusher
2M1
11
R1
12 R3
Circulation kit on/off 01 14 13 TR3
Green
TR3 23
Optional cold weather oil circulation kit
R3
R2
14
(12 gauge)
14
M2
Lube pump
14 15 16 (12 gauge) 16
Red Heater
R4
All wire sizes 16 gauge except where noted otherwise 1 1 T
16
Amber
Figure 7-9 Typical Crusher Wiring Schematic
17
R4 X2
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Crusher start 2 TR1 T.C. 18
18
N.C.
19 Start
Horn
Flow switch Stop N.O. 21 18
Crusher feed
Figure 7-10
X2
Rollercone RC36 RC45 RC54 RC60 RC66
US Gallons per Minute 1.25 gpm 2.00 gpm 4.00 gpm 6.00 gpm 6.00 gpm
The normally-open switch is wired to the start/stop circuit for the crusher feed device. When the lubrication oil flow starts, this switch closes allowing the feed device to be started. If the oil flow falls below the preset rate, the switch will open and the feed device will be turned off. When this circuit is connected through the auxiliary contact, 1M1, on a part-wound motor starter, the warning horn will sound as the crusher is started up. When the oil flow reaches the switch set point, the horn will stop. This lets the operator know that the system is working correctly. If the auxiliary contact is not used the horn will blow continuously from the time power is turned on until the crusher is started.
The flow monitor switch has two contacts, one that is normally open and one that is normally closed. The normally-closed switch (labeled N.C. on the wiring diagram) controls the warning horn mounted on the crusher. It opens when oil flows through the system and closes, sounding the horn, if the oil flow falls below the preset rate.
X1 Fuse 15 R4
Not supplied by ElJay 16 16 Heater
Fuse 1 1
Figure 7-11
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16
Amber
17
R4 X2
LJ0190100-1
A Terex Company
Section 7 Installation Oil Heater All crushers are provided with an oil heater to keep the lubricating oil warm in cold weather. (Wiring Schematic, Figure 7-11). The heater and thermostat are mounted in the bottom of the oil reservoir. The heater requires an external relay, R4, which is actuated by the thermostat. This relay is required because the thermostat will not take the high current required by the heater. The thermostat will turn the heater on when the oil temperature falls below 60F (16C). Weights and Lifting Procedures Refer to the Rollercone Component Weights chart to figure the needed capacity of rigging and lifting equipment. Minimum rigging used for safe lifting should be steel wire rope in good condition, having a break strength of four times the weight to be lifted.
Crusher Model RC36STD RC36FH RC45STD RC45FH RC54STD RC54FH RC60STD RC60FH RC66STD RC66FH RC66FH Remote Adjust Upper Assembly 7,000 7,000 11,000 10,250 14,500 12,500 18,630 18,630 23,500 20,750 23,000 Lower Assembly 6,000 6,000 8,500 8,500 13,500 13,500 34,370 34,370 20,000 20,000 20,000
Warning: When the sling is at any angle but vertical, the allowable load which may be safely supported per rope is reduced. Examples: Each rope of a sling at 60 from the horizontal must be reduced to 85% of its safe vertical lifting capacity. At 45 it must be reduced to 70%. At 30 it must be reduced to 50% of the safe vertical lifting capacity. Remove the feed hopper before attempting to lift the crusher. Lift Rollercone crushers as a unit with the lifting eyes provided on the bonnet. When lifting the entire unit, be sure your hoist has enough capacity. Check the weight of your crusher. If a hoist with marginal capacity is to be used to lift the crusher, remove the upper assembly. See the Changing Manganese part of the Maintenance Section of this manual.
Cone Assembly 2,500 2,500 4,300 4,250 7,500 7,500 10,500 10,250 12,500 12,500 12,500
Wedge Plate Assembly 2,500 2,250 3,500 3,500 5,750 5,750 7,900 7,900 10,000 10,000 10,000
Hydraulic Power Unit 2,250
Figure 7-12 Rollercone Component Weights in Pounds
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Crusher Model Electric Motor HP* 75 RC36 75 125 RC45 125 200 RC54 200 250 RC60 250 300 RC66 300 1200 8-8V-30.0 8-8V-18.0 41.9" 8V 1600 680 - 730 693 1200 1800 8-8V-24.8 10-8V-30.0 8-8V-15.0 10-8V-12.5 38.4" 45.8" 8V 1400 8V 1600 680 - 730 680 - 730 698 722 1200 1800 8-8V-24.8 6-8V-35.5 8-8V-15.0 6-8V-14.0 38.4" 39.7" 8V 1400 8V 1600 680 - 730 680 - 730 698 684 1200 1800 4-8V-24.8 6-8V-35.5 4-8V-16.0 6-8V-14.0 42.7" 39.7" 8V 1500 8V 1600 700 - 750 680 - 730 745 684 1200 1800 5D22 4-8V-30.0 5D14 4-8V-12.5 52.2" 45.8" D158 8V 1600 700 - 750 700 - 750 738 722 Motor RPM 1800 Cone Sheave 6C24 Motor Sheave 6C10 Distance Belts: Between Min. Lenght Shaft Ctrs. Required 46.2" C144 Pinion Speed RPM Desired Range 700 - 750 Full Load Speed 729
*Reciprocating engine HP and kw ratings depend on running speed and altitude. Consult the engine distributor for application assistance.
Figure 7-13 Power and Speed Requirements Chart
The base frame struts have holes to attach lifting devices. With the upper assembly removed, the lower assembly may be lifted by attaching pairs of flat steel bars drilled to receive 1-1/2" (38 mm) bolts at each end. Make the bars at least 1/2" (13 mm) x 4" (100 mm) x 14" (360 mm). Drill 1-5/8" (41 mm) holes centered 2" (51 mm) from each end of the bars. The RC36 and RC45 Rollercones will need two pairs of bars and the RC54, RC60 and RC66 models will need three pairs. Warning: Do not lift or tie down the crusher by attaching to or putting strain to the manifold tubes. These tubes are highly pressurized. Lifting or tie-down forces could rupture them.
On the RC54, RC60 and RC66 Rollercones attach two of the lifting devices to the struts adjacent to the pinion shaft housing. On RC54 Rollercones the third device can attach to any remaining strut. On RC36 and RC45 models, attach balancing straps to the pinion housing. On the RC60 and RC66 models attach the third strap to the strut directly opposite the pinion housing. A balancing strap is not needed with the three-point lifting method on the RC54, RC60, and RC66 models.
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Section 8 Daily Start Up and Maintenance Daily Start Up Always check the oil level each day before operating your Rollercone. See the Lubrication Section for instructions on the right way to check the oil level. Caution: Before starting the crusher make sure the pre-lube pump operates at least 30 seconds to supply oil to the bearings before they roll. Periodic maintenance checks listed in this manual are important to keeping your equipment in good operating condition. Preventive maintenance checks identify problems before they cause equipment failure and downtime. The Rollercone Daily Inspection Form included in this manual and available from your Cedarapids Distributor is designed to help you build an effective preventive maintenance program. A good program will reduce overall maintenance costs and extend the life of your equipment. Cold Weather Start Up Be sure the lube oil is liquid enough to readily drip from the dipstick before starting in cold weather. The thermostatically-controlled heater supplied with all new machines will keep the lube oil temperature from 60 to 80F (16 to 27C) during non-crushing hours. Cedarapids recommends that this system be used when continuous line power is available. This system keeps warm only the oil in the sump. In operating conditions below 0F (-18C), Cedarapids recommends that you drain the factory installed hydraulic fluid from the Hydropneumatic Tramp Iron Relief system. This fluid has a pour point of -20F (-30C), and replace it with fluid that has a pour point of -50F (-45.5C) or colder. Hot Weather Start Up The temperature in a Rollercone under hard crushing conditions and very high ambient temperatures can exceed 200F (93C). Maximum lubrication oil temperature should be kept below 200F (93C) for oil of International Standards Organization (ISO)150 weight. If your crushers lube oil frequently runs at 185F (85C) or higher, change to a lube oil with ISO rating of 220. Daily Maintenance The crusher is designed with enough discharge clearance to pass several hundred tons of rock per hour. You must inspect the underside of your crusher daily. Do not allow the discharge area under your crusher to get clogged or backed up. Caution: A restricted discharge area can become plugged with wood, clay, rubber belting, or metal plates that may pass through the crusher. When stuck there, blockage can allow rock to back up in the machine and cause serious damage to labyrinth seals and counterweight. You can make clearing the discharge area of the crusher easier if you allow clearance at the under crusher conveyor. With the system shut down and locked off at the end of the shift, a worker, in voice contact with other workers, can climb on the conveyor to look under the crusher for blockages. Warning: Climbing onto the conveyor is extremely dangerous unless the feed conveyor, the crusher, and the discharge conveyor are all shut down and locked out! Keeping voice contact with other workers helps assure that no one starts up related machinery at this time. If ten minutes at the end of each shift are planned for this activity, you can save many hundreds of dollars in repairs, replacement parts, and hours of downtime.
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Section 8 Daily Start Up and Maintenance Using the Rollercone Daily Inspection Form The following Daily Inspection Form is for you and your crew to photocopy and use as a standard method to keep your Rollercone in full production and to minimize downtime. The Daily Inspection Form can also be ordered from your Cedarapids Distributor. The inspection form includes procedures for everyday, periodic inspections needed to properly maintain your Rollercone. The procedures are intended as minimum requirements. Your crushing conditions and your geographical location may require more frequent inspections and service. The sheet can serve as a maintenance record for your files. Cedarapids hopes to help you get the most production and the longest life from your Rollercone crusher. Please dont hesitate to call your Cedarapids representative with questions about service and maintenance practices. Supervisors and conscientious operators can periodically review the Daily Inspection Forms to help maintain a detailed, overall picture of machine usage and production costs.
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Section 8 Daily Start Up and Maintenance Rollercone Daily Inspection Form

Operator's Initials
OK OK OK OK OK OK OK
Before Startup Inspect:

1) Undercrusher discharge area for blockage 2) Oil dipstick for proper level, viscosity, cleanliness. 3) Leading counterweight for wear, cracks 4) Drive sheaves for dirt buildup, wear 5) Drive V-belts for wear, fraying, slipping 6) Oil filter indicator for restricted flow 7) Closed side setting for accurate adjustment 8) Crusher hydraulic system for leaks at Jacks Clamps Tramp Iron Relief After Startup, Running Empty, Inspect: 9) For cone spinning (cone should not turn) 10) Flow meter: write down the reading 11) Ammeter: write down the amperage 12) Low oil warning horn system After Crushing Begins, Inspect: 13) Feed location 14 ) Feed rate 15) Feed velocity 16) Ammeter for amp draw under full load 17) Flow meter reading under full load Centered Choke fed
OK OK
OK, No spin
Cleaned Amount oil added Replaced Cleaned Adjusted/ Replaced

Replaced filter element
Adjusted
OK OK OK
Leaking Leaking Leaking Start-up time Yes, cone spins Gpm flow Liters/minute flow Amp reading Not working
Adjusted Not enough volume Too fast Amp reading Gpm flow Liters/minute flow
Total crushing hours this date. Downtime this date. Comments:
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Section 9 Changing Closed Side Settings Description of the Rollercone Hydraulic Setting Adjustment System The upper and lower assemblies of the Rollercone are held in precise position relative to each other by a hydraulic clamping system and adjusting bolts. The adjusting bolts are each double-nutted. Each passes through a hydraulic clamp cylinder and a stack of adjusting shims. The shims are designed to lock in place but be easily removable once pressure on them is released. RC36 and RC45 models each have eight adjusting bolts and clamps. RC54s have twelve , RC60s have fourteen, and RC66 models have sixteen. The clamp cylinders, when pressurized, exert a squeezing force through the adjusting bolts. The force pulls the lower clamp ring upwards and the bonnet support downwards with enough pressure to keep the bowl liner and mantle within a given dimension while crushing many tons of rock per hour.
Shim Thickness
The Rollercone is engineered so that you can precisely control this dimension, called the closed side setting or css, by stacking shims in combinations. The total height of the shim stack remains constant around the adjusting bolt circle, but by placing some shims below the bonnet support and some above it, you vary the closed side setting to the dimension you need. Each adjusting bolt has one set of shim stacks. The shim stacks on every bolt must be arranged so that the bonnet support is level at each css. The shims are color-coded and numbered to help operators check that the stack heights are even and matched all round the crusher.
3-1/2" 3-1/4" 3" 2-3/4" 2-1/2" 2-1/4" 2" 1-3/4" 1-1/2" 1-1/4" 1" 3/4" 1/2" 1/4"
Thickness 1/8" 3/16" 1/4" 5/16" 3/8" 1/2" 5/8" 3/4" 7/8" 1" 1-1/2"
Number Stamp 1 2 3 4 5 6 7 8 9 0 11
Figure 9-1 Shim Set
Color Code White Yellow Black Red Blue Orange Brown Purple
1-1/4"
1-1/2"
1-3/4"
2-1/4"
Green Aluminum
Closed Side Setting (css) Figure 9-2 Ratio of Shim Thickness to CSS
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2-1/2"
1/4"
1/2"
3/4"
1"
2"
Grey
A Terex Company
Section 9 Changing Closed Side Settings Rollercones with Hydraulic Adjust The hydraulic adjustment system is a feature introduced in 1965 and has been standard equipment on all Rollercones manufactured since 1970. This feature greatly reduces the time and effort to adjust the crusher setting. It eliminates all heavy wrenching of nuts and screw jacks. The same shim stacks are used as in Rollercones that have manual adjustment. Hydraulic adjustment works in this way. A pressure tight duct, filled with hydraulic oil, connects to each adjusting jack cylinder and piston assembly around the bonnet support flange. A nipple connector allows oil from the duct to pass to the inside each cylinder. An adjusting bolt passes through the center of each piston. When you pressurize the oil in the duct with the electric hydraulic pump, the pistons collapse against the cylinder heads, gaining about 1/8" (3mm) clearance or looseness in the top of each lower shim stack. A one gallon hydraulic accumulator charged with 1000 psi (6895 kPa) of nitrogen gas connects to the oil duct through a valve. An oil reserve is pumped into the accumulator to a pressure of 1600 psi (11032 kPa). This maintains pressure in the clamp cylinders which hold the bonnet support tightly in place. Maintain each hold down bolt assembly adjustment at about 5/8" (16mm) of brass showing (Figure 9-3) for proper travel of the clamp cylinder and clamp ring and to provide clearance to remove and replace shims for setting adjustment. The clamp cylinder pistons of the hydraulic adjust system are retained or limited by a threaded cap. Rollercones with Remote Auto Adjust Changing the closed side setting to adjust sizing of crushed rock on Rollercones with the Auto Adjust optional feature uses procedures and mechanical processes very different from the Hydraulic Adjustment system. For a complete description of this feature, see the Auto Adjust Supplement to the Rollercone Owner/Operator Manual. How to Change Settings Items needed for settings adjustment on Rollercones with the hydraulic adjustment system are: electric hydraulic adjusting pump
3
/4" or adjustable wrench
small pry bar Follow the steps below (Figures 9-3 and 9-4). 1) Check the toggle switch on the adjusting pump to be sure it is in the off position. Plug in the pump to an appropriate electrical outlet. Caution: 120 volts DC will ruin the toggle switch on your adjusting pump. Be sure to use alternating current in the proper volt range. 2) Connect line B (the bottom hose) to the adjusting jack manifold. Connect line A (the top hose) to the relief valve threaded into the flange of the bonnet support. Be sure the fitting snaps fully into place. Caution: Overtightening ruins the relief valve. Use only gentle force. 3) Use the 3/4" or adjustable wrench. Gently close the relief valve at the bottom of the small (one gallon) accumulator. The purpose of closing the valve at the one gallon accumulator is to retain the oil already trapped in this accumulator. This reduces both the amount of oil needed to repressurize the system and the amount of time required to make an adjustment.
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Section 9 Changing Closed Side Settings 4) Lower the shim guard. 5) Place the valve on the adjusting pump to position B (toward the hoses.) 6) Use the /4" or adjustable wrench to slowly open the clamp cylinder manifold valve. 7) Place the toggle switch on the adjusting pump to the run position until the clamp cylinders are completely collapsed. Use the jog position on the switch to prevent unnecessarily high pressure build-up.
hydraulic fluid pressure 1600 psi (11032 kPa)
3
8) Stop the pump motor. To adjust to a narrower (finer) closed side setting: a) Remove the desired shims from the lower shim stacks (Figures 9-4 and 9-5). To calculate the proper shims to remove, see the Ratio of Shim Thickness to Crusher Setting graph (Figure 9-2). This graph shows the shim thickness required to get the desired closed side setting (css). Place these shims close at hand for use in step c.
nitrogen gas pressure 1000 psi (6895 kPa)
accumulator relief valve one gallon accumulator clamp cylinder relief valve set screw locknut spherical seat adjusting nut spherical seat washer upper shim stack dust seal
adjusting jack manifold block
approx. 5/8" (16 mm) brass showing bonnet support clamp cylinder
pressure hose line A
2" (50 mm)
ram lower shim stack
jog/off/run switch
return hose line B
position A adjusting pump
hold
position B
3-way control valve
Figure 9-3 Hydraulic Adjustment Set-Up

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Section 9 Changing Closed Side Settings Warning: the next step will lower the upper assembly onto the shim stack. Be sure all people are clear. b) Once you have checked to make sure everyone is clear, move the adjusting pump valve to the A position (away from the hoses). As this valve is opened the upper assembly will drop onto the lower shim stacks. c) Replace the shims that were removed from the lower shim stack into the upper shim stack. To adjust to a wider (coarser) closed side setting: a) Move the control valve on the adjusting pump to the A position. This will loosen the upper shim stack and allow the desired shims to be removed. To calculate the proper shims to remove, see the Ratio of Shim Thickness to Crusher Setting graph.
Invert every other shim to porovide locking action
adjusting bolt
shims
open side toward crusher
Figure 9-5
Upper shim stack Bonnet support Clamp cylinder assembly Shim guard Adjusting bolt Lower shim stack Clamp ring Adjusting bolt block Adjusting bolt set screw (or set bolt) Adjusting bolt retainer pad
Figure 9-4 Adjusting Bolt Cutaway
b) After removing the desired shims, move the control valve on the adjusting pump back to the B position. This will raise the upper assembly enough to allow you to place the shims you have removed from the upper stack into the lower shim stack. Warning: The next step will lower the upper assembly. Be sure all people are clear. c) Once all shims are replaced and everyone is clear, move the control valve on the adjusting pump back to position A to lower the upper assembly. As this valve is opened, the upper assembly will drop onto the shim stacks. 9) With the adjusting pump valve in the A position start the pump and pressurize the system to 1600 psi (11032 kPa). Stop the pump at 1600 psi. 10) Open the relief valve on the one gallon accumulator. If the system pressure drops, continue to pressurize with the pump until system pressure stabilizes at 1600 psi (11032 kPa). Stop the pump.
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Section 9 Changing Closed Side Settings 11) Close the clamp cylinder relief valve. 12) Move the control valve on the adjusting pump to the B position to clear lines of pressure. 13) Using the small pry bar, raise any one adjusting jack to a height of approximately 2" (50 mm) (Figure 9-3). This allows room in the system for any hydraulic thermal expansion or contraction without affecting crusher performance. 14) Remove both hoses. Secure the pump. Raise and secure the shim guard. The Rollercone is now ready to operate at your desired setting.
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Section 9 Changing Closed Side Settings
Minimum and Maximum Closed Side Settings Crusher Model & Liner
36" Std w/Coarse Liner 36" Std w/Medium Fine Liner 36" FH w/ Coarse Liner 36" FH w/Fine Liner 45" Std w/Coarse Cavity 45" Std w/Medium Fine Cavity 45" FH w/ Coarse Cavity 45" FH w/Fine Cavity 54" Std w/Coarse Cavity 54" Std w/Medium Cavity 54" Std w/Medium Fine Cavity 54" FH w/Coarse Cavity 54" FH w/Fine Cavity 60" Std w/Coarse Cavity 60" Std w/Medium Cavity 60" Std w/Medium Fine Cavity 60" FH w/Coarse Cavity 60" FH w/Fine Cavity 66" Std w/Coarse Cavity 66" Std w/Medium Cavity 66" Std w/Medium Fine Cavity 66" FH w/Extra Coarse Cavity 66" FH w/Coarse Cavity 66" FH w/Fine Cavity 66" FH w/Extra Fine Cavity
Minimum CSS
1/2" (12.7 mm) 3/8" (9.6 mm) 3/8" (9.6 mm) 1/4" (6.4 mm) 5/8" (15.9 mm) 1/2" (12.7 mm) 3/8" (9.6 mm) 1/4" (6.4 mm) 3/4" (19.1 mm) 1/2" (12.7 mm) 1/2" (12.7 mm) 3/4" (19.1 mm) 3/8" (9.6 mm) 1" (25.4 mm) 3/4" (19.1 mm) 5/8" (15.9 mm) 3/8" (9.6 mm) 1/4" (6.4 mm) 1-1/2" (38.1 mm) 1" (25.4 mm) 3/4" (19.1 mm) 3/4" (19.1 mm) 1/2" (12.7 mm) 3/8" (9.6 mm) 1/4" (6.4 mm)
Maximum CSS
1-5/8" (41.3 mm) 1-5/8" (41.3 mm) 1-5/8" (41.3 mm) 1-5/8" (41.3 mm) 2-7/8" (73.0 mm) 2-7/8" (73.0 mm) 2-1/8" (54.0 mm) 2-1/8" (54.0 mm) 3" (76.2 mm) 3" (76.2 mm) 3" (76.2 mm) 1-3/4" (44.5 mm) 1-3/4" (44.5 mm) 4" (101.6 mm) 3-1/2" (88.9 mm) 3-1/2" (88.9 mm) 3-1/2" (88.9 mm) 3-1/2" (88.9 mm) 4-1/2" (114.3 mm) 4-1/2" (114.3 mm) 4-1/2" (114.3 mm) 3-3/8" (85.7 mm) 3-3/8" (85.7 mm) 3-3/8" (85.7 mm) 3-3/8" (85.7 mm)
Capacity Calculation Dimension A in the capacity charts and manganese cross-sections is the largest dimension in inches that the feed opening on the closed side of the crushing chamber is rated to accept and crush when the closed side setting is Dimension C. Dimension B shows the largest dimension that the feed opening on the open side is rated to accept and crush when the closed side setting is Dimension C.
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Rollercone Capacities in Tons per Hour (Tonnes per Hour) Standard Head in Open Circuit, Gross Throughput
CSS 3/8" (9,5mm) Model RC36 RC45 RC54 RC60 RC66 36-42 (33-38) 7/16" (11mm) 38-52 (34-47) 1/2" (13mm) 44-60 (40-54) 70-87 (62-79) 5/8" (16mm) 55-70 (50-64) 87-106 (79-96) 3/4" (19mm) 65-80 (59-73) 7/8" (22mm) 72-85 (65-77) 1" (25mm) 79-94 (71-85) 1-1/4" (32mm) 85-105 (77-95) 135-170 (122-154) 225-270 (204-245) 292-351 (265-318) 380-456 (345-414) 1-1/2" (38mm) 91-110 (83-98) 140-180 145-185 150-188 (127-163) (132-168) (136-171) 245-295 260-315 270-330 (222-268) (236-286) (245-299) 318-383 338-410 351-429 (288-347) (307-372) (318-390) 414-498 439-532 456-557 (376-452) (398-493) (414-505) 1-3/4" (44mm) 2" (51mm)
105-126 117-144 125-154 (95-114) (106-131) (113-139) 170-200 185-220 200-237 (154-181) (168-200) (181-215) 221-260 240-285 260-308 (200-236) (218-259) (236-279) 265-338 292-350 315-405 (240-307) (265-318) (288-367)
bowl liner A B
new feed Recirculating load in closed circuit, Fine Head application Note: wire cloth equal to css
cone C open side
screen
closed side
cone
cone mantle
net product
Rollercone Capacities in Tons per Hour (Tonnes per Hour) Fine Head in Closed Circuit, Gross Throughput and Net Product
Closed Side Setting % Recirculating Load RC36 Gross Throughput Net Product RC45 Gross Throughput Net Product RC54 Gross Throughput Net Product RC60 Gross Throughput Net Product RC66 Gross Throughput Net Product 100 (91) 82 (74) 1/4" (6mm) 18% 37-43 (34-39) 30-35 (27-32) 57-67 (52-61) 47-55 (43-50) 5/16" (8mm) 18% 49-55 (44-50) 40-45 (36-41) 67-79 (61-72) 55-65 (50-59) 85-97 (77-88) 70-80 (64-73) 110-122 (100-111) 90-100 (82-91) 128-165 (116-150) 105-135 (95-122) 3/8" (9,5mm) 20% 59-65 (54-59) 47-52 (43-47) 81-94 (73-85) 65-75 (59-68) 106-125 (96-113) 85-100 (77-91) 135-175 (122-159) 108-140 (98-127) 164-210 (149-191) 131-168 (119-152) 1/2" (13mm) 24% 72-82 (65-74) 55-62 (50-56) 108-121 (98-110) 82-92 (74-83) 132-178 (120-161) 100-135 (91-122) 192-250 (174-227) 146-190 (132-172) 238-295 (216-268) 181-224 (164-203) 5/8" (16mm) 25% 87-93 (79-84) 65-70 (59-64) 127-153 (115-139) 95-115 (86-104) 180-220 (163-200) 135-165 (122-150) 233-280 (211-254) 175-210 (159-191) 287-340 (260-308) 215-255 (195-231)
Figure 9-6 Capacity Calculation
3/4" (19mm) 26% 95-101 (86-92) 70-75 (64-68) 142-162 (129-147) 105-120 (95-109) 209-257 (190-233) 155-190 (141-172) 270-327 (250-297) 200-242 (181-220) 331-398 (300-361) 245-294 (222-267)
7/8" (22mm) 28% 104-111 (94-101) 75-80 (68-73) 160-188 (145-171) 115-135 (104-122) 239-292 (217-265) 172-210 (156-191) 312-372 (283-337) 225-268 (204-243) 383-451 (347-409) 275-325 (249-295)
1" (25mm) 29.5% 113-123 (103-112) 80-87 (73-79) 170-206 (154-187) 120-145 (109-132) 262-322 (238-292) 185-227 (168-206) 340-409 (308-371) 240-288 (218-261) 418-496 (379-450) 295-350 (268-318)
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standard cone coarse cavity

A B
standard cone medium cavity
Minimum Setting A 12-1/4" (311mm) B 13-1/8" (333mm) C 1-1/2" (38mm)
Minimum Setting A 9-1/16" (230mm) B 10-1/4" (260mm) C 1" (25mm)
standard cone medium-fine cavity
A B
Minimum Setting A 7" (178mm) B 8-1/8" (206mm) C 3/4" (19mm)
fine head cone extra-coarse cavity
A B
fine head cone coarse cavity
Minimum Setting A 5-1/8" (130mm) B 6-5/8" (168mm) C 3/4" (19mm)

C
Figure 9-7 RC66 Rollercone Manganese Options

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fine head cone fine cavity
A B
fine head cone extra-fine cavity
A B
Minimum Setting
C
Minimum Setting C 5/16" (8mm)

C
A 2" (51mm)
B 3-5/8" (92mm)
A 1" (25mm)
B 2-1/2" (92mm)
C 3/16" (5mm)
RC66 Rollercone Standard Head Cone Liners at Various Setting Options

A 12-1/4" (311mm) 12-3/4" (324mm) 13-9/16" (344mm) 14-1/8" (359mm) Coarse B 13-1/8" (333mm) 13-1/2" (343mm) 14-5/16" (364mm) 14-7/8" (378mm) C 1-1/2" (38mm) 2" (51mm) 3" (76mm) 4-1/8" (105mm) A 9-1/16" (230mm) 10-1/2" (267mm) 11-11/16" (297mm) 12-3/4" (324mm) Medium B 10-1/4" (260mm) 11-11/16" (297mm) 12-13/16" (325mm) 13-15/16" (354mm) C 1 (25mm) 2" (51mm) 3" (76mm) 3-7/8" (98mm) A 7" (178mm) 7-1/4" (184mm) 8-1/2" (216mm) 9-13/16" (249mm) 10-15/16" (278mm) Medium-Fine B 8-1/8" (206mm) 8-1/2" (216) 9-11/16" (246mm) 11" (279mm) 12-1/8" (308mm) C 3/4" (19mm) 1" (25mm) 2" (51mm) 3" (76mm) 3-7/8" (98mm)
RC66 Rollercone Fine Head Cone Liners at Various Setting Options

Extra-Coarse
A 5-1/8" (130mm) 5-5/16" (135mm) 6-1/16" (154mm) 6-3/4" (171mm) 7" (178mm) B 6-5/8" (168mm) 6-13/16" (173mm) 7-9/16" (192mm) 8-1/4" (210mm) 8-1/2" (216mm C 3/4" (19mm) 1" (25mm) 2" (51mm) 3" (76mm) 3-3/8" (86mm) A 3-3/4" ( 95mm) 3-15/16" (100mm) 4-1/8" (105mm) 4-7/8" (124mm) 5-11/16" (144mm) 5-15/16" (151mm)
Coarse
B 5-1/4" (133mm) 5-7/16" (138mm) 5-5/8" (143mm) 6-5/16" (160mm) 7-1/16" (179mm) 7-5/16" (186mm) C 1/2" (13mm) 3/4" (19mm) 1" (25mm) 2" (51mm) 3" (76mm) 3-3/8" (86mm) A 2" (51mm) 2-3/16" (56mm) 2-1/4" (57mm) 2-13/16" (71mm) 3-15/16" (100mm)
Fine
B 3-5/8" (92mm) 3-11/16" (94mm) 4-1/8" (105mm) 4-3/8" (111mm) 5-3/16" (132mm) C 5/16" (8mm) 3/8" (10mm) 3/4" (19mm) 1" (25mm) 2" (51mm)
Extra-Fine
A 1" (25mm) 1-3/8" (35mm) 1-3/4" (44mm) 2" (51mm) 2-15/16" (75mm) B 2-1/2" (64mm) 2-13/16" (71mm) 3-3/16" (81mm) 3-7/16" (87mm) 4-3/8" (111mm) C 3/16" (5mm) 3/8" (10mm) 3/4" (19mm) 1" (25mm) 2" (51mm)
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B A standard cone coarse cavity standard cone medium cavity B A
Minimum Setting
A 8-1/4" (210mm)
B 9" (229mm)
C 3/4" (19mm)
B standard cone medium fine cavity A
Minimum Setting
A 5-1/2" (140mm)
B 6-3/8" (162mm)
C 5/8" (16mm)
A fine head cone fine cavity B A fine head cone coarse cavity B
Minimum Setting
C
C 1/4" (6mm)
A 1-1/2" (38mm)
B 2-3/4" (70mm)

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RC60 Rollercone Standard Head Cone Liners at Various Setting Options A 10-3/4" (273mm) 11" (279mm) 11-1/2" (292mm) 12" (305mm) 12-1/2" (318mm) Coarse B 11-1/2" (292mm) 11-3/4" (298mm) 12-1/4" (311mm) 12-3/4" (324mm) 13-1/4" (337mm) C 7/8" (22mm) 1" (25mm) 2" (51mm) 3" (76mm) 4" (102mm) A 8-1/4" (210mm) 8-1/2" (216mm) 9-1/4" (235mm) 10" (254mm) 10-3/8" (264mm) Medium B 9" (229mm) 9-1/4" (235mm) 10" (254mm) 10-3/4" (273mm) 11-1/8" (283mm) C 3/4" (19mm) 1" (25mm) 2" (51mm) 3" (76mm) 3-1/2" (89mm) A 5-1/2" (140mm) 5-3/4" (146mm) 7" (178mm) 8-1/4" (210mm) 8-7/8" (225mm) Medium-Fine B 6-3/8" (162mm) 6-3/4" (171mm) 8" (203mm) 9-1/4" (235mm) 9-7/8" (251mm) C 5/8" (16mm) 1" (25mm) 2" (51mm) 3" (76mm) 3-1/2" (89mm)
RC60 Rollercone Fine Head Cone Liners at Various Setting Options A 3-7/16" (87mm) 3-1/2" (89mm) 3-3/4" (95mm) 4-1/2" (114mm) 5-7/16" (138mm) Coarse B 4-5/8" (117mm) 4-3/4" (121mm) 5" (127mm) 5-3/4" (146mm) 6-1/2" (165mm) C 1/2" (13mm) 3/4" (19mm) 1" (25mm) 2" (51mm) 3" (76mm) A 1-1/2" (38mm) 2" (51mm) 2-1/4" (57mm) 3-1/4" (83mm) 4-3/4" (121mm) Fine B 2-3/4" (70mm) 3-1/4" (83mm) 3-1/2" (89mm) 4-1/2" (114mm) 5-1/2" (140mm) C 1/4" (6mm) 3/4" (19mm) 1" (25mm) 2" (51mm) 3-1/2" (89mm)
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A B
standard cone medium-fine cavity

A B
Minimum Setting A 5" (127mm) B 6-1/8" (156mm) C 1/2" (13mm) A 3-3/4" (95mm)
Minimum Setting B 4-7/8" (124mm) C 1/2" (13mm)
standard cone coarse cavity with enlarged feed
A B
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Minimum Setting A 3-1/4" (83mm) B 4-3/4" (121mm) C 1/2" (13mm) A 1-3/8" (35mm)
RC54 Rollercone Standard Head Cone Liners at Various Setting Options A 10" (254mm) 10-1/4" (260mm) 11-1/2" (292mm) 12-1/2" (318mm) Coarse B 10-3/4" (272mm) 11" (279mm) 12-1/4" (311mm) 13-1/4" (337mm) C 3/4" (19mm) 1" (25mm) 2" (51mm) 2-7/8" (73mm) A 5" (127mm) 5-1/2" (140mm) 6-7/8" (175mm) 7-7/8" (200mm) Medium B 6-1/8" (156mm) 6-5/8" (168mm) 8" (203mm) 9" (229mm) C 1/2" (13mm) 1" (25mm) 2" (51mm) 2-3/4" (70-mm) A 3-3/4" (95mm) 4-3/8" (111mm) 5-5/8" (143mm) 6-3/8" (162mm) Medium-Fine B 4-7/8" (124mm) 5-1/2" (140mm) 6-3/4" (171mm) 7-5/8" (194mm) C 1/2" (13mm) 1" (25mm) 2" (51mm) 2-3/4" (70mm)
RC54 Rollercone Fine Head Cone Liners at Various Setting Options A 3-1/4" (83mm) 3-5/8" (92mm) 4" (102mm) 4-3/8" (111mm) 4-5/8" (117mm) Coarse B 4-3/4" (121mm) 5" (127mm) 5-3/8" (137mm) 5-3/4" (146mm) 6" (152mm) Fine C 1/2" (13mm) 3/4" (19mm) 1" (25mm) 1-1/4" (32mm) 1-1/2" (38mm) A 1-3/8" (35mm) 2" (51mm) 2-1/4" (57mm) 2-1/2" (64mm) 2-7/8" (73mm) B 2-3/4" (70mm) 3-3/8" (86mm) 3-5/8" (92mm) 3-7/8" (98mm) 4-1/4" (108mm) C 3/8" (10mm) 3/4" (19mm) 1" (25mm) 1-1/4" (32mm) 1-5/8" (41mm)
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standard cone medium fine cavity
B A

A
Minimum Setting A 3-1/4" (83mm) B 4-1/8" (105mm) C 1/2" (13mm) A 1-3/8" (35mm)
A B
C C
Minimum Setting A 7" (178mm) B 7-3/4" (197mm) C 5/8" (16mm) A 3" (76mm)
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RC45 Rollercone Standard Head Cone Liners at Various Setting Options A 7" (178mm) 7-3/4" (197mm) 8-7/8" (200mm) 9-5/8" (244mm) Coarse B 7-3/4" (197mm) 8-1/2" (216mm) 9-5/8" (244mm) 10-3/8" (264mm) C 5/8" (16mm) 1-1/8" (29mm) 2-1/8" (54mm) 2-7/8" (73mm) A 3-1/4" (83mm) 3-7/8" (98mm) 5" (127mm) 5-7/8" (149mm) Medium- Fine B 4-1/8" (105mm) 4-3/4" (121mm) 5-7/8" (149mm) 6-3/4" (171mm) C 1/2" (13mm) 1" (25mm) 2" (51mm) 2-3/4" (70mm)
RC45 Rollercone Fine Head Cone Liners at Various Setting Options A 3" (76mm) 3-3/8" (86mm) 3-5/8" (92mm) 4" (102mm) 5" (127mm) Coarse B 4-1/4" (108mm) 4-5/8" (117mm) 4-7/8" (124mm) 5-1/4" (133mm) 6-1/8" (156mm) C 3/8" (10mm) 5/8" (16mm) 7/8" (22mm) 1-1/8" (29mm) 2" (51mm) A 1-3/8" (35mm) 1-3/4" (44mm) 2-1/8" (54mm) 2-3/8" (60mm) 3-1/8" (79mm) Fine B 2-1/2" (64mm) 2-7/8" (73mm) 3-1/4" (83mm) 3-1/2" (89mm) 4-1/4" (108mm) C 1/4" (6mm) 1/2" (13mm) 3/4" (19mm) 1" (25mm) 2" (51mm)
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B A
A B

B A

A B
C C
Minimum Setting A 3" (76mm) B 3-3/4" (95mm) C 3/8" (10mm) A 1-3/8" (35mm)
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RC36 Rollercone Standard Head Cone Liners at Various Setting Options A 5-3/4" (146mm) 6-3/8" (162mm) 7-1/4" (184mm) Coarse B 6-1/2" (165mm) 7-1/8" (181mm) 8" (203mm) C 1/2" (13mm) 1" (25mm) 1-3/4" (44mm) A 3" (76mm) 3-3/4" (95mm) 4-5/8" (117mm) Medium B 3-3/4" (92mm) 4-1/2" (114mm) 5-3/8" (137mm) C 3/8" (10mm) 7/8" (22mm) 1-5/8" (41mm)
RC36 Rollercone Fine Head Cone Liners at Various Setting Options A 3" (76mm) 3-3/8" (86mm) 3-5/8" (92mm) 4" (102mm) 4-3/4" (121mm) Coarse B 3-3/4" (95mm) 4-1/8" (105mm) 4-1/2" (114mm) 4-7/8" (124mm) 5-5/8" (143mm) C 3/8" (10mm) 1/2" (13mm) 3/4" (19mm) 1" (25mm) 1-3/4" (44mm) A 1-3/8" (35mm) 1-5/8" (41mm) 1-7/8" (48mm) 2-1/8" (54mm) 2-7/8" (73mm) Fine B 2-3/8" (60mm) 2-5/8" (67mm) 2-7/8" (73mm) 3-1/8" (79mm) 3-7/8" (98mm) C 1/4" (6mm) 1/2" (13mm) 3/4" (19mm) 1" (25mm) 1-3/4" (44mm)
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Section 9 Changing Closed Side Settings Rollercone Product Gradation Chart: Percent Passing
Product Size (mm) 4" (102) 3-1/2" (89) 3" (76) 2-3/4" (70) 2-1/2" (64) 2-1/4" (57) 2" (51) 1-3/4" (44) 1-1/2" (38) 1-1/4" (32) 1" (25.4) 7/8" (22.2) 3/4" (19.1) 5/8" (15.9) 1/2" (12.7) 3/8" (9.5) 5/16" (7.9) 1/4" (6.4) 4M (4.8) 5/32" (4.0) 8M (2.4) 10M (1.7) 16M (1.0) 30M (0.55) 40M (0.4) 50M (0.3) 100M (0.15) 200M (0.08) 100 98 88 82 69 53 45 33 30.5 22.5 15.5 13 10.8 7.4 5 100 96 92 80 70 57 44 38.5 28.5 26 19.2 13 10.8 9 6.1 4.1 100 95 91 84 69 59 47 37 33 24.6 22.4 16.8 11.4 9.5 7.9 5.3 3.6 100 95 89.5 84 76 58 49 40 32 29 21.5 19.5 14.5 9.8 8.1 6.7 4.4 3 100 93.5 88 81.5 75 66 48 41.5 35 27.8 25 18.6 17 12.5 8.5 7.1 5.8 3.9 2.6 100 95 88 82 74 65 55 40.7 35 29.5 24.2 22 16.3 14.8 11 7.5 6.2 5.1 3.4 2.3 100 94.5 88 80 72 61.5 53 45 33.6 29.5 25 20.5 18.7 14 12.7 9.5 6.4 5.3 4.4 2.9 2 100 95 89 81 70.5 61 51 44 37 27 24 20.3 17 15.5 11.5 10.4 7.7 5.2 4.2 3.5 2.3 1.5 100 97 93.5 88 80 70 57.5 48 40 34 28.2 21.4 18.8 16.2 13.5 12.4 9 8.1 6 3.9 3.2 2.6 1.7 1.1 100 97.5 94.5 91 86 79 67.5 56 45 38 31.5 27.5 23 17.2 15.3 13 10.8 9.8 6.9 6.2 4.3 2.8 2.2 1.7 1.1 0.7 100 95 92 88 83 76 66 56 46 36 30 25.5 22 18.7 14 12.5 10.5 8.6 7.6 5.2 4.6 3.1 1.8 1.4 1.1 0.7 0.5 Crusher Closed Side Setting 5/16" (7.9) 3/8" (9.5) 7/16" (11.1) 1/2" (12.7) 5/8" (15.9) 3/4" (19.1) 7/8" (22.2) 1" (25.4) 1-1/4" (32) 1-1/2" (38) 1-3/4" (44) 2" (51) 100 95 90 86 81 74 65 55 45 37.5 29 24.5 20.5 18 15.5 11.5 10.3 8.5 6.7 5.9 3.8 3.3 2.1 1.2 1 0.8 0.5 0.3
A guide to product sizes: Product sizes followed by M refer to the size of product obtained by using the U.S. Standard Sieve Series for square mesh wire cloth of different M (mesh) sizes. Mesh size is determined by number of openings per linear inch (Example: 4M contains four
openings per linear inch) measured from one wire center to another. Product size depends on mesh size and wire gauge. The narrower the wire gauge, the greater the open area and the larger the product size. Metric sizes are also taken from the U.S. Standard Sieve Series, and may differ slightly from actual inch equivalents.
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Section 10 Maintenance The Right Way To Check Oil Level In The Crusher Since proper lubrication is so important in the Rollercone, each operator should learn the right way to check the oil level. The oil level dip stick is designed to be read after it is unscrewed, wiped clean and replaced lightly (without re-threading) on the filler hole. The length of the stick indicator shows proper oil depth only when used this way. Pull the dip stick up. Look at the oil on the stick to see: if it is between the high and low marks if the oil is clean or dirty if the oil drips readily from the end of the stick. If the dip stick shows oil is too low, add oil before starting crusher. Refer to the Lubrication Section of this manual to determine proper oil. If the dip stick shows oil is too high, be aware that oil will flow out through the labyrinth seal at the pinion housing. If the oil is very dirty, both the filter and the oil may soon need changing. If the oil does not drip readily from the dip stick, it may be too viscous to run the crusher. Either it is too cold, too dirty, or it is the wrong grade of oil. Do not run the crusher if the oil wont drip from the stick. How to Change Lubricating Oil Note: Follow local, state, and federal laws on disposing of oil. 1) See the Lubricating Oil Capacity Chart to see how much oil your crusher nominally contains. Warning: Wear safety glasses and protective equipment. Check oil temperature by laying hand against rectangular oil cover. The next step may result in hot, splashing gear oil. If too hot to touch, wait for machine and oil to cool. Protect your eyes and hands.
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2) Remove one of the two 1/2" Allen head pipe plugs with 5/16" Allen wrench from rectangular cover. 3) Place funnel tight against base frame and hold it there until oil drains. When oil has drained enough, replace the plug. 4) Replace filter element as needed. 5) Add clean oil. See the list of acceptable lubricants for proper oil. 6) Check the oil level. 7) Start the crusher and check for leaks at the filter. Run the crusher one shift, then recheck the oil level. 8) Refill as appropriate. How to Change Lube Oil Filter Element Change oil filter elements when the oil is changed, when the oil flow is slowed by blockage of the filter, when samples show a particulate count that is too high, and every 1000 hours of operation. When the filter indicator shows red, indicating a clogged filter, change the filter element. If you regularly read the oil flow and record the reading on the Daily Inspection Form (provided on page 8.3), you can also note any gradual drop in oil flow to anticipate downtime to change the filter element. 1) Remove the cannister (Figure 10-1). 2) Pull out and properly dispose of the old element. 3) Clean the cannister. 4) Replace the cannister seal. 5) Install a new element. 6) Fill the cannister with approved lubricant. 7) Reinstall the cannister.
Page 10.1
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Section 10 Maintenance
pump motor oil sample port oil guard warning horn
filter indicator
flow switch and meter
Figure 10-1
pump
adaptor
cannister for filter element
Hydraulic Fluid & Nitrogen Gas Pressures in the Relief System The pressure in the tramp iron relief system is very sensitive to volume loss. Losing pressure or grossly over-pressurizing the system is very poor practice with the Rollercone. Relief system pressure is a result of two factors which must work together in proper balance: fluid pressure and gas pressure The two pressures push against one another at the bladder in the accumulators. Too much or too little pressure of either factor can make the system fail. Periodic pressure checks are the best way to control this system.
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Section 10 Maintenance Schematic Description of the HydroPneumatic Tramp Iron Relief System The schematic drawings shown in Figures 10-2 through 10-6 show you how the tramp iron relief system works when it is properly charged and what can go wrong if its not properly charged. In Figure 10-2, the accumulator is charged with nitrogen gas at 1800-2100 psi at 68F (12411 to 14480 kPa at 20C). The relief cylinder manifold is filled with oil. Air is bled out of the system, but no oil is in the accumulator. The oil pressure is equal to or below gas pressure and the bladder protector valve at the oil port is closed. If you were to try to crush rock under these conditions the bonnet would float (bowl float) because overall pressure in the system is too low. In Figure 10-3, the nitrogen gas in the accumulator is charged with 1800-2100 psi at 68F (12411 to 14480 kPa at 20C). The relief cylinder manifold is filled with hydraulic oil and pressurized to 2600 psi (17927 kPa). The bladder protector valve at the oil port of the accumulator is open. Both nitrogen gas pressure and hydraulic pressure are equal at 2600 psi. In these conditions (Figure 10-3), each cylinder exerts a force of 45,000 lbs (20000 kg) on the bonnet. The total combined force of the cylinders pushing the bonnet down against the bonnet support (called the hold down force) on a RC45 crusher is 360,000 lbs (163000 kg). On a RC54 crusher, it is about 540,000 lbs (245000 kg), on a RC60 about 630,000 lbs (286000 kg), and on a RC66 Rollercone about 720,000 lbs (327000 kg). With normal crushing conditions the situation described in Figure 10-3 allows proper crushing. But, if the rock's work factor is great enough to overcome the hold down pressure, the bonnet will float! You will have bowl float. Bowl float must not be permitted. See Preventing Bowl Float in the Troubleshooting Section.
hydraulic oil charging valve bladder protector valve air bleeder valve manifold tube
n gas nitrogen gas nitrogen rogen gas nitrogen gas nitrog n gas nitrogen gas nitrogen g gen gas nitrogen gas nitrogen ga nitrogen gas nitrogen gas nitrogen gen gas nitrogen gas nitrogen gas gen gas nitrogen gas nitrogen ga nitrogen gas nitrogen gas nitrogen gen gas nitrogen gas nitrogen gas gen gas nitrogen gas nitrogen ga nitrogen gas nitrogen gas nitrogen gen gas nitrogen gas nitrogen gas gen gas nitrogen gas nitrogen ga nitrogen gas nitrogen gas nitrogen gen gas nitrogen gas nitrogen gas gen gas nitrogen gas nitrogen gas nitrogen gas nitrogen gas nitrogen gen gas nitrogen gas nitrogen gas gen gas nitrogen gas nitrogen gas nitrogen gas nitrogen gas nitrogen gen gas nitrogen gas nitrogen gas gen gas nitrogen gas nitrogen gas nitrogen gas nitrogen gas nitrogen gen gas nitrogen gas nitrogen gas gen gas nitrogen gas nitrogen gas nitrogen gas nitrogen gas nitrogen gen gas nitrogen gas nitrogen gas gen gas nitrogen gas nitrogen gas nitrogen gas nitrogen gas nitrogen gen gas nitrogen gas nitrogen gas gen gas nitrogen gas nitrogen gas nitrogen gas nitrogen gas nitrogen gen gas nitrogen gas nitrogen gas gen gas nitrogen gas nitrogen gas nitrogen gas nitrogen gas nitrogen gen gas nitrogen gas nitrogen gas gen gas nitrogen gas nitrogen gas nitrogen gas nitrogen gas nitrogen gen gas nitrogen gas nitrogen gas n gas nitrogen gas nitrogen rogen gas nitrogen gas nitrog n gas nitrogen gas nitrogen g
relief cylinder
n s
push rod V-seat
5 gallon accumulator
Figure 10-2
nitrogen gas bladder
gas t oge gas t oge ogen gas nitrogen gas nitrog n gas nitrogen gas nitrogen g gen gas nitrogen gas nitrogen ga nitrogen gas nitrogen gas nitrogen gen gas nitrogen gas nitrogen gas gen gas nitrogen gas nitrogen ga nitrogen gas nitrogen gas nitrogen gen gas nitrogen gas nitrogen gas gen gas nitrogen gas nitrogen ga nitrogen gas nitrogen gas nitrogen gen gas nitrogen gas nitrogen gas gen gas nitrogen gas nitrogen gas nitrogen gas nitrogen gas nitrogen gen gas nitrogen gas nitrogen gas gen gas nitrogen gas nitrogen gas nitrogen gas nitrogen gas nitrogen gen gas nitrogen gas nitrogen gas gen gas nitrogen gas nitrogen gas nitrogen gas nitrogen gas nitrogen gen gas nitrogen gas nitrogen gas gen gas nitrogen gas nitrogen gas nitrogen gas nitrogen gas nitrogen gen gas nitrogen gas nitrogen gas gen gas nitrogen gas nitrogen gas nitrogen gas nitrogen gas nitrogen gen gas nitrogen gas nitrogen gas gen gas nitrogen gas nitrogen gas nitrogen gas nitrogen gas nitrogen gen gas nitrogen gas nitrogen gas gen gas nitrogen gas nitrogen gas nitrogen gas nitrogen gas nitrogen gen gas nitrogen gas nitrogen gas gen gas nitrogen gas nitrogen gas nitrogen gas nitrogen gas nitrogen gen gas nitrogen gas nitrogen gas n gas nitrogen gas nitrogen rogen gas nitrogen gas nitrog n gas nitrogen gas nitrogen g
bowl liner
bonnet
cone mantle
bonnet support Figure 10-3
In Figure 10-4 the tramp iron relief system manifold is charged (Figure 10-3), but in this view a piece of tramp iron, represented by a ripper tooth, is passing through the crusher and has overcome the initial hold down force of the system. The relief cylinder piston has properly moved upward to displace oil into the accumulator. Hydraulic and gas pressure increase at this point. As soon as the tramp iron passes, the bonnet returns to its V-seat on the bonnet support and relief system pressure will return to normal. Note the ample space in the properly charged accumulator to accept the displaced oil without damaging the nitrogen bladder.
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Page 10.3
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Section 10 Maintenance In Figure 10-5 the tramp iron relief system has been recharged without properly checking the nitrogen gas pressure. As nitrogen gas leaked out of the bladder, overall volume of the relief system decreased. When only the oil pressure was checked, it was read as low pressure and the system was repressurized by pumping in more oil. The oil level became lower and lower in the accumulator until the nitrogen bladder was squeezed against the bottom of the bottle. Under this condition (Figure 10-5) the system has less capability of relieving to clear tramp iron. Warning: Never pump oil into the tramp iron relief system without checking the nitrogen gas pressure in each accumulator. Figure 10-6 shows the results of not properly checking nitrogen gas pressure and of overcharging the accumulator with hydraulic oil.
3. piston pushes fluid
s nitrogen gas nitro n gas nitrogen gas s nitrogen gas nitrog s nitrogen gas nitrogen n gas nitrogen gas s nitrogen gas nitrogen nitrogen gas nitrogen as nitrogen gas trogen gas nitrogen
g g as nitrog trogen g nitrogen gas nitrog nitrogen nitrog gas n
Caution: When this condition exists, the nitrogen bladder is damaged and must be replaced.
Figure 10-5
When tramp iron enters the crusher with an already hydraulically locked accumulator, inadequate space is available to accept oil that is displaced by the relief cylinders.
possible burst from manifold tube if bladder damaged or overpressurized !
g it
2. V-seat opens
n ga s ni n
4. displaced fluid compresses bladder
s nitrogen gas nitrog en gas nitrogen gas nitrogen ga itrogen gas nitrogen gas nitroge en gas nitrogen gas nitrogen ga gen gas nitrogen gas nitrogen ga nitrogen gas nitrogen gas nitrogen gen gas nitrogen gas nitrogen gas gen gas nitrogen gas nitrogen gas nitrogen gas nitrogen gas nitrogen gen gas nitrogen gas nitrogen gas gen gas nitrogen gas nitrogen gas nitrogen gas nitrogen gas nitrogen gen gas nitrogen gas nitrogen gas gen gas nitrogen gas nitrogen gas nitrogen gas nitrogen gas nitrogen gen gas nitrogen gas nitrogen gas gen gas nitrogen gas nitrogen gas nitrogen gas nitrogen gas nitrogen gen gas nitrogen gas nitrogen gas gen gas nitrogen gas nitrogen gas itrogen gas nitrogen gas nitrogen gen gas nitrogen gas nitrogen gas n gas nitrogen gas nitrogen rogen gas nitrogen gas nitrog n gas nitrogen gas nitrogen g
1. tramp iron enters chamber
a n n ga en g i
Figure 10-4
nitrogen gas nitrogen gas nitroge ogen gas nitrogen gas nitrogen ga ogen gas nitrogen gas nitrogen ga nitrogen gas nitrogen gas nitroge ogen gas nitrogen gas nitrogen ga en gas nitrogen gas nitrogen itrogen gas nitrogen gas nitro en gas nitrogen gas nitrogen it
g it
tramp iron
Figure 10-6
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Section 10 Maintenance The extremely high pressures that result may: Rupture hydraulic seals Rupture the hydraulic manifold. Break pressure ring hold down bolts. Bend cylinder support beams. Damage other components of the relief system. The factory-approved fluid is Chevron AW46 or equivalent. Any equivalent fluid must be a premium quality, anti-foaming hydraulic oil with oxidation inhibitors and anti-wear additives. Chevron AW46 is a medium viscosity fluid with a pour point of -29 Celsius (-52F). Consult your Cedarapids Distributor before using a fluid with other characteristics. Checking Relief System Pressure: 2 Methods Following are two methods of checking HydroPneumatic Tramp Iron Relief System pressure. Tool List You need the following items to perform the checks. Electric hydraulic adjusting pump
3
This condition may result in substantial damage to the crusher. Relief Accumulator Positions Relief system accumulators mount on Rollercones in two different configurations. RC66, RC60, and RC54 models have accumulators with oil port up and gas port down. RC45 and RC36 models have oil port down and gas port up (Figure 10-7).
/4" box or open end wrench, or adjustable wrench.
hydraulic fluid port
Appropriate wrench for removing protector cap from top (or bottom) of accumulator
1
/4" hose with 1/4" tpt (tapered pipe thread) on one end, long enough to reach containers
Clean containers large enough to hold 10 to 15 gallons (40 to 60 liters) of hydraulic fluid
accumulator position for RC45, RC36, and older RC54 accumulator position for RC66, RC60, and current RC54
0-3000 psi (0 to 20685 kPa) nitrogen gas pressure gauge (Figure 10-9). 0-3000 psi (0 to 20685 kPa) charging gauge assembly (Figure 10-10). Warning: Do not attempt repair to accumulators without proper training. Dangerously high gas/fluid pressure can build up in faulty accumulators. They are pressurecontainment vessels which can remain dangerous even when removed from the Rollercone. Serious injury could result if any pressure remains in the accumulator. Cedarapids does not recommend repairs of any kind to the "flat top" Hydrogen accumulators. Replace these with Bosch accumulators. Cedarapids does not manufacture accumulators. For questions
Page 10.5 LJ0190100-1
Figure 10-7
Relief System Fluid Capacities Model RC66 RC60 RC54 RC45 RC36
Figure 10-8
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Hydraulic Fluid in US Gallons 20 22 17 9 6
A Terex Company
Section 10 Maintenance concerning accumulators, contact your Cedarapids Distributor. See also the technical components manual, Repairing Accumulators.
T-handle
Note: When connecting the electric hydraulic pump to a quick coupler, clean the hose tip and check the quick coupler for dirt or other obstructions. Be sure the threads are in good condition. Before starting the pump, be sure the threaded fittings at the coupler are fully threaded and the couplers are tight. 4) Connect line A (top hose) from the electric hydraulic adjusting pump to the quick coupler at the accumulator relief valve (Figures 10-12 or 10-13).
Figure 10-9 Nitrogen Gas Pressure Gauge Assembly
5) Place the 3-way control valve on the adjusting pump at position A (away from the hoses).
length of tubing or hose high pressure pipe plug
Figure 10-10 Charging Gauge Assembly P/N 02-360-547-0000
Warning: Wear protective goggles or other eye protection when working with pressurized gases and oils. First Method To check the Tramp Iron Relief System fluid pressure follow these directions carefully. See Figures 1011, 10-12, 10-13, and 10-16 for checking and charging relief system fluid pressure. Remember that the entire system pressure depends on both fluid and gas pressure. A measure of system pressure actually measures the higher of either gas or fluid pressures. 1) Make sure the relief valve at the accumulator is closed. If open, close it gently. 2) Remove the 1/4" high pressure pipe plug from the accumulator relief valve (Figure 10-11). 3) Thread the quick coupler (supplied with crusher) into the relief valve.
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Figure 10-11
6) Open the relief valve at the accumulator. Read the pressure indicated on the gauge on the adjusting pump. 7) If the system has lost more than 10% of normal pressure, do not add fluid until you have checked for correct gas pressure in the accumulator bladders. To check for correct gas pressure, you must depressurize the fluid in the system and drain off some of the fluid volume. Follow the steps for depressurizing and draining the fluid in the section on Checking Nitrogen Gas Precharge Pressure.
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Section 10 Maintenance 8) When you are satisfied that the system pressure is operable, close the relief valve. 9) Move the 3-way pump control valve to the B position (toward the hoses). 10) Disconnect the quick couplers. Remove the quick couplers from the relief valve. 11) Install the 1/4" high pressure pipe plug in the relief valve. Secure the adjusting pump.
5 gallon accumulator Line A Gauge Line B capped off
Alternate Method of Checking Relief System Fluid Pressure The alternate method of checking relief system fluid pressure has the advantages of taking less time and of being somewhat easier to perform than the first method. It has the disadvantages that it requires a measuring gauge not supplied with the original purchase of the Rollercone, and that, if you find system pressure to be too low, you must still use the first method to achieve full pressure.
pipe plug 1/4"-18 npt slotted nut bladder
Pump
Figure 10-12 Accumulator Position for RC66, RC60, and Current RC54
bladder protector valve

5 gallon accumulator Line A Gauge Line B capped off
Pump
Figure 10-13 Accumulator Position for RC45, RC36 and Older RC54
If the system has lost less than 10% of normal pressure it may be necessary to add fluid. To add fluid, start the pump. Pump oil into the system until pressure increases to 2600 psi (17927 kPa). Continue pumping until the gauge reads 2600 psi. Stop the pump.
nut
nitrogen gas charging valve protective cap Figure 10-14
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Section 10 Maintenance The tool, called the nitrogen gas pressure gauge (Figure 10-9) can be assembled from the charging gauge assembly, part number 02-360-547-0000, and a pipe plug. For owner/operators with several crushers, this tool can help provide useful information quickly and conveniently. Warning: Wear protective goggles or other eye protection when working with pressurized gases and oils. 1) Remove the accumulator protective cap and valve cap. Install the nitrogen pressure gauge onto the accumulators nitrogen gas valve (Figure 10-15). 2) Tighten the T-handle to open the nitrogen gas valve. Read the pressure indicated on the gauge. If the pressure is low, follow steps 1 through 11 in the First Method, pages 10.6 and 10.7. If pressure is okay, unthread (turn out) the Thandle on the nitrogen pressure gauge.
nitrogen gas pressure gauge T-handle
environment) temperature variations. For example, a system that reads 2500 psi at 40F (17238 kPa at 4C) will read about 2700 psi at 80F (18617 kPa at 27C). Pressure changes about 5 lbs for every degree Fahrenheit (62kPa for every 1C). Caution: Exceeding the rated Tramp Iron Relief System pressures can reduce or void the warranty on your crusher. 2) Make sure the relief valve needle is seated (valve is closed). 3) Remove 1/4" pipe plug from the relief valve. See the accumulator cutaway (Figure10-14) and the accumulator recharging set up (Figure 10-16). 4) Thread 1/4" hose into relief valve where the pipe plug was. Get a clean drum large enough to hold the volume of hydraulic fluid in your Rollercone. See Figure 10-8 for relief system fluid capacities. If you use a clean container, you can reuse the fluid. 5) Very slowly open the relief valve. Carefully drain the hydraulic fluid though the 1/4" hose to the clean container (Figure 10-16). Fluid squirts strongly at first, then slows to a drip or stop.
accumulator
6) Open the valve a little farther to relieve further pressure. Continue opening the valve in small increments, waiting for fluid to slow or stop, then opening further.
Figure 10-15
3) Remove the pressure gauge. Reinstall the valve cap and protective cap. Checking Nitrogen Gas Precharge Pressure 1) Check the pressure during the early morning or the coolest time of day. The pressure may increase or decrease as much as 200 psi (1379kPa) with ambient (surrounding
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7) After the valve is completely open, fluid in the system (but outside of the accumulators) is no longer under pressure. Still, several gallons remain in the system and some of it continues to drain by gravity. The down tubes of the manifold and the relief cylinders hold even more fluid which won't drain by gravity.
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Section 10 Maintenance Warning: Draining one accumulator in a segmented relief system (such as in RC36 and older models of other sizes) relieves pressure only in that segment. Other segments remain pressurized. Accumulators remain charged with gas. Handle with extreme care! After the oil pressure has drained completely off, proceed to the next step. 8) Using the appropriate wrench, remove the protector cap from each accumulator. Caution: Do not force or overtighten. A snug fit on the nitrogen gas charging valve is enough. Be sure the T-handle on the nitrogen pressure gauge is unthreaded (at the out position). Warning: If gas pressure is higher than 2100 psi (14480 kPa), you may have a faulty accumulator port valve spring. Call your Cedarapids Service person. Dangerously high gas/fluid pressures can concentrate in faulty accumulators. They are pressurecontainment vessels which can remain dangerous even when detached from the Rollercone. Do not attempt repair to accumulators without proper training. Cedarapids does not manufacture accumulators. Cedarapids does not recommend repairs of any kind to the "flat top" Hydrogen accumulators. Replace these with Bosch accumulators. If gas pressure is too low, record the pressure. Then back the T-handle off (unthread it) and remove the nitrogen gas pressure gauge slowly. 11) Check all accumulators as described in steps 1 through 10 before recharging any one accumulator. Charging Tramp Iron Relief System
elbow ferrule nut
relief valve
Figure 10-16
12) Do steps 1 through 11 to determine current gas pressure in each accumulator before charging any single accumulator. To increase the gas precharge, use an appropriate charging device, or part #02-360-547-0000 (Figure 10-17). First connect the charging device to a full nitrogen bottle, then connect to the nitrogen charging valve at the accumulator. Note: Use nitrogen bottles with the highest pressure available. It may take several nitrogen bottles to fully charge one accumulator. If your crushing operation is located far from nitrogen supply sources, it may save time to acquire extra fullypressurized nitrogen bottles.
9) Remove the nitrogen gas charging valve cap. (On some accumulators this cap is threaded.) Thread the pressure gauge onto the nitrogen gas charging valve. 10) Slowly tighten the T-handle until needle on gauge stops rising. Record this pressure reading. It should be 1800 to 2100 psi (12411 kPa to 14480 kPa).
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nitrogen gas hydraulic fluid/oil port bottle relief cylinder relief system manifold
Warning: Before charging fluid pressure, follow the steps for checking and recharging nitrogen gas precharge pressure to proper levels. 17) Remove (unthread) the 1/4" line from the accumulator relief valve. Install the quick coupler. Connect line A (top hose) from the electric hydraulic adjusting pump to the quick coupler. Move the 3-way control valve handle on the pump to the A position away from the hoses. Start the pump. 18) Open the manifold air bleeder valves and bleed all air from the relief system. Once clear oil (without bubbles) runs from the bleeders, stop the pump and close the bleeder valves. Caution: Keep pump reservoir full of oil. An empty reservoir could damage your pump. 19) Start the pump. With the bleeder valves closed and air bled from the system, pressure should rise slowly. Watch the pressure gauge carefully. Fluid pressure rises steadily until it equals nitrogen gas precharge pressure. At this point the needle on the oil pressure gauge appears to stop rising, but system pressure is continuing to increase. But it does so very slowly. Keep the pump going and keep watching the gauge carefully until 2600 psi (17927 kPa) is reached. The gauge needle moves very slowly. 20) At 2600 psi (17927 kPa) in the relief system, stop the pump. Close the relief valve gently. Move the pump control handle to the B position (toward the hoses). Disconnect the quick couplers to remove the hose. Remove the quick coupler from the relief valve and reinstall the pipe plug. Secure the electric hydraulic pump.
relief cylinder beam Charging Gauge Assembly 02-360-547-0000 nitrogen gas charging valve
Figure 10-17
13) Slowly thread in the T-handle on the charging device. As you thread in the T-handle, it opens the nitrogen valve on the accumulator. If hydraulic fluid pressure has been drained and reduced to equal to or less than gas pressure, the gauge reads the accumulator gas precharge when the valve is fully opened. 14) Open the valve on the nitrogen bottle. Gas pressure should begin to rise. Allow 2 or 3 minutes for the pressure to stabilize before closing the valve on the nitrogen bottle. 15) Unthread the T-handle (turn out) to close the nitrogen valve on the accumulator. Slowly unthread the charging device from the accumulator. Repeat steps 13, 14, and 15 with fresh nitrogen bottles until you reach correct relief system pressure. 16) Once all accumulators have been checked and filled with the proper precharge, proceed with the following steps to recharge the relief system oil pressure.
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Section 10 Maintenance Bonnet Support The bonnet support skirt thickness can vary on new machines. It wears with use as rock passes through the crusher. New skirts are approximately 1-1/4" (32mm) thick when manufactured. Check bonnet skirt thickness at manganese changes. If you determine that the bonnet support skirt on RC54 or RC66 models has worn until only 3/4" to 1" (19 to 25mm) thickness remains, you can extend the life of the skirt by purchasing and installing bonnet support liner assembly kits 02-540-012-0080 or 02660-012-0080. If the skirt is worn to 1/2" (13mm) or less, replace the entire bonnet support. Replace the bonnet support and bonnet as a matched set. Cedarapids has an exchange program for most major castings. They can be purchased through your Cedarapids Distributor. Bonnet and bonnet support must be matched when either item is replaced. Usually, you can continue running until the exchange unit has arrived. Rotation Stops The oscillating crushing action of the Rollercone imparted by the rotation of the wedge plate results in a tendency of the bonnet to react in a counterclockwise direction. To prevent this motion Cedarapids has designed rotation stops.
cone mantle falling, crushed rock lower seal ring wear band wear plate pinion housing tunnel (part of base frame) pinion assembly
Figure 10-18 Wear Plate and Hard-Faced Surfaces Protect Structural Integrity
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Section 10 Maintenance Rotation stops can be damaged by allowing bowl float, sometimes called bonnet flotation. Do not allow bowl float during operation. Hard-Facing and Wear Components 1) The pinion housing tunnel is protected from abrasion with a piece of formed, abrasionresistant plate welded to the top of the tunnel. This plate must be built-up or replaced periodically to prevent serious erosion of the pinion housing tunnel, which is a structural part of the base frame. Caution: Do not allow hard-facing to wear away entirely. The wear plate and hardfaced surfaces protect the structural integrity of your crusher. See the unwanted pinion tunnel erosion (Figure 10-18). 2) The top edges of the struts and the upper inner edge of the base frame lower flange must also be maintained with hard-facing weld to prevent serious erosion on these important structural members. Inspect these parts each time bowl liners or counterweights are changed. As necessary, deposit hard-facing along top edges where passing rock frequently strikes. 3) At every manganese change closely inspect: all counterweights, especially the leading counterweight. Replace any counterweights that are worn. seal ring (labyrinth seal) wear band. Replace it when worn (Figure 10-18). the thickness of the bonnet support skirt. Measure and record the skirt thickness for comparison with the next manganese change. This will give you an idea of the wear rate of the bonnet support skirt. Adjusting V-Belt Tension 1) Check the drive belt tension daily. Check the condition of the belts and the drive sheaves. See Figure 10-19 to compare the condition of V-belts and sheaves.
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2) If the belts are worn, replace them with a matched set of belts. 3) Look for steps worn in the sheave grooves. Steps are a measure of sheave wear. Belts must not bottom out in the grooves. 4) If the sheaves are worn too much, replace them. 5) If belts are not tight enough, loosen the four mounting bolts of the drive motor. Adjust motor take-up bolts to tighten belts. Retighten the motor mounting bolts to hold the new tension on the belts.
worn belt or sheave proper fit
Figure 10-19
Standard Bolt and Nut Torque Specifications To prevent standard threaded bolts and nuts use on Cedarapids equipment from being overstressed when tightened, use the following torque chart. Follow these specifications unless other specific torques are given in a Cedarapids equipment manual. Cedarapids uses grades 2, 5 and 8. The maximum torque values are based on 75% of specified minimum proof strength of the bolt steel in order to provide a safety factor. The term Lube in the chart includes applying thread lubricants, cadmium plating, and the use of hardened washers.
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Steel Types Plain Low Carbon (SAE 1018 or 1020) Plain Medium Carbon (SAE 1035, 1038 & 1045) Medium Carbon Alloy (SAE 4140, 8642 & 5147)
Hardness Range Rockwell B 85-100 Rockwell C 19-30 Rockwell C 32-38
SAE Grades 2 5 8
SAE Bolt Head Symbols
Recommended Maximum Torque Values 5%

Size SAE Grade 2 inches Torque ft-lbs Clamp diameter- (newtonmeters) Load threads/in. Dry Lube lbs (kg)
4-20 5 (7) 4 (5) 1310 (594) 4-28 6 (8) 5 (7) 1500 (680) 5 16-18 11 (15) 9 (12) 2160 (980) 5 16-24 12 (16) 10 (14) 2390 (1084) 3 8-16 20 (27) 15 (20) 3190 (1447) 3 8-24 23 (31) 17 (23) 3620 (1642) 7 16-14 32 (43) 25 (34) 4380 (1987) 7 16-20 36 (49) 27 (37) 4890 (2218) 1 2-13 49 (66) 38 (52) 5850 (2653) 1 2-20 55 (75) 42 (57) 6590 (2989) 9 16-12 70 (95) 54 (73) 7500 (3402) 9 16-18 79 (107) 60 (81) 8370 (3797) 5 8-11 97 (132) 75 (102) 9320 (4228) 5 8-18 110 (149) 85 (115) 10560 (4790) 3 4-10 170 (231) 130 (176) 13700 (6214) 3 4-16 190 (258) 145 (197) 15380 (6976) 7 8-9 165 (224) 125 (170) 11430 (5185) 7 8-14 180 (244) 140 (190) 12590 (5711) 1-8 245 (332) 190 (258) 14990 (6800) 1-14 270 (366) 210 (285) 16900 (7666) 1 18-7 350 (475) 270 (366) 18880 (8564) 1 18-12 395 (536) 305 (414) 21180 (9607) 1 14-7 495 (671) 380 (515) 23980 (10877) 1 14-12 550 (746) 425 (576) 26550 (12043) 1 38-6 655 (888) 500 (678) 28580 (12964) 1 38-12 745 (1010) 570 (773) 32540 (14760) 1 12-6 865 (1173) 665 (902) 34770 (15772) 1 12-12 975 (1322) 750 (1017) 39120 (17745) 1 34-5 1370 (1858 1055 (1430) 47020 (21328) 2-4 12 2060 (2793) 1585 (2149) 61870 (28064)
1 1
SAE Grade 5 Torque ft-lbs Clamp (newtonmeters) Load Dry Lube lbs (kg)
8 (11) 10 (14) 17 (23) 19 (26) 31 (42) 35 (47) 49 (66) 55 (75) 75 (102) 85 (115) 109 (148) 121 (164) 150 (203) 170 (231) 265 (359) 295 (400) 425 (576) 470 (637) 640 (868) 700 (949) 790 (1071) 890 (1207) 1120 (1519) 1240 (1681) 1465 (1987) 1670 (2265) 1945 (2637) 2190 (2970) 2285 (3098) 3435 (4658)
SAE Grade 8 Torque ft-lbs Clamp (newtonmeters) Load Dry Lube lbs (kg)
9 (12) 2860 (1297) 11 (15) 3270 (1483) 19 (26) 4710 (2136) 21 (28) 5220 (2368) 34 (46) 6970 (3162) 38 (52) 7900 (3583) 54 (73) 9560 (4336) 60 (81) 10680 (4844) 82 (111) 12770 (5792) 92 (125) 14390 (6527) 115 (156) 16380 (7430) 130 (176) 18270 (8287) 160 (217) 20340 (9226) 180 (244) 23040 (10451) 285 (386) 30060 (13635) 320 (434) 33570 (15227) 465 (631) 41580 (18861) 510 (692) 45810 (20779) 695 (942) 54540 (24739) 765 (1037) 59670 (27066) 990 (1342) 68670 (31149) 1110 (1505) 77040 (34945) 1395 (1892) 87210 (39558) 1545 (2095) 96570 (43804) 1830 (2481) 103950 (47152) 2085 (2827) 118350 (53684) 2430 (3295) 126450 (57358) 2735 (3709) 142290 (64543) 3835 (5200) 170990 (77561) 5765 (7817) 225000 (102060)
6 (8) 2020 (916) 12 (16) 7 (9) 2320 (1052) 14 (19) 13 (18) 3340 (1515) 24 (33) 15 (20) 3690 (1674) 27 (37) 24 (33) 4940 (2241) 44 (60) 27 (37) 5590 (2536) 49 (66) 38 (52) 6770 (3071) 70 (95) 42 (57) 7560 (3429) 78 (106) 58 (79) 9040 (4101) 106 (144) 65 (88) 10190 (4622) 120 (163) 84 (114) 11600 (5262) 150 (203) 93 (126) 12940 (5870) 170 (231) 115 (156) 14400 (6532) 210 (285) 130 (176) 16320 (7403) 240 (325) 200 (271) 21290 (9657) 375 (509) 225 (305) 23770 (10782) 415 (563) 330 (447) 29450 (13359) 605 (820) 360 (488) 32440 (14715) 665 (902) 495 (671) 38630 (17523) 905 (1227) 540 (732) 42260 (19169) 990 (1342) 610 (827) 42340 (19205) 1285 (1742) 685 (929) 47500 (21546) 1440 (1953) 860 (1166) 53770 (24390) 1815 (2461) 950 (1288) 59550 (27012) 2010 (2726) 1130 (1532) 64100 (29076) 2380 (3227) 1285 (1742) 72980 (33104) 2710 (3675) 1495 (2027) 77970 (35367) 3160 (4285) 1685 (2285) 87740 (39799) 3555 (4821) 1755 (2380) 78370 (35549) 4985 (6760) 2640 (3580) 103120 (46775) 7500 (10170)
Figure 10-20
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Section 11 Changing Manganese The Rollercones two main wear parts contact the rock during crushing. These are the bowl liner and the cone mantle. Both are cast of special manganese alloys to be highly wear- and abrasion-resistant. Both are available in several configurations to meet different crushing needs. Many different factors affect the performance and wear life of the manganese. The characteristics of the rock itself are critical, but so are the site conditions and knowledge and experience of operators. The shape of the castings, the quality of the metal alloys, the skill with which the mantle and bowl liner were installed, and such factors as feed speeds and volumes, as well as placement of feed hoppers, amount of fines, moisture content, ambient temperature, and other factors all can make observable differences that affect the bottom dollar of your crushing site. This manual does not discuss these factors in detail. Particular applications of manganese liners and mantles must be discussed with your Cedarapids Distributor or call the Service Department of Cedarapids at (319) 363-3511. In all Rollercones you must remove the upper assembly to change manganese. Removing the Upper Assembly Tools Needed electric hydraulic adjusting pump
3
/4" end wrench or adjustable wrench
adjusting bolt wrench supplied with the crusher 2 equal-length cables 2 equal shackles 1) To obtain the necessary clearance for lifting the upper assembly clear of the lower assembly, remove any obstructions, such as feed conveyor, discharge lip, or feed box. See Figure 11-1 and the installation drawings in Section 7.
hopper
hopper gusset
upper assembly
Figure 11-1
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Section 11 Changing Manganese 2) Remove the crushers feed hopper retaining bolts and lift the hopper clear by attaching a lifting device to the two holes in the hopper gussets (Figure 11-2).
holes for lifting hopper
closing relief valve at one (1) gallon accumulator
pump valve in position A (away from hoses)
Figure 11-4
Figure 11-2
3. Lower the shim guard and connect the electric hydraulic pump to the quick couplers at the clamp cylinder relief valve and adjusting jack manifold block as shown in Figure 11-3. Be sure hose A connects to the clamp cylinder relief valve and hose B to the adjusting jack manifold relief block.
Note: When connecting the electric hydraulic pump hoses to the quick couplers, be certain to clean the hose tip and check the quick couplers for dirt or other obstructions. Be sure threads are clean and in good condition. Before starting pump, be sure the threaded fittings at the coupler are threaded fully and couplers are tight. 4) With pump valve in the A position, close relief valve at the one gallon accumulator (Figure 11-4). Then open the clamp cylinder valve.
no brass shows
position B
Figure 11-5
5) Move the pump valve from position A to position B to relieve the pressure on the clamp cylinders (Figure 11-5).
Figure 11-3
6) Turn pump on to pressurize the jack cylinders and raise the upper assembly (Figure 11-6). Note that the clamp cylinders are fully compressed with no brass sleeve showing. A gap is now at the top of the lower shim stack.
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Section 11 Changing Manganese To this point the same procedure is used to readjust the closed side setting. bolts in the lower assembly while lifting the upper assembly clear. Method A takes longer but makes cleaning the clamp ring easier. Removing Upper Assembly by Method A: Adjusting Bolts Remain with Upper Assembly These instructions assume you have already completed steps 1-8 above. 1) Raise the shim guard. Remove twelve 1/2" set screws from the lower block in the cut out windows of the base frame (Figure 11-7). Note: Each set screw threads into a block that is matched and number stamped at the factory. It is important to keep the adjusting bolt and its block together as a matched set. The sets are numbered counterclockwise, 1 through 12 beginning over the pinion as you face the crusher.
Figure 11-6
Warning: Danger! The next step quickly drops the upper assembly down on shims. Be sure all hands and tools are clear! 7) Move the pump handle to the A position. This relieves pressure to the jack cylinders, allowing the upper assembly to fall onto the shim stacks and relieving pressure from the upper shim stacks and adjusting bolts. 8) Keeping each stack separate, remove the shims and place them aside. Keeping the shims in stacks makes later reassembly easier. At this point in removing the upper assembly, you have a choice between two procedures. Pressure has been relieved from the adjusting bolts, but they still prevent you from lifting the upper assembly free of the lower. Method A describes removing the adjusting bolts from the adjusting bolt blocks. This results in lifting the adjusting bolts free of the lower assembly with the upper assembly. Method B describes removing the nuts at the top of each bolt. This method results in leaving adjusting
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Figure 11-7
2) Unthread the adjusting bolts from their blocks. This may require considerable torque (Figure 11-8). 3) Lift the adjusting bolts slightly and tie them to the upper assembly relief cylinder beams with mechanics wire. 4) Make a reference mark across the seam at the joining of the bonnet support and base frame to make alignment easier during reassembly.
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Section 11 Changing Manganese

mechanics wire
Removing Upper Assembly by Method B: Adjusting Bolts Remain with Lower Assembly 1) Loosen set screws in jam nuts (Figure 11-9). Remove jam nuts and adjuster-bolt nuts. wrench. Notice spherical seats on adjusterbolt nuts. 2) Remove upper washers (with spherical seats), upper shim stacks, and lower washers. Notice O-ring seals. 3) Make a reference mark as described in step 4, Method A. 4) Attach lifting tackle to eyes on bonnet.
Figure 11-8
5) Attach shackles and cables to the two lifting ears welded to the bonnet. 6) See the Components Weight Chart, Section 7. With a properly rated lifting device, raise the upper assembly. Sometimes it can be helpful to pressurize the adjusting jacks, as described above in Steps 5 and 6. Be sure to stop and disconnect the quick couplers from the upper assembly before lifting any farther. 7) Slowly lift the upper assembly. Be sure to lift high enough to clear the lower (cone) assembly before swinging the upper assembly. Set assembly carefully down.
5) See the Components Weight Chart in Section 7. Lift slowly with a properly rated lifting device. Sometimes it can be helpful to pressurize the adjusting jacks, as described above in Steps 5 and 6. Be sure the quick couplers are disconnected from the bonnet. 6) Raise upper assembly until it is high enough to clear both cone head and adjusting bolts. Then swing it aside. Changing Manganese Bowl Liners on RC36, RC45, and RC54 Models 1) Loosen bowl-wedge stops 1/2" (13mm) and partly back wedges out during last half hour of operation before shutting down for manganese change. Crushing for a few minutes with wedges loose usually makes liner removal easier (Figure 11-10). 2) Remove bowl-wedge stops, and then remove wedges. If liner does not drop, drive it down with a steel bar and sledge hammer. Drive on upper edge of liner. Do not drive or hammer on loop eyes. They can bulge open and make liner removal even more difficult. If liner is very difficult to remove, use a manganese press to push liner out (Figure 11-11).
Figure 11-9
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Section 11 Changing Manganese Installing Bowl Liners on Models RC36, RC45, RC54
bowl liner loop bowl wedge
2) Wrap new liner loops with tape (Figure 1112). Be sure liner seat is clean and smooth. 3) Place upper assembly over the new bowl liner and raise the liner into place. Placing a steel ring or beam larger than the feed opening of the liner cross-ways in the liner is a handy way to attach a lifting line. 4) Insert the wedges with the matching halfround shoes properly placed in the curve of the liner loop. Tap the wedges lightly to hold liner while adjusting (Figure 11-10). 5) Center the liner on its seat by measuring the margin between the machined surface at the top of the liner and the machined inner bore at the top of the bonnet (bowl). Make this margin even all around. Center the loop eyes in their bonnet openings as much as possible. When the liner is centered, drive the wedges tight by striking them alternately so they tighten up evenly. Use a long, heavy bar as a punch to reach into the upper assembly so you can have room to swing a heavy hammer. When the wedges are tight enough, the bar (not the hammer) will bounce back. 6) On Standard Head crushers push paper wadding or oakum into the liner loop eyes to prevent plastic backing material from rising too high into the sockets around the loops. Do not allow the backing material to rise more than two inches into the loop eyes of the bonnet. If the liquid oozes into the loop eyes, it makes future removal of the bowl liner very difficult. 7) If you are changing the cone mantle at the same time, to minimize waste do not pour liquid plastic backing into the liner until the cone mantle is also ready. When both liner and mantle are ready, pour the liquid plastic in one place until you can see plastic rising around the liner. Then proceed to pour around the liner lip in one direction only, being sure to fill
LJ0190100-1
bonnet
bowl wedge stop
bowl wedge stop bolt bonnet support Figure 11-10 lifting device
hydraulic jack bonnet lip bowl liner loop Figure 11-11 One Type of Manganese Press
1) When the older liner is removed, clean all the remnants of plastic backing from the inside of the bonnet. Be sure the seat surface at the lower edge of the bonnet is clean and smooth. Lightly grease the interior of the bonnet, except the seat.
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Section 11 Changing Manganese 2) Remove the jam nuts from the liner eye bolts (Figure 11-13). 3) 180 apart from each other, remove two spherical-seat nuts, their spherical-seat washers, and the washer stacks from these two bolts. Replace the spherical-seat washers and nuts at least five threads onto the eye bolts. This provides safety against accidentally dropping the bowl liner unexpectedly. 4) Remove the remaining spherical-seat nuts, washers, and washer stacks.
jam nut liner eye bolt Figure 11-12 steel washer plastic washer spherical seat nut spherical seat washer washer stack
masking tape
completely as you go. This method will insure a good solid pour without air pockets. Warning: Be sure to wear protective goggles when mixing or pouring plastic backing material. If it enters the eyes, it can be very harmful. 8) If pouring during cold weather, bring the crusher inside or warm the parts to approximately 60F (16C) before pouring. Cold weather can prevent the plastic from hardening properly. 9) Pour the mantle before pouring the liner so you can better control the amount of plastic that needs to be mixed to complete the job. 10) Plastic is available in containers of 11 lbs (5kg), 22 lbs (10kg), and 33 lbs (15kg). It is good practice to have at least one extra 11 lbs container on hand to help minimize waste. Changing Bowl Liner on RC66 and RC60 Models 1) Remove the upper assembly and set it on blocks.
bonnet
Figure 11-13
5) Use manganese press shown (Figure 11-14). 6) Bolt the manganese press to two lifting eyes 180 apart on the bonnet. 7) Place the hydraulic jack as shown. Use at least a 30-ton (27 tonnes) hydraulic jack to press down on the liners upper edge. 8) Move the jack to the other end of the press. Repeat the downward pressure. 9) Release the pressure and turn the manganese press 90 around the bonnet to the other side of the liner. Repeat steps 7 and 8. 10) When the bowl liner is loose, it will fall against the two bolts which still have nuts attached for
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1/2" (13mm) plate 2" (51mm) 3/8" (10mm) reinforcing plates 10" (254mm) to 12" (305mm) I-beam length varies to match your hydraulic jack
8" (203mm) of flange removed 4" (102mm)
3/8" (10mm) reinforcing plate
end view
side view
A B C
eye bolt with nuts removed hydraulic jack pushes on inner lip of liner
bonnet lifting eye
bonnet
bowl liner
model RC60 RC66
dimension A 68" (1727mm) 74-3/4" (1899mm)
B 62" (1575mm) 66-3/4" (1695mm)
C 3" (76mm) 4" (102mm)
Figure 11-14 Manganese Press Design for RC66 and RC60 Models
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Section 11 Changing Manganese safety. Carefully lower the bowl liner to the ground. 11) Install new liner as described below. Installing Bowl Liner in RC66 & RC60 1) Clean the replacement liner carefully. Use solvent or scraper to remove the protective anti-rust coating from the seat area. Wash the seat area with solvent and make sure the seat area is smooth. 2) Check the hole sizes of all ears, bolts, and pins to be sure they will fit easily. Grind or file as necessary to fit. RC66 uses eye bolts. RC60 has clevis bolts. 3) Grease the area on RC66 where eye bolt and pins fit between the parallel lifting loops on the liner. 4) Grease the pins and eye (or clevis) bolts all the way up to the threads. Insert the pins through the liner loops and the bolts. Center the pins. 5) Use thin foam strips on the RC66 to position eye bolts in the center between both liner ears. Wrap foam around the pins between the eye bolt and the ear on each side of the bolt. Use wide foam strips to fill up the pocket between the liner loops. It takes 5 to 7 strips to do this step. This foam provides enough friction to hold the pin centered and helps hold the bolt upright until placed into the bonnet (Figure 1115 and 11-16). 6) For some bowl liners aluminum filler blocks are needed. If filler blocks are used, grease the blocks and position them on the liner as needed. 7) Wrap the loops and clevis bolts of the RC60 with tape and grease the tape surfaces. Cut foam blocks to fit in the bonnet pockets. Blocks cut to 10" to 12" (254 to 305 mm) wide by 14"
Liner Seat Ear Pocket Foam Strips Eye Bolt Bowl Liner
Foam Block
Figure 11-15 RC66 Eye Bolt with Foam Packing in Liner Ears and Greased Surfaces
clevis bolt, no grease on threads
foam block set in place
tape covers clevis, pin and bowl-liner eye liner seat, clean, no grease here
manganese bowl-liner eye
Figure 11-16 RC60 Clevis Bolt with Grease Foam and Tape Packing Around Liner Loop Eye
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Section 11 Changing Manganese (356 mm) long fit well in the pockets. Cut hole in foam blocks to fit over eye bolts. Slip foam blocks down over eye bolts. Note: The careful placement of the foam strips and blocks is very important to prevent plastic filler material from locking the bowl liner in place. If the liquid plastic oozes into blocked areas before it hardens, the bowl liner can be much more difficult to remove at the next manganese change. 8) Check the liner seat on the bonnet to make sure it is smooth and clean. It should mate smoothly with the seat on the bowl liner. 9) Grease the inside of the bonnet from the top of the liner seat area to the top of the bonnet. Be sure to include the area of the loop pockets. 10) Set the upper assembly over the bowl liner. Lift the bowl liner into the bonnet. Watch the foam blocks to keep them square with the pockets and the bolts to keep them centered and straight upright. Center liner in the bonnet. 11) Use the adjusting shims you removed from the upper assembly as spacers to pull up all bolts and to seat the liner solidly against the bonnet (Figure 11-17). Stack the shims about 2" (50 mm) high with the spherical-seat washers on top of the shims. Turn the spherical-seat nuts onto the eye bolts to pull the liner evenly upwards. Move from bolt to bolt as you pull the bowl liner up into its place, centered and seated against the bonnet. 12) When the bowl liner seats against the bonnet, use the star rotation method to torque each nut to 500 ft-lbs (678 N.m). 13) When all bolts have been torqued to 500 ft-lbs (678 N.m), loosen one at a time and replace the shim stacks with the washer stack. Alternate the four metal washers with the three plastic
bowl liner not seated Figure 11-17
washers, beginning and ending with metal washers. Place the spherical-seat washer on top of the washer stack. Add the spherical-seat nut and torque to 500 ft-lbs (678 N.m). 14) When all nuts are re-torqued to 500 ft-lbs (678 N.m), install the jam nuts and torque them to 500 ft-lbs. Warning: Wear protective goggles when mixing or pouring plastic backing material. If it enters the eyes, it can be very harmful.
not seated bonnet
15) If you are changing liner and mantle, wait until both are ready to pour before mixing plastic backing material. If you are changing only the liner or have completed the change of both, mix and pour the plastic backing material as described in the section above on installing bowl liners in RC36, RC45, and RC54 models. Changing Cone Mantle on Standard Head Crushers 1) Do not remove the cone head from the crusher. Change the mantle with the cone head in place to prevent the entry of dirt and possible damage to bearings and floating plate. If the cone head
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Section 11 Changing Manganese is lifted off the base frame, consult the Rollercone Service Manual or your Cedarapids service representative for proper alignment for installation. 2) Remove the mantle nut protector cap. 3) Top view of a standard cone with the mantle nut cap removed (Figure 11-18). 4) Drill out the 3/8" or 1/2" (10 or 13 mm) steel dowel which locks the nut to the washer. This dowel is centered on joint line between nut and washer and is parallel to the slope of the nut. 5) Insert the mantle nut wrench and secure it with a bolt screwed into the mantle nut protector cap retaining bolt hole. 6) Use a heavy sledge hammer to turn nut clockwise.
mantle nut steel dowel
while you are loosening the mantle nut. 8) If the mantle nut will not come loose, you may cut the manganese mantle adjacent to the washer, or you may cut the washer with an oxyacetylene torch. Be sure to cut straight down, perpendicular to the top of the mantle. See Figures 11-19 and 11-20, showing cutting a mantle washer for mantle removal. If ArcAir is used, be sure to electrically ground directly to the mantle. Be very careful to avoid cutting gouges in the mantle hold down nut. The nut should now be free. If it is not free, lift the mantle off the nut as described in paragraphs 9 and 10. Squirt penetrating oil sideways through the mantle nut cap retaining bolt hole in the hold down nut into the mantle bolt threads; soak oil between the nut and cone until the parts loosen.
mantle washer mantle nut mantle
mantle nut protector cap (removed)
mantle washer
mantle nut cap retaining bolt hole mantle Figure 11-18
retaining lug
standard cone mantle bolt
mantle nut cap retaining bolt hole
Caution: Threads are left hand. 7) If the cone head turns too freely, wedge a piece of bar stock between a cone strut and the inside of base frame to prevent the cone from turning
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Figure 11-19 Standard Head Models RC36, RC45, RC54, RC66
LJ0190100-1
A Terex Company

mantle nut protector cap (removed) mantle nut mantle oxyacetylene torch cutting mantle nut washer
into these depressions and making the next mantle change more difficult (Figure 11-21). 12) Knock the lifting eyes off the old mantle and weld to the new mantle. 13) Turn the new mantle up on its side and thoroughly clean all paint and other irregularities from the seat surface.
silicone sealent RC60 std cone adapter
standard head cone adapter
sponge rubber
fill flush
Figure 11-20 Standard Head Configuration of RC60
Warning: Never use low hydrogen or other mild steel rods or hard face rods. Even when the lifting eyes have been welded on with the best alloy, do not trust the welds more than is absolutely necessary. Handle with extreme caution! Welds break out of manganese very easily. 9) Cut two lifting eyes from /8" (10 mm) mild steel plate and weld 180 apart in the upper third of the mantle. Use a nickel manganese welding rod such as McKay Hardalloy 118, or equivalent. 10) Lift the old mantle slightly. If is does not lift free, rap with a sledge hammer. Lift free and discard. 11) Thoroughly clean old backing material off cone head. Make sure to clean the seat surface until it is smooth. Coat the part of the cone head that will be in contact with backing material with a thin film of grease. Do not grease the seat. On RC60 locate the countersunk holes in the standard cone adaptor where bolts hold the adaptor to the cone head. Fill these holes flush to the top with silicone sealant to prevent plastic backing material from locking
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3
bolts holding cone adapter to cone Figure 11-21
14) Fit the washer into the top of the mantle. It is sometimes necessary to enlarge the smaller notch in the top of the mantle with an oxyacetylene torch so the lug on the side of the washer will fit. 15) If necessary, cut the other notch in the top of the mantle to about 1" (25 mm) diameter to make it easier to pour plastic backing material. 16) Set the mantle on the cone head and bump the mantle with a sledge hammer to center the seating area. When properly seated, the washer sits flush and even all around. Also center by checking that the margin around cone head mantle seat is even. 17) Center large, sponge-rubber, donut washer under mantle washer to prevent backing material from contacting mantle hold down nut.
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Section 11 Changing Manganese 18) Be sure to replace the mantle nut seal (O-ring) in the top bore of the cone head. This is to prevent dust from packing in around the mantle bolt. 19) Lubricate the threads and seating angle of the mantle hold down nut with anti-seize lubricant and turn it as tight as possible with the mantle nut wrench. 20) Center a 1/2" (13mm) drill on the joint line between the nut and washer and drill a hole, 1" (25 mm) deep, parallel to the seat angle of the nut. Drive in a 1/2" x 1" (13 x 25 mm) steel dowel. 21) Build a pouring spout around the 1" (25 mm) pour notch in the top of the mantle. Clay or commercial Damtite work well for the spout. 22) Mix and pour the plastic backing in the mantle first. Pour the excess into the bowl liner and complete pouring the liner. Tapping the mantle around its perimeter with a hammer helps make the backing settle and speeds pouring. A good solid pour with no air bubbles or voids is desirable. 23) Replace the mantle nut protector. 24) On RC36 Standard Rollercone crushers, it is very important to keep the mantle nut and the mantle nut protector cap built-up and protected with hard-facing rod. Caution: If this is not diligently maintained, it is possible that the entire top of the mantle will erode away. This would cause the loss of the hold down washer, and the mantle to be loose. Changing Cone Mantle On the RC66, RC60, and RC54 Fine Head Use same procedure as for standard cone to lift off upper assembly. See the Fine Head cross-sections in Figure 3-2 and the top view of the Fine Head shown in Figure 11-22.
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1) Remove the hex bolts holding the distributor plate to the nut. Remove the distributor plate and set it aside. 2) Remove the hardened block driving lug. 3) Using a torque multiplier and a 2-1/4" socket, gradually loosen the Grade 8 bolts which hold the mantle bolt to the cone head. See Figure 11-23 for various hold down systems used on RC54 and RC66 and Figure 11-24 for RC60.
distributor plate bolts slot cut in mantle
driving lug bolt
hardened block driving lug Figure 11-22
Substantial pressure will have built up in the thread system, so use caution when loosening the bolts to release the pressure slowly. The bolts should not have to be backed out more than one to two turns. 4) Once the pressure on the threads has been released, attach the mantle nut wrench to the nut and drive clockwise to remove the nut. This is a left-hand thread. The nut can now be lifted from the assembly. It is not necessary to remove the bolt from the cone head. Warning: Never use low hydrogen or other mild steel rods or hardface rods. Even when the lift eyes have been welded on with the best alloy, do not trust the welds more than is absolutely necessary. Handle with caution! Welds break out of manganese easily.
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mantle bolt distributor plate mantle nut mantle washer mantle bolt distributor plate mantle nut mantle mantle bolt distributor plate mantle nut mantle
mantle
o-ring plastic backing material RC54 before 1985 Figure 11-23 distributor plate mantle bolt mantle nut mantle sponge rubber plastic backing material RC54 and RC66 plastic backing material 1989 to current, RC66
8) Thoroughly clean and smooth the seat surface of the new mantle. Check to insure the pour hole for the backing is big enough. 9) Place mantle on cone head and center. 10) Press sponge rubber under the inner rim of the mantle. This sponge rubber must seal 360 around to keep the liquid backing material from entering the inner cavity and decreasing the space needed for the self-tightening feature of the mantle hold down system (Figures 1124 and 11-25). 11) Re-install the mantle bolt if it was removed.
filler block plastic backing material Figure 11-24 RC60 Mantle Hold Down System
sponge rubber
5) Cut two lifting ears from 3/8" (10 mm) mild steel plate and weld 180apart to the upper third of the mantle. Use McKay Hardalloy 118 or equivalent nickel manganese welding rod. 6) Lift old manganese off the cone head. 7) Clean the cone head of all dust and old backing material and spread a thin film of grease over cone surface. Do not grease the seat surface. If you are converting an RC60 Fine Head to a Standard, be sure to read the separate steps at the end of this section.
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Figure 11-25
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Section 11 Changing Manganese Apply anti-seize lubricant to the mantle bolt threads and to the threads of the Grade 8 bolts and torque to 1300 ft-lbs (1763 N.m). 12) Apply anti-seize lubricant to the mantle hold down nut threads and to the contact area between the mantle nut and the seat area on the mantle. Spin the nut onto the bolt until it comes in contact with the mantle. Bolt on the mantle nut wrench and drive it counterclockwise till the point of refusal. This is very tight. 13) Notice the location of the milled notch for the driving lug. Using a marker transfer the location to the mantle. With a small tip on an oxyacetylene torch, burn a corresponding notch in the mantle so the lug will sit flush in the milled notch of the nut and flush in the burned mantle (Figure 11-26). Changing Cone Mantle on RC45, RC36 Fine Head Use the same procedure as for standard cones to lift off the upper assembly. 1) Remove the distributor plate. See the illustration showing Fine Head cones on RC45 and RC36 models (Figure 11-27). 2) Pull gasket and felt strips and save for reuse. 3) Use a small scarfing tip on an oxyacetylene torch to remove the locking lugs from between the nut and the washer. With care in removal, these may be saved for reuse. 4) Attach mantle nut wrench to nut and sledge clockwise with a heavy hammer to remove. Caution: This is a left-hand thread.
distributor plate nut split ring
torch ring locking lug mantle washer
burn locking lug notch(es)
Figure 11-26
14) Place 1/4" (6 mm) O-ring stock in machined groove in top side of nut. This seal keeps dust and water from entering the internal cavity. 15) Install the distributor plate on the nut and secure it with 3/4" x 1" hex bolts. Warning: Always use protective goggles while mixing or pouring plastic backing. 16) Make a pour spout of Damtite or other soft clay-like substance and pour in the backing material. Rap around the mantle with a hammer to aid in setting the backing material.
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sponge rubber mantle Figure 11-27 cone
5) If the nut cannot be loosened, torch cut torch ring with a cutting tip having a 1/8" (3 mm) kerf. Tilt the torch 5 so the cutting stream will not cut the shoulder of the washer. Cut a full 360 around the torch ring. Use minimum pre-heat flame to avoid cutting into the cone head. 6) Washer can now be lifted over nut and removed.
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Section 11 Changing Manganese Warning: Never use low hydrogen or other mild steel rods or hard face rods. Even when the lift eyes have been welded on with the best alloy, do not trust the welds more than is absolutely necessary. Handle with extreme caution! Welds break out of manganese very easily. 7) Cut two lifting ears from 3/8" (10 mm) mild steel and weld 180 apart to the upper third of the mantle. Use McKay Hardalloy 118 or equivalent nickel manganese welding rod. 8) Lift old manganese off the cone head. 9) The nut should now unscrew. If dust is packed tightly under the nut, scrape it away and the nut will then unscrew. 10) Clean the cone head of all dust and old backing material. Spread a thin film of grease over the cone surface, but not in the space between the washer shoulder recess and the threaded split ring. This must be kept dry so any dust entering this cavity will filter out through the vent holes. Grease would cake the dust and plug the vent holes. Do not grease the seat surface. 11) Thoroughly clean and smooth the seat surface of the new mantle. 12) Gently press sponge rubber around and under the inner rim of the mantle and flush with its inner edge. Leave a gap for pouring of backing material. This sponge rubber permits compressibility to provide for the downward travel of the mantle during self-tightening. 13) Fit the washer to the new mantle. You may need to cut a notch in the mantle with an oxyacetylene torch so the lug in the washer fits. Trim the pour hole to about 1" (25 mm) diameter. 14) Place mantle on cone head and center until the washer seats properly. 15) If it was necessary to cut the torch ring, remove the remnants of the old one and replace with a new one. 16) Apply an anti-seize lubricant to the threads and thrust surfaces of the mantle hold down nut. Put anti-seize lubricant on the split ring threads and turn them clockwise by hand until well-started. Attach the wrench assembly and torque to the point of refusal with a sledge hammer. This is very tight. In these conditions the wrench will not move further and the hammer rebounds smartly when struck. Caution: When welding on the cone head, be sure to ground directly to the cone head to avoid any possibility of arcing through the bearings. 17) Replace the locking lugs between the nut and washer and weld to the washer only. Grind the welds flush. Lugs must no be above the top surface of the mantle nut. 18) Follow the directions for pouring backing material to be found in the instructions for changing mantles in standard head cones. 19) Replace the felt strips, the gasket, and the distributor plate.
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Section 11 Changing Manganese Plastic Backing Quantity Chart Following is a chart showing the pounds of plastic backing material required to pour a backing cushion into the relief area of the manganese in Rollercones. Casting and machining variations cause some differences in amounts of plastic backing needed. Plastic backing compound is available through Cedarapids Distributors in 11, 22, or 33 lbs (5, 10, 15 kg) buckets. Order at least one extra 11 lbs (5 kg) bucket.
Model STD
RC36
Installing the Upper Assembly 1) See the Component Weights Chart in Section 7. Lift the upper assembly with a properly rated lifting device. Center it above the lower assembly (crusher base). Slowly lower it, being careful to recenter it as needed. 2) Rotate the upper assembly to properly align it. Note: The upper assembly can be rotated to any of four positions. All four work properly. Be sure that the adjusting jacks align directly over the push pins. However, most installations are set up with enough clearance in only one or two of the available rotations, due to interference from other related equipment. The standard practice is to place the quick couplers to the right side of Rollercone as you face the pinion shaft. If you put the upper assembly down in a different position than it was, be sure to also move the adjusting bolt blocks and re-mark the windows to match the new position. When reinstalling the upper assembly follow the steps of Method A below if the adjusting bolts are in the upper assembly. Follow steps of Method B at right if the adjusting bolts are in the lower assembly. See also Removing Upper Assembly, methods A and B above. Method A: Installing the Upper Assembly with the Adjusting Bolts in the Upper Assembly 1) Slowly lower the upper assembly into lower assembly until bonnet support skirt starts about 1 /2" (13 mm) into base frame. 2) Cut wire which temporarily has been holding adjusting bolts to relief cylinder beams. Use the adjusting bolts as aligning pins to guide the upper assembly into its proper position. 3) Continue to lower until bonnet support skirt is about 4" (102 mm) into the base and stop.
Total lbs (kg) Coarse Fine Coarse 51 (23) 55 (25) 143 (65) 136 (62) 88 (40) 63 (29) 205 (93) 227 (103) 242 (110) 170 (77) 111 (50) 106 (48) 295 (134) 402 (182) 350 (159) 180 (82) 206 (93) 385 (175) 576 (261) 457 (207) 248 (112) 305 (138)
Liner lbs (kg) 29 (13) 26 (12) 94 (43) 87 (40) 66 (30) 33 (15) 113 (51) 135 (61) 150 (68) 82 (37) 72 (32) 55 (25) 181 (82) 287 (130) 235 (107) 111 (51) 131 (59) 248 (113) 439 (199) 320 (145) 149 (67) 206 (93)
Mantle lbs (kg) 22 (10) 29 (13) 49 (22) 49 (22) 22 (10) 30 (14) 92 (42) 92 (42) 92 (42) 88 (40) 39 (18) 51 (23) 114 (52) 115 (52) 115 (52) 69 (31) 75 (34) 137 (62) 137 (62) 137 (62) 99 (45) 99 (45)
FH STD
Med Fine
RC45
Fine FH Coarse Coarse Medium STD Med Fine

RC54
Enlarged Feed
Coarse FH Fine Coarse STD

RC60
Medium Med Fine Coarse
FH Fine Coarse STD

RC66
Medium Med Fine Coarse
FH Fine
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Section 11 Changing Manganese 4) Place the lower shim stack around each adjusting bolt between the base and bonnet support flange. 5) Continue to lower the upper assembly until it rests on the shims. Be sure that the adjusting jacks align directly over the push pins. Check the closed side setting and adjust it if necessary. 6) Lower the adjusting bolts until they contact the adjusting bolt blocks in the base frame windows. Thread the adjusting bolts into the blocks. 7) Light the blocks through the base frame windows with a flashlight to align the drilled, tapped hole in the block with the countersunk hole in the side of the adjusting bolt. 8) Install 1/2" set screw (also called set bolt) through the block and into the adjusting bolt. This locks the adjusting bolt to the block. Torque the set screw to 40-45 ft-lbs (54-61 N.m). 9) Replace the upper shim stacks. 10) Connect the electric hydraulic pump to the quick couplers as shown (Figure 11-28). 11) Pressurize the clamp cylinders to 1600 psi (11032 kPa). 12) Open the needle valve on the one gallon accumulator. 13) Recheck the pressure and re-adjust to 1600 psi (11032 kPa) as needed. 14) Raise one of the adjusting jack cylinders at least 2" (50 mm). This allows for thermal expansion and contraction. It also insures that any slight upward motion of the push pins, which may have occurred when the clamp cylinders were pressurized, did not repressurize the adjusting jacks. 15) Raise the shim guard and clamp it securely. Replace the hopper.
Figure 11-28
Method B: Installing the Upper Assembly with the Adjusting Bolts in the Lower Assembly 1) With the upper assembly hanging from a properly rated lifting device, and centered above the lower assembly, align the adjusting bolts with the clamp cylinders. 2) Slowly lower the upper assembly, until the bonnet support flange just touches the top of the adjusting bolts. Check each adjusting bolt carefully for alignment with a clamp cylinder above it. Use caution to prevent pushing clamp cylinder assemblies apart with the ends of the adjusting bolts. 3) Once all the bolts are started, continue lowering carefully, checking each adjusting bolt for alignment as the clamp cylinders pass downwards over the bolts. Stop when the bonnet skirt is about 3 to 4" (76 to 102 mm) into the base frame. 4) Place shim stacks around the adjusting bolts. 5) Lower the upper assembly until it rests on the shim stacks. Check the css (closed side setting) and adjust if needed.
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Section 11 Changing Manganese 6) Replace the O-ring in the lower adjusting bolt washers. Put anti-seize lubricant on spherical seats and bolt threads. Then place the washers over the adjusting bolts with the spherical side down towards the clamp cylinder. 7) Place the upper shim stack on the lower washer. The upper washer has no O-ring. Place the upper washer on the shim stack. Place it so the spherical seat faces upwards. 8) Put anti-seize lubricant on spherical surface of the upper washer and the adjusting bolt threads. 9) Replace the adjusting bolt nuts on the bolts with spherical surface down, matching the upward-facing spherical surface of the washers (Figure 11-29). Thread these nuts down until about four threads are exposed above the nuts. ring wrench) by turning the adjusting bolt nut up or down as needed to achieve 5/8" (16 mm) of brass showing at the seal for new or rebuilt clamp cylinders, 1/2" (13 mm) of brass showing for used clamp cylinders. Move from cylinder to cylinder until all have been adjusted. 12) Pressurize the clamp cylinders to 1600 psi (11032 kPa). Install the top, locking nut and tighten it with the spud wrench against the adjusting bolt nut. 13) Tighten the 1/2" allen set screw in top of locking nut to approximately 20 ft-lbs (27 N.m). 14) Raise the shim guard and clamp it securely. 15) Replace the hopper.
Figure 11-29
10) Connect the electric hydraulic pump to the quick couplers (Figure 11-30). Apply 100 psi (690 kPa) to the clamp cylinders. This lifts the clamp ring and puts a slight pressure on the adjusting bolts. While you are making adjustments, have someone maintain 100 psi (690 kPa) in the system. 11) Adjust the clamp cylinder height with the spud wrench (also called adjusting bolt wrench, and
21280 (3/97)
Figure 11-30
Adjusting Clamp Cylinder Travel 1) Thread all of the adjusting bolt nuts (with spherical seats) on to the adjusting bolts until they contact the adjusting bolt washers (these washers also have spherical seats). Do not confuse these nuts with the adjusting bolt jam nuts, which have welded caps and do not have spherical seats (Figure 11-29).
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Section 11 Changing Manganese 2) Using the electric hydraulic adjusting pump, connect the hose from port A to the clamp cylinder manifold valve. Connect the hose from port B to the adjusting jack manifold. 3) To raise the clamp ring and lock it, place the 3way control valve on the adjusting pump to the A position (away from the hoses). Turn on the pump to pressurize the system and read the
hydraulic fluid pressure 1600 psi (11032 kPa) nitrogen gas pressure 1000 psi (6895 kPa)
rising pressure on the gauge at the adjusting pump. Stop at 1600 psi (11032 kPa). Release the pressure by moving the 3-way control valve to the B position. 4) Place the control valve to the A position and pressurize again, but only to 100 psi (690kPa) this time. 5) Using the adjusting nut wrench, adjust each cylinder until 5/8" (16 mm) of brass is showing above the dust seal. 6) While you are making the adjustments, it is helpful to have a someone maintain 100 psi (690 kPa) in the system by turning on the pump.
accumulator relief valve one gallon accumulator clamp cylinder relief valve
adjusting jack manifold block
set screw locknut spherical seat adjusting nut spherical seat washer upper shim stack dust seal
approx. 5/8" (16 mm) brass showing bonnet support clamp cylinder
pressure hose line A
2" (50 mm)
ram lower shim stack
jog/off/run switch
return hose line B
Figure 11-31 Electric Hydraulic Pump Set Up on Adjusting Jack
position A adjusting pump
hold
position B
3-way control valve
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Page 11.19
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A Terex Company
Section 11 Changing Manganese 7) Move from cylinder to cylinder until all have been adjusted to 5/8" (16 mm). Once all are adjusted, pressurize them to 1600 psi (11032kPa). 8) Thread an adjusting bolt jam nut (with welded cap) on each adjusting bolt. Tighten with wrench. Install the set screws and tighten them. 9) Close the clamp cylinder valve. Open the one gallon accumulator valve. Remove the hoses, and secure the adjusting pump. Converting RC60 from Standard to Fine Head or Fine Head to Standard With manganese mantle removed, the RC60 can be converted easily from standard to fine head or back again. Adaptors bolt to the top of the cone head in either configuration. The fine head adaptor bolts into the same holes as the standard adaptor, but uses longer bolts. When converting to the standard head configuration from the fine head, be sure to fill the countersunk holes around the bolt heads with silicone sealant (Figure 11-21) to prevent plastic backing material from sticking to the bolt heads and making the next mantle change more difficult. To remove either adaptor, loosen the series of 1-1/2" bolts holding the adaptor to the cone. Before replacing either adaptor, blow out any debris from the tapped holes and remove any pooled oil to avoid hydraulic locking. Check for damaged threads. The RC60 cone head is machined with a recessed seating area to recieve either adaptor. Coat the seating area with anti-seize lubricant. Align the adaptor with the bolt holes in the cone head. Coat bolt threads with anti-sieze lubricant and torque with a 4:1 multiplier to 1300 ft-lbs (1763 N.m).
pour hole
Note that the fine head RC60 mantle also requires using filler blocks between the cone head and the mantle. Evenly space these filler blocks around the cone head surface (Figure 11-32). Place the mantle. Coat both male and female threads of the mantle hold down nut with anti-seize lubricant. Figure 11-33 shows a RC60 Fine Head Cone ready to install after torquing the adaptor bolts, installing the mantle, tightening the mantle nut, installing the locking lug, and pouring the plastic backing.
filler block fine head mantle nut adapter
Figure 11-32
mantle nut locking lug
Figure 11-33
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Section 12 Troubleshooting Vibrating Too Much 1) Check for missing or worn counterweight. Replace or repair. 2) Check pinion sheave and motor sheave for dirt build-up. Clean and balance sheaves. 3) Check crusher support, stanchions, or concrete pads for out-of-level or not being properly braced. Replace, repair or level as needed. Running Too Hot 1) Oil viscosity inadequate. Change to heavier grade. See Proper Oil Types, Section 5. 2) Inadequate oil flow. See Rollercone Service Manual or call Service Representative. 3) Excessive ambient temperature. (Very hot weather.) Use heavier grade oil. See Lubricant Section of this manual. 4) Bearing failure. See Rollercone Service Manual or call your Service Representative. Bowl Floating Caution: Bowl float causes excessive wear and premature failure of some components. Allowing bowl float voids the warranty. Bowl float is sometimes called bonnet flotation. It is very important that bowl float is not allowed on your Rollercone crusher. Check the crusher for bowl float after making any change in setting, feed material, or feed rate. Bowl float will cause pitting, metal transfer, and general wearing away of the bonnet and bonnet support seats. If it goes on too long, bowl float will cause the relief cylinder seals to leak. The end result will be costly repairs and downtime. Bowl float may not be visible without careful observation. You can detect it by looking for movement between the bonnet and bonnet support or between the stop blocks. Even a small but continual movement can develop serious problems. A number of factors contribute, separately or in combination, to bowl float. Some common conditions which lead to bowl float are described below. Possible Causes of Bowl Float a) CSS Too Small: The minimum css (closed side setting) of a Rollercone in any application is just above the point of bowl float. The Fine Head Rollercone crusher has a capability for reducing the size of rock in a ratio of up to 4:1. For a Fine Head crusher this means a rock with a maximum dimension of 3" (76 mm) could be reduced to 3/4" (19 mm). The Standard Head Rollercones rock reduction ratio can be as much as 6:1. This reduction capability depends on the rocks compressive strength, friability (how it breaks), and the gradation of the feed. The rock reduction ratio may be less or slightly more in some circumstances. One possible cause of bowl float is trying to make too large a reduction for the conditions. This causes a high enough pressure in the crushing chamber to overcome the relief systems hold down pressure. Remedy: Opening the css slightly reduces or stops the bowl float in these conditions. b) Too Little Feed Into the Crusher: When the crusher is not choke fed, the rock tends to feed to one side of the cone. It also feeds farther down into the crushing chamber with each cycle than if the crusher is choke fed. This can cause a bowl float condition by forcing the cone to make a larger than normal reduction to the rock with each cycle. Localized high pressures can result that overcome the hold down pressure in that area and float the bonnet. Long term feeding of the crusher in this manner will cause uneven wear of the bowl liner since most of the crushing is on one side. This results in a crushing chamber that does not have the
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A Terex Company
Section 12 Troubleshooting same cross-section or css around the whole chamber. This in turn causes further bowl float because a larger volume of material will be fed into one section of the crushing chamber. Remedy: Choke feed into the center of the crusher hopper. c) Excessive Near-Size or Fines in the Feed: In these conditions the near size and fine materials flow farther into the crushing chamber than the larger material. This fills up the spaces in the lower part of the crushing chamber. Bowl float results because all of the voids (spaces between rocks) are filled and no room is left for the rock to move into as it is crushed. A pound of crushed rock takes up more space than a pound of solid rock. See solids-to-voids ratio in the Glossary. In extreme cases of this condition, pancakes form from recompressing crushed rock to the point that it is packed into a solid cake. Pancakes formed in this manner will be warm when leaving the crusher. Remedy: Investigate the screening efficiency. Screen out these fines before crushing. d) High Content of Clay or Plastic Material: Plastic substances (clay or soft rock) may cause material to stick to mantle or liner. The sticky material can build up into a pancake that prevents rock from moving freely through the crushing chamber. Too many pancakes will cause bowl float. Pancakes formed in this manner will be cooler when leaving the crusher than pancakes formed by recompression. Remedy: A wash system or increased washing will remove some of these materials. e) Loss of Relief System Pressure: Pressure in relief system holds bonnet in place against crushing forces. If pressure falls to a point where hold down force is less than crushing forces, the bonnet will float.
21280 (3/97) Page 12.2
Remedy: Check and readjust the pressure in the relief system. The relief system hydraulic pressure should be 2600 psi (17927 kPa). Accumulator gas pressure should be precharged to 1800 (12411 kPa) to 2300 psi (15859 kPa) before the oil in the hydraulic system is charged. See the Maintenance Section of this manual for proper procedures for checking and recharging the gas and hydraulic pressures in accumulators and relief system. Warning: Always completely depressurize accumulators before attempting any repair or maintenance to them. Malfunctioning valves or poor maintenance practices can result in build-up of extremely high hydraulic and/or pneumatic pressures inside the accumulator, which is a pressurecontainment vessel. Allow only qualified, experienced personnel with extensive knowledge of hydraulic systems to attempt maintenance or repair of accumulators. f) Air in the Relief System: Air bubbles in the relief system can contribute to bowl float. Remedy: If you suspect air in the relief system, drain the pressure and all oil from the system. Open bleeder valves and refill relief system with clean, proper oil until clear oil runs from bleeders. Shut off the bleeders and repressurize the system to 2600 psi (17927 kPa). g) Rock material backing up into the crushing chamber. If material does not feed through the crusher due to an obstruction in the discharge area, rock backs up into the crushing chamber. Remedy: Check the under crusher hopper and discharge area to see that the discharge is free of obstructions and that sticky materials are not building up under the crusher.
LJ0190100-1
A Terex Company
Section 12 Troubleshooting To sum up, three rules will usually prevent bowl float: 1) Dont operate on low relief system pressure. 2) Dont let rock back up in the crusher. 3) Dont crush clay or plastic materials that cant clear at close settings. Bowl float is sometimes caused by a combination of the above conditions. If these recommendations have been followed and the bonnet is still floating, contact your Service Representative right away. Dont operate your crusher if bowl float is happening. Take good care of your Cedarapids Rollercone, and it will repay you many times over with many years of faithful service.
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Section 13 Glossary Commonly Used Words in Processing Rock with the Rollercone accumulator: A steel pressure-containment vessel inside of which a bladder is filled with nitrogen gas under pressure. Its purpose is to pre-load the hydraulic relief system and allow for movement of the oil in that system to pass tramp iron through the crushing chamber. batter board: A plate positioned so that feed material will impact it and change the direction of flow. Its purpose is to direct the flow and reduce the forward velocity of the material. bonnet: A component that supports the bowl liner and rises against the relief cylinder pressure to pass tramp iron. bonnet support: The component on which the bonnet rests during normal running and which is adjusted up or down to change the closed side setting. bonnet float: See bowl float. bowl float: The periodic separation of the bonnet from the bonnet support during operation. Excessive pressures in the crushing chamber float the bowl (that is, force the bonnet upwards away from the bonnet support) if the crushing pressures overcome the hold down pressure in the relief system. CSS: closed side setting. The css is the nearest distance the upper and lower crushing surfaces approach each other. choke feed: Feeding the crusher so that the top feed area of the crusher is completely full. The level of material feeding into the crusher fills at least 1/3 of the hopper. closed circuit crushing system: This circuit has a flow pattern which recirculates all material coming out of the crusher. The rock flows over a screen, sending the oversized portion back into the crusher. The material that is to the desired size is removed ahead of the crusher.
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counterweights: Rectangular weights bolted to the side of the wedge plate to balance the wedge plate assembly. cubical fractures: A fracture pattern in rock that results in sides that are 90 to each other, giving a particle that has six approximately equal sides, like a grain of salt. fines: Particles smaller than average in a mixture of particles varying in size. friable, friability: The ease with which a material is crumbled, pulverized, or reduced to powder. hooking, hooks in the manganese: Uneven wear of the manganese bowl or mantle liner that deforms the parallel zone in the crushing chamber. This hook will impede flow of the material through the crusher and is a possible cause of bowl float. igneous rock: Rock that is formed from a molten mass. labyrinth seal: A minimum leakage seal that offers resistance to fluid flow while providing radial and/ or axial clearance. metamorphic rock: Rock formed from pre-existing rocks by mineralogical, structural, and chemical changes, in response to pressure, and shearing stresses. nip angle: The angle between the cone mantle and bowl liner at the css. open circuit crushing system: A processing system that does not return oversized material directly back to the crusher. pancaking: The formation of flat pieces of compressed material in the crushing chamber. parallel zone: The lower end of the crushing chamber where the two liners are parallel at the css. ratio of reduction: the ratio of the size of the feed material to the size of the material discharged by the crusher.
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Section 13 Glossary recirculating load: The amount of material sent back to the crusher in a closed circuit. relief cylinder: A hydraulic jack which is pressurized by the accumulator. It holds the bonnet down to oppose crushing forces, but can relieve (allow pressure to escape) into the accumulator and allow the bonnet to rise when non-crushable material (such as tramp iron) enters the crushing chamber. sedimentary rock: A rock formed by consolidated sand and clay deposited in layers. solids-to-voids ratio: The ratio of the volume of solid material to the volume of space in the crushing chamber. Timken load rating: A measurement of the maximum load a gear lubricant film can withstand without rupturing. tramp iron: Uncrushable metallic items that enter the crushing chamber such as bolts, ripper teeth, hammer heads, etc. wear parts: Replaceable components of the crusher that are worn away by the abrasion of material moving through the crusher. Examples are cone mantles, bowl liners, labyrinth seal wear bands and counterweights. work factor: An expression of how well rock is crushed in the crusher. It is dependent on the compressive strength, friability, and hardness of the rock.
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LJ0190100-1

Operation & Maintenance Instructions: Eljay Rollercone Classic Owner/Operator Manual

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Operation & Maintenance Instructions: Eljay Rollercone Classic Owner/Operator Manual

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Operation & Maintenance Instructions

ElJay Rollercone Classic Owner/Operator Manual

Operation & Maintenance Manual

Operation & Maintenance Manual

Operation & Maintenance Manual

Operation & Maintenance Manual

Operation & Maintenance Manual

Operation & Maintenance Manual

Operation & Maintenance Manual

Operation & Maintenance Manual

Operation & Maintenance Manual

Section 3 Rollercone Description

bonnet and bowl liner

relief system manifold tubes

hopper relief cylinder

cone with mantle shim stack shim guard clamp ring

upper and lower radial bearings

upper and lower thrust bearings

internal oil pump

oil fill pipe

Figure 3-1 General Description

Operation & Maintenance Manual

Operation & Maintenance Manual

Section 3 Rollercone Description

plastic backing mantle hold down bolt

standard head cone

RC60 "convertible" cone in the standard configuration

sponge rubber ring fine head cone

distributor plate o-ring

distributor plate convertible cone

fine head cone

RC60 "convertible" cone in the fine head configuration

Operation & Maintenance Manual

torque bar upper key brake bar

brake cover plate Figure 3-3 Anti-Spin Brake

Operation & Maintenance Manual

Operation & Maintenance Manual

Operation & Maintenance Manual

Operation & Maintenance Manual

Operation & Maintenance Manual

Figure 5-1 Flow of Lubricating Oil

Operation & Maintenance Manual

The lubrication system consists of:

flow switch & meter

cannister for filter element

Figure 5-2 Typical External Lube System

Operation & Maintenance Manual

Operation & Maintenance Manual

Additive Sodium Boron Zinc Phosphorus

Normal Concentration 90 3900 400 300

Minimum Concentration 45 1950 200 180

Lubricating Oil Capacities

Operation & Maintenance Manual

Operation & Maintenance Manual

Operation & Maintenance Manual

Operation & Maintenance Manual

this clearance required to remove pinion assembly.

45-7/8" (1165mm) 51" (1295mm) 60-3/8" (1533mm)

vertical envelope for removal of upper assembly 136" (3454mm)

18" (457mm) 46-13/16" (1189mm) 7-1/2" (191mm) 5-1/2" (140mm)

124-3/16" (3154mm) with hopper extension

Figure 7-1 RC66, Four Views for Installation