Crusher RC Classic RC-II OM FN 23830 (En)

Operation & Maintenance Manual
Rollercone Crusher
Models: RC45-I (Classic), RC45-II,
RC54-I (Classic), RC54-II
This manual is copyrighted. Other than for the purpose of and subject to the provisions of the copyright act, no part of this
manual may in any form or by any method (whether by photocopying, electronic, mechanical, recording or otherwise) be
reproduced or transmitted without TEREX CEDARAPIDS’ written permission.
©2010 Terex USA, LLC
Original Language Instructions
23830-Rev A (03/08)
49999-252-09-06
Rollercone Crusher
Models: RC45-I (Classic), RC45-II,
RC54-I (Classic), RC54-II
This manual is copyrighted. Other than for the purpose of and subject to the provisions of the copyright act, no part of this
manual may in any form or by any method (whether by photocopying, electronic, mechanical, recording or otherwise) be
reproduced or transmitted without TEREX CEDARAPIDS’ written permission.
©2010 Terex USA, LLC
Original Language Instructions
23830-Rev A (03/08)
49999-252-09-06
To the Owner & Operator:
We have tried to provide information that gives our customers a clear understanding of
equipment construction, function, capabilities and requirements. This information is
based on the knowledge and experience of qualified people at our company and in our
field organization. Proper use of this information rewards users of our equipment with
high efficiency, maximum service life and low maintenance costs. That is why we
strongly recommend that anyone using our equipment be familiar with this manual.
Information presented here should not be considered authoritative in every situation.
Users will as a matter of course encounter problems and circumstances that raise
questions not anticipated here. Such questions should be directed to their distributor or
the factory.
Anyone who uses this equipment for any purpose other than that for which it was
intended assumes sole responsibility for dangers encountered and injuries sustained as a
result of such misuse.
DANGER
Federal, state and local safety regulations aim to protect both people and property
from accident, injury and harmful exposure. When complied with, such regulations
are often effective. Hazards to personnel and property are further reduced when this
equipment is used in accordance with all operation and maintenance instructions.
Generally:
(1) Read and heed all danger, warning, caution, and notice decals. Know what guards
and protective devices are included and see that each is installed and in operational
condition. Additional guards and protective devices may be required and must be
installed by the user (owner) before operating.
(2) Never attempt to maintain, lubricate or adjust this equipment while it is running.
Lock out and tag out all energy sources before doing maintenance, cleaning, adjusting or
repairing this equipment. Make it impossible for anyone to start this machine while others
are working on it or in it.
(3) Wear personal protective equipment such as hard hats, ear plugs, safety glasses
and safety shoes when operating this equipment. Do not wear loose clothing or long hair.
(4) Think safety and act safely. Stay alert at all times. Eliminate or neutralize
potential hazards as soon as you spot them. Never allow anyone to engage in horseplay
when near this equipment.
DANGER
Failure to take these precautions will result in death or severe personal injury.
23830-Rev A (03/08) Terex Rollercone Crusher

06/06
CEDARAPIDS NEW PRODUCT WARRANTY

Cedarapids Inc, hereafter referred to as Cedarapids, warrants its new products manufactured and sold worldwide, to be free of defects in material or workmanship for a period of one (1) year
after date of start up, provided that Cedarapids receives written start up report within 6 months after the date of shipment (if no start up report is received from the Buyer or the dealer authorized
by Cedarapids to start up the unit within 6 months after the date of shipment, warranty will expire after one (1) year from the date of shipment from the manufacturer), or 2000 hours of use,
whichever occurs first, provided that Cedarapids receives notice of the defect within thirty (30) days of its discovery and Buyer establishes that (1) the equipment has been maintained and
operated within the limits of rated and normal usage, and (2) the defect did not result in any manner from the intentional or negligent action or inaction by Buyer, its agents or employees. If
requested by Cedarapids, Buyer must return the defective equipment to Cedarapids’ manufacturing facility, or other location designated by Cedarapids, for inspection, and if Buyer cannot
establish that conditions (1) and (2) above have been met, then this warranty shall not cover the alleged defect.
Delivery inspection forms are required for warranty validation and processing.
Cedarapids’ obligation and liability under this warranty is expressly limited to, at Cedarapids’ sole option, repairing or replacing, with new or remanufactured parts or components, any part, which
appears to Cedarapids upon inspection to have been defective in material or workmanship. Such parts shall be provided at no cost to the owner, FOB Cedarapids parts facility.
This warranty shall be null and void if parts (including wear parts) other than genuine OEM Cedarapids parts are used in the equipment.
Accessories, assemblies and components included in the Cedarapids equipment, which are not manufactured by Cedarapids, are subject to the warranty of their respective manufacturers.
Normal maintenance, adjustments, or maintenance/wear parts are not covered by this warranty and are the sole maintenance responsibility of Buyer.
Cedarapids makes no other warranty, express or implied, and makes no warranty of merchantability or fitness for any particular purpose.
No employee or representative is authorized to modify this warranty unless such modification is made in writing and signed by an authorized officer of Cedarapids, Inc.
Cedarapids’ obligation under this warranty shall not include duty, taxes, or any other charges whatsoever, or any liability for direct, indirect, incidental, or consequential damage.
Improper maintenance, improper use, abuse, improper storage, operation beyond rated capacity, operation after discovery of defective or worn parts, or alteration or repair of the equipment by
persons not authorized by Cedarapids shall render this warranty null and void. Cedarapids reserves the right to inspect the installation of the product and review maintenance procedures to
determine if the failure was due to improper maintenance, improper use, abuse, improper storage, operation beyond rated capacity, operation after discovery of defective or worn parts, or
alteration or repair of the equipment by persons not authorized by Cedarapids.
Oil Sampling Program: Cedarapids provides kits for an Oil Sampling Program at no charge with certain products. All Warranty claims will be denied if the Buyer does not participate in this Oil
Sampling Program.
Parts Warranty: Cedarapids warrants the parts ordered from the Parts Department to be free of defect in material or workmanship for a period of 6 months after date of shipment from the
factory or 1000 hours of operation, whichever occurs first, provided that the warranty period for any replacement parts supplied pursuant to a Cedarapids equipment warranty shall in no event
exceed the equipment warranty period.
NO TRANSFERABILITY OF WARRANTY: This warranty is limited to the original purchaser or original end-user if sold to a distributor, and is not assignable or otherwise transferable without
written agreement of Cedarapids. Please contact your local Cedarapids Distributor for additional details if needed.
ITEMS NOT COVERED BY CEDARAPIDS WARRANTY
The following items are NOT covered under the Cedarapids Warranty (the following list is not exhaustive):
1. Items sold by any individual, corporation, partnership or any other organization or legal entity that is not an authorized Cedarapids Distributor.
2. Components which are not manufactured by Cedarapids are not covered by Cedarapids warranty. Such components are covered only by the warranty that is provided by the
manufacturer of such components. Such components include, but are not limited to, engines, electric motors, air compressors, air conditioners, batteries, tires etc.
3. Replacement of assemblies: Cedarapids has the option to repair or replace any defective part or assembly. It is Cedarapids’ policy to refuse claims for the replacement of a
complete assembly that is field repairable by the replacement or repair of defective part(s) within the assembly.
4. Normal Operational Maintenance Services and Wear Parts: Maintenance services and wear parts are excluded from warranty claims. Maintenance services not covered
include, but are not limited to, such items as: sheave adjustments and alignment, screen cloth installation and tensioning, wear liner and chute work, wear or adjustment of jaw and toggle plates,
proper tightening of bolts, nuts and pipe fittings, adding or replacing of fluids, filter, breathers, belts, nozzles, screed plates, adjustments of pumps and motors, spark plugs, etc. Wear parts not
covered include, but are not limited to, screen cloth, wear liners, wear of jaw and toggle plates, fluids, filters, breathers, belts, nozzles, screed plates, spark plugs.
5. Transportation damage: Any damage caused by carrier handling is a transportation claim and should be filed immediately with the respective carrier.
6. Deterioration: Repairs, work required or parts exposed as the result of age, storage, weathering, lack of use, demonstration use.
7. Secondary Failures: Should the owner or operator continue to operate a machine after it has been noted that a failure has occurred, Cedarapids will not be responsible under
the warranty for resultant damage to other parts due to that continued operation.
8. Workmanship of Others: Cedarapids does not accept responsibility for improper installation or labor costs of personnel other than authorized Cedarapids Distributor personnel.
9. Stop and Go Warranty: Cedarapids does not recognize “Stop and Go” warranties.
10. Incidental or Consequential Damage: Cedarapids shall not be liable for any Incidental or Consequential Damages of any kind, Including, but not limited to, lost profits, loss of
production, increased overhead, loss of business opportunity, delays in production, costs of replacement components and increased costs of operation that may arise from the breach of this
warranty. Customer’s sole remedy shall be limited to (at Cedarapids sole option) repair or replacement of the defective part.
THIS WARRANTY IS EXPRESSLY IN LIEU OF AND EXCLUDES ALL OTHER WARRANTIES, EXPRESS OR IMPLIED (INCLUDING THE WARRANTIES OF MERCHANTABILITY AND
FITNESS FOR A PARTICULAR PURPOSE) AND ALL OTHER OBLIGATIONS OR LIABILITY ON CEDARAPIDS' PART. THERE ARE NO WARRANTIES THAT EXTEND BEYOND THE
LIMITED WARRANTY CONTAINED HEREIN. Cedarapids neither assumes nor authorizes any other person to assume for Cedarapids any other liability in connection with the sale of
Cedarapids’ equipment. This warranty shall not apply to any of Cedarapids' equipment or any part thereof which has been subject to misuse, alteration, abuse, negligence, accident, acts of God
or sabotage. No action by any party shall operate to extend or revive this limited warranty without the prior written consent of Cedarapids.
IN THE EVENT OF ANY BREACH OF THE WARRANTY BY CEDARAPIDS, CEDARAPIDS' LIABILITY SHALL BE LIMITED EXCLUSIVELY TO THE REMEDIES (AT CEDARAPIDS’ SOLE
OPTION) OF REPAIR OR REPLACEMENT OF ANY DEFECTIVE EQUIPMENT COVERED BY THE WARRANTY. IN NO EVENT SHALL CEDARAPIDS, OR ANY SUBSIDIARY OR
DIVISION THEREOF BE LIABLE FOR INCIDENTAL, INDIRECT, CONSEQUENTIAL OR OTHER DAMAGES OR LOSSES RESULTING FROM A BREACH OF WARRANTY INCLUDING,
WITHOUT LIMITATION, LABOR COSTS, LOSS OF USE OF OTHER EQUIPMENT, THIRD PARTY REPAIRS, PERSONAL INJURY, EMOTIONAL OR MENTAL DISTRESS, IMPROPER
PERFORMANCE OR WORK, PENALTIES OF ANY KIND, LOSS OF SERVICE OF PERSONNEL, OR FAILURE OF EQUIPMENT TO COMPLY WITH ANY FEDERAL, STATE OR LOCAL
LAWS.
Table of Contents
Section 1 - Introduction
About This Manual .................................................................................................................................. 1-1
Intended Use ............................................................................................................................................ 1-1
Section 2 - Safety
General Safety ...................................................................................................................................... 2-1
Safety Alert Symbol ........................................................................................................................ 2-1
Hazard Classification ...................................................................................................................... 2-1
Safety Signs and Icons ..................................................................................................................... 2-2
Safety Sign Location (ANSI) ............................................................................................................... 2-4
Safety Sign Location (ISO Standard) ................................................................................................... 2-6
Personal Safety..................................................................................................................................... 2-8
Work Area Safety ................................................................................................................................. 2-9
Equipment and Tools ........................................................................................................................... 2-9
Lockout and Tagout ............................................................................................................................. 2-9
Section 3 - Description and Capabilities
General Description ............................................................................................................................. 3-1
Clamp System ...................................................................................................................................... 3-4
Tramp Iron Relief System .................................................................................................................... 3-6
Anti-Spin Brake ................................................................................................................................... 3-6
Bowl Float ............................................................................................................................................ 3-8
Bearing Design..................................................................................................................................... 3-8
Crushing Capabilities ........................................................................................................................... 3-8
Rock Abrasion ................................................................................................................................. 3-8
Rock Compression Strength ............................................................................................................ 3-9
Controlling Wear ............................................................................................................................. 3-9
Production Variations .................................................................................................................... 3-10
Section 4 - Transport and Installation
Transporting the Crusher ..................................................................................................................... 4-1
Block the Cone Head ....................................................................................................................... 4-1
Trailer Mounting ............................................................................................................................. 4-3
Installing the Crusher ........................................................................................................................... 4-3
Mounting and Clearance ................................................................................................................. 4-3
Power and Speed Requirements ...................................................................................................... 4-4
Weights and Lifting Procedure ........................................................................................................ 4-4
Outline and Dimensions .................................................................................................................. 4-6
RC45-I ......................................................................................................................................... 4-6
RC54-I ......................................................................................................................................... 4-8
RC45-II ...................................................................................................................................... 4-10
RC54-II ...................................................................................................................................... 4-12
23830-Rev A (03/08) i Terex Rollercone Crusher

Table of Contents
Intake Design ..................................................................................................................................... 4-14

Electrical System ............................................................................................................................... 4-15
Customer Supplied Components ................................................................................................... 4-15
Lubrication Control Circuit ........................................................................................................... 4-20
Crusher Control and Drive Circuit ................................................................................................ 4-22
Oil Heater Circuit .......................................................................................................................... 4-23
Cold Weather Oil Circulation Kit .................................................................................................. 4-23
Section 5 - Lubrication
Oil Flow Path ....................................................................................................................................... 5-1
System Description .............................................................................................................................. 5-2
Checking Oil Level .............................................................................................................................. 5-3
Oil Specifications and Capacities ........................................................................................................ 5-4
Oil Sample and Analysis ...................................................................................................................... 5-5
Taking Oil Samples ......................................................................................................................... 5-5
Oil Analysis ..................................................................................................................................... 5-5
Section 6 - Maintenance
Daily Maintenance/ Inspection Record ................................................................................................ 6-1
Lubrication Oil and Filter Change ....................................................................................................... 6-3
General ............................................................................................................................................ 6-3
Tools and Equipment ....................................................................................................................... 6-3
Oil Change Procedure ..................................................................................................................... 6-3
Filter Change Procedure .................................................................................................................. 6-4
Tramp Iron Relief System Maintenance .............................................................................................. 6-5
General Description ......................................................................................................................... 6-5
Operation Overview ........................................................................................................................ 6-5
Required Tools ................................................................................................................................ 6-8
System Fluid Capacities .................................................................................................................. 6-8
Checking/ Charging Tramp Iron Relief System Manifold .............................................................. 6-9
Checking Accumulator Precharge Pressure ................................................................................... 6-11
Charging Accumulators ................................................................................................................. 6-13
Hard-Facing and Wear Components .................................................................................................. 6-14
Rotation Stops .................................................................................................................................... 6-15
Adjusting V-Belt Tension ................................................................................................................... 6-15
Shear Bolt Replacement ..................................................................................................................... 6-16
Brake Assembly Removal ............................................................................................................. 6-16
Brake Assembly Installation .......................................................................................................... 6-17
23830-Rev A (03/08) ii Terex Rollercone Crusher

Table of Contents
Changing Manganese ......................................................................................................................... 6-18

Upper Assembly Removal ............................................................................................................. 6-18
Bowl Liner Removal ..................................................................................................................... 6-21
Bowl Liner Installation .................................................................................................................. 6-21
Cone Mantle Removal ................................................................................................................... 6-23
Cone Mantle Installation ............................................................................................................... 6-24
Pouring Plastic Backing ................................................................................................................ 6-29
Upper Assembly Installation ......................................................................................................... 6-29
Storage ............................................................................................................................................... 6-32
General Storage Instructions ......................................................................................................... 6-32
Restarting After Storage ................................................................................................................ 6-32
Section 7 - Operation
Pre-Start Inspections ............................................................................................................................ 7-1
Cold Weather Information ................................................................................................................... 7-1
Hot Weather Information ..................................................................................................................... 7-1
Startup Procedure ................................................................................................................................. 7-1
Shut Down Procedure .......................................................................................................................... 7-1
Production Guidlines ........................................................................................................................... 7-2
Making Cubical Product .................................................................................................................. 7-2
Capacities and Gradations ............................................................................................................... 7-2
Liner Selection ................................................................................................................................ 7-2
Adjust Closed Side Setting ................................................................................................................ 7-13
Section 8 - Troubleshooting
Troubleshooting Helps.......................................................................................................................... 8-1
Vibrating Too Much .............................................................................................................................. 8-1
Running Too Hot .................................................................................................................................. 8-1
Bowl Float ............................................................................................................................................ 8-1
CSS Too Small ................................................................................................................................ 8-1
Too Little Feed Into Crusher ........................................................................................................... 8-1
Excessive Near-Size Fines In Feed ................................................................................................. 8-2
High Content of Clay or Plastic Material ........................................................................................ 8-2
Loss of Relief System Pressure ....................................................................................................... 8-2
Air in Relief System ........................................................................................................................ 8-2
Material Backing Up Into Crushing Chamber ................................................................................. 8-2
Appendix A - Glossary .......................................................................................................................... A-1

Appendix B - Torque Specifications .................................................................................................... B-1
Appendix C - Tools, Parts and Materials List .................................................................................... C-1
Appendix D - Belts and Sheaves .......................................................................................................... D-1
23830-Rev A (03/08) iii Terex Rollercone Crusher

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23830-Rev A (03/08) iv Terex Rollercone Crusher

About This Manual
Section 1 - Introduction
About This Manual This equipment is precisely engineered, highly

This book provides operation and routine functional and heavy duty designed to provide years
maintenance instructions for the owner and/or of excellent service performing to customer
operator of a Terex Rollercone Crusher manufactured specifications. We are proud to manufacture this
by Terex Cedarapids (formerly Cedarapids Inc). equipment for your use and profit. We also take
We strongly recommend that anyone working with pride in the quality of our service and replacement
this equipment become familiar with this manual, parts.
whether or not you have experience with similar This manual, however, is not a parts catalog and
equipment. should not be used to order parts. Only your Parts
This manual will help you understand how to install Book, identified with the serial number of your
your equipment, prepare it for operation, and perform machine, is an authoritative source of part numbers
normal operation and maintenance tasks. and part descriptions for your equipment.
Ongoing improvement of product design may result
in future changes to some parts. Use part numbers,
DANGER model numbers and serial numbers from your Parts
This manual contains information necessary Book to communicate with your distributor.
for proper and safe operation. Carefully read
If anything in this manual is not clear or if you have
this manual before attempting to operate.
questions, concerns or just want some general
Failure to read and heed instructions preceded
information about rock processing, please feel free
by a safety-alert symbol can cause death or
to contact the Terex Cedarapids Crushing &
severe personal injury, as well as equipment
Screening service department, at 1-800-821-5600.
and environmental damage.
Experience has shown it is to your advantage to Intended Use

keep a copy of this manual where personnel can This product and its approved attachments are
consult it as needed and to have a copy on file in your designed to process aggregates, such as shot rock,
office so that shift leaders or supervisors can quarry rock, and sand and gravel deposits and for
conveniently refer to it. Additional copies can be processing recycled concrete and demolition material.
ordered through your distributor. Use of this product in any other way is prohibited and
contrary to its intended use.
The safety alert symbol used in this manual is to alert you to potential
personal injury or hazards. Obey all safety messages that follow this
symbol to avoid possible injury or death.
23830 (01/07) 1-1 Terex Rollercone Crusher


General Safety
Section 2 - Safety
General Safety Hazard Classification

This equipment is designed expressly for processing A multi-tier hazard classification system is used to
rock and recycling concrete and asphalt. When our communicate potential personal injury hazards. The
equipment is used for purposes other than those for following signal words used with the safety alert
which it was designed, user assumes sole symbol indicate a specific level of severity of the
responsibility for any injuries or damage that may potential hazard (Figure 2-2). Signal words used
result from said misuse. without the safety alert symbol relate to property
damage and protection only. All are used as attention-
There are many hazards involved in rock processing
getting devices, throughout this manual as well as
and in the use of rock-processing equipment. That is
on safety safety signs fixed to the equipment, to
why we emphatically recommend that this equipment
assist in potential hazard recognition and prevention.
be operated only by personnel who are trained in its
use.
We make no guarantee, either expressly or by DANGER indicates a hazardous
DANGER
implication, that this equipment meets all local or situation which, if not avoided, will
result in death or serious injury.
federal safety regulations. It is the responsibility of
those individuals who own and/or operate this WARNING indicates a hazardous
machine to verify that all safety regulations are WARNING situation which, if not avoided,
complied with before starting either this unit or any could result in death or serious
associated equipment. injury.
Safety Alert Symbol CAUTION indicates a hazardous

CAUTION situation which, if not avoided, could
The safety alert symbol (Figure 2-1) is used to alert result in minor or moderate injury.
you to potential personal injury hazards. Obey all
safety messages that follow this symbol to avoid NOTICE indicates a message
NOTICE related to property damage only.
possible injury or death.
Figure 2-2 Hazard Classification
Figure 2-1 Safety Alert symbol

General Safety
Safety Signs and Icons The language of the icons is simple and direct
Beneath all safety regulations lies a set of common- (Figure 2-3). Refer to Figure 2-4 and
sense rules. Everyone who works with or near heavy Figure 2-5 to see specific safety signs used on this
equipment must be aware of those rules. To foster equipment.
and maintain such an awareness in our customers,
safety signs are fixed on our equipment.
Icons on our safety signs remind both workers and
supervisors of common hazards and procedures
that, in the course of a busy day, they might otherwise
forget.
Improper operation or maintenance can

result in serious injury or death. Flying material may cause loss or
Read and understand operator’s manual degradation of eye sight.
and all safety signs before using or
maintaining this machine. Wear proper eye personal protection
If you do not understand the information equipment.
in the manuals, consult your supervisor,
the owner of the equipment or the
manufacturer. Death, serious injury, or delayed lung
Lockout/ tagout all electrical equipment disease may result from breathing
prior to performing maintenance or hazardous dusts. Hazardous dusts can
adjustments. be generated during operation of this
Stop machine and lockout/ tagout before equipment.
adjusting or servicing the machine.
Use dust suppression or dust collection
equipment to minimize the dust exposure
Contact with moving belts can result in during operation of this machine.
serious injury or death.
Use approved respiratory protection to
Do not operate this machinery without avoid inhalation of dusts, when required
guards in place. by Federal, State, and Local safety and
health regulations. Contact your employer
to establish whether thse regulations
require that you use respiratory
This equipment may cause loss or protection.
degradation of hearing over a period of
time.
Wear proper hearing personal protection

equipment.
Figure 2-3 Safety Sign Icons

General Safety
Oil lubrication required for operation of Explosion hazard, that will result in death
this equipment. Refer to manuals for or serious injury.
instructions.
Only use dry nigrogen for charging
accumulator. Never use oxygen or air.
N2
Electrocution hazard, that will result in Wear safety glasses whil performing any
death or serious injury. Refer to manuals O2 maintenance.
for instructions.
Escaping fluid under pressure can

penetrate skin, causing serious injury.
Crushing hazard, that may cause death, Fluid injected into skin must be
or severe personal injuty. surgically removed within a few hours or
gangrene will result.
Stay clear of equipment during Use cardboard or paper to check for
operation. leaks, not your hand. Relieve pressure
before disconnecting hydraulic lines.
Falling material can cause death or Falling from this machine can result in
serious injury. serious injury or death.
Stay clear of falling material during Do not climb on machine. Use personal
operation. Use appropriate personal lift or appropriate ladder during setup or
protective equipment. maintenance.
Figure 2-3 Safety Sign Icons - Continued

General Safety
Safety Sign Location (ANSI)
1 2 3
1
2
7 6 4
5
WARNING
CRUSHING HAZARD STAY CLEAR of equipment

May cause death, or during operation.
severe personal
injury. Stop machine and
Lockout/Tagout before
adjusting or servicing the
machine. 04491-500-31
WARNING WARNING WARNING WARNING WARNING WARNING

FALL HAZARD Improper operation or HEARING HAZARD INHALATION HAZARD FALLING MATERIAL FLYING MATERIAL HAZARD
Falling from machine can maintenance can result May cause loss Death, serious injury, or delayed lung disease may HAZARD May cause loss or
result in serious injury or in serious injury or or degradation result from breathing hazardous dusts. Falling material can cause degradation of eye
death. of hearing over death or serious injury sight.
death.
a period of time. Hazardous dusts can be generated during operation
of this equipment.
DO NOT climb on Read and understand Wear proper Use dust suppression or dust collection equipment to STAY CLEAR of falling Wear proper eye
machine. operator’s manualand all hearing minimize the dust exposure during operation of this material during operation. personal protection
safety signs before using personal machine. Use appropriate personal equipment.
Use personnel lift or maintaining machine. protection protective equipment.
or appropriate equipment. Use approved respiratory protection to avoid inhalation
ladder during setup If you do not understand of dusts, when required by Federal, State, and Local
or maintenance. the information in the safety and health regulations.
manuals, consult your
Lockout and tagout. supervisor,the owner or Contact your employer to establish whether these
the manufacturer. regulations require that you use respiratory protection. 04491-500-18
04493-500-15
4 ELECTROCUTION HAZARD
Will result in death or serious
injury.
Lockout/Tagout all electrical
equipment prior to performing
maintenance or adjustments.
04493-500-15
Read Manuals.
04490-400-08
7
04493-500-13
04493-500-16 6
3 5
Figure 2-4 ANSI Safety Sign Location

General Safety
1 2 3
4
5
Injection Hazard
Escaping fluid under pressure
EXPLOSION HAZARD can penetrate skin, causing
Will cause death or serious injury.
serious injury.
Relieve pressure before

disconnecting hydraulic lines.
ONLY USE DRY NITROGEN Keep away from leaks and pin
N2 for charging accumulator. holes. Use a piece of
NEVER use OXYGEN or cardboard or paper to search
AIR. for leaks. Do not use hand.
O2 Use safety glasses while Fluid injected into skin must be
performing any surgically removed within a few
maintenance. hours by a doctor familiar with
04490-400-03 this type of injury or gangrene
04491-500-10 will result.
1 3
2
DANGER WARNING
ENTANGLEMENT HAZARD
Contact with moving belts can result in
serious injury or death. Note:
DO NOT OPERATE THIS MACHINERY
Wire tie to ENTANGLEMENT HAZARD Stay clear of moving belt. Do
WITHOUT GUARDS IN PLACE.
Contact with moving belts not operate this machine
This machinery IS NOT equipped with a
guard to prevent accidental contact with
the drive mechanism.
sheave for can result in serious injury or
death.
without all guards and
covers in place. Stop
machine and Lockout/Tagout
Purchaser is responsible for providing and
installing any guards which may be required
by Federal, State, or local statutes or
shipping. before adjusting or servicing
the machine. 04491-500-17
regulations. 04490-400-07
5
4
Figure 2-4 ANSI Safety Sign Location - Continued

General Safety
Safety Sign Location (ISO Standard)
1 2 3
1
2
7 6 4
5
04491-500-18-01
04491-500-31-01
2
1
04493-500-15
4 04490-400-08-01
04493-500-15
7
04493-500-16
6
04493-500-13
3 5
Figure 2-5 ISO Standard Safety Sign Location

General Safety
1 2 3
4
5
N2
O2
04491-500-10-01
04490-400-03-01
1 3
2
Note:
Wire tie to
sheave for
shipping. 04491-500-17-01
04490-400-07-01
5
4
Figure 2-5 ISO Standard Safety Sign Location - Continued

Personal Safety
Personal Safety • Never attempt to clear away jammed feed

This equipment is designed with the safety of all material, discharge material or other stoppage
personnel in mind. Never attempt to change, modify, while the machine is running. Stop the equipment,
eliminate or bypass any of the safety devices installed lock out and tag out before touching this machine
at the factory. Guards, covers and shields installed with your tools or your hands.
around moving parts at the factory are meant to • Wear proper personal protective equipment,
prevent accidental injury to operators and other including eye protection, hard hat and safety
personnel. Do not remove them. shoes, whenever you’re near this machine while
it is running.
• Dress appropriately in every way. Never wear
DANGER loose clothes, long hair, coat tails, jewelry,
Sometimes, at a customer’s request, pockets full of tools or any other item that could
equipment is shipped without certain features get caught in moving parts.
such as a drive sheave. When this occurs, we • Know where your fellow workers are. Always
attach a safety sign to alert installers that the look around and inside this machine before
related guard or other safety feature is starting it. Make sure nobody is in the way of
missing. In such cases it is the customer’s moving parts or working on the machine.
responsibility to guard the machine properly.
• Lift with your legs, not with your back. Keep the
Make sure that everyone working on or near this weight close to your body. If the load is more
equipment is familiar with safety precautions. We than 40 lbs., get someone to help you.
recommend the following basic safety practices:
• Don’t limit safety practices to the rules listed
• Read all danger, warning, caution and notice here. Think safety and act safely at all times.
signs.
• Become familiar with your equipment, the
• Always lock out and tag out involved energy conditions under which it operates and what it is
sources before performing maintenance or capable of doing.
adjustments on this equipment. Make it
• Report any defective machinery or equipment
impossible for anyone to start this machine while
and unsafe conditions or activity to your
others work on it or in it.
supervisor immediately.
• Never remove any guard, cover or shield when
• Always release pressure from hydraulic systems
this equipment is in motion.
before attempting repair or maintenance on any
• Replace guards, covers and shields when the task hydraulic components.
for which you removed them is finished.
• Block parts as necessary to prevent their sudden
movement while people are working on the
machine.

Work Area Safety
Work Area Safety • Keep your equipment clean, free of dirt and
grease, so that loose, cracked or broken parts
• Keep the work area as neat and clean as practical.
are more easily spotted. Replace defective parts
• Keep all product safety signs clean, clear and as soon as they are discovered.
current.
• Make sure all electrical equipment is properly
Lockout & Tagout
grounded. Wet spots near electrical current are Code of Federal Regulations
!
ate
especially dangerous. number 1910.147 requires that ot O
per
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employers establish and follow
• Store hazardous materials in restricted access a Lockout & Tagout procedure
areas and mark them clearly. Federal regulations and train their employees in
require special labeling of certain materials. that procedure before any employee can operate,
• Never start an engine in an enclosed space without service or maintain any piece of power equipment.
properly venting the exhaust. Employers are required to make periodic inspections
• Do not smoke or allow smoking near fuels and to see that their Lockout & Tagout procedures are
solvents. Never strike a spark or use an open being followed, and they must monitor and update
flame near fuels and solvents. their program on an ongoing basis. Employees are
responsible for seeing that equipment is locked out
• Store flammable fuels, solvents and gases in and tagged out in accordance with the employer’s
secure, well ventilated areas. Never allow fumes policy.
to accumulate in the storage area. Use
To promote safety in its use, we ship a Lockout &
nonflammable solvents for cleaning parts and
Tagout Kit with the equipment. The kit and its
equipment whenever possible.
contents are illustrated in (Figure 2-6).
• Know where fire extinguishers and other fire-
suppression equipment are located. Learn how
to use them effectively.
• Be alert and wary around any pressurized system,
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• Always use mechanical assistance to lift heavy
loads. Never overload a hoist, crane, jack or
Figure 2-6 Lockout & Tagout Kit
other lifting device. Check lifting tackle regularly;
replace it at the first sign of stretch, fraying or
other wear.
Work Area Safety
What is Lockout & Tagout? Who must apply a lock & tag?
Lockout & Tagout is a procedure that’s designed to • Any person working on the equipment.
prevent absolutely the unexpected or accidental
startup of equipment and to alert all workers whenever • Foreman or other person responsible for the
it is unsafe to operate any piece of equipment. When work being done.
used as intended, Lockout & Tagout also protects • If several people are working on a machine at the
personnel from energy stored in devices such as same time, each person must apply his or her
springs, accumulators, batteries, hydraulic systems, own lock and tag.
etc.
When can a lock and tag be removed?
How to Lockout & Tagout
• After performing these six steps:
• Install one or more locks to
hold the master switch lever • All safety guards are back in place.
in the OFF position. • All work is complete and tools are put away.
• If the switch is keyed, turn • All workers are notified that a lock is being
the key to the OFF position removed.
and remove the key.
• All workers are positioned safely for startup.
• Disconnect the batteries.
• Controls are positioned for safe startup.
• Regardless of which lockout method is used,
place one or more tags on machine control panels, • The machine is ready for safe operation.
access doors and electrical panels. Who can remove a lock and Tag?
When is Lockout & Tagout Required? • Only the person who applied a lock and tag is
• Any time anyone is maintaining, repairing, permitted to remove them.
lubricating, or, for whatever reason, working on
the equipment. Lockout & Tagout rules laid out here are generic. To
get instructions for your particular workplace, consult
• When the equipment is broken or, for whatever your employer’s lockout/tagout procedure.
reason, unfit or unsafe to operate.
• Whenever the equipment is left unattended.

General Description
Section 3 - Description and

Capabilities
General Description The upper portion of the crusher contains the tramp
iron relief system. This system is highly pressurized
The Rollercone crushes rock in a continuous action.
but designed to yield if uncrushable material, like
Refer to Figure 3-1 and Figure 3-2 for illustrations of
tramp iron, finds its way into the feed. Without any
a typical Rollercone.
damage to the crusher the upper assembly quickly
Rock is fed through the hopper and into the crushing lifts to pass the tramp iron through the crushing
chamber, an area lined with cast manganese alloy. chamber, then returns to the original position, to go
The upper crushing surface is called the bowl liner; on crushing as before.
the lower the mantle.
After passing through the crushing chamber the rock
The mantle rests on the cone, which in turn mounts falls out through the base to be removed.
on the wedge plate. The rotating wedge plate moves
Below are some highlighted differences between the
under the cone like a cam with an upward thrust to
Rollercone I (classic) crusher and the newer
make the oscillating movement of the cone and
Rollercone II crusher.
mantle. As a point on the mantle comes nearer and
nearer to the bowl liner, the force that can be generated • An advanced crushing chamber design with a
grows rapidly. large, unobstructed feed opening allows more
The gear-driven wedge plate rotates on low-friction rock to enter the crushing chamber, producing a
roller bearings. An electric lubrication pump, more cubical product with a higher percentage
mounted externally, pumps oil to bearing surfaces passing the closed side setting. This feature can
within the crusher. The pump runs continuously increase production up to 35% over the
during operation. A flow-sensing device monitors Rollercone classic..
oil flow and sounds a horn when oil flow drops low • Spiral bevel gears are sized for increased
enough to cause bearing damage. production and more efficient operation.
The movement between the mantle and the stationary
• Replaceable vee seat inserts help prevent metal
bowl liner can be thought of as opening and closing
erosion and transfer occurring during occasional
the crushing surfaces, but it takes place in a circular
bowl float and reduce the cost of vee seat repair.
area around a conical shape. The “closed side setting”
(CSS) is the nearest the two crushing surfaces come • Replaceable wear-resistant strut guards protect
to each other. against strut wear.
180° across the cone from the closed side, the • Larger diameter tramp iron relief cylinders operate
oscillating movement makes an “open side” where at lower pressure, but with a higher hold down
the rock falls lower in the crushing chamber until it force.
is discharged in a steady flow at the lower edge of the Rollercones with serial numbers 052676 and higher
mantle. Under normal “choke feed” conditions, the (except 052677 & 052678) contain an external
rock will be caught three to eight times in the electrically driven oil pump instead of an internal
crushing action. gear-driven pump.
A combined force of pressurized hydraulic fluid and Rollercone models RC45 with serial number 052653
compressed gas pushes steadily downward during and earlier contain a shim stack that is slightly
normal crushing to keep the bonnet in place. The different than described in this manual. Contact your
bowl liner mounts to the bonnet. The bonnet rests on Terex Cedarapids dealer or Cedarapids service
the bonnet support. department for specific information on your machine.

General Description
1
18 2
3
17
16 5
15 6
14
7
13
12
11 10 9
1. Hopper 10. Oil heater
2. Bonnet and bowl liner (manganese) 11. Overruning clutch assembly
3. Bonnet support 12. Brake shaft
4. Clamp cylinder 13. Radial bearings
5. Adjusting bolt/ shim stack assembly 14. Wedge plate
6. Clamp ring 15. Shim guard
7. Shieve 16. Cone head and mantle (manganese)
8. Pinion shaft 17. Tramp iron relief cylinder
9. Thrust bearings 18. Tramp iron relief system manifold
Figure 3-1 Crusher Cutaway
23830 (01/07) 3- 2 Terex Rollercone Crusher

General Description
6 7
Coarse Chamber
8
Profile 9
1
10
11
2 12
3
13
Fine Chamber 14
Profile
1
1. Plastic backing 8. Mantle hold down nut

2. Coarse liner (magnanese) 9. Mantle hold down washer
3. Coarse mantle (manganese) 10. Sponge rubber
4. Fine liner (manganese) 11. Bonnet
5. Fine mantle (manganese) 12. O-ring
6. Mantle nut cap bolt 13. Cone head
7. Mantle nut cap 14. Mantle hold down bolt
Figure 3-2 Crushing Chamber Detail

Clamp System
Clamp System
The upper and lower assemblies of the Rollercone
are held in precise position relative to each other by
shim stacks, a hydraulic clamping system and
adjusting bolts (Figure 3-4). The adjusting bolts pass
through a hydraulic clamp cylinder and a stack of
shims, that determine the adjustment range. The
shims are designed to lock in place but be easily
removable once pressure on them is released. RC45
models each have eight adjusting bolts and clamps.
RC54 models have twelve.
The clamp cylinders, when pressurized, exert a force
through the adjusting bolts to the clamp ring. The
force pulls the lower clamp ring upwards and the
bonnet support downwards with enough pressure to
keep the bowl liner and mantle tight within a given
dimension during crushing operation. This
dimension, called the closed side setting (CSS) is
changed by installing or removing combinations of
various thickness shims. The shim stacks keep the
upper assembly level, preventing downward motion
and therefore, maintaining the closed side setting.
The clamp system accumulator is precharged with
nitrogen gas at 1000 psi (6900 kPa). Hydraulic fluid
is pumped into the clamp system to a pressure of
1600 psi (11032 kPa).This pressure is applied to the
clamp cylinders to hold the bonnet tightly in place.
During normal operation the clamp cylinders create
a force on the clamp ring, which presses inward
against the bonnet support skirt. This system works
together with the shim stacks to lock the selected
CSS in place. The force at the clamp ring prevents
upward motion of the bonnet support (maintaining
the closed side setting).
The total height of the shim stack needs to remain
constant and be equal on all bolts. By placing various
thickness shims above or below the bonnet support
flange, the CSS is changed to the dimension you
need. To help operators match stack heights around
the crusher, the shims are color-coded and numbered.
A complete list of shims is contained in Table 7-4 in
Section 7 - Operation.
Clamp System
1 E 2
D
A
C
11 4
10
1. Clamp system
accumulator
2. Accumulator valve
3. Split Coupler 9
4.Upper Shim Stack
5. Clamp Cylinder
6. Lower shim stack 8 5
6
7. Clamp ring (hidden) 7
8. Adjusting jack
cylinder (Ram)
9. Bonnet support A. Tramp-Iron accumulator
10. Adjusting jack B. Rotation Stops
manifold block C. Tramp-Iron relief cylinder
11. Clamp cylinder D. Tramp-Iron pressure manifold
manifold valve E. Manifold bleeder valve
Figure 3-4 Clamp and Tramp Iron System Detail

Tramp Iron Relief System
Tramp Iron Relief System Anti-Spin Brake

The Rollercone uses a hydro-pneumatic tramp iron The anti-spin brake, shown in Figure 3-3, prevents
relief system that provides protection to the crusher the cone head from spinning when the crusher runs
when an uncrushable object passes through the empty. During crushing, the brake allows the cone
crushing chamber. head to rotate slowly to the right (clockwise), but not
The system includes hydraulic cylinders mounted in to the left (counterclockwise). It provides smoother
individual support beams. The beams mount to the operation, and eliminates unnecessary manganese
bonnet support with hold-down bolts to form a wear.
pressure ring. Push rods extend from sockets in each A torque bar is bolted and dowelled to the underside
piston to sockets in the bonnet. The hydraulic of the cone head. The torque bar slips inside the
cylinders are charged with high pressure fluid and floating plate. A cone brake shaft engages the
are plumbed to a series of accumulators. If an underside slot in the floating plate and is keyed to the
uncrushable item enters the crushing chamber the brake shaft. The brake shaft projects down through
fluid is moved to the accumulators to allow the the base frame spindle into an overrunning clutch,
bonnet to raise, allowing the tramp metal to pass. which is attached to a guide ring with bolts. The bolts
The accumulators are precharged with nitrogen gas are intended to shear off before any damage occurs
at 1950 psi (13450 kPa). Hydraulic oil is then pumped to the shaft or clutch.
into the tramp iron system to a pressure of 2600 psi
(17927 kPa) for the RC-I or 2300 psi (15900 kPa) for NOTICE
the RC-II. This provides reserve energy and storage
For proper equipment protection, do not
capacity to keep the manifold cylinders under constant
replace the shearable bolts with hardened
pressure, to hold the bonnet tight against the bonnet
ones. This can cause damage to the clutch
support.
and/or shaft.
Do not run the Rollercone empty for long periods of

NOTICE time. If sump oil is warm enough to flow freely, no
This system does not tolerate hydraulic oil or further warm-up is necessary. As soon as the drive
nitrogen gas leaks. Any leaks will soon empty sheave is up to speed, crushing can begin.
the available energy reserve in the If the cone head turns left (counterclockwise) at
accumulator. Oil leaks can be seen and are start-up, the shear bolts are proabably damaged.
easier to detect than gas leaks. Nitrogen They need to be replace before crushing operation
leaks are normally found only by periodic begins. Do not operate the Rollercone with damaged
gas pressure checks. or missing shear bolts. Instructions for replacing the
shear bolts are included in Section 6 - Maintenance.
NOTICE
If you allow pressure to bleed off from the
tramp iron relief system, bowl float will
occur. Bowl float is defined as the periodic
separation of the bonnet from the bonnet
support. Bowl float voids your warranty.

Anti-Spin Brake
10
2
1. Cone stem
2. Floating plate 5
3. Upper key
4. Brake shaft
8
5. Overrunning clutch
6. Grade five shear bolts 5/16 x 3/4"
7. Brake cover plate
6
8. Clutch guide ring with 5/16" allen-head cap
screws
9. Brake bar
10. Torque bar 7
Figure 3-3 Anti-Spin Brake Detail

Bowl Float
Bowl Float The roller bearings in the Rollercone need a constant,

clean oil flow. The smooth running, low-vibration
Bowl float is the periodic separation of the bonnet
Rollercone is sensitive to weight imbalances.
from the bonnet support during operation. If crushing
Listening to and watching carefully for unusual
pressures overcome the hold down pressure in the
vibrations can give you an early indication of the
relief system, the bonnet lifts upward away from the
need for maintenance.
bonnet support.
One source of imbalance is wear to the
counterweights, especially the leading
NOTICE counterweight. Dirt or mud build-up in the crusher
Bowl float causes excessive wear and or motor sheaves can also cause unbalanced running.
premature failure of some components. Normally, with plenty of clean oil and smooth, low-
Allowing bowl float voids the warranty on vibration running, the roller bearings will last a long
your machine. time and help you produce profitable margins.
Other factors can reduce the Rollercone performance.
Check the crusher for bowl float after making any
If you are getting lower product rates than expected,
change in settings, feed material or feed rate. The
Section 6- Troubleshooting may help you find the
minimum closed side setting is the closest setting
problem.
possible that does not induce bowl float. Bowl float
causes damage to vee seat wear strips. If it goes on
too long it will cause the relief cylinder seals to leak Crushing Capabilities
and can lead to rotation stop damage and bonnet In any rock crushing operation, the physical
cracks. The end result will be costly repairs and characteristics of the raw material affect the output
downtime. product you can achieve. The characteristics of rock
Bowl float may not be visible without careful of most interest in the rock processing industry are
observation. You can detect it by looking for abrasion, compressive strength, toughness, and
movement between the bonnet and bonnet support specific gravity. Cedarapids Inc uses several material
or between the rotation stop blocks. Even a small but tests to quantify or compare rocks on the basis of
continual movement can develop serious problems. these characteristics. These tests follow American
Standards Testing Methods (ASTM) standard
A number of factors can contribute, separately or in
procedures.
combination, to bowl float. Refer to Section 8-
Troubleshooting, for some hints on how to prevent Rock Abrasion
bowl float.
Tests for chemicals with known abrasive compounds
can determine the abrasion characteristics of specific
Bearing Design rocks. Silica dioxide (SiO2), iron oxide (FeO) and
The roller bearing design of the Rollercone allows aluminum oxide (Al2O3) are commonly found
no significant variation in the length of the oscillating abrasive compounds in rock. Magnesium carbonate
stroke of the Rollercone cone head, whether running (MgCO3) and calcium carbonate (CaCO2) are also
empty or loaded. This virtual zero clearance makes associated with abrasive effects. Abrasive test data
the Rollercone able, under normal conditions, to are needed more for considering impact or grinder
work at very close settings and at effective ratios of crushing, but abrasion is a factor in the wear life of
reduction. This means balanced, vibration-free Rollercone manganese. A high abrasive content
running and better, more consistant, product sizing. causes more liner wear. Rock samples can be sent for

Crushing Capabilities
chemical analysis to Cedarapids Inc through your With this scale a rock that can be scratched with:
Cedarapids Distributor. Such samples should weigh
only 1/2 to 1 kilogram (one to two pounds) and must • Your fingernail = about 2
be representative of the quarry to provide reliable • Copper coin = about 3
information. Check with your distributor to get
details of the sampling process. • Pocket knife = over 5
• Window glass = 5-1/2
Rock Compressive Strength
Generally rock with compressive strength up to • Steel file = 6-1/2
50,000 psi (345,000 kPa) with acceptable hardness For more extensive information about types and
and toughness value is considered suitable for characteristics of rock, consult your Cedarapids
reduction in Rollercones. Before attempting to crush Distributor and the Cedarapids Pocket Reference
rock with greater than 50,000 psi (345,000 kPa) Guide.
compressive strength, consult the factory. A scale
roughly corresponding to that given in more detail in Controlling Wear
ASTM C170 is shown next for your convenience: The manganese wear parts in a Rollercone crusher
5,000 to 10,000 psi are designed to wear well in the hammering,
compressive action created by the oscillation of the
(34000 to 69000 kPa) .................................. Soft mantle against the bowl liner. Manganese wears
10,000 to 20,000 psi faster in highly abrasive conditions.
(69000 to 138000 kPa) ......................... Medium The strategy for controlling wear is to reduce chances
for abrasive action and increase chances for
20,000 to 30,000 psi compressive action wherever possible.
(138000 to 207000 kPa) ............................ Hard Here are five tips to help maximize wear life:
30,000 to 45,000 psi
• Make sure the crushing chamber is choke fed as
(207000 to 310000 kPa) .................... Very Hard often and as much as possible.
Greater than 45,000 psi • Provide efficient screening prior to crushing to
(greater than 310000 kPa) ......... Extremely Hard prevent as much abrasive sand and fines as
possible from entering the crushing chamber.
Some practical testing of hardness you can do in the
field is based on the Mohs Scale of Hardness. Talc • Eliminate as much water as possible from entering
has a Mohs hardness value of one and diamond the the crushing chamber. Water mixed with the
value ten. infeed increases the abrasive characteristics of
Talc = 1 Orthoclase = 6 the rock.
Gypsum = 2 Quartz = 7 • Crush across as much surface area of the mantle

as possible. Try to make the mantle surface work
Calcite = 3 Topaz = 8 (and wear) fully from top to bottom, not just at
Fluorite = 4 Corundum = 9 the parallel zone.
Apatite = 5 Diamond = 10 • 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.
Production Variations Rock pieces that are long and narrow can pass
At any equivalent crusher setting and screen opening, through the crusher without being further reduced in
Cedarapids/ElJay cones yield a higher percentage of size. This type of rock does not compact as well as
product than competitive cone crushers. For you this cubical rock pieces.
means greater net capacity. Although it is best to choke feed the Rollercone,
To get most production, it is best to set the Rollercone sometimes providing a high enough feed rate to
no tighter than minimum necessary to get product choke feed it is difficult. In these conditions, build a
size you want. The unique low angle of fall in surge pile or surge bin and run the crusher only when
crushing chamber and virtual zero clearance at enough material is on hand to choke feed it. Another
bearings allow settings that are very close to finished possible action, when the crusher can't be choke fed,
product size. Make sure feed has only a minimum of is to slow the incoming feed speed with a batter
rock already to size. board or other means. If the incoming rock has too
much velocity, it could pass so quickly through the
Minimum closed side setting is closest setting crushing chamber that it would not be crushed
possible that does not induce bowl float. Actual properly.
minimum closed side setting at a given crushing site
can vary widely, depending on the nature and When the Rollercone is used as a secondary crusher,
condition of the material being crushed, as well as some operators run the primary crusher for an extra
common variations in crusher operating styles. shift to make a surge pile, so a continuous supply of
rock is available to choke feed the Rollercone.
Example: if a Rollercone is in a closed circuit
making 16 mm minus (5/8" minus), screen should Capacity and gradation charts are included in Section
have enough capacity so that very few 16 mm (5/8") 7 - Operation, to aid you in setting the crusher for
or smaller rocks return to crusher. Too much rock your particular application. These charts show typical
that is near size can cause bowl float, an unacceptable capacities of the Rollercone when crushing igneous
condition that can damage your crusher. In an open rocks (granite, trap, basalt, etc). Gradation charts
circuit many operators find that a setting about 3 mm show the average product grades of widely separated
(1/8") tighter than desired product size yields a product tests in open circuit when choke fed. The gradation
with a higher percentage passing sizing screen. and capacity charts are offered as a guide to the
expected production that is possible with a
Under some conditions, when the setting is too Rollercone.
close, “pancakes” form and the bowl will float. If
this condition exists, increase the setting until bowl Actual product grades and capacities may differ
float stops. because different rock characteristics results in
different crushing performance. Also, how you
To get the most production it is also very important operate your crusher will determine its overall
to choke feed your crusher. Uniform choke feeding performance.
not only increases volume going through your crusher
but makes a better quality product. Product is more Carefully study the capacity and gradation charts to
uniformly broken to grade specifications and is make best use of your Rollercone. Your Cedarapids
more cubical in shape when the crusher is choke fed. Distributor will be glad to discuss gradations and
capacities appropriate to your crushing needs. The
Cubical fractures are best for most crushed rock feed openings in the charts are based on new
applications because the right angles compact more manganese and ideal screening conditions.
efficiently and with more stability. Choke feeding
helps reduce occurrences of elongated rock particles.

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 abrasive content of the rock, the condition
and cross-sectional shape of the crushing chamber
manganese, moisture content, and other factors.
The “parallel zone” wears down fastest. Adjust the
closed side setting as needed to compensate for
manganese wear.


Transporting the Crusher
Section 4 - Transport and

Installation
WARNING
Block the Cone Head
Escaping fluid under pressure can penetrate
To prepare the Rollercone for transport, wedge skin, causing serious injury. Be sure to relieve
blocks must be installed between the cone head and pressure before connecting/disconnecting
mantle liner. This prevents the cone head from hydraulic lines. The pump output capacity is
lifting or bouncing during travel. about 10,000 psi (68950 kPa). Before starting
During operation, the cone head rides smoothly on pump, be sure the threaded fittings at the
roller bearings. When not operating, gravity is all couplers are fully engaged and the couplers
that keeps the cone in contact with the roller bearings. are tight.
A rough road that causes bouncing action (even from
the suspension system of the transport vehicle) can NOTICE
lift the cone off the bearings enough to cause damage
when contact is made again. The force of even slight Do not overtighten the accumulator valve.
vertical movements of the cone can result in very The valve seat can be easily damaged.
powerful hammering action. A bounce of the cone in
2) Close the valve at the clamp system
a rollercone of less than 1/16” (1.6 mm) is about
accumulator.
equal to the force of a 10 pound (4.5 kg) hammer
dropping 5 feet (1.5 m). Use the following procedure 3) Open the clamp cylinder manifold valve,
to properly block the cone head for transportation. then set the pump handle to POSITION A.
4) Move the pump handle from POSITION A to
NOTICE POSITION B. Start the pump to pressurize the
adjusting jack system up to 10,000 psi (68900
Always block the cone head before
kPa). This will extend the jacks, disengage the
transporting your Rollercone. This prevents
clamp ring and raise the upper assembly about
the cone from bouncing during travel. Serious
damage to roller bearings could result if the 1/8 inch (3.2 mm) off the lower shim stacks. As
cone head is not blocked properly. soon as the bonnet support lifts off the shim
stack, stop the pump.
1) Lower the shim guard and connect the
5) Cut two wedge-shaped wooden blocks. A 12
portable hydraulic pump quick couplers to the
to 18" (300 to 450 mm) long piece of 4 x 4" (100
clamp cylinder and adjusting jack manifolds.
x 100 mm) wood sawed diagonally works (Figure
Connect hose A (top hose) to the clamp cylinder
4-2). Place these wedge blocks together in the
manifold valve and hose B (bottom hose) to the
widest part of the opening between the cone
adjusting jack manifold block (Figure 4-1). Do
mantle and the bowl liner. Position them so they
not start the pump until you are instructed to do
are about 30° apart. Tap the wedges tight with a
so. Set the pump handle to the NEUTRAL position.
hammer.
NOTICE WARNING
When connecting the portable hydraulic
The next step will lower the upper assembly
pump hoses, be sure to clean the hose tips
down onto the shim stacks. Make sure
and quick couplers of any dirt or other
personnel are clear of the area before doing
obstructions. Be sure the threads are clean
step 6.
and in good condition.
6) Make sure all personnel are clear of the 7) With the pump handle still in POSITION A,
crusher. Move the pump handle to start the pump, and charge the clamp cylinder
POSITION A. As the upper assembly settles down system to 1600 psi (11032 kPa). Open the valve
it will compress the wooden blocks. on the clamp system accumulator. If the pressure
drops off, continue to run the pump until the
pressure stabilizes at 1600 psi (11032 kPa).
Stop the pump.
3 8 30°
4 9
5 10
6 11
7 12
50 mm
(2")
POSITION A NEUTRAL POSITION B
1. Clamp system accumulator

2. Clamp system accumulator valve
3. Adjusting jack manifold block Figure 4-2
4. Pump power switch (JOG/OFF/RUN) Cone Head Wooden Block Position
5. Adjusting jack/ ram
6. Portable hydraulic pump 8) Close the clamp cylinder manifold valve.
7. 3-way control valve (pump handle) Using a small pry bar, raise any one of the
8. Clamp cylinder manifold valve adjusting jack rams at least 2" (50 mm). This
9. Upper shim stack allows for any thermal expansion in the jacking
10. Hose A (top hose) system. Move the pump handle between
11. Hose B (bottom hose) POSITIONS A and B a couple times to release all
12. Lower shim stack pressure in the hydraulic hoses. Disconnect the
hoses from the quick couplers and install the
Figure 4-1 Hydraulic Pump Set Up
dust covers on the couplers. Raise and secure the
shim guard in place.
Installing the Crusher
Trailer Mounting Installing the Crusher

If the Rollercone is mounted to a trailer not supplied
by Terex Cedarapids, be sure to check the mounting, Mounting and Clearance
and alter it as needed, to spring-mount the base The Rollercone must be mounted level. This is very
frame to the trailer frame. At least two adjacent important and should be checked carefully in both
mounts must have mounting springs (Figure 4-3). “east-west” and “north-south” directions. Refer to
Order spring part #04-70-1130-0460 and foot bolt installation drawings for illustrations and dimensions.
part #04-70-1135-0313.
NOTICE
NOTICE Operating the crusher out-of-level will reduce
Without spring mounting, the base frame both its useful life and its operating
behaves like a structural member of the effectiveness. Out-of-level operation can
trailer. Flexing of the trailer in transit can cause premature pinion bearing failuire.
crack the crusher base frame or the trailer
frame.Spring mounting is required for the If your Rollercone is not mounted on a plant, make
RC54. sure the support structure is heavy enough to carry
the working load of the crusher. Working load includes
the weight of the crusher plus the weight of the rock
passing through it.Your Rollercone is well-balanced
and normally runs smoothly, with very little vibration.
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 with
the ground, the vibration of the equipment running
may damage the wheel bearings and/or axle assembly.
It is a good idea to wrap the brake drums to protect
them from dirt and dust.
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 because
the collecting chutes are too small. Any restriction to
the discharge may reduce the flow of material through
your crusher and may cause damage.
Providing an access area under the crusher will make
the daily check for obstructions and material buildup
in the crusher easier.
Figure 4-3 Typical Spring Mount

When wiring the crusher during installation, the Power and Speed Requirements
normally open contacts on the flow switch (see the Rollercone power and speed requirements are listed
wiring schematics supplied with the crusher) in Table 4-1. Speed selection depends on application
areconnected to the start/stop circuit of the device and model of crusher. Coarse crushing requires a
feeding the crusher. This interlocks the feed device slower speed than fine crushing.
so it cannot be started unless the crusher is running.
Make sure the lubrication pump relay is wired into
the crusher start/stop circuit. This way the crusher
NOTICE
cannot be started until the lube pump is operating. It is important that the following items be
This ensures a flow of oil through the bearings to checked before initial startup, and before
prevent a dry start. startup each and every time the crusher has
been moved. Failure to perform these checks
Install the Rollercone with enough clearance to
may result in damage to the machine.
allow easy daily service, adjustment, visual
inspection, and routine maintenance. Minimum
clearance dimensions for maintenance and • Be sure direction of motor rotation is correct for
replacement of major components are shown in the both crusher and lubrication pump. Arrows
mounted on the crusher indicate proper pinion
installation drawings.
shaft and pump direction of rotation. The oil
pump will not pump oil if the rotation is reversed.
NOTICE
• Make sure the transportation wedge blocks are
It is absolutely essential that enough overhead removed from the crushing chamber before start
clearance be provided to allow for the up. It is a good idea to store the wedge blocks for
maximum travel of the feed hopper for tramp use next time you transport your crusher.
iron relief when the crusher is set at its
maximum discharge opening. • Be sure crusher feed is interlocked with the
oil-flow monitoring system.
• After first shift of operation, check V-belt tension
WARNING and adjust to belt manufacturer’s specification.
When the Rollercone is operating, keep Refer to Section 6 - Maintenance to adjust V-belt
clear at all times from the area above the tension.
crusher for tramp iron relief. At any moment,
the bonnet and hopper can jump upwards to Table 4-1 Power and Speed Requirements
pass uncrushable material in the crushing
Crusher Electric Pinion Speed
chamber. Model Motor Range
RC45-I 93 kW (125 hp) 745 RPM
RC54-I 149 kW (200 hp) 700 RPM
RC45-II 149 kW (200 hp) 750-900 RPM
RC54-II 225 kW (300 hp) 750-900 RPM

Weights and Lifting Procedure weight of your crusher. If a hoist with marginal
Refer to the Rollercone Component Weights chart capacity must be used to lift the crusher, remove the
(Table 4-2) to determine the needed capacity of upper assembly and lift the two halves separately.
rigging and lifting equipment. The base frame struts have holes to attach lifting
Minimum rigging used for safe lifting is steel wire devices. With the upper assembly removed, the
rope in good condition, having a break strength of lower assembly may be lifted by attaching pairs of
four times the weight to be lifted. flat steel bars drilled to receive 1-1/2" (40 mm) bolts
at each end. Make the bars at least 1/2" x 4" x 14" (12.5
x 100 x 360 mm). Drill 1-5/8" (41 mm) holes centered
WARNING 2" (51 mm) from each end of the bars. The Rollercone
When the sling is at any angle but vertical, will need three pairs of bars.
the allowable load which may be safely
supported per rope is reduced. WARNING
Examples: Each rope of a sling at 60° from the Do not lift or tie down the crusher by attaching
horizontal must be reduced to 85% of its safe vertical to or putting strain to the manifold tubes.
lifting capacity. At 45° it must be reduced to 70%. At These tubes are highly pressurized. Lifting
30° it must be reduced to 50% of the safe vertical or tie-down forces could rupture them.
lifting capacity.
Attach two of the lifting devices to the struts adjacent
Remove the feed hopper before attempting to lift the to the pinion shaft housing. The third device can
crusher. Lift the crusher as a unit with the lifting eyes attach to any remaining strut.
provided on the bonnet. When lifting the entire unit,
be sure your hoist has enough capacity. Check the
Table 4-2 Rollercone Component Weights
Total Upper Lower Cone Wedge Plate

Model
Weight Assembly Assembly Assembly Assembly
12066 kg 4990 kg 3860 kg 1950 kg 1590 kg
RC45-I
26,600 lbs 11,000 lbs 8,500 lbs 4,300 lbs 3,500 lbs
19051 kg 6577 kg 6125 kg 3402 kg 2608 kg
RC54-I
13180 kg 5670 kg 7510 kg 1860 kg 1474 kg
RC45-II
19280 kg 6804 kg 12480 kg 3630 kg 2270 kg
RC54-II

Outline and Dimensions - RC45-I

The following views are general dimensions and
clearances needed for access and service. Dimensions
are in inches unless otherwise listed.
TOP VIEW
NOTE
BOTTOM VIEW
Figure 4-4 RC45-I Outline and Dimensions

Figure 4-4 RC45-I Outline and Dimensions - Continued

Outline and Dimensions - RC54-I

TOP VIEW
NOTE
BOTTOM VIEW
Figure 4-5 RC54-I Outline and Dimensions

Figure 4-5 RC54-I Outline and Dimensions - Continued

Outline and Dimensions - RC45-II

TOP VIEW
NOTE
NOTE
BOTTOM VIEW
Figure 4-6 RC45-II Outline and Dimensions

Figure 4-6 RC45-II Outline and Dimensions - Continued

Outline and Dimensions - RC54-II

TOP VIEW
NOTE
NOTE
BOTTOM VIEW
Figure 4-7 RC54-II Outline and Dimensions

Figure 4-7 RC54-II Outline and Dimensions - Continued

Intake Design
Intake Design For example, a 305 mm (12") round rock falling

3050 mm (10') will be moving at a speed of over
Controlling the speed (velocity) of rock entering the
7,625 m/s (25 ft/s). At this velocity that rock can
Rollercone is as important as maintaining clearance
strike mantle cap with over 11564 N (2600 lb) of
for inspection and service. See Figures 4-8 and 4-9
force. Repeated strikes of this or greater force will
for examples of designs for controlling feed speeds.
eventually damage or destroy mantle cap, which
The Rollercone is designed to work while being could lead to even greater damage to the Rollercone.
choke fed. This means that the volume of rock
2) At this velocity rock can pass entirely through the
material should be great enough that it backs up into
open side of the crushing chamber without being
the hopper. The feed hopper should be at least one-
adequately crushed.
third full continuously during crushing. If rock enters
the crushing chamber too fast, two undesirable effects Under normal crushing conditions rock is caught
can result: three to eight times in the crushing action, if the cone
is choke fed. Achieving proper gradation of rock
1) The velocity (speed) of the larger rocks, due to
product depends in part upon maintaining a high
excessive drop distance into the crushing chamber
volume of rock mass in 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 when using coarse
liner configurations, which are often fed larger size
rock.
Figure 4-8 Figure 4-9

Choke Feeding Using a Rock Box Choke Feeding Using Rock Shelves

Electrical System
Minimizing feed velocity while keeping feed volumes Circuit descriptions and diagrams that follow are
high generally maximizes product gradation. based on the 115 volt control system. The basic
operating principles are the same for the 230 volt
To help prevent damage to your crusher and to help
system, except for the difference in operating voltages
maintain “spec” product, it is important to break the
and circuit breaker current capacities. The 115-Volt
fall of rock into the crushing chamber and limit the
system wiring diagram is provided in Figure 4-10.
height of fall to 36 inches (910 mm) or less.
The 220-Volt system wiring diagram is provide in
A rock box or other flow diversion device mounted Figure 4-11.
above the feed hopper will help reduce the possibility
of impact damage to the mantle and help get product Customer Supplied Components
that consistently meets your specifications. The diagrams that follow are intended to provide a
basic understanding of the electrical circuits for your
Electrical System crusher. When reviewing the diagrams, keep in
The Rollercone crusher is designed to work with a mind that only the devices shown inside dashed
3-phase, 50 Hz or 60Hz primary power source. The boxes are supplied by Terex Cedarapids. All other
crusher is normally configured at the factory for devices and associated wiring must be supplied by
connection to 460 Vac to 575 Vac, 3-phase, 60 Hz the customer.
supply power. The crusher drive motor(s) and For installation purposes, always use the latest
lubrication pump are driven directly by the supply Engineering Electrical Assembly Diagram supplied
power. A transformer reduces the line voltage to with your model crusher when it was shipped from
115 Vac, 60 Hz, single phase power for control the factory. All electrical switches and indicators are
voltages of the various crusher electrical systems. the the sole responsibility of the customer and must
An optional configuration of 380 Vac to 415 Vac be connected as indicated in the applicable diagrams
3-phase, 50 Hz supply power provides control power for the supply voltage at your site. Be sure to have a
of 230 Vac, 50 Hz, single phase. qualified electrician perform the necessary work.
All components are wired to a junction box
(sometimes called J-box) mounted on the crusher.
The junction box also contains a convenient electrical
WARNING
outlet matched to the control voltage. Wires from the Failure to have the system connected and
oil flow monitor switch, warning horn, and oil safety interlocked as shown in the diagrams
heater/ thermostat terminate in the junction box. could result in death or serious injury.
When the emergency stop (E-Stop) button is pressed,
the emergency stop relay ESR opens, removing NOTICE
power from all crusher control circuits. The crusher
motor, lubrication pump motor and external feed Failure to have the system connected and
interlock circuit is disabled. Be aware that primary safety interlocked as shown in the diagrams
power is still applied to each motor contactor (M1 may cause damage to your equipment and
and M356) and power transformer T1. Secondary will void the warranty.
power is still applied to the convenience outlet and
relay contacts CR4 of the oil heater.

Electrical System
NOTICE
115V ac
Configuration
Only devices shown inside the dashed boxes

are supplied by Terex Cedarapids. All other
devices must be supplied by the customer.
A B C
Figure 4-10 Typical 115 Volt Crusher Wiring Diagram

Electrical System
A B C
CONE MOUNTED
CONE MOUNTED
CONE MOUNTED
CONE MOUNTED
Figure 4-10 Typical 115 Volt Crusher Wiring Diagram - Continued

Electrical System
NOTICE
230V ac
Configuration
Only devices shown inside the dashed boxes
are supplied by Terex Cedarapids. All other
devices must be supplied by the customer.
A B C
Figure 4-11 Typical 230 Volt Crusher Wiring Diagram

Electrical System
A B C
CONE MOUNTED
CONE MOUNTED
CONE MOUNTED
CONE MOUNTED
Figure 4-11 Typical 230 Volt Crusher Wiring Diagram - Continued

Electrical System
Lubrication Control Circuit It is important to note that once the crusher has been
Refer to Figure 4-12. The lubrication pump control started, loss of oil flow will not stop the crusher. The
circuit consists of the lube pump start and stop operator must be alert to the warning horn and
switches, control relay CR1, timer relay TR1 and the activity of the feed equipment. The operator must
motor starter M356. manually stop the crusher by pressing the crusher
stop switch.
When the lube pump start switch is closed, power is
simultaneously applied to CR1, timer TR1 and motor
starter M356. CR1 normally open contacts close. NOTICE
One set (8 & 6) supply power to the flow switch Loss of oil flow during operation does not
circuit. The other contact set (1 & 3) is used to stop the crusher. It only sounds the alert horn
maintain power to the pump circuit when the start and stops the external feed equipment. The
switch is released. operator must manually stop the crusher.
With power applied, lube pump motor starter M356
turns on and 3-phase primary power is supplied to
the lubrication pump motor. Timer relay TR1 begins
its 90-second countdown cycle. At the end of the
countdown, TR1 contacts close and supply power to
the cone crusher start circuit.
The flow monitor switch is a safety device to alert the
operator in the event of a lubrication system failure.
The switch is mounted in the oil pressure line, just
after the oil filter. It is set to trip when the oil flow
decreases below a safe operating level. The flow
switch has both a normally open and normally closed
set of contacts. The normally-closed switch contacts
control power to the warning horn. The horn sounds
as soon as the lube pump switch is pressed. The
normally-open switch contacts are wired to the start/
stop circuit of the crusher feed device.
When oil flow reaches a preset level, the flow switch
activates. The horn stops and power is supplied to
relay CR2 to enable the external feed equipment. If
oil flow stops or is reduced enough that the flow
switch trips, such as a plugged oil filter, the horn
again sounds and CR2 is deactivated, stopping the
feed equipment. A green indicator lamp signals the
operator that oil flow is ok.
The lube pump runs continuously during normal
operation until the crusher stop switch or the pump
stop switch is pressed, removing power from the
circuit.

Electrical System
A C
CONE MOUNTED
CONE MOUNTED
TO CONE CRUSHER
CONTROL CIRCUIT
Figure 4-12 Lubrication Circuit Electrical Diagram

Electrical System
Crusher Control and Drive Circuit

Refer to Figure 4-13. The crusher drive circuit is
designed to allow starting of the crusher only after
the lubrication pump has run for the 90-second
pre-lubrication cycle. When the cycle is completed,
power is supplied to the crusher start circuit.
When the cone crusher start switch is closed, power
is supplied to the soft start controller M1. Once
activated, 3-phase primary power is applied through
the soft start circuitry directly to the crusher drive
motor(s) to begin operation. A red indicator lamp on
the control panel alerts the operator that the crusher
has been started.
FROM LUBRICATION
CONTROL CIRCUIT TR1
Figure 4-13 Crusher Control Electrical Diagram

Electrical System
Oil Heater Circuit Cold Weather Oil Circulation Kit

Refer to Figure 4-14. All crushers are provided with An automatic cold weather oil circulation kit (not
an oil heater to keep the lubricating oil warm and shown) is available as an add-on option. A timer
fluid in cold weather. The heater and thermostat are circuit cycles the oil pump every 15-30 minutes
mounted internally, in the bottom of the oil reservoir. during times when the crusher is not operating. This
The heater receives power via two sets of 20-ampere feature, together with the oil heater, keeps the
contacts of relay CR4. The relay is actuated by a lubrication oil fluid during cold weather. Contact
thermostatic switch. The heater is turned on when your Terex Cedarapids representative for information
the oil temperature falls below 60°F (16°C), and off about the cold weather circulation kit.
when the oil temperature rises above 80°F (26.7°C).
Table 4-3 Oil Heater Current Requirements
Relay CR4 is required because the thermostat would
not take the high current required by the heating Circuit Circuit
Model Heater
element (Table 4-3). 110V 220V
A convenience outlet is provided in the junction box RC45-I
1500 W 15 A 7A
for your use. The outlet is wired to a separate RC45-II
20-ampere circuit breaker for protection. RC54-I
2000 W 20 A 10 A
RC54-II
A B C
CONE MOUNTED
CONE MOUNTED
A C
Figure 4-14 Oil Heater Circuit Electrical Diagram


Oil Flow Path
Section 5 - Lubrication
Oil Flow Path Bearings can be severely damaged if any of the following
oil characteristics are inadequate:
Lubrication is critical in the Rollercone crusher. The
lubrication system carries oil to crusher components, • Quality/ Viscosity (oil grade)
protecting them from friction and heat. Not only • Quantity and flow
does lube oil prevent metal-to-metal contact between
• Cleanliness
components, but it also acts as a coolant by carrying
heat to the sump, where it radiates out of the machine. • Toughness (Timken load rating)
Oil flow through the Rollercone is shown below (Figure
NOTICE 5-1).
Make sure that the main return oil hose
is free from tight bends/kinks and is not
trapped. Any hose restrictions can cause
the hose to burst from an overload.
4&5
1. Oil flow from pump 1 2 3

2. Oil sump
3. Oil flow to oil pump
4.Oil-full level relative to bottom of shaft, 1.0 inch (25 mm) on RC45-I and RC45-II
5. Oil-full level relative to bottom of shaft, 1.13 inch (29 mm) on RC54-I and RC54-II
Figure 5-1 Lubricaton Oil Flow Paths

Lubrication System Description
System Description • Oil Lines and Galleries

The lubrication system consists of the following: • Oil Sump
• Oil Pump (external, electrically driven) These features together ensure that the Rollercone
bearings are covered with a continuous flow of cool,
• Oil Heater
clean oil. Refer to Figure 5-2 to identify components
• Oil Filter (replaceable) that are part of the lubrication system. Table 5-1 lists
• Flow Monitoring System expected oil flow rates for the Rollercone.
2
RC 54 3
1
4
3
2
RC 45
6 4
1. Dipstick 5
2. Oil sampling valve
3. Filter housing
4. Filter element
Note
5. Drain plugs (hidden)
External Oil Pump System Shown
6. Pump/ electric motor
Figure 5-2 Lubrication Oil System Components

Checking Oil
Table 5-1 Typical Oil Flow Rates The filter has a replaceable element. Change the
Crusher Flow Rate Flow Rate
element when the indicator shows a change is needed.
Model Gallons / Minute Liters/ Minute It is important to use the proper replacement element
in the filter. An element that is too fine plugs quickly.
4.0 nominal One that is too coarse allows too many particles to
RC45-I & -II (2.0 minimum) 15 (7.6)
pass. See How to Change Lube Oil Filter Element.
6.0 nominal Important: Take precautions to prevent water from
RC54-I & -II (4.1 minimum) 23 (15.5)
getting in oil. Store oil barrels where rain and
condensation cannot get in.
The oil heater is specially designed to keep oil Checking Oil Level
flowing freely in cold weather. The large aluminum
fins transfer heat to a larger surface area of the oil Be sure your crusher has plenty of oil. Check the oil
without burning it. in your crusher daily. Each operator should know the
correct way to check the oil level.
The lubrication pump circulates oil to the bearings.
It can be used together with the oil heater to lubricate Accurate readings cannot be obtained unless all oil
the bearings for cold weather conditions before is in the sump. Oil should be checked daily before
turning the pinion shaft. See Cold Weather Start-up. starting the crusher, or waiting at least 20 to 30
minutes after crusher shutdown.
The flow monitoring system includes the:
The oil level dip stick is designed to be read after it
• Flow meter is unscrewed, wiped clean and replaced lightly
• Flow switch (without re-threading) on the filler pipe.
• Warning horn
If a breakdown in oil flow occurs, the flow monitoring
NOTICE
system can alert the operator that a malfunction To check oil, dipstick pipe cap must be
needs to be corrected. As an added safeguard, it is sitting loosely on pipe filler tube. Do not
recommended to have the flow monitor switch shut thread the dipstick onto the filler tube to
down the feed to the crusher if the oil flow is check oil level.
interrupted.
When checking oil, pull the dip stick up and observe
Continued operation of the crusher with insufficient the oil on it to see:
oil flow will severely damage the bearings. We urge
you to use the flow monitoring system to its full • If it is between the high and low marks
advantage to prevent costly repairs and downtime • If the oil is clean or dirty
resulting from insufficient oil flow. The flow
monitoring system must be interlocked properly to • If the oil drips readily from the end of the stick
protect the crusher or the warranty will be voided. If the dip stick shows oil is low, add oil before
To further ensure that only clean oil flows over the starting crusher.
roller bearings, each Rollercone is equipped with an If the dip stick shows oil is high, be aware that excess
external oil filter. The filter is designed to have a oil may flow out through the seal at the pinion
high dirt-holding capacity and to filter harmful housing when the crusher is running. Drain enough
particles out of the lubricating oil. oil to achieve the proper level.

Oil Types and Capacities
If the oil is very dirty, both the filter and the oil may Table 5-2 Acceptable Lubricants
need changing. See Oil Sample Analysis paragraph.
Oil Company Brand Name/Grade
If the oil does not drip readily from the dip stick, it
may be too viscous to run the crusher. Either it is too Chevron Gear Compound EP 150
cold, too dirty, or it is the wrong grade of oil - none Exxon Spartan EP 150
of these conditions are permissable. Find out what is Mobil Mobilgear 629
wrong and correct the problem.
Shell Omala 150
Texaco Meropa 150
NOTICE
Do not start the Rollercone if oil won’t drip Cold weather operation may require the use of oil
from the dipstick. Serious and expensive heaters to keep the oil fluid and prevent damage to
equipment damage may result. the main lubrication pump. Before starting in cold
climates, always be sure that the oil in the sump and
external lines is fluid.
Oil Specifications and Capacities
Continuous operation in subzero temperatures may
Rollercone crushers are filled with filtered ISO 150 allow use of lighter oils. For example, ISO 68 oil
oil at the factory when they are tested. This oil will may be used in subzero climates to maintain fluid
protect the gears and bearings to an operating liquidity as long as oil temperature does not exceed
temperature of 85°C (185°F). 65.6°C (150°F). Above 65.6°C the ISO 68 thins out
This oil minimizes cold weather start-up problems below the minimum viscosity of 20.58 cSt (100
and still supplies adequate viscosity for bearing SUS). At this point it should be replaced with
lubrication. The lubrication specifications follow. heavier oil.
Oil capacities for the different models of the
• Minimum Viscosity- 20,58 centistokes (cSt)
Rollercone are listed in Table 5-3.
(100 Saybolt Universal Seconds (SUS))
• Minimum Timken OK Load- 55 lb
NOTICE
• Minimum Viscosity Index- 90 Oil capacities shown in the accompanying
All oils should have extreme pressure (EP) additives. chart are guidelines only, based on averages.
Table 5-2 lists the lubricants that can be used as long Actual oil capacity of your Rollercone may
as the above listed specifications are met. differ from those listed in the chart.
For conditions above -17.8°C (0°F) with no wind
chill, internal bearing temperature is independent of
the outside (ambient) bearing temperature and can Table 5-3 Lubricating Oil Capacities
reach 82°C (180°F) in any size crusher. Crusher Oil Capacity Oil Capacity
Model Gallons Liters
If the oil temperature in your crusher exceeds 85°C
(185°F) with the ISO 150 grade of oil, we recommend RC45-I 18.0 68.0
changing to ISO 220 or equivalent. This will not RC45-II 16.0 61.0
make the crusher run any cooler, but the oil will be RC54-I 22.0 83.3
able to maintain an adequate oil film thickness in the
RC54-II 24.0 91.0
bearings at the higher operating temperatures.

Oil Sample and Analysis
Oil Sample and Analysis Oil Analysis

Lubrication oil must be changed at least every 1,000
Taking Oil Samples hours of operation or every six (6) months, whichever
The Rollercone has an oil-sampling valve located comes first, or sooner as indicated by a qualified lab
conveniently atop the fitting that joins the line from analysis. For a new or rebuilt Rollercone, perform
the pump to the filter canister. The location of this the first oil change at between 50 to 100 hours of
valve eleminates unnecessary downtine by allowing operation. In addition, Terex Cedarapids
you to collect samples while the machine is working recommends that oil samples be taken every 200
under load. To collect an oil sample, proceed as hours of operation and analyzed by a qualified lab.
follows (Figure 5-3). Data from a proper oil analysis indicates:
1) Unscrew the protective cap. • Contaminants in the oil
2) Lightly push on the sampler needle assembly. • Condition of the oil
Allow a small amount of oil to escape to avoid
possible contamination of the sample by dirt on The best indicator of condition of your oil is the
Total Acid Number, the TAN. The TAN gets larger
the sampling valve.
as the oil degrades. Generally, a 100% increase in
3) While holding open end of sampling tube in the TAN indicates that you should change your oil. As
sampling bottle, thread sampling tube onto the TAN continues to increase, the oil carries more
sampling valve. Fill bottle and cap it tightly. contaminants and the viscosity increases, decreasing
4) Remove the sampling tube and replace the the lubrication effectiveness.
protective cap on the valve. A good lab analysis will provide a report that shows
5) Wipe up any spillage of oil. concentrations of wear metal elements in parts-per-
million. Typical concentrations and limits are shown
6) Label the sample. Write the date, machine in Table 5-4.
identification (serial) number, oil type, number
The elements from an oil analysis report that indicate
of hours run, and other useful data on the label.
contamination and /or wear inside the machine are
Make a copy to keep with your records. Send
Silica, Water, Iron and Copper.
the sample and data to an analysis lab.
Table 5-4 Metallic Contaminant Levels
Wear Typical Upper

Metal Concentration Limit
Aluminum 0-10 –
Copper 0-15 75
Nickel 0-5 10
Chrome 0-5 10
Lead 0-20 75
Iron 30-50 150

Figure 5-3 Oil Sampling Valve
Silicon (dirt) 10-30 150

Oil Sample and Analysis
Silica in the oil usually means dirt or rock dust is Other oil measures that indicate condition of the oil
getting inside the machine to contaminate the oil. are the Total Acid Number (TAN) and the Total
This may indicate a problem with the seals, or the oil Base Number (TBN). These tests are not always
filter has not been changed often enough to keep the included in a typical oil sample report, but can be
oil clean. The oil sampling valve is upstream of the requested.
oil filter, so it represents the condition of the oil in the The Total Acid Number (TAN) is an indicator of the
sump. If the filter is working properly, the oil delivered extreme pressure (EP) additives contained in the oil.
to the bearings will have a lower silica value than The TAN increases as the oil degrades. The TAN
reported on the oil analysis report. values should be compared with the TAN of unused
Water contamination is usually reported as a oil of the same type. If you have the base-line TAN
percentage, or sometimes a YES or NO on the oil for comparison, the oil should be changed before the
analysis report. Water in the oil severely reduces the TAN increases by 100%.
ability of the oil to protect the bearings from damage. The Total Base Number (TBN) is a somewhat better
Any water indication greater than 1% is excessive. indicator of the condition of the EP additives in the
The source of the water ingestion into the oil sump oil. As with the TAN, the test data must be compared
needs to be found and corrected. with base-line (unused oil) data to be useful. The
Iron in the oil sample is an indicator of wear inside TBN will decrease gradually as the oil EP additives
the machine. Although some iron will always be degrade. Change oil if the TBN drops more than
present in the oil sample, a sharp increase in the 50%.
quantity of iron particles may indicate abnormal Most oil sample reports will also contain data on
interior wear. elements not listed in Table 5-4. Some of these
Copper contamination in the oil sample report is an elements are constituents of the EP additives. Two
indictor that the bearing cages are wearing. As in the common EP additives are Phosphorus and Sulfur.
case of iron, there will always be some copper Phosphorus is commonly reported, but Sulfur requires
present, but increases over time should be monitored. a special test and is not commonly reported. A
Copper content may be higher than normal during reduction in the Phosphorus content indicates a
the initial break in period., but should level off. deterioration of the EP additives. The oil should be
Increases after this leveling off period should be changed before the EP additives drop by 50%.
monitored.
Viscosity is the most common indicator of oil
condition on the oil sample report. It is reported as a
viscosity number with units of SSU (Saybolt
Universal Seconds) or CSt (Centistokes) at a
particular temperature. When comparing against the
base line (new oil) viscosity, be sure that the base
line data is measured in the same viscosity units and
at the same temperature. The oil should be changed
before the viscosity changes by 20%. The viscosity
can increase or decrease over time, but in a rock
crusher application it usually increases as the oil
breaks down.

Daily Maintenance/
Inspection Record
Section 6 - Maintenance
General each shift for this activity, expensive repairs,

replacement parts, and downtime may be saved. For
Before performing any maintenance on the crusher,
stationary installations, building on access door in
be sure to Lockout & Tagout crusher drive power
the under-crusher hopper will allow easy access to
and power for all peripherals.
this area for cleaning.
Daily Maintenance/ Inspection The employee needs to keep in voice contact with
other workers to assure that no one starts up any
Record
machinery at this time.
The Rollercone is designed with enough discharge
clearance to pass several hundred tons of rock per WARNING
hour. However, you must inspect the underside of
Failure to Lockout & Tagout before climbing
your crusher daily and take actions to prevent the
onto a conveyor or inspecting the Rollercone
discharge area under your crusher from getting
could result in death or severe personal injury.
clogged or backed up.
The Daily Inspection Record, shown on the next
NOTICE page, is for convenience. Reproduce it as necessary
A discharge area can become plugged with and maintain copies for your records.
wood, clay, rubber belting, or metal plates Use it to build a standard maintenance procedure
that may pass through the crusher. When that will keep your Rollercone in full production and
allowed to pile up there, such trash can cause keep downtime to a minimum.
rock to back up in the machine, causing
The inspection record includes procedures necessary
serious damage to labyrinth seals and
to properly maintain your Rollercone. The procedures
counterweights.
are intended as minimum requirements. Your
crushing conditions and your geographical location
WARNING may require more frequent inspections and service.
Lockout & Tagout power to crusher and Supervisors and operators can periodically review
peripherals before climbing onto or under the Daily Inspection Records to help build and
the unit. Failure to Lockout & Tagout before maintain a detailed, overall picture of machine use
climbing onto or under the crusher could and production costs.
result in death or severe personal injury. Completed inspection sheets can serve as a
You can make clearing the discharge area of the maintenance record for your files. Terex Cedarapids
crusher easier if, during installation, you allow enough aims to help you get the most production and the
space for an employee to work between the crusher longest life from your crusher. Please don’t hesitate
and the under-crusher conveyor. Whenever a shift to call your Terex Cedarapids representative with
change occurs, you can Lockout & Tagout the crusher questions about service and maintenance practices.
and all peripherals, and send an employee down the
discharge conveyor, under the crusher, to clear away
any blockages. By taking a few minutes at the end of
23830-Rev A (03/08) 6-1 Terex Rollercone Crusher

Daily Maintenance/
Inspection Record
Rollercone Daily Inspection Record
Rollercone Model/ Serial number __________ / __________ Date ____________
Before start-up inspect: Operator’s initials
1. Under-crusher discharge area for blockage ❐ OK ❐ Cleaned _____

2. Oil dipstick for proper level,
viscosity, and cleanliness ❐ OK Amount oil added _____ _____
3. Leading counterweight for wear, cracks ❐ OK ❐ Replaced _____
4. Drive sheaves for dirt buildup, wear ❐ OK ❐ Cleaned _____
5. Drive V-belts for wear, fraying, slipping ❐ OK ❐ Adjusted/replaced _____
6. Oil filter indicator for restricted flow ❐ OK ❐ Replaced filter element _____
7. Closed side setting for accurate adjustment ❐ OK ❐ Adjusted _____
8. Crusher hydraulic system for leaks at:
Jacks ❐ OK ❐ Leaking _____
Clamps ❐ OK ❐ Leaking _____
Tramp iron relief ❐ OK ❐ Leaking _____
After start-up, running empty, inspect: Start-up time _____ _____
9. For cone spinning (cone should not turn) ❐ OK, no spin ❐ Yes, cone spins _____
10. Flow meter: write down the reading Flow rate _____ _____
11. Ammeter: write down the amperage Ampere reading _____ _____
12. Low oil warning horn system ❐ OK ❐ Not working _____
After crushing begins, inspect:
13. Feed location ❐ Centered ❐ Adjusted _____

14. Feed rate ❐ Choke fed ❐ Not enough volume _____
15. Feed velocity ❐ OK ❐ Too fast _____
16. Ammeter for ampere draw under full load Ampere reading _____ _____
17. Flow meter reading under full load Flow rate _____ _____
Total crushing hours this date _____

Downtime this date _____
Comments:

Lubrication Oil and Filter Change
Lubrication Oil and Filter Change Oil Change Procedure

1) Shut down the crusher and follow all lockout/
General tagout regulations and procedures.
Refer to Section 5, Lubrication to identify
components of the oil lubricaton system and oil WARNING
capacity of your Rollercone model. Lockout & Tagout all energy sources before
Regular oil change intervals are extremely important pulling maintenance on this equipment.
in the life of the rollercone. When this equipment is Failure to lockout & tagout will result in
first put into operation or following a major repair, death or severe personal injury, system loss
change oil after 50 to 100 working hours of operation. or severe system damage.
After the initial period, change oil every 1000 hours
or at least every six (6) months of operation, which 2) Check oil temperature using a magnetic sensor,
ever comes first. heat gun or equivalent device against the
Before starting the oil change procedure, make sure rectangular plate on bottom of crusher
you have enough oil on hand. (Figure 6-1). As a guideline, it is recommended
to add 10° to the measured value. If too hot, wait
All Rollercone crushers use the same oil-filter
for machine to cool.
canister, which requires the same filter element and
O-ring seals. If you don’t have a spare cartridge and
O-rings handy, get them from your Terex Cedarapids
dealer before you start this procedure.
Tools & Equipment

• Oil filter (spin on type) or filter cartridge
• Oil filter seal kit (for cartridge filter type)
• Large funnel
• Empty 55-gallon barrel Check Oil
Temperature
• 4-point, 3/4-inch socket wrench
Here
Drain Plug
• 18-inch adjustable wrench
• 8-inch adjustable wrench Procedures
Secondary
Drain Plug
Figure 6-1 Bottom View of Rollercone

Lubrication Oil and Filter Change
CAUTION Filter Change Procedure

Replace the lubrication oil filter as follows (Figure
Wear safety glasses and protective clothing
6-2).
when changing oil. Failure to do so may
result in severe personal injury when hot oil 1) Shut down the crusher and follow all lockout/
splashes. tagout regulations and procedures.
1) While oil drains from crusher, unscrew and
CAUTION remove the filter.
2) Clean filter mounting surface of the head.
Never drain used oil onto the ground. Always
drain used oil into an appropriate container 3) Wipe a film of oil on the O-ring attached to the
and either recycle the oil or dispose of it in new filter. Carefully screw on the new filter.
accordance with federal, state and local Tighten filter 1/2 to 3/4 turn after initial contact
regulations. Failure to do so will cause severe with the mounting surface. Do not overtighten.
environmental damage. 4) Dispose of used oil and filter in accordance with
federal, state and local regulations.
3) Use 4-point, 3/4-inch socket to loosen (but not
remove) drain plug from rectangular plate on CAUTION
bottom of crusher (Figure 6-1).
Improper disposal of used oil is not only a
4) Place barrel under drain plug. Put funnel spout violation of the law: It could result in severe
in barrel and position so that funnel is directly personal injury and/or environmental
under crusher drain plug. damage.
You might need to rig some sort of plumbing to carry
5) Remove cap and dipstick from filler pipe.
the oil from the funnel to the barrel. Some find it
convenient to install a valve, with attached hose 6) Fill Rollercone lube sump with clean oil of the
barb, into the drain hole. When it is time to change type recommended in Section 5, Lubrication.
oil, simply slip one end of a hose over the hose barb, After filling to within a gallon or two of your
stick the other end in a barrel and open the valve. crusher’s rated capacity, stop adding oil for about 60
seconds. Use the dipstick to check oil level in the
NOTICE crusher sump. The dip stick is designed to be read
Using a valve/ hose barb is convenient, but when sitting on top of the filler pipe. Do not thread
prone to leaks. Always make sure there is the the dipstick onto the filler pipe when checking oil
proper level of oil in the sump before you level. Add oil as necessary until oil level reaches
start the crusher. FULL mark on dipstick. Do not overfill.
7) Replace dipstick in crusher fill pipe and screw
5) Remove plug, or open the installed valve, and let the cap on snugly.
oil drain into barrel.
8) Clear away used oil receptacle and all trash.
6) Remove secondary oil drain plug, and let oil Replace all guards and dislocated equipment.
drain into barrel.
9) After warning everyone clear, remove lock and
7) After all oil has drained from both sections, re- tag from crusher power.
install both drain plugs. 10) Perform startup procedure to start the crusher.
While crusher runs, watch for leaks. Run crusher
one shift, then check oil level and fill as necessary.

Head Operation Overview

Figures 6-3 through 6-5 illustrate how the tramp iron
relief system works when it is properly charged.
Figure 6-6 and Figure 6-7 shows what can go wrong
O-Ring if the system is not properly charged.
In Figure 6-3 the accumulator is charged with nitrogen
gas at 1950 ± 50 psi (13450 ± 345 kPa) at ambient
temperature. The relief cylinder manifold is filled
with fluid, but not yet pressurized. Air is bled out of
Filter the system, but no fluid is in the accumulator. The
fluid pressure is equal to or below gas pressure and
the bladder protector valve at the fluid 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 6-4, The relief cylinder manifold is filled
with hydraulic fluid and pressurized to 2600 psi
Figure 6-2 Lube-Oil Spin-on Filter Assembly (17927 kPa) for the RC-I, or 2300 psi (15900 kPa)
for the RC-II. The RC-II relief cylinders are slightly
larger in volume so the operating pressure required
Tramp Iron Relief System is lower.
Maintenance The bladder protector valve at the fluid port of the
General Description accumulator is open. Both nitrogen gas pressure and
hydraulic pressure are equalized. In these conditions
The tramp iron relief (TIR) system is a balanced each cylinder exerts a hold down force on the bonnet
hydro-pneumatic system. An equalized force of of about 45,000 lbs (20,000 kg) for the RC-I or
pressurized hydraulic fluid and compressed gas 50,000 lb (23,000 kg) for the RC-II. The total
steadily hold the bonnet on the vee seat, above the combined force of the system holding the bonnet
oscillating cone. When tramp iron enters the crushing down against the bonnet support (called the hold
chamber, the bonnet raises, forcing fluid into the down force) is substantial.
accumulators, against pressurized rubber bladders
Once the object passes the chamber the bonnet is • RC45-I: 360,000 lbs (163,000 kg)
forced back down to the normal position.
• RC54-I: 540,000 lbs (245,000 kg)
A sensitive balance of fluid pressure and gas pressure
is key to proper operation of the system. Each • RC45-II: 400,000lbs (180,000 kg)
accumulator is pressurized with nitrogen gas. • RC54-II: 600,000 lbs (270,000 kg)
Hydraulic fluid is then pumped into the manifold The condition described above is considered the
under pressure. This provides a sealed system where normal operating state, and allows for standard
the fluid can move in and out of the accumulators crushing operation of the equipment.
against the pressured bladders. Periodic pressure
checks of the accumulator bladders and hydraulic
fluid in the manifold are the only way to properly
maintain this system.
3 4 5
5
6
4
2
3
7
1
8
1
2
1. Tramp iron relief
system accumulator
1. Nitrogen gas bladder
2. Bladder protector valve
2. Bonnet support
3. Hydraulic fluid charging valve
3. Bonnet
4. Manifold tube
4. Cone mantle
5. Manifold bleeder valve
5. Bowl liner
6. Relief cylinder
7. Push rod Figure 6-4
8. Vee seat Tramp Iron Relief System
Properly Pressurized; Ready To Operate
Figure 6-3
Without Fluid in the Accumulator seat of the bonnet support and relief system pressure
returns to its normal state.
In Figure 6-5 the tramp iron relief system manifold In Figure 6-6 nitrogen gas has leaked from the
is charged as shown in Figure 6-4, but in this bladder. The tramp iron relief system has been
illustration a piece of tramp iron, represented by a recharged without first checking the nitrogen gas
ripper tooth, is passing through the crusher and has pressure. In this state, the overall volume of the relief
overcome the initial hold down force of the system. system has decreased. When only the fluid pressure
The relief cylinder piston has properly moved upward was checked, it was read as “low pressure” and the
to displace fluid into the accumulator. Hydraulic and system was repressurized by pumping in more fluid.
gas pressure increase at this point. In a properly The increased fluid level filled more and more of the
charged and operating system, there is ample space accumulator until the nitrogen bladder was finally
in the accumulator to accept this displaced fluid squeezed against the bottom of the bottle. Under this
without any damage occuring. condition the system has less capability of passing
As soon as the tramp iron passes, the bladder forces tramp iron because the available accumulator volume
the oil from the accumulator back to the cylinder. has been reduced.
The bonnet returns to its normal position on the vee

1. Tramp iron enters chamber

Notice: When this condition exists, the
2. Vee seat opens
nitrogen bladder is damaged and must be
3. Relief piston pushes fluid
replaced.
4. Displaced fluid compresses bladder
Warning: A damaged bladder can

Figure 6-5 Vee Seat Open
be dangerous!
NOTICE Figure 6-6

A nitrogen gas leak can only be determined Tramp Iron Relief System Near Failure;
by checking/ monitoring nitrogen gas Relief Capacity Overloaded
pressure. Never pump fluid into the tramp
iron relief system without first checking the cylinders. This situation can damage your equipment
nitrogen gas pressure in each accumulator. or may cause death or serious injury. Any of the
following may occur as a result of extremely high
pressures:
WARNING
• Stall the machine
A damaged accumulator bladder can be
dangerous. High pressures during a tramp • Rupture hydraulic seals
iron event can lead to a system failure that • Rupture the hydraulic manifold
could result in death or serious injury.
• Break pressure ring hold down bolts
Figure 6-7 shows the results of passing tramp iron • Bend cylinder support beams
with the accumulator filled with hydraulic fluid.
• Damage other components of the relief system
When tramp iron enters the crusher with an already
hydraulically locked accumulator, little space is • Damage major castings
available to accept fluid that is displaced by the relief • Damage the roller bearings
0 - 3000 psi
Warning: Possible burst from (0 - 20,000 kPa)
manifold tube if bladder is T-handle
damaged or over-pressurized!
Figure 6-8
Nitrogen Gas Pressure Gauge Assembly
0 - 3000 psi
(0 - 20,000 kPa)
Length of tubing or hose
Figure 6-9
Tramp iron Charging Gauge Assembly, Part #02-360-547-0000
Figure 6-7
Tramp Iron Relief System Failure
System Fluid Capacities
The factory-approved hydraulic fluid is Chevron
AW46 or equivalent. Any equivalent fluid must be
Required Tools and Accessories a premium quality, anti-foaming hydraulic fluid
You need the following items to maintain the tramp with oxidation inhibitors and anti-wear additives.
iron system. Chevron AW46 is a medium viscosity fluid with a
pour point of -20°F (-29°C). Consult your Cedarapids
• Electric hydraulic adjusting pump Distributor before using a fluid with other
• ", 3/4", and 1-1/4" open end or adjustable
9/16 characteristics. Use the following chart (Table 6-1)
wrenches as a guide. Remember that the actual hydraulic fluid
capacity of your Rollercone may differ slightly from
• / " hose with 1/4" npt (pipe thread) on one end,
1 4
what is listed.
long enough to reach containers
• Clean containers large enough to hold at least 20 Table 6-1 Relief System Fluid Capacities
gallons (76 liters) of hydraulic fluid
Model US Gallons Liters
• 0-3000 psi (0-20000 kPa) nitrogen gas pressure
gauge assembly, as shown in Figure 6-8 . RC45-I 9 34
RC45-II 10
• 0-3000 psi (0-20000 kPa) charging gauge 38
assembly, as shown in Figure 6-9. RC54-I 17 65
RC54-II 20 76

Checking/ Charging Tramp Iron Relief

System Manifold High pressure
pipe plug
Before you start, read this entire section and be sure
you understand how the TIR system works, and what
is required to maintain it properly. When fully
charged, the TIR system contains about 2300 psi of
hydraulic fluid pressure. Use extreme caution while
performing this procedure.
WARNING
skin, causing serious injury. Be sure to relieve
pressure before connecting/disconnecting Figure 6-10 Accumulator High Pressure Pipe Plug
hydraulic lines.The hydraulic pump output
capacity is about 10,000 psi (68950 kPa).
Before starting pump, be sure the couplers 3) Thread the quick coupler (supplied with
are fully engaged and tight. Wear protective crusher) into the valve. Be sure the threads are in
goggles or other eye protection when working good condition.
with pressurized gases and fluids. 4) Connect line A (top hose) from the portable
adjusting pump to the quick coupler at the
WARNING pressure valve as shown in Figure 6-11. Be sure
Do not attempt repair to accumulators without the threaded fittings at the coupler are fully
proper training. Dangerously high gas/fluid engaged and the couplers are tight. Do not start
pressure can build up in faulty accumulators. the pump until instructed to do so.
They are pressure-containment vessels which
can remain dangerous even when removed NOTICE
from the Rollercone. Death or serious injury When connecting a pump hose to a quick
could result if accumulator is disassembled coupler, clean the hose tip and quick coupler
while holding pressure. of dirt or other obstructions. Be sure the
threads are clean and in good condition.
To check or charge the tramp iron relief system fluid
pressure, follow these procedures carefully. 5) Set the control valve on the pump to POSITION A
1) Shut down the crusher and follow all lockout/ (away from the hoses).
tagout regulations and procedures. 6) Slowly open the accumulator pressure valve.
1) Locate the accumulator equipped with a 7) Read the pressure indicated on the gauge,
pressure valve (only one accumulator has the mounted on the adjusting pump. Normal pressure
valve). Make sure valve is closed (Figure 6-10). should be about 2600 psi (17927 kPa) for the
RC-I or 2300 psi (15900 kPa) for the RC-II. If
2) Remove the 1/4" high pressure pipe plug from the system has lost more than 10% of normal
the accumulator valve. pressure it may be necessary to add hydraulic
fluid, by using the hydraulic adjusting pump.

8) If indicated pressure is correct, do not add 1

fluid. Go to step 12 and complete the procedure.
OR 2
If pressure is low, continue below.
3
NOTICE
A significant loss of fluid pressure may 4
indicate a leak in the TIR system or a faulty
accumulator. A nitrogen gas leak can only be 5
accurately determined by checking and
monitoring precharge pressure. Before 6
pumping fluid into the system, it is always a
good idea to check nitrogen gas precharge 7
pressure of each accumulator. Refer to the
Checking Accumulator Precharge Pressure
paragraph that is next.
9) Start the hydraulic pump. Open the manifold

bleeder valves, if required, (do not remove) to 1. Pressure valve
bleed air from the reflief system as fluid is being 2. Quick coupler
pumped in. Once clear fluid (with no bubbles) 3. Tramp iron relief system accumulator
escapes from the bleeder valves, stop the 4. Hose line A
hydraulic pump and close the valves. 5. Handle shown in POSITION A
6. Pressure gauge
NOTICE 7. Hose line B
It should only be necessary to use the bleeder Figure 6-11
valves if the TIR system has been opened or Hydraulic System Charging Set-up
otherwise air allowed to enter the system. pressure gauge appears to stop rising, but system
pressure is continuing to increase very slowly.
NOTICE 11) When pressure on the gauge indicates 2600
Keep the hydraulic reservoir filled with fluid psi (17927 kPa) for the RC-I or 2300 psi (15900
during pump operation. If reservoir becomes kPa) for the RC-II, stop the pump.
empty, the pump can be damaged. Stop pump
occasionally to check fluid level and refill as NOTICE
necessary. Exceeding the rated tramp iron relief system
pressure for your crusher model can cause
10) Start the hydraulic pump. With the bleeder damage and reduce or void the warranty on
valves closed and air out of the system, pressure your crusher.
should rise quickly. Watch pressure gauge
carefully. Fluid pressure rises steadily until it 12) Close the pressure valve on the accumulator.
equals the nitrogen gas precharge pressure in the 13) Move the pump control valve to POSITION B
accumulators. At this point the needle on the TIR (toward the hoses). This relieves the pressure in
the hose.
14) Disconnect the hose, and remove the quick 1

coupler from the accumulator.
15) Install the 1/4" high pressure pipe plug in the
pressure valve. Secure the adjusting pump. 2
3
Checking Accumulator Precharge
Pressure 4
It is best to check the pressure early in the morning
or the coolest time of day. The pressure may increase 5
or decrease as much as 200 psi (1500 kPa) with
ambient temperature variations. Pressure changes
about 5 psi for every degree Fahrenheit of change
(65 kPa for every degree Celsius change). For
example, a system that reads 2200 psi at 40°F
increases to about 2400 psi at 80°F (15000 kPa at
4°C will read about 16500 kPa at 27°C). Check and
adjust pressures as needed during operation. A
nitrogen gas pressure gauge assembly is required to
properly check accumulaotor pressure. The gauge
should be capable of reading 0-3000 psi
(0-20,000kPa) (Figure 6-8). A cutaway view of a
typical accumulator is shown in Figure 6-12.
WARNING
6
Wear protective goggles or other eye
protection when working with pressureized 7
gases and fluids.
Before checking accumulator precharge pressure, it 1. Pressure valve 8

is first necessary to remove hydraulic fluid pressure 2. Pipe plug 1¦4"-18 npt
from the manifold. 9
3. Slotted nut
4. Bladder protector valve
NOTICE 5. Bladder
Before attempting to check accumulator 6. Nut
precharge pressure, relieve all hydraulic 7. Apply silicone sealer here
pressure in the tramp iron system. 8. Nitrogen gas charging valve
9. Protective cap
tagout regulations and procedures. Figure 6-12
2) Locate the accumulator equipped with a Typical Accumulator Cutaway
pressure valve (only one accumulator has the
valve). Make sure valve is closed (Figure 6-12
and Figure 6-13).
2) Remove the 1/4" high pressure pipe plug from 1 2

the accumulator valve (Figure 6-10).
3) Thread 1/4" hose onto pressure valve where
the pipe plug was. See Table 6-1 to determine
relief system fluid capacity of your crusher, and
get a clean container large enough to hold the
applicable volume of hydraulic fluid. If you use
a clean container, you can reuse the fluid (Figure
6-13).
4) Very slowly open the accumulator pressure
valve a small amount, carefully draining the
hydraulic fluid though the 1/4" hose into the
container. Fluid squirts strongly at first, then
slows to a drip or stop. 1. Pressure valve
2. Manifold assembly 3
5) Continue opening the valve in small
increments, waiting for fluid to slow or stop each 3. Drain hose
time. Continue in increments until the valve is Figure 6-13 Drain Hydraulic Fluid
fully open.
7) Fully open the T-handle counter clockwise on
NOTICE the nitrogen gas pressure gauge assembly. Install
Even when the valvle is fully open and the pressure gauge assembly onto the accumulator
pressure is relieved, some fluid remains in charging valve. Do no force or overtighten the
the system and may continue to drain by gauge. A snug fit is adequate for the test.
gravity. You will never be able to completely 8) Slowly tighten the T-handle (turn clockwise)
drain all fluid from the system. Be sure to until the needle on the gauge stops rising. Record
allow the pressure to drain off completely the pressure reading. Proper pressure reading in
before proceeding to the next step. the accumulator should be 1950 ± 50 psi (13450
6) Using a wrench, remove the protective cap, ± 345 kPa), at 70 °F (21 °C).
then the nitrogen gas charging valve cap on the If pressure is higher than 2100 psi (14500 kPa), the
accumulator. During removal of protective cap, accumulator port valve spring may be defective and
be sure the valve body does not rotate on the hydraulic fluid may be trapped in the accumulator.
cylinder. If the valve rotates, damage can occur Contact your Terex Cedarapids representative before
to the bladder inside the accumulator, and the proceeding.
accumulator must be replaced (Figure 6-14). WARNING
Dangerously high gas/fluid pressures can
WARNING concentrate in faulty accumulators. They are
Before installing the gas pressure gauge pressure containment vessels which can
assembly, be sure the T-handle is opened remain dangerous even when removed from
fully counter clockwise. Personal injury could the crusher. Do not attempt repair to
occur if you attempt to install the gauge accumulators without proper training.
assembly when the valve is turned in.
If gas pressure is too low, the accumulator will need 11) Apply silicone sealant liberally to the threads
to be charged to the proper pressure. Refer to the of the accumulator protective cap, and install
cap on the accumulator. Tighten just snug. Do
Charging Accumulators procedure paragraph that is
not overtighten.
next. Cedarapids recommends you check all
accumulators before taking the time to recharge any Charging Accumulators
one of them If gas pressure is within specification,
proceed to step 9. To increase gas precharge pressure in an accumulator,
use an appropriage charging device (pump system,
9) Fully open the T-handle (counter clockwise) pressurized bottles, etc.) that is capable of producing
on the pressure gauge assembly. Slowly remove at least 2000 psi (13790 kPa) of pressure.
the pressure gauge assembly from the
accumulator. WARNING
Wear protective goggles or other eye
NOTICE protection when working with pressurized
Be sure the T-handle valve is completely gases and fluids.
open counter clockwise before attempting to
remove the pressure gauge assembly from WARNING
the accumulator. If the valve is still open, Only use dry nitrogen gas to charge
high pressure in the accumulator could cause accumulators.
serious injury. 1) Shut down the crusher and follow all lockout/
tagout regulations and procedures.
10) Install the charging valve cap on the
accumulator. 2) Connect the nitrogen supply source to the
charging gauge assembly (part no. 02-360-547-
0000, ore equivalent (Figure 6-9).
3) Fully open the T-handle counter clockwise on
the charging assembly. Install the charging
assembly onto the accumulator charging valve.
1 Do no force or overtighten the gauge. A snug fit
is adequate (Figure 6-15).
4) Slowly tighten the T-handle (turn clockwise),
thus opening the valve on the accumulator. When
the valve is fully open, the gauge will read the
existing accumulator precharge pressure.
5) Open the valve on the nitrogen supply tank
2 (or start the supply pump). Indicated gas pressure
should begin to rise. When the accumulator is at
1950 psi (13450 kPa), close the valve on the
1. Accumulator
3 4 nitrogen bottle or stop the pump.
2. Protective cap 5) Fully open the T-handle counter clockwise
3. Nitrogen gas pressure gauge assembly on the charging assembly. Slowly remove the
4. T-handle valve charging assembly from the accumulator. Some
remaining gas from the line will bleed off as you
Figure 6-14 Accumulator Pressure Check
remove the charging assembly. Remove it slowly.
Rotation Stops
WARNING erosion of the pinion housing tunnel, which is a

structural part of the base frame. See Figure 6-16.
Be sure the T-handle valve is completely
open counter clockwise and the nitrogen NOTICE
source is closed/ disabled before attempting Do not allow hard-facing to wear away
to remove the charging assembly from the entirely. The wear plate and hard-faced
accumulator. High pressure in the charging surfaces protect the structural integrity of
line could cause serious injury. your crusher.
10) Install the charging valve cap on the
On the Rollercone, replaceable wear-resistant strut
accumulator.
guards protect the base frame struts. Do not apply
11) Apply silicone sealant liberally to the threads hard-facing weld to the strut guards. The upper inner
of the accumulator protective cap, and install edge of the base frame lower flange is protected with
cap on the accumulator. Tighten just snug. Do wear plates. Inspect these parts each time bowl liners
not overtighten. or counterweights are changed. As necessary, hard-
face weld along top edges which are subjected to
1 rock abrasion.
Figure 6-16
Pinion Housing Tunnel Wear Plate
4
3
1. Accumulator At every manganese change closely inspect:
2. Nitrogen bottle
3. Charging gauge assembly • All counterweights, especially the leading one.
4. T-handle valve Replace any worn counterweights.
Figure 6-15 Charging Accumulator • Seal ring (labyrinth seal) wear band. Replace it
when worn (Figure 6-17).
Hard-Facing and Wear Components • The thickness of the bonnet support skirt
The pinion housing tunnel is protected from abrasion Measure and record the skirt thickness for comparison
with a piece of formed, abrasion-resistant plate with the next manganese change. This will give you
welded to the top of the tunnel. This plate must be an idea of the wear rate of the bonnet support skirt.
built up or replaced periodically to prevent serious
Adjusting V-Belt Tension
1 Adjusting V-Belt Tension

2 tagout regulations and procedures.
2) Check the drive belt tension periodically.
3 Check the condition of the belts and the drive
sheaves. See Figure 6-18 to compare the condition
4 of V-belts and sheaves. Additional information
on belt care can be found in Appendix D.
5
3) If the belts are worn, replace them with a
6 matched set of belts.
7 NOTICE
For any new belts or sheaves check the
V-belt tension after two, eight and 40 hours
of operation. Adjust V-belt to manufacturer’s
specifications. Failure to do so may result in
belts damaged beyond use and costly
downtime.
4) Look for steps worn in sheave grooves. Steps

are a measure of sheave wear. Belts must not
bottom out in grooves. If so, replace belts.
1. Liner
2. Cone mantle
5) If sheaves are worn too much, replace them.
3. Falling, crushed rock 6) If belts are not tight enough, loosen the four
4. Lower seal ring wear band mounting bolts of the drive motor. Adjust motor
5. Pinion housing tunnel wear plate take-up bolts to tighten belts. Retighten the motor
6. Pinion housing tunnel (part of base frame) mounting bolts to hold the new tension on the
7. Pinion assembly belts.
Figure 6-17
Wear Plate and Hard-Faced Surfaces 2 3
1
Rotation Stops
The oscillating crushing action of Rollercone results
in a tendency of bonnet to rotate in a counterclockwise
direction. Bolt-on rotation stops prevent counter-
rotation and are easy to remove and install when they
wear. Rotation stops are easily damaged by allowing 1. Belt touches bottom of sheave
bowl float. Do not allow bowl float during operation. 2. Worn belt or sheave
3. Proper fit
Figure 6-18 Belt Fit

Shear Bolt Replacement
Shear Bolt Replacement jack screws to press the brake cover loose.
Shear bolts protect the clutch/ brake system from 6) Alternately tighten these bolts to press the
overloads. The bolts are intended to shear off before cover off. The cover is bonded with silicone
any damage occurs to the shaft or clutch assembly. adhesive. Once loose, lower the cover onto the
When the shear bolts have failed, the cone head will long bolt you installed earlier. Swing the cover
freely rotate with the wedge plate when the Rollercone out of the way.
runs empty. If bolts are not replaced, your maganese
liners will wear at an abnormal rate during operation. NOTICE
The following procedure is used to replace the bolts Depending on the model of your crusher,
(Figure 6-19). either three (3) or four (4) bolts are used to
secure the clutch to the guide ring. A series
WARNING of extra holes have been machined in the
Lockout and tagout all electrical drive power clutch. If the shear bolts have sheared, you
to the crusher before entering the may be able to make the brake work properly
undercrusher area and performing this without removing the clutch and guide ring.
procedure. Failure to lockout & tagout could Rotate the cone head to line up three (3) more
result in death or severe personal injury. bolt holes and replace the sheared bolts with
new bolts. Use 5/16” x 3/4” long grade 5
Brake Assembly Removal (G5) bolts as shear bolts.
1) Using a heat gun, magnetic sensor or If it is not possible to install new shear bolts as
equivalent, check that oil temperature is at a safe described above, you will need to remove the clutch
level before proceeding. assembly. Perform the following steps to remove the
2) Remove the center oil drain plug from the clutch assembly,
brake cover plate, and drain the oil. This only 7) Remove the four (4) socket-head cap screws
drains oil from the center cavity and not the that hold the clutch guide ring to the base frame
entire crusher. Approximately one (1) gallon of spindle.
oil drains out.. 8) Lower the clutch guide ring and the clutch
3) Remove one of the bolts holding the brake assembly.
cover and replace it with a 5” or longer bolt.
DANGER
WARNING Do not position any part of your body directly
Do not proceed until the 5” bolt is installed. below the brake shaft. If the brake shaft
This bolt prevents the brake cover from remains up in the spindle, be very careful it
falling unexpectedly and causing injury. does not fall out. Only the suction of an oil
film is holding the shaft in place. This can
4) Remove the remaining bolts holding the brake break free without warning allowing the
cover in place. shaft to fall out. This could result in death or
5) Remove the two (2) Allen-head set screws serious injury.
and install two (2) of the brake cover bolts in
their place. The brake cover bolts are used as 9) Slide the clutch guide ring off the clutch.
Remove broken shear bolts. These bolts are soft

Shear Bolt Replacement
and designed to shear. The factory installs only 7) Refill oil to proper level. After the first shift of
grade five (G5) bolts as shear bolts. operation following assembly, check the
lubricating oil level. Normally, the oil level is
NOTICE not significantly reduced by repairing the brake
You must be able to install at least three (3) assembly, but you should always check for proper
shear bolts. If the brake is disassembled, you oil level.
will save time in future replacements if you
remove the sheared off bolts now while its
convenient. Usually drilling and tapping is
not necessary. A small chisel and hammer
can be used to get the bolts started to back
out. You can then usually turn them by hand.
Brake Assembly Installation

1) Install only new 5/16” x 3/4” long grade 5
(G5) bolts as shear bolts.
2) If the brake shaft comes out with the clutch
assembly, slide the shaft back into the center of
the spindle as follows.
RC45: Install the shaft with the short keyway
down.
RC54: Install the shaft with the 3/8” keyway
down. 1
Slide the clutch onto the end of the shaft, aligning
the key with the keyway. When the top end of the 2
6
shaft contacts the brake bar, rotate the clutch 3
guide ring, clutch and shaft to align the upper key
4
with the keyway in the brake bar.
5
3) Install the clutch guide ring, on the base frame
spindle, using four (4) socket-head cap screws.
4) Install the two (2) Allen-head set screws in the
brake cover. Do not allow the screws to extend 1. Brake shaft
below the mating surface of the plate. These are 2. Clutch assembly
Bottom View
only to protect the threads of the plate for future 3. Guide ring
use. 4. Brake cover plate
5. Oil drain plug
5) Clean the brake cover and its mating surface.
6. Allen-head screw/ Jack screw
Apply a small bead of silicone sealant around the
installation location
brake cover before installation.
Figure 6-19 Anti-Spin Brake System
6) Install the brake cover. Install the oil drain
plug in the brake cover.
Changing Manganese
Changing Manganese
4
The bowl liner and the cone mantle are both cast of 3
highly wear- and abrasion-resistant manganese
alloys. During operation the maganese provides the 3
wear surfaces that crush the material fed into the 2
crusher. They have to be periodically replaced as
they wear. In order to change either maganese liner,
1
it is necessary to remove the upper assembly of the
Rollercone (Figure 6-20). Before starting any
procedure steps, shut down the crusher and follow
all lockout/ tagout regulations and procedures.
Upper Assembly Removal

Refer to Appendix C- Tools, Parts, and Materials
List, for the items needed to change the Rollercone
wear parts.
1) To obtain the necessary clearance for lifting
the upper assembly clear of the lower assembly,
1. Cone mantle (manganese)
remove any obstructions, such as feed conveyor,
2. Bowl liner (manganese)
discharge lip, or feed box.
3. Upper assembly (bonnet) lifting eyes
On plants with restricted overhead clearance, it may 4. Hopper lifting eyes
be necessary to remove the adjusting bolts along one
side of the crusher and then lower the adjusting bolts Figure 6-20 Rollercone Upper Assembly
into the base frame, allowing the upper assembly to
be moved sideways. On the bolts you lower into the
frame, replace the split couplers and O-rings. This
NOTICE
helps to keep them within reach for assembly when When connecting the portable hydraulic
done. pump hoses, be sure to clean the hose tip and
quick couplers of dirt or other obstructions.
2) Remove the crusher’s feed hopper retaining
Be sure the threads are clean and in good
bolts and lift the hopper clear by attaching a
condition.
lifting device to the two holes in the hopper
gussets.
3) Lower the shim guard and connect the WARNING
portable hydraulic pump to the quick couplers at Escaping fluid under pressure can penetrate
the clamp cylinder manifold valve and adjusting skin, causing serious injury. Be sure to relieve
jack manifold block as shown in Figure 6-21. Be pressure before connecting/disconnecting
sure hose A (top hose) connects to the clamp hydraulic lines.The pump output capacity is
cylinder manifold valve and hose B (bottom about 10,000 psi (68950 kPa). Before starting
hose) to the adjusting jack manifold block. Set pump, be sure the threaded fittings at the
couplers are fully engaged and the couplers
the pump handle to the NEUTRAL position. Do not
are tight.
start the pump until you are instructed to do so.
Changing Manganese
4) Close the valve at the clamp system 5) Move the pump handle from POSITION A to
accumulator. Open the clamp cylinder manifold POSITION B. Start the pump to pressurize the
valve, then set the pump handle to POSITION A, adjusting jack system to 10,000 psi (68900 kPa).
(Figure 6-22). This will extend the jack cylinders and raise the
upper assembly about 1/8” (3.2 mm) off the
NOTICE lower shim stacks. There is now a gap above the
Do not overtighten the accumulator valve. lower shim stack. Stop the pump. Remove a
The valve seat can be easily damaged. shim from each of the lower shim stacks (Figure
6-23).
WARNING
The next step will lower the upper assembly
down onto the shim stacks. Make sure
personnel are clear of the area before doing
step 6.
1 2 3 4 5
1. Pump handle in NEUTRAL position

2. Adjusting jack manifold block
3. Clamp cylinder manifold valve 3
4. Hose B (bottom hose) 2
5. Hose A (top hose) 1
Figure 6-21 1. Pump handle in POSITION A
Electric Hydraulic Pump Connections 2. Clamp cylinder manifold valve
3. Clamp system accumulator valve
Figure 6-22
Clamp System Accumulator Valve

Changing Manganese
6) Move the pump handle to POSITION A. This 9) Close the clamp cylinder manifold valve.
relieves pressure to the jack cylinders, allowing Move the pump handle between POSITIONS A and
the upper assembly to settle onto the lower shim POSITION B a couple of times to release all
stacks, leaving a gap in the upper shim stack. pressure in the hydraulic hoses. Disconnect hose
7) Remove O-ring from the split coupler. A and hose B from the quick couplers, and install
Remove both split coupler halves (Figure 6-24). the coupler dust covers.
8) Remove the upper spherical seat washers, 10) Attach shackles and cables to the lifting eyes
the upper shims (one by one), and the aligning on the bonnet.
washers. Note the position and condition of the 11) Lift slowly with a properly rated lifting device
O-ring seals. Check them for wear. (Section 4, Transport and Installation, contains a
table of Rollercone component weights).
NOTICE
Make a reference mark to help align upper NOTICE
assembly and base frame during reassembly. Sometimes it can be helpful to briefly
pressurize the adjusting jacks to help release
the clamp ring from the bonnet support skirt.
12) Raise upper assembly high enough to clear

both the cone head and adjusting bolts. Swing it
clear of the crusher frame and set it down.
13) Keeping each stack separate, remove lower
shims, one by one and put aside in stacks. Keeping
shims in organized stacks makes assembly easier.
1 2 3
4
4 5
2 3 6
1
1. Pump power switch (JOG/OFF/RUN)
2. Pump handle in POSITION B
3. Pressure gauge
4. Jack in extended position
1. Aligning washer
5. No brass showing
2. Split coupler
6. Shims
3. Upper spherical seat washer
Figure 6-23 Pressurize Jack Cylinder
4. O-ring
Figure 6-24 Split Coupler Assembly

Changing Manganese
Bowl Liner Removal

1
1) Loosen the bowl wedge stops 13 mm (1/2") 2
and partly back the wedges out during the last
half hour of operation before shutting down for 3
manganese change. Crushing for a few minutes
with the wedges loose usually makes the liners
easier to remove (Figure 6-25). 4
10
2) Remove the bowl wedge stops that bolt into 5
the wedge tips to hold the liner loop wedges in
place, and remove the wedges. If the liner does 9
not drop, drive it down with a steel bar and sledge
hammer. Drive on the upper edge of the liner. Do 8
not drive or hammer on the loop eyes. They can
bulge open and cause the liner to become even 7
harder to remove. If the liner is very difficult to
remove, press out the liner using a manganese 6
press (Figure 6-26).
1. Plastic backing
3) Clean all the remnants of plastic backing from 2. Loop eye
the inside of the bonnet. 3. Bowl wedge
4. Vee seat
Bowl Liner Installation
5. Bonnet support
1) Be sure the seat surface at the lower edge of 6. Seat surfaces
the bonnet is clean and smooth. Lightly grease 7. Bonnet
the interior of the bonnet, including inside of the
8. Bowl liner
pockets. Do not grease the bonnet seat surfaces.
9. Bowl wedge stop
2) Wrap the new bowl liner loops with duct 10. Half-round shoe
tape as shown in Figure 6-27. Be sure the seat
surface of the liner is clean and smooth. Figure 6-25 Bowl Wedge Stops
3) Place the 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.
WARNING
4) Insert the wedges with the matching half-
round shoes properly placed in the upper curve Be sure the bowl liner is secured from falling!
of the liner loop eye (Figure 6-28). Tap the All wedges must be secured from backing
wedges lightly until a wedge lock and bolt can be out of the liner loops before allowing anyone
installed loosely at each liner loop. Wedges and to climb inside.
locks keep the liner from falling while a person
climbs inside the upper assembly to make final
centering adjustments.

Changing Manganese
1. Loop eye 1 2 3
2. Shoe
3. Wedge and lock
4. Loop pocket
1. Hydraulic jack
1 3
2. Loop eye
3. Block 2
Figure 6-28 Centering the Bowl Liner
Figure 6-26 Typical Manganese Press
A B
Duct tape
Figure 6-29 Center Bowl Liner -

“A” Must Equal “B” All Around the Bonnet
6) When the liner is centered, the person inside

the upper assembly climbs out.
7) Drive the wedges tight by striking them
alternately so they tighten up evenly. Drive all
wedges clockwise as viewed from top of bonnet
Figure 6-27 Tapeing Bowl Liner Loops
(Figure 6-25). Use a long, heavy bar as a punch
to reach the wedges so you can have room to
5) One person climbs inside upper assembly to swing a heavy hammer. When the wedges are
check position of lower edge of bowl liner, while tight enough, the bar (not the hammer) bounces
a second person taps wedges until liner is even back.
all around the circumference of bonnet
(Figures 6-28 and 6-29). If the bowl liner is not 8) Refer to Plastic Backing paragraph later in
centered properly, the crusher will have an uneven this section, to prepare the plastic backing. To
closed side setting. minimize waste do not mix backing until the
cone mantle is also ready to be poured.

Changing Manganese
Cone Mantle Removal NOTICE

1) It is not necessary to remove the cone head
If cutting with an Arc-Air torch, electrically
from the crusher to change the mantle. It is
ground (earth) the mantle. Take care not to
recommended that you change the mantle with
damage the mantle or cone head. Be very
the cone head in place to prevent the entry of dirt
careful to avoid cutting gouges in the mantle
and possible damage to bearings and floating hold-down nut.
plate. If the cone head has been lifted off the base
frame, consult your Terex Cedarapids Distributor 3) Cut the mantle washer with an oxyacetylene
or service representative for proper alignment torch. Be sure to cut vertically, between the
and installation instructions. mantle and the mantle nut (Figure 6-30 and
2) Remove the mantle nut protector cap bolt 6-31). If Arc-Air is used, be sure to electrically
using the supplied allen wrench. Remove the ground (earth) the mantle as follows: (a) replace
mantle nut protector cap (Figure 6-30 and 6-31). the mantle nut protector cap bolt, (b) leave the
allen wrench in the bolt, (c) ground to the allen
wrench (Figure 6-32).
4) After cutting, the mantle nut should be free
to turn. Remove the ground clamp and the mantle
nut protector cap bolt.
1 2 3 4
1 2 3 4 5 6
7
1. Mantle
1. Mantle nut
2. Pour notch
2. Mantle nut protector cap (removed)
3. Mantle nut
3. Protector cap bolt (removed)
4. Mantle washer
4. Cut vertically to allow manganese to be
5. Steel dowel
removed if threads are jammed
6. Mantle washer lug
5. Mantle
6. Mantle nut seal (O-ring) Figure 6-31 Cone Head, Top View
7. Mantle hold-down bolt
Figure 6-30 Mantle, Cross-Section View

Changing Manganese
10) Attach a ground (earth) directly to the top of

the mantle (Figure 6-34).
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.
Figure 6-32 Grounding for Arc-Air 11) Weld the lifting eye to the mantle using
welding rod specifically designed to weld
5) Insert the mantle nut wrench and secure it manganese steel to mild steel, such as McKay’s
with a bolt screwed into the mantle nut protector Chrome-Mang® or equivalent. Make a first-pass
cap’s retaining bolt hole. weld on each side of the eye. Repeat for a total of
three passes to form a 1/4" (6 mm) fillet on each
NOTICE side to give enough strength to lift the mantle.
Mantle nut has left-hand threads. Weld the second eye 180° apart from the first.
6) Mantle nut has left-hand treads. Use a heavy 12) Connect a separate lifting chain to each eye,
sledge hammer to turn the mantle nut clockwise. (Figure 6-35), and lift the old mantle slightly. If
it does not lift free, rap with a sledge hammer.
7) If the cone head turns too freely, wedge a
piece of bar stock between a cone strut and the
inside of the base frame to prevent cone from WARNING
turning while you are loosening the mantle nut. Do not allow anyone to stand, walk, or work
8) Cut two lifting eyes from /2" (13 mm) mild
1 underneath the mantle while it is in the air.
steel plate. The minimum width between the Severe personal injury or death can occur.
edge of the burned-out hole and the lifting eye’s 13) Lift mantle from cone head and discard.
outside diameter (OD) should be 1-1/2" (38 mm) Knock the lifting eyes off the old mantle for later
all around (Figure 6-33). use on a new mantle.
9) Measure 8" (200 mm) from the top of the
mantle down the side for placement of the upper Cone Mantle Installation
end of the lifting eye. Sand or grind the area 1) Prepare a new mantle for use. Invert and clean
down to clean bare metal to prevent weld the new mantle as follows. Rest one edge of the
contamination. mantle on a block to provide clearance for a
lifting chain. Pass the chain through the hole in
NOTICE the top of the mantle to make a complete circle
Before doing any welding, connect the (Figure 6-36).
electrical ground directly to the mantle. Lack
of proper grounding could send an arc through
the bearings, causing damage.
Changing Manganese
1. Weld 3 passes (1/4" (6 mm) fillet)

with McKay Chrome-Mang®
2. Mantle
3. Top of lifting eye should be almost
level with top of mantle
1 4. Minimum 1-1/2" (38 mm) all around
5. Lifting eye
13 mm 15
2m
(1/2") m
1 (6"
)
76
m
4 (3" m
)
2 38 mm (11/2")
200 mm (8") 5
(3" m
)
m
(6"
)
76
3
m
2m
15
Figure 6-33 Mantle Lifting Eyes Attachment
NOTICE
Use a bolted shackle on the end of the chain
to lift mantle. Do not use an open hook.
2) Secure the shackle near the base of the mantle,

carefully taking up all slack in the circle of chain.
Next, take up all slack in the vertical length of the
chain.
WARNING
Figure 6-34
Do not allow any slack in the chain as the
Ground Connection for Mantle Welding
mantle rolls over. Slack chain can allow the
mantle to fall or slip loose, causing serious
personal injury.
Changing Manganese
Figure 6-37
Turning Mantle with Chain Taut
Figure 6-35 Chains Attached to Lifting Eyes 5) Clean the mantle’s cone head seating area.
First, use a scraper to remove all protective
sealant. Next, sand or grind to ensure a smooth,
clean surface.
1. Hook 6) Replace the lifting chain to turn the mantle
2. Seating area (inside) back to an upright position. This time, secure the
1 2 shackle on the outside of the mantle as close to
its small top hole as you can easily reach (Figure
6-38). Remove all the slack in the chain circle.
WARNING
Do not allow any slack in the chain as the
mantle rolls over. Slack chain can allow the
mantle to fall or slip loose.
Figure 6-36
Shackle Bolted Near Base of the Mantle
3) Keeping the chain taut at all times, slowly lift

the mantle to a vertical position (Figure 6-37).
As you lift the mantle, move the chain slightly in
a horizontal direction so the base of the mantle
pivots in place.
148) Keeping the chain taut at all times,
continue moving horizontally while lowering
the mantle to the upside-down position. Again,
rest the chained side on a block. Unfasten the
shackle and remove the chain.
Figure 6-38 Shackle Bolted
Near Top Hole of Mantle
Changing Manganese
7) Turn the mantle right side up by repeating 13) Clean the cone head’s seating surface. Use a
steps 3 and 4 (in the reverse direction). Keeping scraper, then grind or sand until the surface is
the chain taut at all times, slowly lift the mantle clean and smooth.
to a vertical position. Continue the rotation until 14) Coat the outside of the cone head down to the
the mantle is right-side up. seating surface with a thin film of grease. This
allows backing material to release from the cone
WARNING head during the next backing change and saves
Never use low hydrogen or other mild steel cleanup time later. Do not grease the seat.
rods or hard face rods. Even when lifting
15) Form a piece of foam rubber into a donut
eyes have been welded on with best alloy, do
shape and place it on top of the cone head. While
not trust welds more than is necessary. Handle
pouring backing material, this foam ring prevents
with extreme caution! Welds break out of
the backing material from flowing onto the
manganese very easily.
threads of the mantle nut and bolt (Figure 6-39).
16) Connect separate lifting chains to each of the
8) Remove the lifting eyes you installed in the eyes on the mantle, as instructed in the mantle
Removal Procedure, steps 8 through 11, and removal procedure (Figure 6-35).
weld the eyes onto the new mantle. Be sure to
weld with three passes, as shown in Figure 6-33. WARNING
9) Fit a new mantle washer (also called a torch Do not allow anyone underneath the mantle
ring) into the top of the mantle. It should fit flat while it is in the air. If the mantle falls, death
without gaps. Check for any interference or or severe personal injury or death could occur.
rocking motion. It is sometimes necessary to
enlarge the smaller notch in the top of the mantle 17) Lift the mantle into position over the cone
so the lug on the side of the washer can fit. head. Be sure the foam rubber remains in position
on top of cone head. Slowly lower the mantle
10) Remove any excess metal on the angled
onto the cone head and bump the mantle with a
mantle hole surface that interferes with proper
sledge hammer to center the seating area.
washer fit. When you have a good fit, sand or
grind the torched area until the surface is clean 18) Put a heavy coat of anti-seize grease on the
and smooth. inside edge of the mantle hole.
11) If necessary, cut the other notch in the top of 19) Remove and replace the mantle nut seal
the mantle to about 1" (25 mm) diameter to make (O-ring) in the top bore of the cone head (Figure
it easier to pour the plastic backing material. 6-30). This is to prevent dust from packing in
around the mantle bolt.
12) Thoroughly clean old backing material off
the cone head. Fill any holes flush to the top with 20) Install mantle washer. Apply a coat of
silicone sealant to prevent plastic backing anti-seize grease on the exposed angled surface
material from locking into these depressions and of the washer.
making the next mantle change more difficult.

Changing Manganese
21) Lubricate the threads on the mantle hold-

down bolt, and threads and outside surface of the
mantle hold-down nut (Figure 6-30) with Thread
Grease, Cedarapids part no. 01-730-000-0200.
NOTICE
The mantle nut has left-hand threads.
22) Using a sledge hammer, drive the nut in a

counterclockwise direction (left hand threaded)
until it stops turning. Drive the nut onto the bolt
as tight as possible. It is impossible to over
tighten the mantle nut.
1 2
23) Center punch a hole on joint line between the
nut and washer. Drill a small pilot hole. With a 1. Cone head
1
/2" (12 mm) (approximate size) bit, drill a hole 2. Foam rubber donut
1" (25 mm) deep, parallel to the seat angle of the Figure 6-39 Foam Donut Location
nut. Drive in a 1/2" (12 mm) steel dowel full depth
of the hole. Cut off the excess dowel flush with
the mantle nut (Figure 6-31).
1
24) Prepare and pour the plastic backing. Refer
to Pouring Plastic Backing procedure that
follows. To minimize waste pour the liner and
the mantle at the same time.
25) Position the mantle nut protector cap on the
cone head. Insert mantle nut protector cap bolt.
Tighten bolt with supplied allen wrench.
NOTICE 1. Ground (earth)

Before doing any welding, ground welder 2. Welds
2
directly to the cone head.
Figure 6-40 Mantle Nut Welding
26) Connect the grounding clamp to the allen
wrench. Weld mantle nut cap to washer in three
places, 120° apart. Use McKay Chrome-Mang®,
or equivalent (Figure 6-40).
27) Remove the allen wrench, and fill the mantle
protector cap bolt hole with silicone caulk. This
makes it easier to remove at the next manganese
change.

Changing Manganese
Pouring Plastic Backing To prepare the mantle for pouring, build a pouring
Pro-Bac® plastic backing material, a 2-part epoxy spout around the 25 mm (1") pour notch in the top of
compound, is available through Cedarapids the mantle. Clay or commercial Damtite work well
Distributors in 22 or 55 lb (10 or 25 kg) buckets. It for the spout.
is good practice to have at least one extra 22 lb (10 Mix and pour the plastic backing in the mantle first
kg) container on hand to help minimize waste. so you can better control the amount of plastic that
Always mix the backing material according to the needs to be mixed to complete the job. Tapping the
manufacturer’s instructions. mantle around its perimeter with a hammer helps
Table 6-2 contains a list showing the weight of the make the backing settle and speeds pouring. A good
Pro-Bac® plastic backing material required to pour a solid pour with no air bubbles or voids is desirable.
backing cushion into the manganese relief area of Pour any excess mixed backing into the bowl liner.
the Rollercone. Casting and machining variations Complete pouring the liner. Pour the liquid plastic in
cause some differences in amounts of Pro-Bac plastic one place until you can see plastic rising around the
backing needed. liner. Then proceed to pour around the liner lip in one
direction only, being sure to fill completely as you
CAUTION go. This method assures a good solid pour without
Be sure to wear protective goggles when air pockets.
mixing or pouring plastic backing material.
Personal injury will result is backing material Upper Assembly Installation
is splashed in the eyes. 1) Attach lifting device to lifting eyes on the
bonnet (Figure 6-20).
If pouring during cold weather, bring the crusher
inside or warm the parts to approximately 16°C
(60°F) before pouring. Cold weather can prevent the WARNING
plastic from hardening properly. Do not allow anyone underneath the
To prepare the bowl liner for pouring, push paper mantle while it is in the air. If the mantle falls,
wadding or oakum into the liner loop eyes to prevent death or severe personal injury or death could
plastic backing material from flowing out of the top occur.
of the pocket.
Table 6-2 Approximate Plastic Backing Quantities
Model Chamber Total Weight Liner Mantle
Coarse 65 kg (143 lb) 43 kg (94 lb) 22 kg (49 lb)
RC45-I Med Fine 62 kg (136 lb) 40 kg (87 lb) 22 kg (49 lb)
and
RC45-II Fine 75 kg (165 lb) 35 kg (77 lb) 40 kg (88 lb)
Extra Fine 76 kg (168 lb) 36 kg (80 lb) 40 kg (88 lb)
Enlarged Feed 77 kg (170 lb) 37 kg (82 lb) 40 kg (88 lb)
Coarse 93 kg (205 lb) 51 kg (113 lb) 42 kg (92 lb)
RC54-I Medium 103 kg (227 lb) 61 kg (135 lb) 42 kg (92 lb)
and
RC54-II Med Fine 110 kg (242 lb) 68 kg (150 lb) 42 kg (92 lb)
Fine 102 kg (224 lb) 59 kg (130 lb) 43 kg (94 lb)
Extra Fine 123 kg (271 lb) 80 kg (177 lb) 43 kg (94 lb)

Changing Manganese
2) Lift the upper assembly with a properly rated If you have lowered the adjusting bolts into the
lifting device (see the Rollercone Component base frame to make removing the upper assembly
Weights chart in Section 4 - Transport and easier, carefully push the bolts up through the
Installation). Center it above the lower assembly clamp cylinders. Replace the split couplers, O-
(crusher base). Slowly lower it, being careful to rings, and lower spherical seat washers to hold
re-center it as needed. them in place. When the upper assembly is
3) Rotate the upper assembly to properly align seated, be sure to replace the adjusting bolt
it. Note the aligning mark you made during support bolts.
disassembly. The upper assembly of the 7) Place the shim stacks around the adjusting
Rollercone can be rotated to any of four positions. bolts (Figure 6-41).
All four work properly. Be sure that the adjusting 9) Lower the upper assembly until it rests on the
jacks align directly over the push pins. shim stacks. With the lifting device still attached,
adjust the shim stacks as necessay to get the
NOTICE desired Closed Side Setting (CSS). Remember
Most installations are set up with enough that it will be different than before the manganese
clearance in only one or two of the available repalcement.
rotations, due to interference from other
10) Replace the O-ring in each aligning washer.
related equipment. The standard practice is
Put anti-seize lubricant on spherical seats. Then
to place the quick couplers to the right side of
place each aligning washer over its adjusting
the Rollercone as you face the pinion shaft.
Due to a notch in the bonnet support, the bolt with the spherical side down, towards the
upper assembly of the RC45 can only be clamp cylinder.
installed one way. 11) Place the upper shim stack on top of the
aligning washer. Place the upper spherical seat
4) With the upper assembly hanging centered washer on the shim stack. Install the washer so
above the lower assembly, align the adjusting that the spherical seat faces upwards.
bolts with the clamp cylinders.
12) Install each set of split coupler halves and
5) Slowly lower the upper assembly to a point install an O-ring over the two coupler halves to
just before the bonnet support flange touches the secure them on the adjusting bolt.
top of the adjusting bolts. Check each adjusting
13) Refer to Section 7, Operation, to connect the
bolt carefully for alignment with a clamp cylinder
portable hydraulic pump and adjust the CSS, in
above it. Use caution to prevent pushing clamp
preparation for operation.
cylinder assemblies apart with the ends of the
adjusting bolts.
6) Once all the adjusting 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" (75 to 100 mm) into
the base frame.

1
2
3
4
5
6
10
11
12
13
14
15
1. Split coupler
2. O-ring
3. Upper spherical seat washer
4. Upper shim stack
5. Aligning washer
6. Clamp cylinder assembly
7. Shim guard
8. Bonnet support flange
9. Lower shim stack
10. Adjusting bolt
11. Clamp ring
12. Lower spherical seat washer
13. O-ring
14. Split coupler
15. Adjusting bolt retainer
Figure 6-41 Adjusting Bolt Cutaway

Storage
Storage to keep rain or other water from entering the

crushing chamber. Water leaking through seals
General Storage Instructions will eventually contaminate the lubricating oil.
Once every thirty (30) days, during storage or idle During freezing weather, water inside the
time of the crusher, it is important to follow specific labyrinth seals could freeze and lock the seals
maintenance procedures to avoid potential damage. together.
The purpose of the these procedures is to keep a film Consult your Terex dealer if you have any questions
of lubricant on bearings, races and gears, to prevent regarding proper storage procedures.
flat spots from developing on bearing surfaces, and
to prevent contaminants from entering the crusher. Restarting After Storage
• Run lubrication pump for two (2) to three (3) • Change the lubricating oil and filter to get rid of
minutes. any contaminants that may have entered the oil.
• Turn the sheave over at least 1/4 turn (90°). Mark • Run the lubrication pump several minutes before
the sheave with chalk to be sure this is done and starting the crusher.
to use as a reference next time. This 1/4 turn of
• Be aware that any dirt left in the seal rings at the
the sheave prevents possible rust formation at
time of storage can harden and make re-starting
the contact points between bearing rollers and
difficult, especially after freezing conditions have
race by moving each roller about one revolution.
occurred.
Be sure to remove any wedges or chocks in the
crushing chamber before attempting to turn the Consult your Terex dealer if you have difficulty
sheave. starting your crusher and suspect that contamination
of seals or lubricating oil has occurred.
NOTICE
Before attempting to turn the sheave, be sure
any wedges or chocks are removed from the
crushing chamber.
Be sure to run the lubrication pump for at
least two (2) minutes before turning the
sheave.
• Store crusher level, sitting on blocks above the

ground surface. Do not store your crusher in an
out-of-level position. If your crusher sits for 30
days or longer, it is especially important to keep
the crusher level. Over time, lubricating oil may
leak out of the pinion seal.
• Storage under roof is best. Any machine tends to
collect condensation if stored in an unheated
space. If you must store your crusher outside
while it is idle, put plywood over the bonnet
opening, then tarp the plywood and feed opening

Pre-Start Inspections
Section 7 - Operation
Pre-Start Inspections Startup Procedure

The Rollercone Daily Inspection Record included in
Section 6 of this manual is designed as a guide to help you WARNING
buildaneffectivepreventivemaintenanceprogramthrough Before starting crusher, verify that all personnel
daily inspections. A good program will reduce overall are clear of the area in, under or above the
maintenance costs and extend the life of your equipment. crusher. Verify that all personnel are clear of
drive motors, belts as well as feed and discharge
NOTICE conveyors.
Before crusher startup, complete the Rollercone
Daily Inspection Record found in Section 6, WARNING
Maintenance.
When the Rollercone is running, keep clear at all
times from the clearance area above the crusher
Cold Weather Information designed for tramp-iron relief. At any moment,
the bonnet/ hopper can jump upward to pass
Before starting the crusher in cold weather, be sure the
uncrushable material in the crushing chamber.
lube oil is liquid enough to readily drip from the dipstick.
A thermostatically-controlled heater supplied with all
new machines keeps the lube oil temperature from 60 to NOTICE
80°F (15 to 27°C) during non-crushing hours. Before starting the crusher, make sure that the
Cedarapids recommends that this system be used only lube pump operates for at least one (1) minute
when continuous line power is available. This system so that bearings are oiled before operation.
warms the oil in the sump.
1) Run through the pre-start information check list.
In operating conditions below 0°F (-17.8°C), Terex
Cedarapids recommends that you drain the factory- 2) Make sure all personnel are clear and safe.
installed hydraulic fluid from the hydro-pneumatic tramp 4) Turn on main system power.
iron relief system. This fluid has a pour point of -20°F 3) Start under crusher (discharge) conveyor.
(-28.9°C), so replace it with fluid that has a pour point
5) Turn on the Rollercone lubrication oil pump.
of -50°F (-45.6°C) or colder.
Wait about two (2) minutes before proceeding.
Hot Weather Information 6) Start main crusher drive motor(s).
The temperature in a Rollercone under hard crushing 7) Start material feed conveyor.
conditions and very high ambient temperatures can
exceed 200°F (93.3°C). Maximum lubrication oil
Shut Down Procedure
temperature should be kept below 180°F (82.2°C) for 1) Stop material feed conveyor. Wait for the crusher
oil of ISO150 weight. If your crusher’s lube oil frequently to clear before proceeding.
runs at 185°F (85°C) or higher, change to a lube oil with 2) Turn off crusher drive motor(s). Let the crusher
ISO rating of 220. This will not make the oil run cooler, come to a complete stop before proceeding.
but it sill increase the oil viscosity to protect the bearings
at the higher operating temperature. 3) Turn off power to the lubrication pump.
4) Turn off power to the undercrusher conveyor.
5) Turn off main system power. Lock out and tag
out system power.
Production Guidelines
Production Guidelines vary due to differences in material characteristics and

circuit design. Carefully study the capacity and gradation
In any crushing operation, physical characteristics of the
tables to make best use of the Rollercone in your
raw material affect the output product. Following are
application. Your Terex Cedarapids distributor will be
some guidelines for operating your Rollercone to its
glad to discuss gradations and capacities relative to each
maximum efficiency for your application.
particular installation and application.
Making Cubical Product The product gradation chart (Table 7-2) lists some
A cone crusher tends to produce a slabby product. One product sizes followed by the letter M (example: 8M,
way to enhance the product shape and minimize the flat 10M etc.) These listings refer to the size of product
and elongated particles is to force rock-on-rock attrition obtained by using the U.S. Standard Sieve Series for
crushing in the crushing chamber. To accomplish this, it square mesh wire cloth of different “M” (mesh) sizes.
is important to follow these guidelines. Mesh size is determined by number of openings per
linear inch measured from one wire center to another.
• Keep the cone under choke-fed conditions with (Example: 4M mesh contains four openings per linear
proper feed distribution 360° around feed opening inch) Product size depends on mesh size and wire gauge.
• Provide an even and consistent feed to the machine The narrower the wire gauge, the greater the open area
- use surge hoppers if necessary and the larger the product size. Metric sizes are also
taken from the U.S. Standard Sieve Series, and may
• Maintain uniform feed and do allow more than 10% differ slightly from actual inch equivalents.
undersize material in the feed
• Operate the cone in closed circuit mode Liner Selection
The cone mantles and bowl liners are wear parts. They
• Restrict the final stage reduction ratio to 4:1 maximum
are the part that compresses the rock until it breaks into
• Open the CSS 1/8" to 1/4" larger than product to get smaller and smaller pieces. When the rock breaks, it
particle on particle attrition crushing acquires sharp edges at the fracture face that wear away
the manganese surface. As the crushing surfaces wear,
• Re-circulated load is to be 25% to 30% of total load
the CSS will gradually increase. Rate of wear depends
• Restrict material with high plasticity (ex: clay, wet on the amount of rock being crushed, hardness of the
dirt, etc.) to where no pancakes are being formed. rock, abrasive content of the rock, moisture content and
other factors.
• Moisture content of material should be less than 5%
The “parallel zone”, the lower part of the crushing
• Use the proper crushing chamber for the application chamber where the manganese parts are parallel to one
• Maintain proper crusher operating rpm range another, wears the quickest. As the manganese wears,
the machine needs to be adjusted to maintain the proper
Capacity and Gradations CSS in order to maintain product specification. Because
Gross output capacities related to various closed side the parallel zone wears faster than the top part of the
settings (CSS) are listed in Table 7-1. Gradation charts manganese, as the parts are adjusted to compensate for
are shown in Table 7-2 and Table 7-3. The tables list this wear, the feed opening reduces. It is not unusual to
typical capacities of the Rollercone when crushing igneous loose up to 30% of the feed opening through the useful
rock (granite, trap, basalt etc.). The values in these life of the manganese liners. This must be taken into
tables are estimates, to be used as guidelines for what account when selecting a liner for a particular application.
can be expected from the Rollercone. Actual results may

Manganese liner and mantle configurations available for • The maximum feed size should be no larger than the
the Rollercones are shown in Figure 7- 1 through Figure average between the open side feed opening and the
7 - 5. In these illustrations, dimension ‘A’ represents the closed side feed opening.
feed opening on the closed side of the crushing chamber
when the minimum closed-side setting (CSS) is dimension • Remember that up to 30% of the feed opening will
‘C’. Dimension ‘B’ represents the feed opening on the be lost as the manganese wears.
open side of the crushing chamber when the minimum • Carefully compare the entire feed gradation.
closed side setting (CSS) is dimension ‘C’.
* 90% to 100% of the feed must pass the closed side
Illustrations and charts are to be considered guides only
feed opening .
to proper mantle and liner selection. Terex Cedarapids
offers standard and special liner configurations. Consult * No more than 10% of the feed should be smaller
your dealer for details. than the CSS.
Use the following general guidelines when selecting the * 50% to 80% of the feed should be smaller than the
right liners for your application. mid point dimension of the liners (CSS plus the
• The most efficient crushing chamber for a particular Closed Side Feed Opening) /2).
application will allow for 4 to 7 hits on the material Example: 9" feed opening with 1" CSS [(9+1)/ 2 =
as it passes through the crushing chamber. 5]. Five (5) is the midpoint dimension.
• The reduction ratio should be limited to 6:1 for With the proper liner configuration, worn parts should
coarse crushing (CSS greater than 3/4") and 4:1 for weigh 35% to 45% of what they weighed when new.
fine crushing (CSS less than 1/2"), with no bowl float Poor liner wear results in a worn set of liners that weigh
in either case. 60% or more of their original weight.
B A
Bowl Liner
C
Open Side Closed Side
Cone Mantle
Cone Head
Figure 7-1 Chamber Cross-Section Diagram

Table 7-1 Rollercone Capacities - Relative to Closed Side Setting (CSS)
Rollercone Classic (RC45-I & RC54-I)

Closed Side 1/2" 5/8" 3/4" 7/8" 1" 1-1/4" 1-1/2" 1-3/4" 2"
Setting (13mm) (16mm) (19mm) (22mm) (25mm) (32mm) (38mm) (44mm) (51mm)
RC45-I 70-87 87-106 105-126 117-144 125-154 135-170 140-180 145-185 150-188
(63-79) (79-96) (95-114) (106-131) (113-140) (122-154) (127-163) (132-168) (136-171)
RC54-I 170-225 185-240 200-275 225-310 245-340 260-360 270-380

(154-205) (168-218) (181-250) (204-282) (222-309) (236-328) (245-346)
Rollercone II (RC45-II & RC54-II)

Closed Side 1/2" 5/8" 3/4" 7/8" 1" 1-1/4" 1-1/2" 1-3/4" 2"
Setting (13mm) (16mm) (19mm) (22mm) (25mm) (32mm) (38mm) (44mm) (51mm)
RC45-II 135-170 150-200 170-225 185-245 205-270 220-320 240-340 260-360 270-380
(122-154) (136-181) (154-204) (168-222) (186-245) (200-290) (218-308) (236-327) (245-345)
RC54-II 180-210 210-250 230-280 240-300 250-340 280-385 305-405 325-450 335-475
(163-191) (191-227) (209-254) (218-272) (227-308) (254-350) (277-368) (295-409) (304-431)
Note:
All measurements with Open Circuit Capacities in
tons-per-hour (tonnes-per-hour)

Table 7-2 RC-I Nominal Product Gradation Chart

Crusher Closed Side Setting
Product Size
(mm) 5/16" 3/8" 7/16" 1/2" 5/8" 3/4" 7/8" 1" 1-1/4" 1-1/2" 1-3/4" 2"
(7.9) (9.5) (11.1) (12.7) (15.9) (19.1) (22.2) (25.4) (32) (38) (44) (51)
4" (102) 100
3-1/2" (89) 100 95
3" (76) 100 95 90
2-3/4" (70) 97.5 92 86
2-1/2" (64) 100 94.5 88 81
2-1/4" (57) 97 91 83 74
2" (51) 100 93.5 86 76 65
1-3/4" (44) 100 95 88 79 66 55
1-1/2" (38) 100 94.5 89 80 67.5 56 45
1-1/4" (32) 100 95 88 81 70 56 46 37.5
1" (25.4) 100 93.5 88 80 70.5 57.5 45 36 29
7/8" (22.2) 100 95 88 82 72 61 48 38 30 24.5
3/4" (19.1) 100 95 89.5 81.5 74 61.5 51 40 31.5 25.5 20.5
5/8" (15.9) 100 96 91 84 75 65 53 44 34 27.5 22 18
1/2" (12.7) 98 92 84 76 66 55 45 37 28.2 23 18.7 15.5
3/8" (9.5) 88 80 69 58 48 40.7 33.6 27 21.4 17.2 14 11.5
5/16" (7.9) 82 70 59 49 41.5 35 29.5 24 18.8 15.3 12.5 10.3
1/4" (6.4) 69 57 47 40 35 29.5 25 20.3 16.2 13 10.5 8.5
4M (4.8) 53 44 37 32 27.8 24.2 20.5 17 13.5 10.8 8.6 6.7
5/32" (4.0) 45 38.5 33 29 25 22 18.7 15.5 12.4 9.8 7.6 5.9
8M (2.4) 33 28.5 24.6 21.5 18.6 16.3 14 11.5 9 6.9 5.2 3.8
10M (1.7) 30.5 26 22.4 19.5 17 14.8 12.7 10.4 8.1 6.2 4.6 3.3
16M (1.0) 22.5 19.2 16.8 14.5 12.5 11 9.5 7.7 6 4.3 3.1 2.1
30M (0.55) 15.5 13 11.4 9.8 8.5 7.5 6.4 5.2 3.9 2.8 1.8 1.2
40M (0.4) 13 10.8 9.5 8.1 7.1 6.2 5.3 4.2 3.2 2.2 1.4 1
50M (0.3) 10.8 9 7.9 6.7 5.8 5.1 4.4 3.5 2.6 1.7 1.1 0.8
100M (0.15) 7.4 6.1 5.3 4.4 3.9 3.4 2.9 2.3 1.7 1.1 0.7 0.5
200M (0.08) 5 4.1 3.6 3 2.6 2.3 2 1.5 1.1 0.7 0.5 0.3

Table 7-3 RC-II Nominal Product Gradation Chart

Crusher Closed Side Setting
Product Size
(mm) 5/16" 3/8" 7/16" 1/2" 5/8" 3/4" 7/8" 1" 1-1/4" 1-1/2" 1-3/4" 2"
(7.9) (9.5) (11.1) (12.7) (15.9) (19.1) (22.2) (25.4) (32) (38) (44) (51)
4" (102) 100
3-1/2" (89) 100 95
3" (76) 100 95 90
2-3/4" (70) 98 92 86
2-1/2" (64) 100 95 88 81
2-1/4" (57) 97 91 83 74
2" (51) 100 94 86 76 65
1-3/4" (44) 100 97 88 79 66 55
1-1/2" (38) 100 96 91 80 68 56 45
1-1/4" (32) 100 97 90 83 70 56 46 38
1" (25.4) 100 99 90 82 72 58 45 36 29
7/8" (22.2) 100 99 93 86 74 64 48 38 30 25
3/4" (19.1) 100 97 94 87 80 65 54 40 32 26 21
5/8" (15.9) 98 94 87 80 69 55 46 34 28 22 18
1/2" (12.7) 100 95 88 80 69 58 47 39 28 23 19 16
3/8" (9.5) 91 84 73 63 52 44 37 28 21 17 14 12
5/16" (7.9) 85 74 63 54 46 37 31 25 19 15 13 10
1/4" (6.4) 74 61 50 44 36 32 26 21 16 13 11 9
4M (4.8) 58 48 42 35 32 26 21 18 14 11 9 7
5/32" (4.0) 50 41 36 30 28 23 18 15 12 10 8 6
8M (2.4) 40 35 30 26 24 20 16 12 9 7 5 4
10M (1.7) 35 31 26 22 20 18 14 10 8 6 4 3
16M (1.0) 28 24 21 17 15 13 10 8 6 4 3 2
30M (0.55) 20 18 15 11 9 8 6 5 4 3 2 1.5

40M (0.4) 18 15 14 10 8 7 5 4 3 2 1.5 1
50M (0.3) 14 12 12 8 7 6 4 3 2 1.5 1 0.8
100M (0.15) 11 9 9 7 6 5 4 3 1.5 1 0.5 0.5
200M (0.08) 8 7 6 6 5 4 3 2 1 0.5 0.5 0.3

527 mm 467 mm
(203¦4") (183¦8")
B A
B A
C
C
Coarse Chamber Medium Fine Chamber
A B C A B C
7" (178 mm) 7-3/4" (197 mm) 5/8" (16 mm) 3-1/4" (83 mm) 4-1/8" (105 mm) 1/2" (13 mm)
7-3/4" (197 mm) 8-1/2" (216 mm) 1-1/8" (29 mm) 3-7/8" (98 mm) 4-3/4" (121 mm) 1" (25 mm)
8-7/8" (225 mm) 9-5/8" (244 mm) 2-1/8" (54 mm) 5" (127 mm) 5-7/8" (149 mm) 2" (51 mm)
9-5/8" (244 mm) 10-3/8" (264 mm) 2-7/8" (73 mm) 5-7/8" (149 mm) 6-3/4" (171 mm) 2-3/4" (70 mm)
Mantle P/N: 02-450-022-0004 Liner P/N: 02-450-023-0010 Mantle P/N: 02-450-022-0004 Liner P/N: 02-450-386-0000
527 mm 527 mm
(203¦4") (203¦4")
A
B A B
C C
Fine Chamber Extra Fine Chamber
A B C A B C
1-3/8" (35 mm) 2-7/8" (73 mm) 3/8" (10 mm) 1-1/4 (32 mm) 2-5/8" (67 mm) 1/4" (6 mm)
1-1/2" (38 mm) 3" (76 mm) 5/8" (16 mm) 1-5/16" (33 mm) 2-3/4" (70 mm) 3/8" (10 mm)
1-5/8" (41 mm) 3-1/8" (79 mm) 7/8" (22 mm) 1-3/8" (35 mm) 2-7/8" (73 mm) 1/2" (13 mm)
1-7/8" (48 mm) 3-3/8" (86 mm) 1-1/8" (29 mm) 1-7/16" (37 mm) 3" (76 mm) 5/8" (16 mm)
2-1/4" (57 mm) 3-1/2" (89 mm) 2" (51 mm) 1-9/16" (40 mm) 3-1/2" (89 mm) 3/4" (19 mm)
Figure 7-2 RC45-I (Classic) Chamber Settings

762 mm 660 mm
(30") (26")
B A B A
C C
Coarse Chamber Enlarged Feed Coarse Chamber

A B C A B C
9-1/2" (241 mm) 10-1/4" (260 mm) 3/4" (19 mm) 10" (254 mm) 10-3/4" (273 mm) 3/4" (19 mm)
10-1/8" (257 mm) 10-7/8" (275 mm) 1" (25 mm) 10-1/4" (260 mm) 11" (279 mm) 1" (25 mm)
10-7/8" (275 mm) 11-5/8" (295 mm) 1-1/2" (38 mm) 10-7/8" (275 mm) 11-5/8" (295 mm) 1-1/2" (38 mm)
11-1/2" (292 mm) 12-1/2" (318 mm) 2" (51 mm) 11-1/2" (292 mm) 12-1/4" (311 mm) 2" (51 mm)
12-1/2" (318 mm) 13-1/4" (337 mm) 2-7/8" (73 mm) 12-1/2" (318 mm) 13-1/4" (337 mm) 3" (76 mm)
610 mm 584 mm
(24") (23")
B A B A
C C
Medium Chamber Medium Fine Chamber
A B C A B C
5" (127 mm) 6-1/8" (156 mm) 1/2" (13 mm) 3-3/4" (95 mm) 4-7/8" (124 mm) 1/2" (13 mm)
5-1/2" (140 mm) 6-5/8" (168 mm) 1" (25 mm) 4-3/8" (111 mm) 5-1/2" (140 mm) 1" (25 mm)
6-1/8" (156 mm) 7-3/8" (187 mm) 1-1/2" (38 mm) 5" (127 mm) 6-1/8" (156 mm) 1-1/2" (38 mm)
6-7/8" (175 mm) 8" (203 mm) 2" (51 mm) 5-5/8" (143 mm) 6-3/4" (172 mm) 2" (51 mm)
7-7/8" (200 mm) 9" (229 mm) 2-3/4" (70 mm) 6-3/8" (162 mm) 7-5/8" (194 mm) 2-3/4" (70 mm)
Figure 7-3 RC54-I (Classic) Chamber Settings

660 mm 660 mm
(26") (26")
B A B A
C
C
A B C A B C
1-1/2" (38 mm) 2-7/8" (73 mm) 3/8" (10 mm) 1-5/16" (33 mm) 2-3/4" (70 mm) 1/4" (6 mm)
1-5/8" (41 mm) 3" (76 mm) 5/8" (16 mm) 1-3/8" (35 mm) 2-7/8" (73 mm) 3/8" (10 mm)
1-7/8" (48 mm) 3-1/8" (79 mm) 7/8" (22 mm) 1-1/2" (38 mm) 3" (76 mm) 1/2" (13 mm)
2-1/8" (54 mm) 3-1/2" (89 mm) 1-1/8" (29 mm) 1-9/16" (40 mm) 3-1-8" (79 mm) 5/8" (16 mm)
2-1/2" (64 mm) 4-1/8" (105 mm) 2" (51 mm) 1-5/8" (41 mm) 3-1/4" (83 mm) 3/4" (19 mm)
Figure 7-3 RC54-I (Classic) Chamber Settings - Continued

527 mm 467 mm
(203¦4") (183¦8")
B A
B A
C C
Coarse Chamber Medium Fine Chamber

A B C A B C
7-3/4" (197 mm) 8-3/4" (222 mm) 3/4" (19 mm) 3-5/8" (92 mm) 5" (127 mm) 1/2" (13 mm)
8" (203 mm) 9" (229 mm) 1" (25 mm) 4-3/8" (111 mm) 5-1/2" (140 mm) 1" (25 mm)
8-3/8" (213 mm) 9-3/8" (238 mm) 1-1/2" (38 mm) 5" (127 mm) 6-1/8" (156 mm) 1-1/2" (38 mm)
8-7/8" (225 mm) 9-3/4" (248 mm) 2" (51 mm) 5-1/2" (140 mm) 6-3/4" (171 mm) 2" (51 mm)
9-3/4" (248 mm) 10-3/8" (264 mm) 3" (76 mm) 6-1/4" (159 mm) 7-3/8" (187 mm) 2-1/2" (63 mm)
527 mm 527 mm
(203¦4") (203¦4")
A
B A B
C C

A B C A B C
1-3/8" (35 mm) 3" (76 mm) 3/8" (10 mm) 1-1/4 (32 mm) 2-3/4" (70 mm) 1/4" (6 mm)
1-5/8" (41 mm) 3-1/4" (83 mm) 5/8" (16 mm) 1-5/16" (33 mm) 2-7/8" (73 mm) 3/8" (10 mm)
1-7/8" (48 mm) 3-1/2" (89 mm) 7/8" (22 mm) 1-3/8" (35 mm) 2-15/16" (75 mm) 1/2" (13 mm)
2" (51 mm) 3-5/8" (92 mm) 1-1/8" (29 mm) 1-7/16" (37 mm) 3-1/16" (78 mm) 5/8" (16 mm)
2-3/4" (70 mm) 4-3/8" (111 mm) 2" (51 mm) 1-9/16" (40 mm) 3-1/8" (79 mm) 3/4" (19 mm)
Figure 7-4 RC45-II Chamber Settings

762 mm 660 mm
(30") (26")
B A B A
C C
Coarse Chamber Enlarged Feed Coarse Chamber

A B C A B C
9-3/4" (248 mm) 10-7/8" (276 mm) 3/4" (19 mm) 10-1/8" (257 mm) 11-1/8" (283 mm) 3/4" (19 mm)
10-1/8" (257 mm) 11-1/8" (283 mm) 1" (25 mm) 10-3/8" (264 mm) 11-3/8" (289 mm) 1" (25 mm)
10-3/4" (273 mm) 11-7/8" (302 mm) 1-1/2" (38 mm) 10-5/8" (270 mm) 11-3/4" (298 mm) 1-1/2" (38 mm)
11-3/8" (289 mm) 12-3/8" (314 mm) 2" (51 mm) 11-1/8" (283 mm) 12-1/8" (308 mm) 2" (51 mm)
12-1/4" (311 mm) 13-3/8" (340 mm) 3" (76 mm) 12" (305 mm) 13" (330 mm) 3" (76 mm)
610 mm 584 mm
(24") (23")
B A B A
C C
Medium Chamber Medium Fine Chamber

A B C A B C
5-1/8" (130 mm) 6-1/2" (165 mm) 1/2" (13 mm) 3-5/8" (92 mm) 5" (127 mm) 1/2" (13 mm)
5-3/4" (146 mm) 7-1/8" (181 mm) 1" (25 mm) 4-1/4" (108 mm) 5-5/8" (143 mm) 1" (25 mm)
6-1/2" (165 mm) 7-3/4" (197 mm) 1-1/2" (38 mm) 4-7/8" (124 mm) 6-1/4" (159 mm) 1-1/2" (38 mm)
7" (178 mm) 8-3/8" (213 mm) 2" (51 mm) 5-1/2" (140 mm) 6-7/8" (175 mm) 2" (51 mm)
8-3/8" (213 mm) 9-5/8" (244 mm) 3" (76 mm) 6-3/4" (171 mm) 8" (203 mm) 3" (76 mm)
Figure 7-5 RC54-II Chamber Settings

660 mm 660 mm
(26") (26")
B A B A
C
C

A B C A B C
1-1/2" (38 mm) 3" (76 mm) 3/8" (10 mm) 1-5/16" (33 mm) 2-15/16" (75 mm) 1/4" (6 mm)
1-5/8" (41 mm) 3-1/4" (83 mm) 5/8" (16 mm) 1-3/8" (35 mm) 3" (76 mm) 3/8" (10 mm)
1-7/8" (48 mm) 3-1/2" (89 mm) 7/8" (22 mm) 1-1/2" (38 mm) 3-1/16" (78 mm) 1/2" (13 mm)
2-1/8" (54 mm) 3-3/4" (95 mm) 1-1/8" (29 mm) 1-9/16" (40 mm) 3-3/16" (81 mm) 5/8" (16 mm)
3" (76 mm) 4-1/2" (114 mm) 2" (51 mm) 1-5/8" (41 mm) 3-1/4" (83 mm) 3/4" (19 mm)
Figure 7-5 RC54-II Chamber Settings - Continued

Adjusting Closed Side Setting
Adjust Closed Side Setting Table 7-4 Shim Set

When adjusting the closed side setting (CSS), be sure Approximate
Color Number Expected
the reduction ratios for the Rollercone are limited to 6:1 Thickness
Code Stamp Change
for coarse crushing (CSS greater than 3/4") and 4:1 for in CSS
fine crushing (CSS less than 1/2"). Do not allow bowl Green – 1.6 mm (1/16") 1 mm (3/64")
float in either case.
White 1 3 mm (1/8") 2 mm (3/32")
Minimum CSS is defined as the closest setting possible
that does not induce bowl float. However, the practical Yellow 2 5 mm (3/16") 4 mm (9/64")
minimum CSS at a given crushing site can vary widely, Black 3 6 mm (1/4") 5 mm (3/16")
depending on the nature and condition of the material
being crushed, as well as variations in crusher operating Red 4 8 mm (5/16") 6 mm (1/4")
styles.
Blue 5 10 mm (3/8") 7 mm (8/32")
CSS is adjusted by removing or installing various thickness
Orange 6 13 mm (1/2") 9 mm (3/8")
shims on the clamp cylinders. The total height of the shim
stack must always remain constant at each clamp cylinder, Brown 7 16 mm (5/8") 12 mm (15/32")
but by placing some shims below the bonnet support
Purple 8 19 mm (3/4") 14 mm (9/16")
flange and some above it, you vary the CSS to the
dimension you need. Be sure the respective upper and Grey 9 22 mm (7/8") 16 mm (21/32")
lower shim stack on each of the clamp cylinders match
exactly. Refer to Table 7-4 for a listing of available shims Green 10 25 mm (1") 19 mm (3/4")
and the relative change in CSS for each shim used. To White 11 38 mm (1-1/2") 28 mm (1-1/8")
help match stack heights around the crusher, the shims
are color-coded and numbered.
Before the CSS can be changed, the clamp pressure WARNING
must be relieved and the weight of the upper assembly
lifted so shims can be moved. Use the following procedure
skin, causing serious injury. Be sure to relieve
to adjust the CSS (Figure 7-6 and Figure 7-7).
pressure before connecting/disconnecting
1) Lower the shim guard and connect the portable hydraulic lines.The pump output capacity is
hydraulic pump quick couplers to the clamp cylinder about 10,000 psi (68950 kPa). Before starting
and adjusting jack manifolds. Connect hose A (top the pump, be sure the threaded fittings at the
hose) to the clamp cylinder manifold valve and hose couplers are fully engaged and the couplers are
B (bottom hose) to the adjusting jack manifold block tight.
(Figure 4-1). Set the pump handle to the NEUTRAL
position. Do not start the pump until you are instructed 2) Use a wrench to close the valve at the bottom of
to do so. the clamp system accumulator.
NOTICE NOTICE
When connecting the electric hydraulic pump Do not overtighten the accumulator valve. The
hoses to the quick couplers, be sure to clean the valve seat can be easily damaged.
hose tip and quick couplers of dirt or other
obstructions. Be sure threads are clean and in
good condition.
2 9
3
10
4 11
5 12
6
13
7 14
15 (about 1/4" (7mm) to 5/8"
(16mm) brass showing
when fully clamped)
16
17
8 2" (50mm) 18
20 19
A Neutral B
1. Clamp system accumulator 7. Pressure gauge 14. Aligning washer

2. Clamp system accumulator 8. Control valve (pump handle) 15. Brass showing
valve 9. Clamp cylinder manifold valve 16. Clamp cylinder
3. Adjusting jack manifold 10. Split coupler 17. Hose A
block 11. O-ring 18. Hose B
4. Jack/ ram 12. Upper spherical seat washer 19. Bonnet support
5. Portable hydraulic pump 13. Upper shim stack 20. Lower shim stack
6. POWER switch (JOG/OFF/RUN)
Figure 7-6 Adjusting Closed Side Setting (CSS)

Closing the valve at the accumulator retains the fluid NOTICE

already trapped in the accumulator. This reduces both
the amount of fluid needed to repressurize the system To reduce the CSS do step 5. To increase CSS
and the amount of time required to make an adjustment. do step 6. Go to step 7 when step 5 or step 6 is
completed. Refer toTable 7-4 as an aid in
3) Use a wrench to slowly open the clamp cylinder
estimating the shims required for a desired CSS
manifold valve. Set the pump handle to POSITION A.
Pressure is released on the clamp cylinders as fluid is 5) a. Remove the desired shim(s) from each lower
routed to the pump reservoir. shim stack.
4) Move the pump handle from POSITION A to
POSITION B. Start the pump to pressurize the adjusting WARNING
jack system to 10,000 psi (68900 kPa). This will When the control valve is set to position A the
extend the jacks and raise the upper assembly about upper assembly may drop suddenly to fill a gap
1/8 inch (3.2 mm) off the lower shim stacks. When in the shim(s). Be sure all personel and tools are
the exposed brass sleeve on the clamp cylinder can clear of the area before operating the pump
no longer be seen, stop the pump. control valve.
Note: 1
Invert every other 2
shim to provide a 3
locking action 4
5
6
1. Split coupler 10
9. Lower shim stack
2. O-ring
10. Adjusting bolt
3. Upper spherical seat washer 11
11. Clamp ring
4. Upper shim stack 12
12. Lower spherical seat washer
5. Aligning washer 13
13. O-ring
6. Clamp cylinder assembly 14
14. Split coupler
7. Shim guard 15
15. Adjusting bolt retainer
8. Bonnet support flange
Figure 7-7 Adjusting Bolt/ Shim Stack Cutaway

b. With the pump power off, set the pump handle to

POSITION A. The upper assembly settles onto the
lower shim stacks.
c. Install the shims, removed from the lower stack,
into the upper shim stack. Be sure the shim stacks on
all adjusting bolts match exactly. Proceed to step 7.
6) a. With the pump power off, set the pump handle
to POSITION A. The upper assembly will lower
slightly and loosen the upper shim stack. Remove the
desired shim(s) from the upper shim stack.
b. Set the pump control valve to POSITION B. Using
the JOG position on the pump power switch,
intermittantly run the pump to raise the upper assembly
just enough to install the shims, you removed above,
into the lower shim stack.
c. With the pump power off, set the pump handle to
POSITION A. The upper assembly settles onto the
lower shim stacks. Be sure the shim stacks on all
adjusting bolts match exactly. Proceed to step 7.
7) With the pump handle still in POSITION A, start the
pump and charge the clamp cylinder system to 1600
psi (11032 kPa). Open the valve on the clamp system
accumulator. If the pressure drops off, continue to
run the pump until the pressure stabilizes at 1600 psi
(11032 kPa). When properly clamped, there should
be about 1/4" (7mm) to 5/8" (16mm) of brass
showing on the clamp cylinder. Stop the pump.
9) Close the clamp cylinder manifold valve.
11) Using a small pry bar, raise any one of the
adjusting jack rams at least 2" (50 mm) above the
bonnet support frame. This allows for any thermal
expansion in the jacking system.
13) Move the pump handle between POSITION A and
POSITION B a couple times to release all pressure in
the hydraulic hoses. Disconnect the hoses from the
quick couplers and install the dust covers on the
couplers.
14) Raise and secure the shim guard panel in place.

Troubleshooting Helps
Section 8 - Troubleshooting
Troubleshooting Helps float causes damage to vee seat wear strips. If it goes
In this section, some operating problems are listed on too long, bowl float will cause the relief cylinder
along with possible remedies. The remedies given seals to leak and can lead to bonnet cracks. The end
here may not apply in every case, but they represent result will be costly repairs and downtime.
sound thinking and experience of service and Bowl float may not be visible without careful
engineering departments at Cedarapids. observation. You can detect it by looking for
This list is not intended to be exhaustive. If your movement between the bonnet and bonnet support
or between the stop blocks. Even a small but continual
Rollercone has any operating problem not listed
below, consult your Terex Cedarapids Distributor, movement can develop serious problems.
or Cedarapids Inc at 1-800-821-5600. A number of factors can contribute to bowl float.
Some of the common conditions which lead to bowl
Vibrating Too Much float are described below.
1) Check for missing or worn counterweight. • CSS Too Small
Replace or repair. Minimum closed side setting is the closest setting
2) Check crusher support, stanchions, or concrete possible that does not induce bowl float. The actual
pads for out-of-level or not being properly minimum closed side setting at a given crushing site
braced. Replace, repair or level as needed. can vary widely, depending on the nature and
3) Check the counterweights for wear, especially condition of the material being crushed, as well as
common variations in crusher operating styles. The
the leading counterweight. Improper balance
Rollercone crusher is able to reduce the size of rock
can cause excessive vibration.
in a ratio of up to 6:1.
4) Check the condition of the drive sheave
This reduction capability depends on the rock’s
whenever vibration is detected. Dirt or mud
compressive strength, friability (how it breaks), and
buildup in the crusher or motor sheaves can the gradation of the feed. The rock reduction ratio
also cause unbalanced running. may be less or slightly more in some circumstances.
Running Too Hot One possible cause of bowl float is trying to make
too large a reduction for the given conditions. This
1) Oil viscosity inadequate. Change to heavier causes a high crushing pressure in the crushing
grade. chamber, that overcomes the relief system’s hold
2) Inadequate oil flow. See the Rollercone Service down pressure.
Manual or call your service representative. Remedy: Opening the CSS a small amount reduces
3) Excessive ambient temperature (very hot or stops bowl float in these conditions.
weather). Use heavier grade oil.
• Too Little Feed Into the Crusher
4) Too small a closed side setting (CSS). When the crusher is not choke fed, the rock tends to
feed to one side of the cone. It also feeds farther
Bowl Float down into the crushing chamber with each cycle
Bowl float is sometimes called bonnet flotation. It is than if the crusher is choke fed. This can cause a
very important that bowl float is not allowed on your bowl float condition by forcing the cone to make a
Rollercone crusher. larger than normal reduction to the rock with each
Check the crusher for bowl float after making any cycle. Localized high pressures can result that
change in setting, feed material, or feed rate. Bowl overcome the hold down pressure in that area and
float the bonnet.
Troubleshooting Helps
Long term feeding of the crusher in this manner will Remedy: Check and readjust the pressure in the
cause uneven wear of the bowl liner since most of the tramp iron relief system.
crushing is on one side. This results in a crushing
chamber that does not have the same cross-section or WARNING
CSS around the whole chamber. This in turn causes
further bowl float because a larger volume of material Do not attempt any repairs to accumulators
will be fed into one section of the crushing chamber. unless properly trained. They are pressure-
containment vessels which can remain very
Remedy: Choke feed into the center of the crusher
dangerous even when detached from the
hopper.
Rollercone.
• Excessive Near-Size or Fines in the Feed
In these conditions the near size and fine materials • Air in the Relief System
flow farther into the crushing chamber than the Air bubbles in the relief system can contribute to
larger material. This fills up the spaces in the lower bowl float.
part of the crushing chamber. Bowl float results Remedy: If you suspect air in the relief system, drain
because all of the voids (spaces between rocks) are the pressure and all oil from the system. Open the
filled and no room is left for the rock to move into as bleeder valves located around the top of the manifold
it is crushed. A pound of crushed rock takes up more and bleed all air from the system. Refill the relief
space than a pound of solid rock. system with clean, proper oil until clear oil runs from
In extreme cases of this condition, pancakes form the bleeders. Shut off the bleeders and repressurize
from recompressing crushed rock to the point that it the system.
is packed into a solid mass. Pancakes formed in this
manner will be warm when leaving the crusher. • Material Backing Up into the Crushing
Chamber
Remedy: Investigate the screening efficiency. Screen
If material does not feed through the crusher due to
out these fines before crushing.
an obstruction in the discharge area, rock backs up
• High Content of Clay or Plastic Material into the crushing chamber.
Plastic substances such as clay or soft rock may Remedy: Check the under-crusher hopper and
cause material to stick to the mantle or liner. The discharge area to see that the discharge is free of
sticky material can build up into a “pancake” that obstructions and that sticky materials are not building
prevents rock from moving freely through the up under the crusher.
crushing chamber. Too many pancakes will cause Three rules will usually prevent bowl float:
bowl float. Pancakes formed in this manner will be
1) Don’t operate on low relief system pressure.
cooler when leaving the crusher than pancakes formed
by recompression. 2) Don’t let rock back up in the crusher.
Remedy: A wash system or increased washing will 3) Don’t crush clay or plastic materials that can’t
remove some of these materials. clear at close settings.
• Loss of Relief System Pressure Bowl float is sometimes caused by a combination of
the above conditions.
The pressure in the relief system holds the bonnet in
place against the crushing forces. If the pressure falls If these recommendations have been followed and
to a point where the hold down force is less than the the bonnet is still floating, contact your Service
crushing forces, the bonnet floats. Representative right away. Don’t operate your crusher
if bowl float is happening.
Glossary
Appendix A - Glossary
Accumulator: A steel pressure-containment vessel Counterweights: Rectangular weights bolted to the

inside of which a bladder is filled with nitrogen gas side of the wedge plate to balance the wedge plate
under pressure. assembly.
Batter board: A plate positioned so that feed material Cubical fractures: A fracture pattern in rock that
will impact it and change the direction of flow. Its results in sides that are 90° to each other, giving a
purpose is to direct the flow and reduce the forward particle that has six approximately equal sides.
velocity of the material. Fines: Particles smaller than average in a mixture of
Bonnet: A component that supports the bowl liner particles varying in size. When feeding a Rollercone
and rises against the relief cylinder pressure to pass II, any material smaller than the closed side setting.
tramp iron. Friable, friability: The ease with which a material
Bonnet support: The component on which the bonnet is crumbled, pulverized, or reduced to powder.
rests during normal running and which is adjusted up Igneous rock: Rock that is formed from a molten
or down to change the closed side setting. mass.
Bonnet float: See bowl float. Labyrinth seal: A minimum leakage seal that offers
Bowl float: The periodic separation of the bonnet resistance to fluid flow while providing radial and/
from the bonnet support during operation. Excessive or axial clearance.
pressures in the crushing chamber “float the bowl” Metamorphic rock: Rock formed from pre-existing
(that is, force the bonnet upwards away from the rocks by mineralogical, structural, and chemical
bonnet support) if the crushing pressures overcome changes, in response to pressure, and shearing
the hold down pressure in the relief system. stresses.
CSS: Closed side setting. The CSS is the nearest Open circuit crushing system: A processing system
distance the upper and lower crushing surfaces that does not return oversized material directly back
approach each other. to the crusher.
Choke feed: Feeding the crusher so that the top feed Pancaking: The formation of flat pieces of
area of the crusher is completely full. The level of compressed material in the crushing chamber.
material feeding into the crusher fills at least 1¦3 of the
hopper. Parallel zone: The lower end of the crushing chamber
where the two liners are parallel at the CSS.
Clamp cylinder: A hydraulic jack which is
pressurized by the clamp system accumulator. It Ratio of reduction: The ratio of the size of the feed
allows the Rollercone II to maintain an accurate material to the size of the material discharged by the
closed side setting so that rock of a uniform size can crusher.
be produced. Recirculating load: The amount of material sent
Clamp system accumulator: A steel pressure- back to the crusher in a closed circuit.
containment vessel inside of which a bladder is filled Relief cylinder: One of a group of hydraulic cylinders
with nitrogen gas under pressure. which is pressurized through a manifold, holding
Closed circuit crushing system: This circuit has a the bonnet down to oppose the crushing forces.
flow pattern which recirculates all material coming When non-crushable material (such as tramp iron)
out of the crusher. The rock flows over a screen, enters the crushing chamber, the relief cylinders
sending the oversized portion back into the crusher. allow fluid to escape into the accumulator, permitting
The material that is to the desired size is removed the bonnet to rise and pass the non-crushable material.
ahead of the crusher.
23830 (01/07) A-1 Terex Rollercone Crusher
Glossary
Relief system 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.
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.
23830 (01/07) A-2 Terex Rollercone Crusher

Torque Values
Appendix B - Torque
Specifications
NOTICE
Maximum torque values listed are based on 75% of
the specified minimum proof strength of bolt steel
in order to provide a safety factor. Hardened washers
should always be used regardless of whether
standard nuts or lock nuts are employed. The term
“lube” applies to cadmium plating and/or
application of thread lubricants.
Table B-1 Torque Values for Metric Hardware
Property Class = 8.8 Property Class = 10.9 Property Class = 12.9

8.8 10.9 12.9
dia pitch Dry Lube Dry Lube Dry Lube

(mm) (mm) (ft-lbs) N-M (ft-lbs) N-M (ft-lbs) N-M (ft-lbs) N-M (ft-lbs) N-M (ft-lbs) N-M
10 1.5 37 50 29 39 53 72 41 56 62 84 48 65
10 1.25 39 53 30 41 56 76 43 58 66 89 51 69
12 1.75 65 88 50 68 93 126 71 96 109 148 83 113
12 1.25 71 96 55 75 101 137 78 106 119 161 91 123
14 2 104 141 80 108 148 201 114 155 173 235 133 180
14 1.5 112 152 86 117 160 217 123 167 187 254 144 195
16 2 161 218 124 168 230 312 177 240 269 365 207 280
16 1.5 172 233 132 179 246 334 189 256 287 389 221 300
18 2.50 230 312 177 240 318 431 245 332 372 504 286 388
18 1.5 258 350 199 270 357 484 275 348 418 567 321 435
20 2.5 325 441 250 339 450 610 346 469 525 712 404 548
20 1.5 360 488 277 376 499 677 384 521 583 791 448 607
22 2.5 443 601 341 462 613 831 471 639 716 971 551 747
22 1.5 486 659 374 507 673 913 518 702 786 1066 605 820
24 3 562 762 432 586 777 1054 598 811 908 1231 698 946
24 2 612 830 471 639 847 1149 652 884 990 1342 762 1033
27 3 823 1116 633 858 1139 1544 876 1188 1331 1805 1024 1389
27 2 889 1205 683 926 1229 1667 945 1281 1436 1947 1105 1498
30 3.5 1117 1514 859 1165 1541 2089 1185 1607 1810 2454 1392 1887
30 2 1236 1676 951 1289 1705 2312 1312 1778 2004 2717 1541 2089
33 3.5 1520 2061 1169 1585 2096 2842 1613 2187 2463 3339 1895 2569
33 2 1667 2260 1282 1738 2299 3117 1768 2397 2701 3662 2078 2817
36 4 1952 2647 1501 2035 2692 3650 2071 2808 3163 4288 2433 3299
36 3 2067 2802 1590 2156 2850 3864 2193 2973 3349 4540 2576 3493
39 4 2526 3425 1943 2634 3484 4724 2680 3634 4094 5551 3149 4269
39 3 2666 3615 2051 2781 3677 4985 2828 3834 4320 5857 3323 4505
23830 (01/07) B-1 Terex Rollercone Crusher

Torque Values
Table B-2 Torque Values for Standard Hardware
S.A.E Grade 2 S.A.E Grade 5 S.A.E Grade 8
Torque (ft-lbs) Torque (ft-lbs) Torque (ft-lbs) Clamp

dia. pitch Clamp Clamp
Load
(inches) (thread/in.) Dry Lube Load (lbs) Dry Lube Load (lbs) Dry Lube (lbs)
1/4 20 5 4 1310 8 6 2020 12 9 2860
1/4 28 6 5 1500 10 7 2320 14 11 3270
5/16 18 11 9 2160 17 13 3340 25 19 4710
5/16 24 12 10 2390 19 15 3690 27 21 5220
3/8 16 20 15 3190 31 24 4940 44 34 6970
3/8 24 23 17 3620 35 27 5590 49 38 7900
7/16 14 32 25 4380 49 38 6770 70 54 9560
7/16 20 36 27 4890 55 42 7560 78 60 10680
1/2 13 49 38 5850 75 58 9040 106 82 12770
1/2 20 55 42 6590 85 65 10190 120 92 14390
9/16 12 70 54 7500 109 84 11600 150 115 16380
9/16 18 79 60 8370 121 93 12940 170 130 18270
5/8 11 97 75 9320 150 115 14400 210 160 20340
5/8 18 110 85 10560 170 130 16320 240 180 23040
3/4 10 170 130 13770 265 200 21290 375 285 30060
3/4 16 190 145 15380 295 225 23770 415 320 33570
7/8 9 165 125 11430 425 330 29450 605 465 41580
7/8 14 180 140 12590 470 360 32440 665 510 45810
1 8 245 190 14990 640 495 38630 905 695 54540
1 14 270 210 16400 700 540 42260 990 765 59670
1-1/8 7 350 270 18880 790 610 42340 1285 990 68670
1-1/8 12 395 305 21180 890 685 47500 1440 1110 77040
1-1/4 7 495 380 23980 1120 860 53770 1815 1395 87210
1-1/4 12 550 425 26550 1240 950 59550 2010 1545 96570
1-3/8 6 655 500 28580 1465 1130 64100 2380 1830 103950
1-3/8 12 745 570 32540 1670 1285 72980 2710 2085 118350
1-1/2 6 865 665 34770 1945 1495 77970 3160 2430 126450
1-1/2 12 975 750 39120 2190 1685 87740 3555 2735 142290
1-3/4 5 1370 1055 47020 2285 1755 78370 4985 3835 170990
2 4.5 2060 1585 61870 3435 2640 103120 7500 5765 225000
2-1/4 4.5 3015 2320 80430 5025 3865 134060 10960 8435 292500
2-1/2 4 4125 3170 99000 6875 5285 165000 15000 11530 360000
2-3/4 4 5590 4300 122010 9320 7165 203360 17790 13680 388230
3 4 7385 5680 147750 12310 9470 246260 23500 18080 470130
23830 (01/07) B-2 Terex Rollercone Crusher

Tools, Parts and Materials List
Appendix C - Tools, Parts and

Materials List
NOTICE Special Requirements

Always check your parts book for correct Section 4 - Transport and Installation
part number of special tools or required
Block the Cone Head
parts.
Materials:
General Requirements • Wooden block, at least 300 x 300 x 100 mm
Hoist or other lifting device: (12 x 4 x 4")
• For lifting weights, see Table 4-2, Rollercone Setting Up On Site (if portable plant)
component weights Tools:
Rigging: • Level, at least 1000 mm (39") long
• 2 equal-length lifting cables or chains (steel Parts:
wire rope or chains with a minimum break
• Trailer support jacks and appropriate bar for
strength of 4 times weight to be lifted)
turning screwjacks
• 2 equal shackles with bolt or pin fasteners
Trailer Mounting (if not an CR trailer)
Tools:
Parts:
• Safety glasses or goggles
• Mounting springs (2 minimum), ElJay part
• Work and welding gloves #04-70-1130-0460
• Portable hydraulic pump • Foot bolts (2 minimum), ElJay part
• Quick coupler (supplied with the crusher), #04-70-1135-0313
ElJay part #01-224-005-0260 Weights and Lifting Procedures
• Oxyacetylene torch Materials:
• Arc welder • 3 pairs of flat steel bars at least 12.5 x 100 x
9
• /16", 3/4", 1-1/4" open end or adjustable wrenches 360 mm (1/2 x 4 x 14") drilled in accordance
• 1" Allen wrench (supplied with the crusher) with Section 7
• Small pry bar • 6 bolts, 40 mm (1-1/2")
• Sander or grinder Section 5 - Lubrication
• Heavy hammer Taking Oil Samples
Materials: Parts:
• Silicone sealer • Sampler needle assembly
• Cedarapids Rollercone® Thread Grease (part • Sampling bottle

#01-730-000-0200), or anti-seize grease
• McKay’s Chrome-Mang® welding rod, or
equivalent
23830 (01/07) C-1 Terex Rollercone Crusher

Tools, Parts and Materials List
Section 6 - Maintenance Changing Bowl Liner Manganese

How to Change Lubricating Oil Tools:
Parts: • Steel bar (to drive down bowl liner, if necessary)
• Oil filter replaceable element* • Manganese press (if liner is very difficult to
• Filter housing seal (for fixed cap on RC45II) remove).
• Canister seal and O-ring (for fixed canister on • Steel ring or beam larger than liner feed opening
RC54II) • Long, heavy bar (to use as a punch to reach into
Materials: upper assembly when replacing wedges)
• Oil (see Figures 5-4 and 5-7 for type and Changing Cone Mantle Manganese
quantity) Tools:
• Funnel • Mantle nut wrench (supplied with the
• Container for used oil. Rollercone)
• Bar stock to use as a punch, if necessary
Checking Relief System Fluid Pressure;
Checking Nitrogen Gas Precharge Pressure; • Drill with 12 mm (1/2") bit (approximate size)
Charging the Tramp Iron Relief System Materials:
Tools: • Mild steel plate for lifting eyes, 13 mm (1/2")
• Charging gauge assembly, 0-20000 kPa (0- thick
3000 psi), See Figure 10-10. ElJay part #02- • Foam rubber strip (supplied with Rollercone)
360-547-0000 or equivalent • Steel dowel, 12 x 15 mm (1/2 x 1")
• Nitrogen gas pressure gauge, 0-20 000 kPa (0- Pouring Plastic Backing Material
3000 psi), see Figure 10-9. Can be assembled
from the charging gauge assembly and a 1/4" Materials:
high pressure pipe plug, • Masking tape
• Hose, 1/4" with 1/4" npt (pipe thread) on one • Clay or commercial Damtite
end, long enough to reach container • Oakum or paper wadding
• Clean container for hydraulic fluid, 60 liter (15 • Pro-Bac® liquid plastic backing material, or
gallon) minimum capacity equivalent
Materials: Installing the Upper Assembly
• Hydraulic fluid (see Figure 10-8 for the capacity Materials:
for your model)
• O-rings
• Nitrogen gas bottle(s), fully pressurized (one
or more depending on how much the actual
pressure in each accumulator deviates from
the correct pressure. A new, fully pressurized
nitrogen gas bottle must be used each time the
pressure in the old bottle drops too low to raise
the pressure in the accumulator(s) to 13450 ±
345 kPa (1950 ± 50 psi))
23830 (01/07) C-2 Terex Rollercone Crusher
General Belt Care
Appendix D - Belts and Sheaves
General Belt Care tension frequently during this period. Slack belts
cause slipping and excessive wear. They cost you
You get more service from V-belts if you keep them money by delivering less power and causing more
clean and dry. Rock dust and rust from metals are frequent replacement.
abrasive. Oils and acids deteriorate belt material.
5) Periodically inspect V-belt drives for proper
Dust buildup in sheaves causes harmful vibration. On
belts, dust or water causes slippage. sheave alignment (Figure D-1) and wear to
the belts or sheaves (Figure D-2)
Belt dressing compounds are generally worthless.
6) Do not overtighten belts.
Most belt dressings actually shorten belt life. Clean,
well cared for belts are the best answer to problems Overtightening shortens useful life of belts and
that belt dressings are meant for but do not solve. sheaves and also places undue strain on shafts
Daily cleaning of belts and sheaves by blowing them which, in turn, causes premature bearing failure.
off with compressed air increases their useful life and Ideal belt tension is the lowest at which belts won't
saves you money. slip under peak load.
Store belts in a cool and dry environment with no
direct sunlight. Store on shelves or in original
containers. Belts may be stored by hanging on a wall
rack if they are hung on a saddle with a diameter at
least as large as the minimum diameter sheave
recommended for the belt cross section. Do not ever
allow belts to be bent to diameters smaller than what
is recommended for the belt cross section.
1) Keep belts and sheaves clean. OK
2) Avoid belt or sheave rubbing. Don't let belts or
sheaves rub against the guard (or anything else)
while they’re running.
3) Drive your belts with motors mounted on adjustable
bases. OK
Mount drive motors on a slotted base, so you can

shorten the distance from motor to driven sheave Figure D-1 Align Sheaves
when you need to do so. This allows convenient and 7) Keep belts straight (Figure D-1).
proper installation of belts. Prying on belts with tools
cracks and prematurely breaks them. With belts already Don't allow V-belts to run out of alignment. To
lightly seated in their grooves, you can tighten the run properly, sheaves must be parallel and grooves
belts correctly by moving the motor and rolling the must be in line.
sheaves at the same time. 8) Use only matched belts. A matched set of belts
4) Keep belts tight. lasts longer because loading is evenly divided
among all the belts.
Most belt stretch occurs in the first 30 to 40 hours of
Belts often wear at the sides, so their cross-
operation after new belts are installed. Check belt
sectional area decreases. They stretch with use
and age. New belts ride higher in sheave grooves.
23830-Rev A (03/08) D-1 Terex Rollercone Crusher
General Belt Care
They travel faster and take higher tension than worn much strain on remaining ones. They will break
belts. If it's center cord breaks, a belt stretches and down quickly and cause you downtime.
won't carry it's load. Installing one or two new belts 10) Replace worn sheaves.
with a partially used set very soon wears and stretches
the new ones until they are in poor condition. Worn sheaves reduce belt life. If the sheave is worn
enough that belts touch bottom in the grooves, belts
Belts from different manufacturers should not be soon start to slip and burn.
mixed in a set because of slight material and quality
differences that could reduce the life of all the belts. If your maintenance program takes all of these
Always replace belts in full sets. things into account, you should experience minimal
trouble with belts and sheaves. Still, you’re bound
9) Don't overload. to experience some problems, sooner or later. When
If the sheave has 10 grooves, use 10 belts. Using less you do experience problems, refer to Table D-1 as
than the designed number of drive belts puts too a troubleshooting tool.
Trouble Cause Correction

Belts slip (sidewalls glazed) Insufficient tension Replace belts; increase tension
Overloaded drive. Find cause and correct.
Drive squeals. Arc of contact too short. Increase distance between hubs.
Heavy starting load. Increase tension.
Broken cord caused by prying. Replace belt correctly.

Overloaded drive. Redesign drive.
Impulse Loads. Apply proper tension.
Misalignment. Realign drive.
Belt rolls over. Worn sheave grooves. Replace sheave.
Flat idler sheave. Align and reposition.
Excessive vibration. Check drive design, mounting.
Consider banded belts.
New belts installed with old. Replace belts with matched set.
Sheave grooves worn unevenly. Replace sheaves.
Mismatched belts
Improper groove angle.
Shafts not parallel. Align drive.
Shock loads. Apply proper tension.
Heavy starting load. Apply proper tension.

Use compensator starting.
Belt breaks
Belt pried over sheaves. Replace belt correctly.
Foreign object in drive. Determine source of object, design
guard to correct problem.
Sheave grooves worn. Replace sheaves.

Sheave diameter too small. Redesign drive.
Mismatched belts. Replace with matched set.
Drive overloaded. Redesign drive.
Belt wears prematurely. Belt slips. Increase tension.
Sheaves misaligned. Align sheaves.
Oil present. Eliminate oil.
Excess heat present. Ventilate drive.
Table D-1 Belt-Drive Troubleshooting

Maintaining V-Belt Tension
Maintaining V-Belt Tension 4) Use a sheave gauge (Figure D-3) to look for steps
worn in sheave grooves. Steps are a measure of
General Recommendations
sheave wear. Belts must not bottom out in
1) Check drive belt tension daily. Check condition grooves.
of belts and sheaves for excessive wear (Figure
5) If the belts are not tight enough, loosen drive
D-2).
motor mount bolts and adjust take-up bolts to
2) If belts are worn, replace with a new matched set. tighten belts. Retighten motor mount bolts to
3) If sheaves are worn excessively, replace them. hold tension.
Worn Sheave Worn Belt Just Right

or Sheave
0
Ov PD
PD 17.
.0 ”
38 17.0
e
13 36
o
r
”
t
Standard
D
Section
PD
12.0 to 12.99
34”
Figure D-2 Belt & Sheave Wear Figure D-3 Sheave Gauge Shows Wear
Each 1/64" mark equals 1" of belt span Each Mark Equals 1 Pound Pressure
(Centimeters on Opposite Side) (Kilograms on Opposite Side)
1 INCHES 2 5 15 20 25 30
10
Large O-ring
Small O-ring
1 CM 2 3 4 5 6 0 2 4 6 8 10 12 14
Figure D-4 Belt Tension Tester (Cedarapids P/N 45500-036-08)

Using Mechanical Tester

.38” .62” 1.0”
1) Measure span length "T" (Figure D-5).
3V .31” 5V 8V
2) Position large O-ring on tester at 1/64 inch (0.397 .54”
mm) for each inch of belt span. Set small O-ring .88”
at zero (Figure D-4) and (Figure D-5). Example:
For belt span of 48 inches (1.219 m), setting
would be 48/64 inch (3/4 inch, or 19.05 mm).
.50” 1.25”
3) At center of belt span, push yellow tipped plunger
until bottom of large O-ring is level with top of A .31”
adjacent belt (Figure D-5). If there is no adjacent D .75”
belt, lay straight edge between sheaves for .66”
reference.
4) Remove tester and read belt deflection force, in B .41”
pounds, at small O-ring. Compare this figure 1.5”
with values given in Table D-2 and Table D-3.
.88”
Use Figure D-6 to help find the belt cross section E
style. If required force is within limits shown in .91”
table for that particular belt, drive tension should C .53”
be satisfactory. If required force is outside these
limits, drive should be re-tensioned.
Figure D-6 Belt Types in Cross Section
5) When installing new belts, tension may be adjusted
to twice normal to allow for drop in tension
Belt Guards
during run-in. After drive is operated for several
days, tension should be checked and adjusted to V-belt drive guards promote both cleanliness and
recommended tension values. safety. Screened, meshed or grilled guards are best
because they allow air to circulate and heat to
escape.
Small O-ring
Bottom of
Straightedge or Top of
Adjacent Belt
Span "t"
Large O-ring
Deflection to be 1/64"
Per Inch Span
Figure D-5 Using the Belt Tension Tester

Belt Deflection Force Belt Deflection Force

(Pounds) (Pounds)
Uncogged Cogged Cogged Hy-T
Smallest Uncogged Hy-
Hy-T Belts Torque-Flex Wedge Belts
Cross Sheave RPM Smallest T
& Uncogged & Machined & Hy-T
Section Diameter Range Cross Sheave RPM Wedge Belts
Hy-T Torque Edge Torque Wedge
Range Section Diameter Range & Uncogged
Team Belts Team Belts Machine
Range Hy-T Wedge
Used New Used New Edge
Torque Team
Belt Belt Belt Belt Torque Team
1000 - 2500 3.7 5.5 4.1 6.1 Used New Used New
3.0 - 3.6 Belt Belt Belt Belt
2501 - 4000 2.8 4.2 3.4 5.0
1000 - 2500 4.5 6.8 5.0 7.4 1000 - 2500 3.3 4.9
2.2 - 2.4
A, AX 3.8 - 4.8 2501 - 4000 2.9 4.3
2501 - 4000 3.8 5.7 4.3 6.4
1000 - 2500 5.4 8.0 5.7 9.4 1000 - 2500 3.6 5.1 4.2 6.2
3V, 3VX 2.65 - 3.65
5.0 - 7.0 2501 - 4000 3.0 4.4 3.8 5.6
2501 - 4000 4.7 7.0 5.1 7.6
860 - 2500 4.9 7.2 1000 - 2500 4.9 7.3 5.3 7.9
4.12 - 6.90
3.4 - 4.2 2501 - 4000 4.4 6.6 4.9 7.3
2501 - 4000 4.2 6.2
860 - 2500 5.3 7.9 7.1 10.5 500 - 1749 10.2 15.2
B, BX 4.4 - 5.6 4.4 - 6.7 1750 - 3000 8.8 13.2
2501 - 4000 4.5 6.7 7.1 9.1
3001 - 4000 5.6 8.5
860 - 2500 6.3 9.4 8.5 12.6
5.8 - 8.6 5V, 5VX 500 - 1740 12.7 18.9 14.8 22.1
2501 - 4000 6.0 8.9 7.3 10.9 7.1 - 10.9
1741 - 3000 11.2 16.7 13.7 20.1
500 - 1740 11.5 17.0 14.7 21.8
7.0 - 9.0 500 - 1740 15.5 23.4 17.1 25.5
1741 - 3000 9.4 13.8 11.9 21.6 11.8 - 16.0
CX 1741 - 3000 14.6 21.8 16.8 25.0
500 - 1740 14.1 21.0 15.9 23.52
9.5 - 16.0 200 - 850 33.0 49.3
1741 - 3000 12.5 18.5 14.6 1.6 12.5 - 17.0
851 - 1500 26.8 39.9
200 - 850 24.9 37.0 8V
12.0 - 16.0 200 - 850 39.6 59.2
851 - 1500 21.2 31.3 18.0 - 22.4
D 851 - 1500 35.3 52.7
200 - 850 30.4 45.2
18.0 - 20.0
851 - 1500 25.6 38.0
Table D-2 Belt Deflection Forces

Idlers
Idlers
A properly designed V-belt drive does not require
an idler to deliver full rated horsepower if proper
belt tension can be maintained. Idlers should be
avoided if possible because an idler puts an additional
bending stress point on the belt. This reduces the Driver
belt’s horsepower rating and its life expectancy.
The smaller the idler, the greater the stress and the Driven
more belt life is reduced.
Kiss Idler
Inside Idler A kiss idler differs from the backside idler because
A V-grooved idler located on the inside of the belts the kiss idler does not penetrate the belt span and
on the slack side of the drive is recommended over create a back-bend on the belt. Consequently, the
a backside idler. The idler should be located near kiss idler does not contribute to premature belt
the large sheave to minimize reduction of the arc of failure.
contact across the small sheave. The diameter of the Use of a kiss idler can help control belt vibration and
V-idler pulley should be equal to or larger than that whip on drives subject to shock and pulsating loads.
of the small sheave. Kiss idlers can be used in single-belt drives where
joined belts are not applicable.
If a kiss idler is used, diameter of the flat pulley
should be at least 1-1/2 times (1.5x) greater than the
diameter of the small sheave.
Driver
Driven
Driver
Backside Idler Driven

A backside idler increases the arc of contact on both
sheaves. However, it forces a backward bend in the
V-belt that contributes to premature belt failure.
The idler puts additional stress on the bottom portion
of the belt which will result in bottom cracking. If
a backside idler must be used, the diameter of the
flat idler pulley should be at least 1-1/2 times (1.5x)
the diameter of the small sheave. A backside idler
should be located as close as possible to the small
sheave.

Banded Drive Belts
Banded Drive Belts

CAUTION
Drive power to crushers is usually provided using a
group of V-belts. A banded V-belt may be used, and Be sure to remove the tension finder from the
consists of individual belts joined together with a drive belt before starting the crusher. Personal
bonded, reinforced tie-band. Banded belts are injury or equipment damage may result when
designed to resist heat, whipping, rollover and wear the tension finder contacts a sheave.
in high vibration and shock-load applications.
The V-belt Tension Finder (Cedarapids PN 45825-
004-12) can be used to properly tension grouped
single belts or a banded belt. The tension finder
should be used only to adjust the crusher drive belts.
For proper belt adjustment, locate the tension finder
approximately mid point between the drive sheave
and the crusher sheave (Figure D-6).
Procedure
Step 1: Install belts loosely on the drive.
Step 2: Apply enough tension to take the slack out of the belts.
Step 3: Scribe a line on the Step 5: With the line in the

belt using the Tension-Finder Start Slot attach the spring to Step 7: Determine the
as a square. the belt. required slot for your drive
from chart below. Tighten belt
until the line has moved to
the designated slot. (In this
example the line is in Slot 3.)
Step 8: Remove the

Tension-Finder from the belt,
tighten mounting bolts, and
replace belt guards.
Step 4: Place the Start Slot Step 6: Scribe a line at the

over the line. spring end of the Tension-
Finder. Use this line as a
reference point in case the
spring slips off the belt.
Slot Number
Belt Type New Belt Used Belt
5V, 8V 3 2
Figure D-6 Belt Deflection Forces


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Operation & Maintenance Manual

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Original Language Instructions

23830-Rev A (03/08) Terex Rollercone Crusher

CEDARAPIDS NEW PRODUCT WARRANTY

23830-Rev A (03/08) i Terex Rollercone Crusher

Intake Design ..................................................................................................................................... 4-14

23830-Rev A (03/08) ii Terex Rollercone Crusher

Changing Manganese ......................................................................................................................... 6-18

Appendix A - Glossary .......................................................................................................................... A-1

23830-Rev A (03/08) iii Terex Rollercone Crusher

This page intentionally blank

23830-Rev A (03/08) iv Terex Rollercone Crusher

About This Manual

About This Manual This equipment is precisely engineered, highly

Experience has shown it is to your advantage to Intended Use

23830 (01/07) 1-1 Terex Rollercone Crusher

This page intentionally blank

23830 (01/07) 1-2 Terex Rollercone Crusher

General Safety Hazard Classification

Safety Alert Symbol CAUTION indicates a hazardous

Figure 2-1 Safety Alert symbol

23830 (01/07) 2-1 Terex Rollercone Crusher

Improper operation or maintenance can

Wear proper hearing personal protection

Figure 2-3 Safety Sign Icons

23830 (01/07) 2-2 Terex Rollercone Crusher

Escaping fluid under pressure can

Figure 2-3 Safety Sign Icons - Continued

23830 (01/07) 2-3 Terex Rollercone Crusher

Safety Sign Location (ANSI)

CRUSHING HAZARD STAY CLEAR of equipment

WARNING WARNING WARNING WARNING WARNING WARNING

Figure 2-4 ANSI Safety Sign Location

23830 (01/07) 2-4 Terex Rollercone Crusher

Relieve pressure before

Figure 2-4 ANSI Safety Sign Location - Continued

23830 (01/07) 2-5 Terex Rollercone Crusher

Safety Sign Location (ISO Standard)

Figure 2-5 ISO Standard Safety Sign Location

23830 (01/07) 2-6 Terex Rollercone Crusher

Figure 2-5 ISO Standard Safety Sign Location - Continued

23830 (01/07) 2-7 Terex Rollercone Crusher

Personal Safety • Never attempt to clear away jammed feed

23830 (01/07) 2-8 Terex Rollercone Crusher

Work Area Safety

hydraulic or pneumatic. High-pressure oils and FED

P ions is tin prov

Equipment & Tools

this ion prov this bl

tiny ided ock

Loc desOto a_jo_

are safer tools. Keep your tools in good order. b

P NLY TEHRISET & LO

b lav ate ech

dangerous, they cost you downtime.

Work Area Safety

23830 (01/07) 2-10 Terex Rollercone Crusher

Section 3 - Description and

23830 (01/07) 3-1 Terex Rollercone Crusher

23830 (01/07) 3- 2 Terex Rollercone Crusher

1. Plastic backing 8. Mantle hold down nut

Figure 3-2 Crushing Chamber Detail