Roller Cone Service Manual Exerpts

8/3/2019 Roller Cone Service Manual Exerpts

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Base Frame~ CedarapidsIIIiIii A Terex CompanyCast Base Frame

Section 2 - Base Frame into a high quality, precision mold. Thestructurally sound, medium-carbon steel castingsare designed for long life under high stress, heavyloading and vibration. (Figure 2 - 1)Cast Base Frame

The base frames for RC36, RC45, and RC54Rollercones are cast of ASTM A-27, 70-40 highstrength steel from a single-heat, continuous pour

Clamp Ring Pad

Floating Brake PlateThrust Plate

Lower Radial Bearing'sInner RaceExpansion RingPush Pin

/ Ad justing BaH

Clamp Ring

Base FrameSeal Ring

Base FrameSpindleAnti-Spin Brake Adjusting Bolt Retainer Pad

Figure 2 - 1 Cast Base Frame

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Base Frame~Ced.r ... idsIIIIiI A Terex CompanyFabricated Steel Base Frame

Fabricated Steel Base FrameThe base frames for RC60, RC66, RC45I1, andRC54II Rollercones are fabricated from A36carbon steel. Frame members are welded togetherwith alloy plate used in critical areas to give addedstrength where needed. (Figure 2 - 2)

Brake ShaftFloating Brake Plate

Thrust PlateLower Radial Bearing'sInner Race

Clamp Ring

Adjusting Bolt

Expansion Ring

Base FrameSpindleAnti-Spin Brake Clamp Ring Pad

Figure 2 - 2 Fabricated Base Frames

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Base Frame~ Cedarapids.... A Terex Company

Serial Number SystemYour Rollercone has a serial number associatedwith it at the factory. To get accurate informationfrom your Cedarapids Distributor and the factory,always reference the serial number of your crusher.This number is stamped on the identification plateattached to the base. Serial numbers will come inone of two forms. Serial plates such as the onepictured in Figure 2 - 3 are used on all currentproduction. The serial number will consist of fivenumbers.Serial numbers on older units can be found on aplate similar to the one pictured in Figure 2 - 4. Thisserial number system uses a seven-character series;the third character is a letter. The others arenumerals. 22A1394 is an example.

Figure 2 - 3 Current Serial Plate

Serial Number System

CedarapidsElJay Division

_ ' 1 1 0 I RC54STD I " " . . . . I 22A1394 I o

fr.a JVD!ilSlj 7212U2U

Figure 2 - 4 Older Serial Plate

Clamp RingRemoving the Clamp Ring1) The upper assembly, adjusting bolts, and push

pins must first be removed before you canremove the clamp ring. To remove the upperassembly, see instructions in Section 14 -"Upper Assembly", of this manuaL

2) If you have removed the upper assemblyfollowing method B of Section 14 - "UpperAssembly", next remove the adjusting bolts.See page 2 - 7. If you followed method A, theadjusting bolts will already have been removedwith the upper assembly.

3) Remove the push pins as shown in "Push Pins"on page 2 - 6.

4) The clamp ring is cut into four (4) segments tomake installation and repair practical. Three(3) of the saw cuts are at 90. The fourth is cutat 45. See Figure 2 - 5. Seeing the clamp ringmounted in the base, all four (4) cuts appear tobe vertical from that angle of view and lookthe same. Mark the clamp ring segments and

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Base Frame~ Cell.rapidsI I I I i I I I i A Terex Company

base frame with the numbers 1 through 4, asshown in Figure 2 - 6. This makes installingthem in the same positions easier.

Clamp Ring

9090

45Figure 2 - 5 Four Segment Clamp Ring

Base Frame

Figure 2 - 6 Mark Clamp Ring Posit ions5) Standing outside the base near the pinion

housing, the segment to the left of the pinionhousing is normally removed first, since itusually is the segment with the 45 angle cut.If the vertical cuts in the clamp ring segmentsare filled with dirt, determine for certain

which segment has the angle cut by diggingsome ofthe dirt out of the cracks with ascrewdriver or other pointed tool.

Warning - The clamp ring segmentsare heavy, sharp edged, and may beslippery with grease. We recommend alifting device such as an overheadcrane. Even then the awkward shapecan be tricky.

6) On some Rollercones the ring segment withthe 45 cut is on your right as you face thepinion housing from outside. In these casesthe segment over the pinion housing will bethe last removed and the first installed.

7) After you have removed the push pins, attachtwo (2) chains with hooks into two (2) of theadjusting bolt holes. See Figure 2 -:7 for apractical way to rig up your lifting device.Carefully lift out each clamp ring segmentwith your hoist.

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Base Frame~ Cedarapids_ A Terex Company

Figure 2 - 7 Clamp Ring Lifting DeviceInstalling the Clamp Ring1) Clean the clamp ring seat area in the base

frame. Remove any burrs or high spots. Coatthis area with a layer of heavy grease. SeeFigure 2 - 8 to determine seat area to begreased.Grease Contacting Surfaces

o8 lD Older Rollercone Classic ShownFigure 2 - 8 Grease Clamp Ring Surfaces

2) Thoroughly clean and deburr all four segmentsof the clamp ring.

Clamp Ring

3) Prepare to place the clamp ring in the base bylooking closely atFigure 2 - 5. Note that twoof the clamp ring segments are cut at diagonalangles. Looking down from the top, the onewith the point on the outer diameter of thecurve must go in first. The segment with thepoint on the inner diameter must go in last. (Itwas the first one removed).

4) If you numbered the segments 1 through 4,putting "1" on the first one you removed, then"4" will be the first to go back into the crusher.Starting with Segment 4, lift the clamp ringsegment into the base and rest it on the clampring pads. (Figure 2 - 8) The ends or joints ofthe segments rest on the double clamp ringpads. Each segment will be supported by three(3) pads, one at either end and one in themiddle.

5) Continue around the base, putting Segments 3and 2 on the clamp ring pads. With eachsegment, approximately align the push pinholes and adjusting bolt holes by eye. Exactalignment will follow when the push pins andadjusting bolts are installed.

6) Last, lift Segment 1 into the base and rest it onthe clamp ring pads. If the first three (3)segments were placed correctly, the last pieceshould go in smoothly and the holes should beapproximately aligned.

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Base Frame~ CedarapidsIIIiIIIi A Terex Company

Push PinsRemoving Push Pinsl) Insert a long punch up through the push pin

removal holes in the bottom of the clamp ring.Each push pin has a hole directly below it. Tapthe punch with a hammer to drive push pin upout of its hole. See Figure 2 - 9.

Push Pin

Base Frame

.Figure 2 - 9 Push PinsNotice - A few older model RollerconeClassics were made without this pusherhole. To remove the push pins on thesecrushers, weld a flat washer on edge (like acoin standing up) to the top center of thepush pin. Use the hole in the washer as alifting eye and pull the pin up out of thehole. See Figure 3-11. To make removingthe pins easier next time, drill a 3/8" holethrough the clamp ring at the bottom ofeach push pin hole. Remove thewasher andgrind flat before assembling pin into base.

Push Pins

Older units only

Washer

....__ PushPin

Figure 2 - 10 Use Washer To Remove Push PinInstalling Push Pins1) To install the push pins in the base and clamp

ring, begin by cleaning the D-ring groove atthe head of each push pin. Install D-rings inthe grooves in push pins. See Figure 2 - 9.

2) Clean the push pin holes in the base frame andapply a thin coat of anti-seize lubricant on theD-ring and push pin.

3) Install each push pin in the appropriate hole inthe base frame. The pin descends to the bottomof the corresponding hole in the clamp ringand stops there.

4) Repeat with all push pins.

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Base Frame~.edarapidsIIIiIIi A Tel'9x Company

Adjusting BoltsGeneralAdjusting bolts have been built to three differentdesigns over time. We will refer to the most currentdesign as "Style 1". The oldest design will bereferred to as "Style 3".Removing Adjusting Bolts (Style 1)

Split CouplerUpper SphericalSeat WasherUpper Shim Stack

Lower SphericalSeat Washer

Clamp CylinderAssembly

Shim Guard

Lower ShimStackAdjusting Bolt

Lower SphericalSeat WasherD-Rlng

Split Coupler Adjusting Bolt RetainerFigure 2 - 11 Adjusting Bolt System (Style 1)

Adjusting Bolts

1) This style adjusting bolt can be removed withthe upper assembly by following theinstructions in Section 14 - "Upper Assembly".

2) If the upper assembly has been removed usingSection 14 - "Upper Assembly", the adjustingbolts will remain in the lower assembly. Toremove adjusting bolts from the lowerassembly, disassemble and remove the splitcouplers by removing the O-Rings. This willenable the adjusting bolt to be removed fromabove.

3) The adjusting bolt retainer can be removed ifnecessary. The retainer is threaded into thebase frame.

Installing Adjusting Bolts (Style 1)I) Install adjusting holt retainer if removed.

(Figure 2 - 11)2) Install adjusting bolts through the clamp

cylinder assembly, base frame, and clamp ringuntil it rests on the adjusting holt retainer.

3) Put anti-seize lubricant on lower spherical seatwasher and install each washer on adjustingbolt with spherical seat side down.

4) Install each set of split coupler halves andinstall O-Ring over the two coupler halves.

5) Install upper assembly as instructed in Section14 - "Upper Assembly",

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Base Frame~ Cedar.pidsiIIIIIii A Terex Company

Removing Adjusting Bolts (Style 2)Jam Nut Adjusting Nut

Upper SphericalSeat WasherUpper Shim Stack



Shim Guard

Lower ShimStackAdjusting Bolt

Clamp Ring Adjusting Bolt RetainerAdjusting Bolt Block

Figure 2 - 12 Adjusting Bolt System (Style 2)I) This adjusting bolt design varies from style 1

and style 3 designs in that the lower adjustingbolt block is welded to the adjusting bolt. Theadjusting bolts cannot be removed with theupper assembly.

2) Remove the upper assembly using Method Bin Section 14 - "Upper Assembly", theadjusting bolts will remain in the lowerassembly. To remove adjusting bolts from the

Adjusting Bolts

lower assembly, remove the adjusting boltretainer to drop the adjusting bolt out thebottom of the base frame. The retainer isthreaded into the base frame.

Installing Adjusting Bolts (Style 2)1) Install adjusting bolt from the bottom of the

base frame through the clamp ring, base frameand clamp cylinder assembly.

2) Install adjusting bolt retainer. (Figure 2 - 12)3) Install upper assembly as instructed in Section

14 - "Upper Assembly".

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Base Frame~ Ced.rapids_ A Terex Company

Removing Adjusting Bolts (Style 3)Jam Nut Adjusting Nut

Upper SphericalSeat WasherUpper Shim Stack



Shim GuardLower ShimStack

Adjusting Bolt

Adjusting Bolt Block

Adjusting Bolt Set ScrewClamp Ring Adjusting Bolt Retainer PadFigure 2 - 13 Adjusting Bolt System (Style 3)

1) The adjusting bolts and the blocks into whichthey thread are individually matched at thefactory. Blocks and bolts are not interchange-able. When installing, rematch bolts to blocks.They are stamped at the factory, but wear ordirt may make these marks unreadable.

2) Adjusting bolts can be removed with the upperassembly by following the instructions inSection 14 - "Upper Assembly", Method A.

Adjusting Bolts

3) To remove adjusting bolts from the lowerassembly, disassemble the adjusting boltblocks from the adjusting bolts.

4) Look in the "windows" cut in the base framedirectlybelow the adjusting bolts. See Figure 2- 13. Remove each set screw from its block.(The set screw is sometimes called a set bolt,adjusting bolt screw, or an adjusting bolt setbolt.) This can be done through the window inthe base frame. With the set bolt removed, theadjusting bolt can then be unscrewed from theblock and lifted out of the base.

Installing Adjustlng Bolts (Style 3)1) To reassemble the blocks and bolts in the base,

apply anti-seize lubricant to all threads. Besure to match the bolt number to the blocknumber.

2) Insert each block through its window in thebase frame. Remember to follow numericalorder. (Figure 2 - 13) Rest the block on theadjusting bolt retainer pad. Ifthe retainer padshave been worn or broken off, see "Hardfacingand Wear Components" on page 2 - 17.

3) While shining a flashlight in the base framewindow, install the adjusting bolt downthrough the proper holes in the base frame andthrough the clamp ring. Screw the bolt into itsblock until the countersink in the adjusting boltthreads lines up with the set bolt hole in theadjusting bolt block. Section 14 - "UpperAssembly" has more information aboutadjusting bolts.

4) Install the set bolt in the adjusting bolt blockand torque to 50 - 60 ft-lbs.

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Base Frame~ Dedarapills_ A Terex Company

Lower Radial Bearing Inner RaceRemoving Lower Radial Bearing's Inner RaceThe inner race of the lower radial bearing has aninterference fit to the spindle. To remove the race,you must heat the race to expand it and use a pullerto force it up off the spindle.1) Place jack and puller as shown in Figure 2 -

14.

Race Lif ting Device

Figure 2 - 14 Remove Lower Radial Bearing Inner Race

2) Heat the race with a large oxyacetyleneheating tip (rosebud) with a long, featheredflame. Use a 2500 F "temp stick" frequently tohelp you prevent overheating the race.

Warning - Do not heat any portion ofthe bearing or race above 250F.Always apply even heating by movingthe torch smoothly but rapidly aroundthe race. No hot spots! Overheatingcan damage the bearings.

Lower Radial Bearing Inner Race

3) Use the jack to put upward pressure on thepuller. Heat expands the race slightly,releasing it from the spindle.

4) Apply further pressure with the jack. Thisforces the race upward. When the race moves,repressurize the jack to keep the race movingupwards. Continue the heating and movinguntil the race can be lifted free of the spindle.Use proper lifting procedures, as shown inFigure 2 - 14.

A Warning - Use proper liftingprocedures. Do not strain your backtrying to remove the race without heat.Expansion Ring (Torrington Bearings Only)The Rollercone main bearings bear only minimalloads when the crusher is not actually crushingrock. The crushing action creates heavy loadingthat the bearing rollers are designed to withstand,allowing smooth, precision-balanced, low-vibration operation of the crusher.The purpose of the expansion ring is to lightlypreload the rollers of the lower radial bearing toprevent any sliding or "scooting" action of therollers any time the crusher is running but notcrushing. Such sliding action at the rollers couldresult in scuffing or smears on the races or rollers,a condition that could lead to premature bearingfailure. The expansion ring is used only on RC 54,RC60, RC66 and RC54II models using Torringtonbearings. See also Section 3 - "Bearings".

Z17BB (1101) Z -10 Rollercone@ Service Manual


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Base Frame~ Cell.rapidsiIiIIIi A Terax Company

Removing and Installing the Expansion RingRemove the expansion ring as shown in Figure 2 -15. Be sure to note the positions of the dowel pin,and notch.

Dowel Pin Expansion RingFigure 2 - 15 Lower Thrust Bearing Expansion Ring

Install the expansion ring around the spindle withthe notch over the dowel pin. Be sure the doweldoes not hold the ring up. The expansion ring musthave full-face contact with the base frame hub.To be sure the expansion ring is evenly spacedaround the spindle, place pieces of 1/2" round stockaround the spindle as shown in Figure 2 - 16.Spacethem evenly around the spindle. Remove thesepieces of round stock after the expansion ring is inplace. They are only to help fit the expansion ringand inner race to the spindle.

Figure 2 - 16 Positioning Expansion Ring

Install Lower Radial Bearing InnerRace

Install Lower Radial Bearing InnerRaceRollercones use one of two bearings. One style,made by Torrington, uses an expansion ring fittedto the bottom of the inner race on certain models ofcrushers. The expansion ring is used only on RC54, RC60, RC66 and RC54II models usingTorrington bearings. A second style of bearing,made by FAG, does not use an expansion ring.The inner race of the lower radial bearing has aninterference fit on the spindle. Proper fittingrequires heating of the race.The best method of heating the race to the propertemperature without risking damage to the race is aheated oil bath.Ifyou do not have a large oil bath available, or donot have time to build one, you may use torches.Heat very carefully to avoid overheating the race.Have a 250F temperature stick handy beforebeginning the heating.I) Remove the bearing race from the packaging,

but do not clean the preservative oil from race.2) If your crusher uses Torrington bearings with

an expansion ring, be sure you have alreadyinstalled and centered the expansion ring overthe spindle as described above.

3) Place the puller on the bearing race andposition the race so it is centered over the baseframe spindle.Notice - Ifyour crusher uses Torringtonbearings with an expansion ring, be sure therace end with the cutout that fits inside theexpansion ring starts first onto the spindle.See Figure 2 - 17.

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Base Frame~ Oed.rapids_ A Terex CompanyInstall Lower Radial Bearing InnerRace

Inner Race SpindleollerOuter Race

Base Frame

Expansion RingFigure 2 - 17 Torrington Bearing With Expansion Ring

Inner Race Spindle~=====nOuter Race

Base Frame Dowel Pin

Figure 2 - 18 FAG Bearing - No Expansion Ring Used4) Apply a light film of gear oil over the surface

of the spindle.5) Adjust the flame of two (2) torches with large

heating (not cutting) tips to a carbonizingflame. A carbonizing flame is one in which

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Base Frame~ Cedarapids.... A Terex Company

the proportion of acetylene to oxygen is high.The flame looks yellowish, not bluish. Withthe torch flames adjusted, heat the race evenlyfrom top to bottom around the fullcircumference of the race.A Warning - Do not overheat the race.

.. Temperatures higher than 250F candamage the race.

6) Check the temperature of the race frequentlywith a "temp stick."

Warning - Do not allow any hot spots!Keep the torch moving! Build up thetemperature slowly and evenly throughthe whole race. Use the "temp stick" toverify that the race is heated to 250F.

Notice - The inner race of an FAG bearingdoes not use an expansion ring. Instead, theinner race has a hole in it that must be linedup with the dowel pin before lowering therace completely.

7) When the race is at 250F, lower it onto thespindle. Be sure it goes completely down,without getting stuck on the expansion ring (ifused) or dowel pin. The race must seat againstthe base frame. See Figure 2 - 17 and Figure 2- 18.

8) While the race is still warm, apply a lightlubricant over the entire surface to preventoxidation.

9) For installation of the remaining portions ofthe lower radial bearing, see Section 15 -"Wedge Plate".

Thrust Plate

Thrust PlateThe purposes of the thrust plate are to control theflow of oil to the upper and lower bearings and tocontain the wedge plate, preventing the bevel gearfrom becoming disengaged from the pinion gear.The thrust plate clearance is a gap" between thethrust plate and the wedge plate that helps meter thequantity of oil supplying the upper and lowerbearings. See Figure 2 - 19 and Figure 2 - 22.Table 2 - 1Recommended Thrust Plate Clearance

Minimum MaximumModel Inches mm Inches mmRC36 0.025 0.635 0.035 0.889RC45 0.025 0.635 0.035 0.889RC45 II 0.025 0.635 0.035 0.889RC54 0.025 0.635 0.035 0.889RC54 II 0,025 0.635 0.035 0.889Re60 0.030 0.762 0.040 1.016RC66 0.030 0.762 0.040 1.016

If you replace any of the following parts ... wedge plate thrust plate lower thrust bearing base frame lower radial bearing... check thrust plate clearance. Itmay need to beadjusted. Before checking this clearance,determine if the inner race of the lower radialbearing protrudes above the spindle. If it does, arelief cut will need to be made on the thrust plate.

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Base Frame~ Ced.rapidsI i I I I I I I I i A Terex CompanyThrust Plate

Thrust Plate

_ ... ----

Wedge Plate

Spindle

Figure 2 - 19 Thrust Plate ClearanceChecking thrust plate relief1) Remove wedge plate.

4) Make the relief O.75" wide and 0.005" deeperthan the amount the race protrudes above thetop of the base frame spindle. See Figure 2 -20.2) Lay a straight edge over the spindle and lower

radial bearing inner race.3) Ifthe straight edge is resting on the inner race

with clearance between the straight edge andthe spindle, a relief will need to be machinedon the thrust plate. See Figure 2 - 20. Theamount of relief needed can be determined byinserting various size feeler gauges under thestraight edge until the proper size is found.

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Base Frame~ Ced.rapidsI i I I I I I I I I I A Tel'9x CompanyThrust Plate

'--- Machine 0.75" Wide Relief For Lower Radial Inner Race Clearance

Machine Here ToIncrease Clearance

Machine Here To Decrease Clearance

Figure 2 - 20 Machining Trust Plate ReliefChecking the Thrust Plate Clearance

Warning - The thrust plate is heavyenough that it is difficult to handlealone. TWopeople may be needed tolift and position the thrust plate. Useproper lifting and lowering techniques.

I) Use T-handles threaded into the 3/8" holes inthe thrust plate to lift and lower the plate.Place the thrust plate on the spindle.

Caution - Before installing thrust platebolts in the spindle, remove any pooledoil that may be in the bolt holes. Thisprevents the bolts from becominghydraulically locked while they arebeing tightened. Before installingthrust plate bolts, coat the bolts with athin film of anti-seize lubricant.

2) Install four (4) bolts. Tighten them to 200 ft-lbs torque. This is for testing thrust plateclearance only. Final thrust plate installation,after testing for clearance requires 250-300 ft-lbs for all thrust plate bolts.

3) To check the thrust plate clearance, attach amagnetic-base dial indicator to the outer, upperradial bearing race. Place the dial indicatorplunger on the thrust plate. See Figure 2 - 21.

Iuter Bearing RaceThrust Plate

Figure 2 - 21 Measure Thrust Plate Clearance4) Thread two (2) 1" diameter bolts at least 4"

long into the two (2) threaded lifting holes, oneon either side of the top of the wedge plate.Set the dial indicator to zero.

5) Use a crane with sufficient lifting capacity.Attach two equal length chains (or cables).

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Base Frame

6) Gently lift the wedge plate until the inner stepof the wedge plate contacts the bottom of thethrust plate. Read the dial indicator. It nowshows the thrust plate clearance.

ThrustPlate

~ Cell.rapidsIiIIIIIiI A Terex CompanyThrust Plate

Adjusting the Thrust Plate ClearanceYou could have three (3) conditions: properclearance, too much clearance, or too littleclearance. See Figure 2 - 22 and Table 2 - 1. If youhave proper clearance, continue with thrust plateinstallation. The following examples, A and B,show what to do if you have too much or too littleclearance.Too MuchClearance

EXAMPLE A

Too LittleClearance

Example A: See Figure 2 - 22. You have boltedthe thrust plate properly to the spindle. The wedgeplate turns freely. You check the thrust plateclearance as described above. Thrust plateclearance is determined to be 0.100". This is toomuch clearance. In order to obtain proper thrustplate clearance, you must machine 0.070" off of thebottom of the thrust plate and to machine a racerelief as appropriate. See Figure 2 - 20.Example B: See Figure 2 - 22. You have bolted thethrust plate properly to the spindle. You are unableto tum thewedge plate freely. This means you havea "minus" thrust plate clearance, an interference.You must determine how much material tomachine off to get both free motion of the wedgeplate and proper thrust plate clearance.To determine the amount of material to machineoff to get proper thrust plate clearance when aninterference (no clearance) condition exists:1) Remove the thrust plate.2) Find four (4) flat washers of equal thickness.

Check them with a micrometer to be sure theyare equal in thickness. Space them evenlyaround the top of the spindle.

3) Then bolt the thrust plate into position andrecheck thrust plate clearance.

EXAMPLE B

PROPER CLEARANCE \ Spindle

Figure 2 - 22 Check Thrust Plate Clearance21788 ( 1 1 0 1 ) 216 R olle rc on e@ S er vic e M an ua l


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Base Frame~ Bed_rapids_ A Terex Company

In this example, suppose you found four flatwashers with a thickness 0.120". After checkingtheir thickness with a micrometer, you placed themon top of the spindle, set the thrust plate back inplace, tightened four (4) bolts, then checked thrustplate clearance as above.You found the thrust plate clearance then to be0.100". This indicates you have a 0.020"interference. (0.120" - 0.100" =0.020")To obtain proper thrust plate clearance you wouldneed to again remove the thrust plate and machine0.050" from the bottom of the outer flange. SeeFigure 2 - 20, and compare to example B in Figure2 - 22. You find this by adding the existinginterference (0.20") to the desired clearance(0.030"). The amount to be machined from thethrust plate is 0.050". (0.030'1 + 0.020" = 0.050").When you have proper thrust plate clearance andrace relief, torque the thrust plate bolts to 250-300ft-lbs,

Base Frame Seal RingThe Rollercone has four (4) labyrinth seal rings.Each ring is mated with another to form a seal of atype called a labyrinth seal. Each labyrinth seal isformed with an upper and lower seal ring. They arediscussed more extensively in Section 14. Thebase frame seal ring usually has oil drain-backholes that allow lubricating oil to drain back towardthe sump in the base frame.

Lubrication Fill PipeThe lubrication fill pipe is located to the left of thedrive shaft when facing the drive sheave. SeeFigure 2 - 23. Keep it and the area near it clean andclear of debris. The lubricant level dipstick is .welded to the fill pipe cap. Regular maintenance

Base Frame Seal Ring

includes checks of oil level with the dipstick. SeeSection 9 - "Lubrication", for proper oil level checkprocedures.

Pipe Cap With Dipstick

Figure 2 - 23 Lubrication Fill Pipe

Hardfacing and Wear ComponentsSee Figure 2 - 24. At every manganese changeclosely inspect: all counterweights, especially the leading

counterweight. Replace any worncounterweights.

seal ring (labyrinth seal) wear band. Replace itwhen worn.

inner edge of the base framepinion housing tunnel

struts bonnet support skirt

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Base Frame~ Oell.rapids_ A Terex Company

Hardfacing and Wear Components

Pinion Housing TunnelWear P la te

Figure 2 - 24 Pinion Housing Tunnel

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Base Frame~ BedarapillsIIIIIi A Terex Company

Pinion Housing TunnelThe pinion housing tunnel is protected fromerosion with a wear plate welded to the top of thetunnel. This plate must be maintained periodicallyto prevent serious erosion of the pinion housingtunnel, a structural part of the base frame.

A Warning - Do not hardface the pinionhousing tunneL Repeated heating of thepinion housing can cause heat stressand cracking of the pinion housing. Thepinion housing must be protected by awear plate which can be built up andhardfaced when worn.

Two styles of wear plates have been used.1) The current style of wear plate used on the

RC36 and on older RC45 and RC54 modelsused an abrasion-resistant plate welded to thetop of the tunneL This plate must be built-up orreplaced periodically to prevent seriouserosion of the pinion housing tunneL

2) The current style for RC45, RC54, RC60,RC66, RC45II, and RC54JI is pictured inFigure 2 - 25. This plate has four protrudingplates designed to retain a small amount ofmaterial on the plate. This buildup of materialreduces wear inflicted on the metal wear parts.The protruding plates or the entire wear platemust be replaced periodically.When used in recycle applications, it may benecessary to trim the protruding plates tominimize buildup of tramp iron.


Protruding Plates

Figure 2 - 25 Pinion Housing Tunnel Wear Plate

A Caution - Do not allow hardfacing towear away entirely. The wear plate andhardfaced surfaces protect thestructural integrity of your crusher.

AWarning - Be sure ground (earth)connection is complete and does notallow arcing through bearings. Whenwelding anywhere on or near theRollercone with electric are, be sure thewelding ground (earth) iswell-attachedas near as possible to the weld area.Serious damage to bearings could occurif arc passes through bearings.

Welding On StrutsItmay be necessary to weld replacement strut wearplates tothe struts as shown in Figure 2 - 27, Figure2 - 28, and Figure 2 - 29. Weld only longitudinallyalong the strut as shown in Figure 2 - 26.

A Warning - Welding laterally across thetop of the strut will create a stress pointwhich will crack the strut. Weld onlylongitudinally along the strut.

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Base Frame~Ceda ...pidsIIIIiIi A Terex Company

Figure 2 - 26 Do Not Weld Across StrutsBase Frame Hardfacing RC36, RC45 &RC54

Strut Wear ~=~it:2j~~Plates

Inner EdgeWear Plates

Figure 2 - 27 Cast Base Frame HardfacingThe inner edge at the base of.the base frame andstruts are subjected to erosion from crushedmaterial. (Figure 2 - 27) A replaceable wear plateis welded to extend 3/4" above the inner edge of thebase frame to form a rock shelf. Rock shelf plates


also extend 3/4" above the top of each strut. Thehardfacing on the top of the wear plates must bemaintained to prevent damage to the base frame.Hardface the top edge of plates if replacementplates are installed.Base Frame Hardfacing RC60 & RC66

Strut WearPlates


Figure 2 - 28 Fabricated Base Frame HardfacingThe inner edges of the base frame and struts aresubjected to erosion from crushed materiaL(Figure 2 - 28) A replaceable wear plate is weldedto extend 3/4" above the inner edge of the baseframe to form a rock shelf. Plates on the top of eachstrut form a rock shelf on each strut. Thehardfacing on the top of the wear plates must bemaintained to prevent damage to the base frame.Hardface the top edge of plates if replacementplates are installed.

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Base Frame~ Cedarapids_ A Terex Company

Base Frame Hardfacing RC45II &RC54II

ReplaceableStrut Guard


Figure 2 - 29 RCI! Base Frame HardfacingThe inner edges of the base frame and struts aresubjected to erosion from crushed material.(Figure 2 - 29) A replaceable wear plate is weldedto extend 3/4" above the inner edge of the baseframe to form a rock shelf. The hardfacing on thetop of the wear plates must be maintained toprevent damage to the base frame. Hardface the topedge of plates if replacement plates are installed.A replaceable strut guard sets on each strut. Theguard is cast from hardened material and can beeasily replaced when worn. Hardfacing is notnecessary on the strut guard.Replacing Worn Adjusting Bolt Retainer PadsUnits equipped with Style 3 adjusting bolts (Figure2 - 13)use a retaining pad welded to the base frameto retain adjusting bolts when removing upperassembly. Sometimes adjusting bolt retainer padsare eroded from rock wear. New adjusting boltretainer pads can be ordered from your Cedarapids


dealer. Tack weld them in place below theadjusting bolt windows as shown in Figure 2 - 30,then weld both sides of the pad. Remember to placegrounding connection near weld area.

Adjusting BoltRetainer Pad

Figure 2 - 30 Replacing Adjusting Bolt Retainer PadsBonnet Support LinersThe bonnet support is SUbjectedto wear frommaterial as it falls out of the crushing chamber.Typically, the lower edge of the bonnet supportskirt will wear. Check skirt thickness each timemanganese is changed. If skirt wear is excessive,liners can be added to protect the lower edge of theskirt.Table 2 - 2 Bonnet Support Liner Part Numbers

Model Part Number QuantityRC36 Consult Factory -RC45 02-450-012-0070 7RC4511 02-450-012-0070 7RC54 02-540-012-0070 8RC54II 02-540-012-0070 8RC60 02-600-012-0070 10RC66 02-660-012-0070 10

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Base Frame~ Cedaraliids_ A Terex Company


o o 0 () 0o ()0Hardface Over WeldLower 8", Typ.

Figure 2 - 31 Bonnet Support Liner InstallationTo install bonnet support liners: 5) Place two clamps toward the edges of each

liner to pull the edges of the liner tightly1) Refer to Table 2 - 2 for liner part numbers and against the skirt.

quantities.6) Weld both ends of each liner using a E 11 0 18

2) Refer to Figure 2 - 31 for additional liner rod. Lay a hardfacing bead over the lower 8welding instructions. inches of each end weld.Notice - Some hardface welding is 7) Plug weld each of the four holes in each linernecessary when installing liners. Hardface and allow everything to cool thoroughly beforewelding is best done in the horizontal continuing.position. Remove bonnet support and lay iton its side. 8) After liners have cooled completely, check

each weld for cracking and reweld as needed.3) Position and clamp liners 114" from the lower

edge of the skirt. Ensure liner is aligned 9) Weld the top and bottom of each liner with theparallel with the bottom edge of the skirt. specified skip weld.Install a111iners spaced evenly. 10) After everything has cooled, recheck and

4) After all liners are spaced evenly, tack weld repair any cracked welds.each liner.

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Cone Head~ Cedar.pidSI i I I I I I I I I I I A Terex CompanyGeneral

Section 4 - Cone Head GeneralMantle Nut Cap

Bonnet Mantle Nut

Bonnet Support

Standard Head Cone Mantle Bolt Manganese Bowl Liner

Figure 4 - 1 Standard Head Chamber

Mantle Bolt Distributor PlateBonnet - , Mantle Nut

Bonnet Support

Fine Head Cone Manganese Bowl LinerFigure 4 - 2 Fine Head Chamber

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Cone Head~ Ced_rapidsi I I I I I I I I I i A Terex Company

Cone heads are made in two configurations,standard and fine. Fine head cones are used whenproducing sand or small material. Standard headcones are more common and are used whenproducing larger material. Both heads can beequipped with a variety of mantles and bowl linersranging from coarse to extra fine chambers. SeeFigure 4 - I and Figure 4 - 2.Tools Needed Offset cone lifting eye, provided with

Rollercone purchase or available from yourCedarapids Distributor. Overhead crane or equivalent to lift complete

cone. See Table 6 - 1 "Rollercone ComponentWeights".

Proper lifting shackles, cables. Allen wrench, provided with purchase of new

Rollercone. 1-1/8" socket and breaker bar or impact

wrench (Fine head only, for use on distributorplate).

Oxyacetylene torch with large rosebud(heating tip) and oil bath for heat-expandingbearing race(s).

Lifting devices for bearing race and cage. Three (3) pieces rubber belting, each

approximately 12" x 12".

Removing the Standard Head ConeNotice - To remove the cone from the lowerassembly, the entire upper assembly mustfirst be removed. For removal procedures

Tools Needed

see Section 14 - "Upper Assembly". Thefollowing instructions assume you haveremoved the upper assembly.

Mantle Nut Cap Bolt

Mantle Washer

Figure 4 - 3 Standard Cone Mantle Nut1) After crushing rock the Allen-head mantle nut

cap bolt is tightly packed with dust and gritand requires high torque to remove it. (Figure4 - 3 ) Dig out and remove dirt and grit fromthe groove between the mantle nut cap bolt andthe mantle nut cap. This slightly reduces thetorque needed to loosen the bolt.

2) Insert the Allen-head wrench into the mantlenut cap bolt and over it slip a sturdy length ofpipe as a "cheater" to increase leverage. SeeFigure 4 - 4.

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Cone Head

Strike Here Cheater Bar

Figure 4 - 4 Remove Mantle Nut Cap3) While one person applies torque by pulling on

the pipe extension, a second person, using aheavy hammer, strikes the mantle nut cap.Make the point of hammer impact as shown inFigure 4 - 4. This helps loosen the mantle nutcap.

4) You may wish to remove the mantle nut capnow. If you do, use an oxyacetylene torch tocut the short welds holding the mantle nut capto the mantle washer.

If you wish to remove the cone but leave the mantlenut cap in place, be sure the cone offset lifting eyecan thread at least four (4) to five (5) threads intothe top of the cone where you have just removedthe mantle nut cap bolt.5) When the distributor plate on a Fine Head

model or the mantle protector cap bolt on aStandard Head model has been removed,screw cone offset lifting eye at least four (4) tofive (5) threads into the top of the cone. Stopturning lifting eye when the offset hole in thelifting eye lines up with the high side of thewedge plate, which is directly opposite the

~ Cetlarapidsi I I I I I i A Tel'8x Company

Removing the Standard Head Cone

center of the counterweights. Determine thecorrect placement of the lifting eye, as shownin Figure 4 - 5 .

Cone Lift Eye

Torque BarFigure 4 - 5 Installing Cone Lift Eye

Notice - The cone fits in the wedge plate ata slight angle from vertical. This angle is anessential design characteristic for efficientcone operation. Properly using the offsetlifting eye ensures that the cone, whenlifted, continues to hang at the correct angleas it is pulled free.

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Cone Head~ .edarapids_ A Tel'9x Company

Warning - Ifyou lift the cone at anincorrect angle, you will damage thebearing race and/or rollers duringremoval. This can be a very expensivemistake. Pull only straight up (vertical)with the lifting device. Side pull candamage the radial bearings while beingremoved.

6) Attach a properly rated lifting device to theoffset lifting eye. Be sure the lifting hook andcables hang exactly vertical above the liftingeye.

Warning - Do not lift more than two(2") inches until you are certain wherethe top race of the upper thrust bearingis. Oil suction can temporarily hold therace to the cone. Lifting too far with therace stuck to the cone can damage thebearing rollers and race. As the suctionbreaks; the race can drop onto therollers, damaging both.

7) Slowly, while gently turning the cone fromside to side three or four (3" - 4") inches, liftthe cone about two (2") inches vertically andstop. The gentle turning or rocking from sideto side reduces the chance of scuffing the raceor rollers of the radial bearing as you lift thecone out. Slightly above two (2") inches, thewide, machined portion of the wedge plateknocks the top race of the thrust bearing loose.Do not allow this to happen when the race androllers are unprotected.

Warning - Look quickly with aflashlight through the holes in the baseframe from which the adjusting boltblocks have been removed. See if theupper bearing race is stuck to, or


released from, the cone. Ifit is stuck,immediately lower the cone back downto 112"or less above the rollers.

8) Determine whether the top race of the upperthrust bearing has pulled away with the cone.

9) If the race is still in place down on the rollers,proceed to step 14).

10)If the race has been lifted because it is stuck tothe upper thrust bearing surface of the cone,leave the cone not more than about 112"abovethe rollers. Wait a few minutes to see if the oilsuction will break loose, letting the race fall tothe rollers. Be sure this fall is less than 1/2".If the suction breaks, you can hear the race fallto the rollers.

Warning - Take the next step verycarefully. Incorrect procedure couldresult in injury to hands or fingers.Follow directions carefully. Rememberthat the "stuck" race can release at anysecond and fall.

11) If the bearing race doesn't release at step (7),cautiously lift the cone again, but not morethan 2", as noted above. Place three (3) piecesof rubber belting on top of the rollers. SeeFigure 4 - 6. Use pieces large enough to safelyreach the rollers without placing fingers underthe cone.

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Cone Head~ Ced.rapids_ A TUl1Ix C,ompany


Rubber Belting

Offset Lifting Eye

Upper Race

Rubber Belting

Figure 4 ~6 Protect Upper Thrust Bearing With Belting12)With rubber pieces in place, continue slowly

lifting the cone off the wedge plate. Slightlyabove 2", the wide, machined portion of thewedge plate knocks the top race of the thrustbearing loose. It falls onto the rubber.

Warning ~During this lifting process,make sure the cone lifting eye is alwayslined up with the wedge plate'S highside. This reduces the chances ofscuffing the bearing race or rollers bykeeping the cone stem at the properangle. Remember, the cone fits on thewedge plate at a slight angle fromverticaL The offset cone lifting eyecompensates for this angle.

13)When the race is free and lying safely on therollers (or rubber pieces), lift the cone off thewedge plate. To prevent scuffing the race orthe radial bearing rollers, continue gentlyrotating the cone 3" or 4" to each side in arocking motion while lifting. Keep thismotion going until cone stem entirely clearsthe wedge plate. See Figure 4 ~7.

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Cone Head~ Ced.rapids_ A Terex CompanyReplacing the Mantle Bolt

Mantle Bolt Cage, Rollers, & Inner RaceOuter Race

Upper Race RestsOn Rubber

Torque Bar

Figure 4 - 7 Lift Cone Free From Wedge PlateReplacing the Mantle Bolt4) When the cone is lifted free of the wedge plate,

set it carefully down on a clean wood orpadded surface. RC 36, RC45, & RC54

15) You can now see the outer race of the upperradial bearing still mounted in the wedge plate.The upper radial bearing cage, rollers, andinner race stay with the cone as it is removed.

1) See Figure 4 - 7. The mantle bolt, togetherwith the mantle nut, hold the manganesemantle to the cone. During the process ofchanging manganese, you may discover a needto remove the mantle bolt. You do not need toremove the upper radial bearing to change themantle bolt, but you must remove the cone andturn it upside down.

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Cone Head~ CedarapidsI I I I I i I I I I A Terex Company

2) With the manganese removed, turn the coneover as described later in this section.

3) Remove the two bolts holding the torque bar inplace. Pry the torque bar upwards. Work itloose and upwards by prying on alternate sidesof the bar until the pins slip up out of the conestem.

4) Attacha lifting eye to the mantle bolt at thethreaded hole in the center locating stub.Notice the locating dowel pin exposed byremoving the torque bar. Ifrust is present,lubricate the pin.

5) Attach a properly rated lifting device and pullthe mantle bolt up out of the cone. The dowelpin will come out with the bolt.

6) Inspect the mantle bolt before installing.Check the condition of the mantle bolt O-ringand replace if necessary. (Figure 4 - 7)

7) Lubricate mantle bolt O-ring with oil andapply anti-seize lubricant to the mantle boltmating surfaces.

8) Reverse the removal sequence to replace themantle bolt. Refer to See "Installing StandardCone Mantle" on page 10 - 12. for instructionson installing the mantle nut.

Removing the Fine Head (FH) ConeNotice - To remove the cone from the lowerassembly, you must first remove the entireupper assembly. See Section 14 - "UpperAssembly", for proper procedures. Thefollowing instructions assume you haveremoved the upper assembly.

Removing the Fine Head (FH) Cone

Except for the mechariisms which hold the mantledown, procedures for removal of Standard Headand Fine Head cones are the same. See Figure 4-1 and Figure 4 - 2 for illustration of the differencesbetween the two. In general, the Fine Head has alower profile than the Standard Head, and the twohave differing application ranges.1) To remove the distributor plate, remove the

bolts holding the distributor plate to the mantlenut. These bolts are often very tightly packedwith dust and grit. Be sure to have adequatetorquing power available.

BoltsLocking Lug

Lug Retaining BoltCone Mantie

Figure 4 - 8 Remove Distributor Plate2) Refer to Figure 4 - 8 , showing the manganese

locking lug in later models. Be sure not to losethe lug after removing it. Earlier models donot have this locking lug.

A Warning - When welding anywhere onor near the Rollercone with electric are,be sure the welding ground (earth) iswell-attached as near as possible to the

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Cone Head

weld area. Serious damage could occurto bearings if arc passes through thebearings.

3) The distributor plate is heavy and sharp-edged,so it is difficult to lift by hand. Connectwelding ground to the distributor plate. Weld aheavy nut to the center of the plate. Thread alifting eye into the nut. Using a crane, liftdistributor plate to expose the center top of thecone.

4) After the distributor plate is removed,procedures for removing the Fine Head coneare the same as for the Standard Head cone.Follow the directions for Standard Head coneremoval.

/ L ifting Eye

Ears

~ Cedarapills~ A Terex Company

Turning the Cone Over

Turning the Cone Over1) Refer to component weights charts, Section 6-

"Handling, Installation & Storage".2) To further disassemble the upper radial bearing

cage and roller assembly and to remove theinner race of the upper radial bearing from thecone stem, the cone must be turned upsidedown. To do this safely in a shop requires two(2) lifting devices.

A Warning - The cone will roll quicklyand unexpectedly unless carefullycontrolled. See Figure 4 - 9 forsuggested field procedures.

Correct WrongThis will happen

Figure 4 - 9 Turning the Cone Over3) If two (2) properly rated cranes or hoists are

available, attach one hook with shackle to thecenter cone lifting eye. Also using a shackle,attach a second hook from the second hoist to

one (but only one) of the lower two coneturning ears welded to the underside of thecone.

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Cone Head~ CedarallidsIIIIIiI A Terex Company

Warning - Do not attach hoist to bothlower turning ears. This can causesudden slack in the chains or cables asthe cone rolls over.

4) Lift the cone four to five (4'-5') feet from theground with the first hook attached to thecenter lifting eye.

Warning - You can easily lose controlof the cone's weight. If this shouldhappen, serious injury is possible.Proceed alertly in small, slow steps.Make sure to have a place to step awayfrom the cone if it slips or turns tooquickly. Keep all unnecessary personsaway from the turning activity. Onlyvery careful handling will prevent itsrolling quickly and unexpectedly.

5) Using the second crane, while the cone issuspended from the center lifting eye,gradually lift the hook attached to the onelower turning ear and let down the hookholding the center eye. Turning the coneupside down goes smoothly and safely ifproper equipment is used and if it is done insmall, slow steps.

6) See Figure 4 - 10. When the weight of thecone hangs entirely from the second hook(attached to the turning ear on the underside ofthe cone), release the hook and shackle fromthe top center lifting eye. Unscrew the liftingeye and put it safely aside. Remember theoffset lifting eye is an important Rollerconetool, because it is manufactured to lift the coneat the proper angle.

Disassembling the Upper RadialBearing

Cone lifting EyeFigure 4 - 10 Remove Lifting Eye

7) Slowly spin the hanging cone so you can re-attach the free lifting device. Now attach theshackle and hook to the second lower turningear on the underside of the cone. Lift thehanging cone until it is level, but upside down.Then rest the cone flat on a level surface orstabilizing ring. Detach the hooks andshackles.

8) To turn the cone back over when work iscompleted, lift it clear of the ground with two(2) cranes and follow this procedure in reverse.

Disassembling the Upper RadialBearingThe following steps for disassembling the upperradial bearing cage and rollers assume the cone hasalready been turned upside down.1) Early Rollercone models used safety wire to

prevent the bearing retainer bolts from comingloose. Later models use Loctite on these bolts.Ifthe six retainer bolts are safety wired, cut thesafety wire before removing the bolts. SeeFigure 4 - 11 .

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Cone Head~ Ced.rapidsIIIiIII A Terax CompanyDisassembling theBearing

Upper Radial

Torque Bar

Torque Bar Lifting EyeBearing Retainer Bolts Bearing Retainer

Figure 4 - 11 Remove Bearing Retainer Figure 4 - 12 Attach Lifting Eye To Upper RadialBearing

2) Remove the bearing retainer bolts.3) Lift the bearing retainer ring free.

6) Using a lifting device with a minimum 114 tonrating, carefully lift the roller and cageassembly free, leaving the inner race on thecone stem.) To remove the cage and roller assembly,special lifting eyes are required. This assembly

weighs over 200 Ibs.5) Attach lifting eyes. (Figure 4 - 12 )

Notice - The inner bearing race isinterference fit to the cone stem and mustbe pressed off using both hydraulicpressure and heat expansion. Please followdirections carefully to avoid damaging therace.

7) Remove the two (2) retaining bolts in thetorque bar.

8) Pry torque bar upwards. Work it loose andupwards. Pry on alternate sides of the torquebar until the pins slip up out of the cone stem.

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Cone Head~ Cedarapills_ A Terex Company

9) Attach the bearing race lifting fixture shown inFigure 16 - 4 to the holes halfway down therace.

Removing Inner Race1) Place a hydraulic ram on a steel plate between

the cone stem and the race lifting device.(Figure 4 - 13) A 30-ton ram is commonlyused for this procedure. Pressurize the ram to2500 psi and stop, holding pressure at 2500pSi.

Race Lifting Device'

Hydraulic Ram

Keep Torch MovingFigure 4 - 13 Remove Upper Radial Bearing Inner Race2) Gently warm the entire race with a large

heating (rosebud) tip on an oxyacetylene torch.

Disassembling the Upper RadialBearing

A Warning - No Hot Spots! Only evenheating can properly remove the racewithout damaging it. The race will beruined if the heat distorts the circularshape or tempers the steel incorrectly.Keep the torch moving! Use temp sticksto measure race temperature. Do notheat the race above 2500 F

3) Keeping the heating tip constantly moving incircles around the race, gently warms it untilthe race expands slightly in diameter. You willknow this has happened when the race jumpsupward 114" to 3116" and the pressure on thehydraulic ram suddenly decreases.

4) Stop heating the race. Repressurize the ram to2500 psi. The race continues to move upwardswith the pressure from the ram. At the top ofthe ram stroke, while the race is still warm,continue moving the race upward by liftingwith the overhead crane.

5) As the race comes free of the cone stem, itlifts easier. Set the race on a clean, paddedsurface.Notice - If a crane with enough capacity tolift the entire cone head is available, it maynot be necessary to use the hydraulic ram toremove the inner race. The cone head canbe lifted I"while the inner race is heated.The cone head will drop to the floor whenthe race expands. This process can becontinued until the race is removed.

A Warning - A safe lifting device isimportant for this operation. See theComponent Weight Chart in Section 6 -"Handling, Installation & Storage", todetermine the weights to be lifted.

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Cone Head~ OedarapidsI i I I I I I i A Terax Company

6) Newer Rollercone models have a bearingretainer ring at the base of the cone stem.Remove the retainer ring. See Figure 4 - 14 .

Inner RaceFigure 4 - 14 Bearing Retainer Ring

Cone Seal RingThe cone seal ring is one of four (4) seal ringswhich are part oftSection 13 - "Seal Rings"heRollercone's lubrication system. See Section 13 -"Seal Rings", for seal ring removal and installation.The cone seal ring attaches to the lower side of thecone casting with a precision-machinedinterlocking seal that is heat-shrunk into place. Itforms a labyrinth seal with the upper wedge plateseal ring when the cone is properly in place andoperating.

Repairing Manganese Seat Area ofConeIf the cone seat area for the manganese mantleneeds repair, follow the detailed steps for weldingand machining the seat provided in Section 10 -"Manganese"

Cone Seal Ring

Installing Upper Radial BearingThese steps assume cone has been removed,stripped of bearing, rollers, race, and seal, and thatit is upside down.1) Check the surface of the cone stem for burrs,

dirt, or any abrasive particles. Coat themachined surface with a layer of light oil.New model Rollercones use a bearing retainerring between the cone stem and inner race(Figure 4 - 14 ). Ifyour Rollercone uses thisretainer ring, install this first.

2) To get proper fit you must expand the upperradial bearing's inner race with heat. The bestmethod is a heated oil bath. If no oil bath isavailable, you can heat it carefully with a largeheating (rosebud) tip torch. If you heat the oilin a kettle with a burner below the kettle, raisethe bearing race a minimum of one (1") inchoff the bottom with evenly spaced metalsupports .: Ifyou use an immersion heater,place it a minimum of four (4") inches fromthe race. A heavy concentration of heat couldcause uneven heating, risking damage to therace.

Warning - Do not heat the race hotterthan 250F. Higher heat can distort ordamage the race. 250F providesenough expansion of the race to allowproper fit over the cone stem.

3) Attach the race lifting device to the inner race.Radial bearing design has evolved over theyears. Some inner races of upper radialbearings were made with chamfers of differentdimensions. lfthe bearing you are installinghas two (2) different size chamfers, install it so

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Cone Head~ Oedarapids_ A Ternx Company

the larger chamfer is placed over the cone stemfirst (in the "down position"). Ifthe chamfersare equal, the inner race can be installed eitherend up. With the race attached to the liftingdevice, heat race to 250F. See Figure 4 - 15 .

Race Lifting Device

Cone Stem

Figure 4 - 15 Install Inner Race4) When the race has reached temperature (after

about one-half hour in the oil bath), slide itcarefully onto the prepared cone stem. Iftherace has been properly heated, it slides all theway down the stem from its own weight. Itstops when the race is flush with the "top" ofthe cone stem. (Remember the cone is upsidedown, so the top is really the bottom.) Whenflush all around, the race is correctly seated.

5) Ifthe race does not slide all the way down, pullit back off as described in Removing the Cone.Check the race and stem for correctdimensions, and look carefully for burrs, dirt,or other signs of abrasion on the race and stem.When you are convinced that a proper fit can

Installing Cone onto Wedge Plate(Std. or FH)

be achieved, reheat the race to 250F and tryagain. Let the race cool before installing therollers and cage assembly.

6) Install the roller and cage assembly. Be sure touse the correct lifting fixture and handle thebearing parts carefully.

7) Install the torque bar. Newer Rollerconemodels use Polylok bolts to retain the torquebar. These bolts should be replaced ifremoved.Ifnew Polylok bolts are not used, apply a dropof Loctite 271 to the bolt threads beforeassembly. Then replace and tighten the boltsthat hold the torque bar in place. On RC36,RC54, RC54II, RC60, & RC66, tighten thesebolts to 200 ft-lbs. On RC45 &RC45II, tightenthese bolts to 330 ft-lbs.

8) Install the bearing retainer ring and bearingretainer bolts. Apply a drop of Loctite 271 tothe threads of these bolts. On RC36, RC45,RC45II, RC54, &RC54II torque these bolts to24 ft-lbs On RC 60 & RC66 torque these boltsto 58 ft-Ibs.

9) To install the seal ring, see Section 13 - "SealRings". Allow seal ring to cool before turningthe cone right side up.

Installing Cone onto Wedge Plate(Std. or FH)I) Tum the cone to its upright position. See thespecial handling procedures for See "Turning

the Cone Over" on page 4 - 8.uTuming theCone Over" on page 4 - 8 Reverse theprocedures for turning the cone upside down.

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Cone Head

2) Looking down on the lower assembly into thewedge plate, align the top slot in the floatingplate with the drilled oil passage in the highside of the wedge plate. See Figure 4 - 16.The high side of the wedge plate is also exactlyopposite the center of the counterweights. Seealso Figure 15 - 1.

, I I ~ ~ ! I r FloatingPlate

Drilled Oil Passage

Figure 4 - 16 Aligning Cone For Installation3) Looking at Figure 4 - 17 and Figure 4 - 18 ,

turn the cone lifting eye to its proper positionby lining it up with the torque bar on theunderside of the cone. See also Figure 4 - 5 ,

~ CedarapidsIiIIIIII A Terex CompanyInstalling Cone onto Wedge Plate(Std. or FH)

Ear Does Not AlwaysAlign With Torque Bar

21788 ( 1 1 0 1 )

Align Lift Eye With Torque Bar

Torque Bar

Figure 4 - 17 Align Lift Eye

Cone Diameter

Floating Plate1 14 " to 1 /2 "

B Wedge PlateFigure 4 - 18 Center Cone Bearing Over Cone Stem

4) As the cone is lowered onto the wedge plate,neither the torque bar nor the floating plate canbe seen, but they must still be preciselyaligned. Make a first mark outside of the coneseal ring in line with the center of the long axis

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Cone Head

of the torque bar. Make this mark on the lowside of the cone as it hangs from the offsetcone lifting eye. Make a second mark on theoutside of the upper wedge plate seal ringbetween the eighth (8th) and ninth (9th)counterweights. These marks help align thetorque bar on underside of the cone with theslot in the floating plate at the top of the wedgeplate. As you lower the cone onto the wedgeplate, the marks you made will match up,helping make a proper fit.

5) Using a properly rated crane, lift the cone byits offset lifting eye to center it over the wedgeplate. Visually align the cone with the wedgeplate. The cone must start precisely down ontothe bearing housing portion of the wedge plate .

.Warning - Remember that you arepreparing to place the inner race androllers of the upper radial bearing (inthe cone) into the outer race of thebearing (in the wedge plate). Bumpingor scuffing could damage the bearing!

6) Notice that the upper radial bearing housingportion of the wedge plate looks roughly like acam with lobes and flat sides. The cone shouldhang above the wedge plate so that thedistance from the flat sides of the lobe to theinner well of the cone are equaL

7) Walk 90 around the crusher and visually alignagain. From this angle the distances fromoutside of wedge plate to the inner well of thecone is very unequaL The low side of the conemust hang approximately 114"to 112"outsidethe counterweighted "lobe" of the wedge plate.The high side of the cone should have aboutthree (3") inches of clearance, as shown inFigure 4 - 19.

~ CedarapillsIIIiIII A Terex CompanyInstalling Cone onto Wedge Plate(Std. or FH)

Warning - Proceed slowly with cautionto avoid scuffmg the rollers and race.The rollers (in the cone) engage theouter race (in the wedge plate) when thewell of the cone has already started overthe wedge plate and the seal rings areabout ten (10") inches apart. The pointsof potential scuffing are thus out ofsight. You can't see, soyou must "feel"your way down carefully.

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Cone Head~ Oed.rapids~ A Terex Company


1 /4 " to 1/2"3"

Figure 419 Align Cone Before Lowering8) Begin slowly lowering the cone onto the

wedge plate. As the rollers in the cone nearcontact with the outer race in the wedge plate,begin gently rotating cone two to three (2- 3")inches back and forth by hand as it descends.This action helps the rollers keep a slightrotary motion and may prevent any scuffing.Watch the alignment marks you made on theupper and lower seal rings to see that the ringsare approximately aligned.

9) When the seal rings are I" to 1-112"apart,stop the rotating motion and precisely align themarks on the seal rings.

10)When the marks are aligned, lower conestraight down (without any rotating motions).

11)Rotate the cone by hand clockwise on thewedge plate. Ifthe cone sets down correctly, sothe seal rings seat properly together, it rotateseasily, turning smoothly on the bearings. Ifyou cannot easily rotate the cone by hand, thecone did not seat properly.

12)If the two marks on the seal rings won't fittogether (seal rings did not seat properly),raise the cone a little, rotate it very slightly toright or left, and let it down again. If this

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Cone Head~ Ced.rapidsIiIIIIIIi A Terex Company

doesn't work, the torque bar and slot in thefloating plate are misaligned. Carefully lift thecone entirely free from the wedge plate andbegin the realignment process again step (2).

13)Try to rotate the cone counterclockwise. Theanti-spin brake should stop this motion, exceptin a few older Rollercones, which require oilpressure for the anti-spin brake to work. If youare able to rotate the cone counterclockwise,you could have a faulty anti-spin brake. SeeSection 11- "Anti-Spin Brake"

14) If you removed the mantle nut protector capfrom your Standard done, replace it now andtighten the mantle protector cap bolt.

Warning - When welding anywhere onor near the Rollercone with electric are,be sure the welding ground (earth) iswell-attached as near as possible to theweld area. Serious damage could occurto bearings if arc passes through thebearings. Here attach the ground to thecone head.

15)Weld the mantle nut cap to the mantle washerwith two (2") inch long welds in three (3)places, each with three (3) passes. Use McKayHardalloy 118 or equivalent welding rod.Make the welds 1200apart.

16) If you are replacing a Fine Head Cone, workbackwards through the steps for removing aFine Head in this Section. Remember to avoidinjury by lifting the distributor plate with acrane or hoist.


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Seal Rings

Section 13 - Seal RingsPurpose of Seal RingsSeal rings serve to keep the dust and dirt generatedby the crushing of rock from entering the machineand contaminating the oil system. See Figure] 3 - 1and Figure 13 - 2. They are designed so that two(2) rings act as mates, one remaining still, the otherrotating .. Together, machined with very closetolerances for precise fits, they make a labyrinth toseal dirt out and lubricant in. Lubricating oil worksits way through the labyrinth preventing dirt anddust from entering the seal.

~ CedarallidsIiIIIiIi A Terex CompanyPurpose of Seal Rings

Each ring has an interlocking seat which locks theseal ring to its seating surface. The ring is installedat the factory using heat expansion. As it cools itshrinks into its proper fit. Proper removal and re-fit require the heating and cooling processdescribed below.

Wear BandMoving Seal Ring

Cone Seal Ring

Upper Wedge PlateSeal Ring

Lower Wedge PlateSeal Ring

Base Frame Seal Ring -t---=~~

Figure 13 - 1 Seal Ring and Wear Band

Figure 13 - 2 Seal Rings21788 (1/01) 13 . 1 R o lle rc on e S e rv ic e M a nu al


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Seal Rings... CedaraJlids_ A Tarax Company

Tools Needed oxyacetylene torch with large tip ("rosebud" or

"heating" tip) locking pliers weighted, or shot-loaded, hammerSeal Ring Removal & InstallationThe Rollercone has four (4) seal rings which usethe labyrinth principle to seal lube oil duringoperation. They are located in the base frame,lower wedge plate, upper wedge plate, and cone.The base frame seal ring mates with the lowerwedge plate seal ring. The upper wedge plate sealring mates with the cone seal ring. The designprinciples are similar for all four, sothe procedureswhich apply to removal and installation are similar.With just a few exceptions, the followinginstructions can be applied to any or all of thelabyrinth seals of the Rollercone.Removing a Seal RingBefore removing the base frame seal ring, mark itslocation relative to the base frame so the drain-backholes in the seal ring align with the cored drain-back holes in the base.

A Warning - Driving a "cold" seal ring offdamages themachined interlocking seatthat holds it in place. Do not attempt toremove an old seal ring withoutheating.

Some seal rings were manufactured with oil drain-back holes. Look ring over carefully for theseholes before removing it. Mark the location ofholes so they can be returned to proper alignment.

Tools Needed

1) Heat the seal ring evenly with a rosebud tip onan oxyacetylene torch. Do not allow the torchto dwell on the seal ring. Seal rings must beheated to be removed without damagingsurrounding parts. Check to see that the sealring has not been spot welded in place.

2) Keep the torch moving rapidly around the seal.Tap the ring with a rubber or loaded hammeras the heat is applied. Tapping the outerperimeter of the seal ring as it is heated helpsdetermine when it is loose enough to be liftedoff the seat. Do not tap hard enough to damagethe ring. See Figure 13 - 4. You can see itmove slightly as it loosens, but itmust expandfar enough to lift over the machinedinterlocking seat that retains the seaLIn Figure13 - 3 notice the slight angle that forms theinterlock.

Upper WedgePlate Seal Ring

Wedge Plate

Slight Taper

Figure 13 - 3 Seal Ring Taper3) Have a pair of locking pliers handy to grip one

of the seal lips and lift upward. As you heat theseal, keep testing it by lifting upward slightly.See Figure 13 - 4.

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Seal Rings

)) --_/\

4) When the ring has expanded enough to releasethe interlock, it loosens easily. Lift it freewhile it is still hot.

Inspecting the Seal Ring Area1) With the seal ring removed, look for contact

marks and wear points. Look especially on thelower wedge plate seal ring where rockfrequently wears and can damage the seal.Reject and replace the ring if-significant wearis found.

2) Look carefully at the mating surfaces shown inFigure 13 - 3 for any upset metal or burrs. Fileor sand down any high spots. Use ascrewdriver to clean dirt or debris from thegrooves. Inspect them closely for any damage.Replace any seal ring where significantdamage or wear is found.

3) Check the condition of the wear band.Replace it if worn. See Figure 14-5. You canorder this part from your CedarapidsDistributor.

~ CedarapidsI i I I I I I I I I I J A Terex Company

Seal Ring Removal & Installation

Plug Weld Through Holes and EndsFigure 13 - 5 Welding Wear Bands

Installing a Seal Ring

133

1) Thoroughly clean the seal ring and seatingbase surfaces for the seal ring. Remove anyburrs or upset metal. In some cases the areabetween counterweights must be ground top.roperly re-seat the lower wedge plate sealnng.

2) Place the seal ring on the interlocking seat. Ifyou are reusing the lower wedge plate sealring, make sure the ring is placed so the wearband is located between the counterweights.

3) On the base frame and upper wedge plate sealrings, make sure the oil drain holes in theinner perimeter of the seal ring are clean andallow oil to drain through. Some early upperwedge plate seal rings were not made withthese drilled holes.

4) Heat the seal ring evenly with a rosebud (largeheating) tipped torch until a slight tap will dropit in place. Do not allow the torch to dwell onthe seal ring. Keep it moving rapidly aroundthe seal.

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Seal Rings~ Cedarallids_ A Terex Company

5) The seal drops into place when theinterlocking seat has expanded enough to fit itsmating surface. Be sure the seal ring is evenlyseated by tapping it down with a rubber orloaded hammer.

Seal Ring Removal & Installation

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Wedge Plate~ CedarapldsIIIIIi! A Terex CompanyGeneral

Section 15 - Wedge PlateGeneralThe wedge plate is the heart of the Rollercone. Incontact with the four (4) major roller bearingassemblies, the rotating, precisely-machined,wedge-shaped plate provides moving support forthe cone. It is the main moving part in the crusherand creates the cone action in the crushingchamber. See Figure 15 - 1 and Figure 15 - 2.

Wedge Plate Assembly

Figure 15 - 1 Wedge Plate Assembly21788 (1 / 01) Ro lle rc on e Se rv ic e Ma nu al5 - 1


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Wedge Plate~ Oedarapidsi I I I I I I I I A Terex CompanyTools Needed

Race Retainer Wedge Plate Counterweight Lobe

Upper Radial BearingLoose Ring

Upper Wedge PlateSeal RingUpper ThrustBearing Rollers

\ounterweightsLower Radial Bearing Outer Race

Lower Thrust Bearing CageLower Radial Bearing Loose Ring

Lower Radial Bearing Rollers

Figure 15 - 2 Wedge Plate Cross-section

Tools Needed 1" x 4" coarse thread bolts lifting handles (114" and 5/] 6" T-handles)

wedge plate turning devicelifting eyes (3/8" and 1/2")

upper thrust bearing retaining strapswedge plate lifting beamheavy duty lifting device for turning wedgeplate and lifting itout of base

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Wedge Plate~ aetlarapids_ A Terex Company

counterweights will need to be determined. A newconfiguration of counterweights will also need tobe determined ifthe wedge plate or cone head arereplaced. Balancing the wedge plate is done by trialand error.1) Make a copy of Tab le 15 - 1. This table can be

used to record weight changes and how theweight change affects cone vibration.

2) Obtain an ample supply of various sizedweights and shims. After the balancing processis complete you should have several unusedweights left over.

We will be measuring vibration by feel. Vibrationwill be measure in the lateral as well as thehorizontal direction as shown in Figure 15 - 4.3) As a starting point, install the counterweight

configuration that the crusher was equippedwith when it shipped from the factory. Thisconfiguration can be found in the parts book.Record the counterweight configuration onTable 15 - l.

4) Run the crusher for several seconds atfullspeed. Place your hand on the lateral side ofthe crusher (Figure 15 - 4). Remember theamount of vibration you feel. Repeat this forthe horizontal side of the crusher.

Warning - Do not run the crusher formore than 20 minutes without rock inthe crushing chamber. The cone headcould separate from the bearingscausing severe equipment damage.Shut down the crusher and let it sit idlefor at least 30 minutes before runningagam.

Balancing Wedge Plate

5) Change the trailing weight (#16 if all weightsare used) to a lighter weight and record thenew weight size on the next open line on Table15 - l.Repeat step 4).

6) Record the changes in vibration by placing a Bfor Better or W for worse in the lateral (L) andhorizontal (H) rows in Table 15 - 1.

7) If this change improved the balance, tryputting an even lighter weight on the trailingweight and putting a lighter weight on the nextweight. If the vibration increased, reinstall theoriginal weight configuration and try changingweights on the lead (LD) weight side of thewedge plate. As weight changes are tested andrecorded, you should start to see a pattern ofchanging weight in a certain location changingthe amount of vibration in the horizontal and!or lateral direction.

8) Fine tuning can be done by adding shims underthe weights. Installing a lighter weight with ashim can have the affect of installing a weightbetween the medium and heavy weights.

Horizontal

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Figure 15 - 4 Check Crusher Vibration154 Ro lle rc on e Se rv ic e Ma nu al


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Wedge Plate~ eedarapidsI I I i I I I I I A Tel"Bx CompanyBalancing Wedge Plate

Table 15 ~1 Wedge Plate Balance SheetBetter/ Weight NumberWorse 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 LDLHLHLHLHLHLHLHLHLHLHLHLHLHLH

.LH

L-Light WeightH - Heavy Weigh114- Quarter Inch Thick Shim

M - Medium Weight1/8 Eighth Inch Thick Shim

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Wedge Plate~ OatllarapidsI11III A Terex Company

Removing the Wedge Plate from theBase FrameYou would normally remove the wedge plate onlyduring a major overhaul, to inspect the bevel gear,to adjust the pinion-to-bevel-gear backlash, toinspect the wedge plate itself, or to inspect themajor bearings (except the upper radial bearinginner race, cage and roller assembly, which remainin the cone.)The following instructions assume that the upperassembly and cone have been removed. See alsoSection 14 - "Upper Assembly" and Section 4 -"Cone Head" for Removing the Cone ..1) Remove floating plate, brake shaft, and thrust

plate. Refer to Figure 11 - 1.2) To pull the floating plate, thread two (2) T-

handles into the two (2) tapped holes in thefloating plate and lift clear. Approximateweight of the floating plate is thirty (30) lbs.,but, due to oil suction, breakaway force maybe greater. Set the plate on a clean, drysurface.

3) Thread a T-handle or lifting eye into the topcenter tapped hole in the brake shaft. SeeFigure 15 - 5. As you lift the shaft you'll bepulling about thirty (30) lbs. plus releasing oilsuction. Set the shaft on a clean, dry surface.

Removing the Wedge Plate from theBase Frame

Brake Shaft & Bar)Thrust Plate

Figure 15 - 5 Remove Brake Shaft4) Remove eight (8) bolts that retain the thrust

plate to the base frame spindle.Warning - The thrust plate is heavy andmay also be held down by oil suction.Do not strain your back. Approximateweight of the thrust plate is 110-120 lbs.

5) Use a lifting device or get two (2) persons andtwo (2) T-handles to remove the thrust plate.Strong oil suction can be broken by threadingpuller handles all the way through to push onthe top of the spindle. Set it on a clean, drysurface.

6) Thread two (2) 1" diameter NC bolts into thewedge plate sides near the top. See Figure 15 -6. Thread them well in but do not tighten thembecause this could upset the bore of the upperradial bearing. These bolts must hold the entireweight of the wedge plate as it is being liftedclear. If you do not have the wedge plate liftingbeam (shown as a turning fixture in Figure 16 -2) , suspend equallengtb, properly rated liftingstraps from a properly rated lifting device and

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Wedge Plate~ aedarallidsIIIiIii A Tarax Company

attach them to bolts. Without the wedge platelifting beam, use bolts two to three (2-3")inches long.

Wedge Plate

Figure 15 - 6 Install Wedge Lift ing Bolts7) Center the lifting device carefully over the

wedge plate. The trick to properly removingthe wedge plate is to pull perfectly straight upwhile someone slowly rotates the wedge plateback and forth four to five (4"-5") inches.Continue this rocking, rotating motion untilthe wedge plate is entirely clear of the spindle.

Warning - The lower radial bearing canbe damaged if the wedge plate is notlifted straight up. Only 0.006" to0.008" clearance is available at thelower radial bearing. Pulling at anangle can force the rollers to dragagainst the race, possibly damaging thebearing.

8) Carefully lift the wedge plate clear and set iton a clean, dry surface.

9) The inner race of the lower radial bearingremains on the base frame spindle. Inspect itcarefully. Ifin good condition, you may notwish to remove it. Ifyou decide to remove it,

Removing the Upper Radial Bearing

detailed instructions for removing andreinstalling the race are provided in Section 2 -"Base Frame"

Removing the Upper Radial BearingThe wedge plate does not have to be removed fromthe lower assembly to remove the upper radialbearing outer race or the upper thrust bearing. Theupper radial inner race, rollers and cage remainwith the cone as it is removed.1) To remove the upper radial bearing outer racefrom the wedge plate, cut the safety wire from

the bolts holding the retainer (if used) andremove the bolts.

2) Attach the lifting fixture shown in Figure 15 -7 at the three (3) holes in the bearing race.

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Wedge Plate~ .ed.rapidsIIIiIIII A Terex CompanyRemoving the Upper Thrust Bearing

Upp er R a dia l B ea rin g O ute r R a ce

F igu re 1 5 - 7 R emo vin g U ppe r R ad ial B earing O ute r R ac e3) Lift race straight up out of the wedge plate.

Set it carefully on a clean, padded surface. Ifrace, rollers, and cage are to be used again, besure to keep a light film of oil on all surfaces.Cover these parts to prevent dust or otherabrasive particles from clinging to the oil film.Store any exposed bearing parts in a dry, room-temperature area.

Removing the Upper Thrust BearingThe wedge plate does not have to be removed fromthe lower assembly to remove the upper radialbearing outer race or the upper thrust bearing, butthe following steps assume the wedge plate hasbeen removed and placed on a flat, clean surface.This practice helps reduce possible contaminationof machined surfaces.

4) If the race is difficult to remove, be sure thelifting force is straight up. Attach a 30-ton ram Aas shown in Figure 15 - 7. ~

5) When the race is clear, lift out the loose ringthat lies below it.

Warning - The first step in removingthe upper thrust bearing requires two(2) people working closely incommunication to avoid pinchedfingers or strained backs. Notice thatafter you have lifted the race several

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Wedge Plate~ CedarallidsI I I I i I I I A Terex Company

inches, you must move it sideways toclear the built-in counterweight of thewedge plate.

1) With two (2) people handling it carefully, asshown in Figure 15 - 8, lift off the top race andset it on a clean, dry surface.

Figure 15 - 8 Remove Thrust Bearing Upper Race2) The design of the tapered rollers and cage of

the upper thrust bearing has evolved throughthe years the Rollercone has beenmanufactured. Some bearings have a one-piece cage and rollers. That is, each roller istrapped in a pocket of the cage. This bearing isremoved and installed as a unit. The cage ofthis design has drilled and tapped lifting holes.On current cage and roller designs, each rollercan be removed separately. To make removalof this design easier, take out three (3) rollersfrom each side. This leaves a "handle" forlifting the cage clear.

3) Place the cage and rollers on a clean, dry,padded surface.

4) Locate the drilled and tapped lifting holes inthe lower race. This race may have oil suctionholding it down.

Turning the Wedge Plate Over

Notice - For RC54s manufactured after June, 1987,the inside diameter of the upper wedge plate sealring is smaller than the outside diameter of theupper thrust bearing's lower race. For thesecrushers, the seal ring must be removed before thelower race can be removed.5) Lift the race straight up, keeping it level. The

race has a tight tolerance fit to the wedge plateand could jam if tilted. If it jams, put slightupward tension with a lifting device andlightly rap with a soft, loaded hammer.

Turning the Wedge Plate OverThese instructions assume that the wedge plate hasbeen removed from the crusher and has beenplaced on a clean, dry, flat surface for further work.

Warning - Lifting the wedge plate inthis operation can be very hazardous!Allow only experienced personnel andlift operators to take the next step. Asthe weight of the wedge plate comes offthe ground you must prevent it fromrolling until it is high enough to clearthe ground, then allow it to spin into anupside down position. This happensvery fast! A rocking, pendulum-likemotion follows, which can strike anunwary worker. Be sure there's enoughroom and clearance to step backquickly.

1) If the upper thrust bearing is still in place, bolttwo retaining straps as shown in Figure 15 - 9.

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Wedge Plate~ CedarallidsIIIIIIIl A Tarax Company

Upper Thrust Bearing Retainer StrapFigure 15 - 9 Install Thrust Bearing Retaining Strap

2) If the counterweights have not already beenremoved, remove at least the last four (4)counterweights from each end of thecounterweight configuration. Mark reusablecounterweights for convenient replacement.

3) Attach the trunnions of the Wedge PlateTurning Fixture. They bolt on where thecounterweights were attached. Be sure thetrunnions are 1800 apart. Carefully noteorientation of the trunnions shown in Figure 15- 10. The trunnion pins are offset to let youcenter the weight of the wedge plate forturning it both upside down and right side up.

Turning the Wedge Plate Over

Trunnion

Figure 15 - 10Wedge Plate Turning Fixture InstalledWarning - Positioning the trunnionsincorrectly can make the wedge platecome over too fast! Be careful toposition it correctly.

Suspend the wedge plate lifting beam directlyabove the wedge plate and attach the speciaUy-designed lifting cables provided with the WedgePlate Turning Fixture. Attach the lifting rig exactlyas illustrated in Figure 15 - 10.A Warning - Lifting the wedge plate in

.. this operation can be very hazardous!Allow only experienced personnel and

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Wedge Plate~ Cedarapill.iIIIIIIIi A Terax Company

lift operators to take the next step. Besure there's enough room and clearanceto step back quickly.

4) Proceed with this step only when all personnelare ready. Hold the wedge plate vertical untilthe lift operator has lifted it high enough toclear the ground when it spins. Release andstep back briskly.

5) Let it rock until it stops.6) Carefully set it down on a clean, dry surface.

Removing the Bevel Gear1) Remove the safety wire from the bevel gear

(also called ring gear) bolts.2) Remove the bevel gear bolts.3) Remove the bevel gear with three (3) 112"

lifting eyes threaded into spaced holes aroundthe gear. Lift the gear clear and

Roller Cone Service Manual Exerpts

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