ElJayRollerconeClassic

®

Certificate No. 007289

A Terex Company

Often Imitated, Never Equaled...The Cedarapids/ElJay Rollercone® Classic is the high

performance crusher. As with most leaders, it’s often imitatedbut never equaled. “New” innovations from competitors haveusually been proven for years in the Rollercone.

Rollercones produce more sized product on the first passthan any competitive cone. Roller bearing tolerances are tentimes less than on bronze-bushing shaft cones. The rollerbearings ensure a true setting.

Eighty percent of the force through the wedge plate isdirected to crushing because roller bearings run moreefficiently. With its all-roller-bearing construction, horsepower

is applied to crushing, not overcoming friction as in shaft-typebronze-bushing cones.

Proof is that Rollercones require less oil than competitivecones — up to 77% less — because forces are spread over awider area, not concentrated on one point of the bushing. Thusfriction is greatly reduced.

The Rollercone hydropneumatic tramp iron relief systempasses tramp iron efficiently and quickly. Originally invented byElJay, the superior Rollercone design has never been equaledby competitive cone manufacturers.

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Hydraulic tramp iron reliefpasses large uncrushableobjects that could jam andstall competitive cones.

Massive shaftless cone headrides on close-tolerance rollerbearings which maintainaccurate setting and productgradation.

Large unobstructed feedopening allows rocks with atleast one dimension equal to thenominal feed opening to becaught and crushed where theymight block another crusher.

Cone manganese can bechanged with cone head inplace so critical downtimeis reduced.

V-seat is not part of the baseframe. If damaged, it can bereplaced quickly and does notrequire the extensive downtimeassociated with machines whichhave the V-seat as part of thebase frame.

Close-running deep-taperednon-contact labyrinth sealsprevent entrance of dust andwater.

Massive base frame directsthe compression forces tothe product, greatly reducingenergy losses due to structuraldeflection common in competitiveshaft-type cones.

Two oil systems assureadequate lubrication, anexternal bearing pre-lubepump for start-up and internalpinion-shaft driven pump foroperation. Oil reservoir iscompletely self-contained.

Anti-spin mechanism preventscone head from turning whenrunning empty. Wear fromscuffing is greatly reduced whenrock is fed into the cavity.

Counterweights balance thecone and protect the seal areaby clearing away any built-upmaterial. High hydropneumatichold-down pressure permitscloser setting without bowl float.

Roller bearings have superiorload capacity—more than to beexpected during crushing—andtherefore provide a very longservice life.

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UpperThrustBearing

LowerThrustBearing

WedgePlate

Mantle

DischargeSide

BowlLiner

ClosedSideSetting

BevelGear

More Crushing Power

The unique Cedarapids/ElJay rotatingwedge plate transmits 80% of the forcethrough it to direct compression crushing.

In fact, a Rollercone Classic produces moreto-size product on the first pass than anycompetitive cone.

The combination of the balanced wedgeplate with bolt-on counterweights, and largeroller thrust and radial bearings produces anaction that is smooth, efficient and nearlyvibration free.

The cone head rides the wedge plate with aslight eccentric motion, squeezing rockbetween the mantle and stationary bowl liner.

Rock is crushed as the thick part of thewedge closes the mantle on the liner, creatingthe closed-side setting. Crushed materialdischarges simultaneously as the thickerportion of the wedge moves away, creatingthe open-side setting.

More Sized Product

Roller bearings have a greater load carryingcapacity, can withstand greater forces,minimize friction and generate considerablyless heat, thus doing more work than bronzebushings in shaft-type cones.

The wedge plate, which extends into thecone head, rides on the lower thrust bearingsin the base and rotates around the massivecentral spindle on the lower radial bearings.The upper thrust and radial bearings allow thewedge plate to rotate inside the cone head.

Due to the roller bearing’s tighter tolerances— 1/10 those of a bronze-bushing cone—a true setting is maintained. The tightertolerances reduce oversize to about 25%instead of the 50% in shaft-type cones whenmaking a 1/2" (12.7 mm) minus product. Thisallows more feed material in the circuit with lessrecirculation and that means more production.

PinionGear

PinionShaft

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One Crusher For All Applications

The RC45, RC54 and RC60 feature easy-to-change crushingchambers. Switching from a standard to a fine crushingchamber is all that’s required to change to a new application.

With several liner configurations for the fine and standardcrushing chambers, the Rollercone is truly a highly versatilecone crusher. Rollercone crushing chambers incorporate the

Standard chamber Fine chamber

Self-contained oil sump Internal oil pump

same advanced engineering technology as found in allCedarapids/ElJay products.

Chamber liners are designed for maximum wear life with aminimum loss of feed opening during normal lifetime operation.Liners are easily changed without dismantling the uppersection or removing the cone head.

Rollercone Classicoil flow

Non-contactlabyrinth seals

Self-Contained Oil Lubrication System

Rollercone Classics run cooler than competitive conesbecause there is less internal friction. The weight and crushingstresses are spread over two radial and two thrust bearings sothe pressure in any one area is reduced.

The bronze bushings in ashaft-type cone mustwithstand all the forces, oftenconcentrated in one spot.This can lead to breakdownof the oil film, heat-producingmetal-to-metal contact andincreased tolerances.

All the oil is self-containedin the crusher base. Noexternal cooling tanks arenecessary. The tightly sealedsystem reduces the chance of contamination by water and grit.

Low friction generates less heat and less oil is needed. The54" (1372 mm) Rollercone requires only a 27-gallon (102 liter)reservoir. A comparable shaft-type cone requires up to 200gallons (757 liters) plus needs an extra cooler to dissipate heat.

A separate external pre-lubrication pump assures anadequate oil supply to the bearings prior to start-up. After thepinion shaft is turning, an internal pump, driven through ahardened gear, provides running lubrication. An alarm hornalerts the operator if oil flow drops below the required level.

Changing crushingchambers only requiresinstalling manganesebowl and mantle on theRC45 and RC54.

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No Head Spin at Start-up

The anti-spin brake deviceprevents the cone head fromspinning when the crusher isrunning empty.

During crushing the brakeallows the cone head torotate slowly to the right(clockwise) but not in theopposite direction. Thisprovides smoother operationand eliminates unnecessaryscuffing wear on the manga-nese at start-up.

The brake shaft is attachedto an overrunning clutch atthe base of the spindle. Aguide ring in the mechanismhas shear bolts which willbreak before there is anydamage to the shaft or clutch.

Best Crusher Protection

The hydropneumatic trampiron relief system providesunequaled protection againstdamage and allows muchhigher crushing forces.

The lift of a 54" (1371 mm)Rollercone Classic enables itto pass a 51/2" (139 mm)object while a spring systemon a comparable cone wouldbottom out at less thanone-half this size.

Hydraulic cylinders and gas-filled accumulators replace theold spring system. Just one cylinder has a hold-down pressureequal to six to ten springs.

The hold-down pressure—700,000 pounds (317,520 kg) ona 66" (1676 mm) Rollercone - is 11/2 times that used on mostcompetitive cones. That means the Rollercone can be setcloser without bowl float.

As diagrammed, the bonnet is forced upward against thesystem’s oil pressure in the relief cylinders. The oil pressure inturn compresses a nitrogen gas bladder in the accumulator.

Once the crushing cavity is cleared, the gas forces the oilback into the relief cylinder and the bonnet lowers to itsoriginal position.

This relief system also speeds clearing the cone should itever become blocked due to power failure or other difficulty.The bonnet is raised by relieving oil pressure without loss ofgas pressure.

The cavity can be cleared quickly and easily without damageto the crusher or danger to employees. Pressure is quicklyrestored by an electrically-driven pump.

Shock loads to the relief system are minimized through theuse of large-diameter tubing, a minimum of bends in the pipingand oversize accumulators.

BrakeFloatingPlate

BrakeShaft

ClutchGuideRingAccessCover

MantleTorqueBar

BrakeCrossBar

BaseFrameSpindle

OverrunningClutch

ShearBolts

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Solid Construction

The base frame consists of a massive stationary central huband three or more extremely strong beams joining it to theperimeter wall.

The even distribution of forces on the Rollercone bearings isa big factor in the extremely long life of the bearings.

The roller bearing design minimizes frame deflection so allcrushing energy is directed to the product.

Concentrated bending stresses that occur in shaft type conecrushers are evenly distributed in the Rollercone.

Relative placement of the bearings directs crushing forcesthrough the bearing envelope. This eliminates all edge loadingof the bearings and tipping of the cone.

Auto Adjust

The ElJay “AutoAdjust” system allowssetting adjustmentunder load. Shim stacksare replaced byhydraulic cylinders.

The system can becomputer-controlled oroperator-controlled froma remote console.Unlocking, settingchange and locking areall done automatically,within seconds.

No special mechanicalcomponents are needed.All are off-the-shelfheavy-duty itemsproviding long servicelife and dependableoperation.

Quick Adjustment System

Hydraulic/shim adjustment makes changing the dischargeopening fast and easy. Adjustment is vertical using hydraulicrams, therefore bowl rotation is not necessary.

This design requires less headroom, less weight andeliminates the problem of threads jamming with rock dust.

Exact setting is maintained by shim stacks of equal height.Shims vary in thickness and are color-coded and numberedfor quick recognition. The shims have offset slots for easyinstallation and are interlocking.

To tighten the settings, release the clamp ring and raise thebonnet. Remove shims from the lower stack to establish thenew setting. Removed shims are stored in the upper stack.

The bonnet is then lowered and the clamp ring tightenedhydraulically. Tensioning of clamp bolts is also done hydraulically.

Cedarapids Inc Telephone 319 363 3511 Sold and serviced by:909 17th St NE Fax 319 399 4871Cedar Rapids IA 52402 USA

Bulletin EJRC-5 (3/02)Design and specifications subject to change without notice.Design features may be covered by patents issued and/or patents applied for.

Send us your crushing challenge.

A Terex Company