Jaques JW40 Manual - ENGLISH

I N S T A L L A T I O N , M A I N T E N A N C E
A N D O P E R A T I O N M A N U A L
J-1160 ENGLISH JAQUES
TEREX JAQUES
Single Toggle Jaw Crusher

Instruction Manual
MODEL No: JW40/JW55
SERIAL No: XXXXXX
FEED OPENING: 1000 x 625/1400 x 814
39.4” x 24.6”/55” x 32”
MASTER SCHEDULE: N/A
MACHINE SCHEDULE: AW1726/AW1749/

AW1750
ISSUED: September 2007
 Terex Jaques
Head Office: End Osborne Avenue, off Clayton Road, (PO Box 1525), Clayton, 3169, Victoria, Australia.
Phone +61 3 8551 9300 • Fax +61 3 8551 9364 • E-mail jaques@jaques.com.au
“This manual is copyright. Other than for the purpose of and subject to the provisions of the copyright act, no part of this
manual may in any form or by any method (whether by photocopying, electric, mechanical, recording or otherwise) be
reproduced or transmitted without JAQUES’ written permission”
ISSUE SEPTEMBER 07
Rev 00
DISCLAIMER
Due to the complex nature of the Jaw Crusher, this Instruction Manual provides only general
information as to the operation, maintenance and repair of the product. The Instruction Manual
may not include all information which may be required to operate, maintain and repair the
product and any queries regarding specific problems of procedures should be addressed to an
authorised Jaques representative.
Careful attention must be paid to all instructions in this Instruction Manual, as failure to follow
the procedure set out in the Instruction Manual will cancel any and all warranties which may
exist between Jaques and the Purchaser. Further, any modification, customisation or variation of
design of the product not authorised by Jaques will cancel any warranty which may exist
between Jaques and the Purchaser.
WARNING
The Jaw Crusher is a potentially hazardous machine. Only qualified persons should operate,
maintain and repair this machine. Grave injury to persons and damage to property may result if
the machine is incorrectly operated. The instructions in this manual must be strictly observed. It
must be ensured that every person charged with the assembly, operation and maintenance of the
machine has read and understood this instruction manual before commencing work. Any repair
or maintenance operations must be carried out in accordance with local safety regulations and
should follow National Standard for Plant guidelines [NOHSC:1010(1994)].
ISSUE SEPTEMBER 07
Rev 00 PAGE i
TABLE OF CONTENTS
Disclaimer _____________________________________________________________ i
Warning _______________________________________________________________ i
Addresses _____________________________________________________________ ii
Table of Contents _______________________________________________________ iii
Introduction ___________________________________________________________ vi
Use Of This Manual ____________________________________________________ vi
Safety & Risk Assessment ________________________________________________vii
General Information ___________________________________________________ viii
Safety Hints ____________________________________________________________x
Working Environment (SITE) Checklist ___________________________________ xiii
Critical Components List ________________________________________________xv
Certificate of Conformity________________________________________________ xvi
Risk Assessment _______________________________________________________ xix
Section 1 - Technical Description

General Description ___________________________________________________ 1 - 1
Design Criteria _______________________________________________________ 1 - 2
Machine Specification _________________________________________________ 1 - 2
Table Of Weights _____________________________________________________ 1 - 4
Section 2 - Installation
Foundation Design ___________________________________________________ 2 - 1
Shipping Weights _____________________________________________________ 2 - 2
Frame ______________________________________________________________ 2 - 3
On mobile chassis/fixed steel structure ___________________________________ 2 - 3
On concrete foundation _______________________________________________ 2 - 4
Fitting Pulley & Flywheel ______________________________________________ 2 - 5
Exposed Surfaces _____________________________________________________ 2 - 7
ISSUE SEPTEMBER 07
Rev 00 P A G E iii
Vee Belt Drive________________________________________________________ 2 - 8

Jaques Installation drawing
Section 3 - Operation
Preparing the Crusher _________________________________________________ 3 - 1
Running In __________________________________________________________ 3 - 2
Feeding _____________________________________________________________ 3 - 3
Setting______________________________________________________________ 3 - 4
Setting Adjustment ____________________________________________________ 3 - 5
Section 4 - Lubrication
Care of Lubricants and Equipment_______________________________________ 4 - 1
Applications of Lubricants _____________________________________________ 4 - 2
Equivalent Lubricants _________________________________________________ 4 - 3
Manual Lubrication - Jawholder and Main Bearings ________________________ 4 - 4
Automatic Lubrication - Optional________________________________________ 4 - 4
Section 5 - Maintenance
Preventative Maintenance ______________________________________________ 5 - 1
Inspection Schedule & Log _____________________________________________ 5 - 2
Fixed and Moving Jaw Backing Plates____________________________________ 5 - 4
Crusher Jawfaces _____________________________________________________ 5 - 5
Moving Jawface Service _______________________________________________ 5 - 6
Fixed Jaw Service ___________________________________________________ 5 - 11
Side Liners _________________________________________________________ 5 - 14
Toggle and Toggle Seats ______________________________________________ 5 - 15
Removal of Tension Rod Assy, Toggle, Toggle Spacer, & Seat ______________ 5 - 18
Replacement of Tension Rod Assy, Toggle, Toggle Spacer, & Seat___________ 5 - 22
Removing the Jawholder Assembly______________________________________ 5 - 24
Jawholder Protector Plate _____________________________________________ 5 - 26
Tension Rod Assembly________________________________________________ 5 - 26
Removal Tension Rod Assembly _________________________________ 5 - 27
ISSUE SEPTEMBER 07
Rev 00 P A G E iv
Refitting Tension Rod Assembly _________________________________ 5 - 27

Removal of Bearings _________________________________________________ 5 - 28
Removal of Main Bearings ____________________________________________ 5 - 29
Removal of Jawholder Bearings ________________________________________ 5 - 29
Inspection of Bearings ________________________________________________ 5 - 30
Failure of Bearings __________________________________________________ 5 - 31
Overheating of Bearings ______________________________________________ 5 - 32
Mounting of Bearings ________________________________________________ 5 - 34
Mounting of Jawholder Bearings _______________________________________ 5 - 35
Mounting of Frame Bearings __________________________________________ 5 - 38
Refitting the Jawholder Assembly _______________________________________ 5 - 42
Toggle Wedges ______________________________________________________ 5 - 44
Removal___________________________________________________________ 5 - 46
Reassembly ________________________________________________________ 5 - 50
Jaques Fixed and moving jawface backing plates drawing
Jaques Hydraulic mounting and dismounting of main bearings drawing
Section 6 - Spare Parts

Ordering ____________________________________________________________ 6 - 1
Manufacturing Information - Jaques Master Schedule ______________________ 6 - 1
Spare Parts __________________________________________________________ 6 - 3
Wearing Parts_______________________________________________________ 6 - 3
Other Parts _________________________________________________________ 6 - 4
Jaques Crusher Assembly drawing
Jaques Jawholder Assembly drawing
Bearing Assembly Arrangements
Hydraulic Adjustment Arrangement
ISSUE SEPTEMBER 07
Rev 00 PAGE v
I N S T A L L A T I O N , O P E R A T I O N
A N D M A I N T E N A N C E M A N U A L
S A F E T Y S E C T I O N
INTRODUCTION
We would like to welcome you as a user of a Terex Jaques product, which with reasonable care
and attention, will give a long and trouble-free service. High quality materials and engineering skills
make this a simple machine to install and operate.
This instruction manual is for the new operator and a refresher for the experienced one. It will
acquaint you with the easiest and most practical way to install, operate and maintain your machine.
The operating techniques outlined in this book are basic. Operating skills and additional techniques
will develop as the operator becomes familiar with the machine and its capabilities. Read this
manual carefully before installing or operating the machine and keep it readily available for future
reference.
For assistance regarding training, understanding your machine, or this publication, please consult
your local Terex Jaques representative.
USE OF THIS MANUAL

Continuing improvement and advancement of product design may result in changes to your
machine, which may not be included in this manual. In order to keep this manual up to date in the
light of operating experience, or when modifications are carried out and approved, amendments to
this manual may be necessary from time to time. New sections will be supplied as necessary.
Modifications to the machine prior to acceptance, including any made during commissioning or
afterwards by the users or suppliers engineers should be recorded under Modification Details.
Additional copies of any page or section of this manual may be obtained by contacting Terex
Jaques. Additional copies of the complete manual may be obtained upon request.
ISSUE SEPTEMBER 07
Rev 00 P A G E vi
SAFETY
Operator safety and the safety of others depend on reasonable care and judgement in the
operation of this machine. A careful operator is good insurance against an accident.
Most accidents, no matter when they occur, are caused by failure to observe and follow simple
fundamental rules or precautions. For this reason, most accidents can be prevented by recognising
hazards and taking steps to avoid them before an accident occurs.
STOP ACCIDENTS BEFORE THEY STOP YOU!
Regardless of the care used in the design and construction of this type of equipment, there are
conditions that cannot be completely safeguarded against without interfering with reasonable
accessibility and efficient operation.
It is important to prepare a Job Safety Analysis (J.S.A.) for all major work planned.
REMEMBER
• Be alert for possible hazards before they cause trouble.

• Know your employer’s safety program.
• Dress properly for the job.
• Understand your machinery – read your manual.
• Know your work areas.
• Prepare for emergencies.
• Report defective equipment.
ISSUE SEPTEMBER 07
Rev 00 P A G E vii
Equipment not properly prepared for operation is unsafe equipment.
Run a careful check at the beginning of your shift. If you find something that needs attention,
THINK TWICE before deciding to start. Don’t use damaged equipment. If in doubt consult your
supervisor. Even minor mechanical defects can lead to personal injury and accidents.
GENERAL INFORMATION
The regulations which must be complied with for the safe operation of the machine are
summarised in this manual as “Safety Instructions”. Throughout this manual, “Danger” and
“Warning” signs are used to highlight particular risks. These are defined as follows.
Danger denotes a particular hazardous or hazardous conditions that is

likely to be life threatening.
These hints must be closely adhered to. Please hand over these
documents to the machine operating personnel.
ISSUE SEPTEMBER 07
Rev 00 P A G E viii
WARNING
Warning denotes a hazard or hazardous conditions that is not likely to be

life threatening. It is also assigned to those hints, regulations and guidelines
which are designed to prevent damage to or destruction of the machine due
to improper operation.
Make sure that every person responsible for the assembly, operation and
maintenance of the machine has read and understood these regulations and
operating instructions before work is started.
This machine is built to the latest technology and is safe to operate.

However, if it is improperly operated by non-trained staff it may be a
source of danger.
Before initial operations, the operator of the machine is obliged to check

that the machine and its safety devices are in a safe condition. During
operation these must be repeated at regular intervals.
In addition to the safety at work hints contained below the general and
local safety and accident prevention regulations must also be complied with.
ISSUE SEPTEMBER 07
Rev 00 P A G E ix
SAFETY HINTS
WARNING
This machine is intended solely for the application agreed to with Terex Jaques.
Terex Jaques are not liable for damage resulting from non-compliance.
• Appropriate Personal Protective Equipment (PPE) should be worn while undertaking all
maintenance.
Eye Protection Head Protection Foot Protection Hearing Protection
• It must be clear which members of staff are responsible for the assembly, commissioning,
operation and maintenance of this machine so that safety is not impaired.
• The machine may only be transported and set up using proper recognised methods.
DANGER
It is forbidden to stand under suspended loads.
• The machine must be set up so that its moving parts do not impact against stationary
structure or other machinery.
ISSUE SEPTEMBER 07
Rev 00 PAGE x
DANGER
Electrical connections and work on the machine’s electrical equipment may

only be carried out by skilled authorised personnel.
DANGER
Protective earthing must be carried out and checked with special care.
i NOTE:
If it is necessary to do any welding on the crusher, the earth wire must not
be connected to any part of the Jawholder assembly such that current is
drawn through the bearings, as rapid bearing failure could result. The earth
wire should be connected directly to the part to be welded.
DANGER
Before starting initial operations check that the machine and its safety
devices are in a safe condition.
• The machine may only be operated when complete and with all accessories fitted (original
condition).
• The operator must notify their supervisor of any deviations from the original condition.
ISSUE SEPTEMBER 07
Rev 00 P A G E xi
WARNING
Unauthorised modification and changes to the machine carried out by the

operator and which could impair the safety of the machine are not permitted
and relieve Jaques of all liability.
DANGER
The electrical connection of the drives must be sufficiently protected.

Electrical wires which are damaged must be replaced immediately.
• The machine must be inspected once each shift for outwardly visible damage and defects.
DANGER
Never put your hands in the space between securely fixed components and
swinging components when the machine is in operation!
• All maintenance and setting work may only be carried out when the machine is at a
standstill and by qualified personnel. A tag-out procedure that ensures the complete
isolation of the crusher drive to prevent starting must be in place before starting such
work, to sure that the machine cannot be started accidentally or started by unauthorised
persons.
• After maintenance and repair work has been carried out the operator must ensure that the
machine and its safety devices are in a safe condition.
ISSUE SEPTEMBER 07
Rev 00 P A G E xii
WORKING ENVIRONMENT (SITE) CHECKLIST

Before work is carried out at each site, it is recommended that additional assessment of risks be
carried out by the user of the plant. This checklist is provided as guidance for the different work
environmental conditions that may affect the risk when using the plant or equipment. Due to the
variety of working environmental conditions, this checklist is not exhaustive in every possible risk.
i REMEMBER
Work to and follow your Job Safety Analysis (J.S.A.)
Note as the following checklist refers to Australian Standards, it will be necessary to substitute
equivalent standards applicable in the locality the machine is to be installed.
Site Address:
............................................................................……………….
Site Conditions that May Are the Risk Control Comment
Increase Risk of Accident Measures Adequate?
Yes No
Is the concrete foundation or steel structure
where the plant is installed stable?
Site Conditions that May Are the Risk Control Comment
Increase Risk of Accident Measures Adequate?
Yes No
Are all guards fitted and effective to
prevent unauthorised access and comply
with AS4024.1?
Are field welding carried out in
accordance with designer/ manufacturer's
specifications?
Are lifting devices, cranes appropriate for
the tasks? Cranes must comply with
AS1418.
Are appropriate tools such as hydraulic
torque wrench provided?
Are access to plant adequate and platforms
complying with AS1657?
ISSUE SEPTEMBER 07
Rev 00 P A G E xiii
Are electrical wiring appropriately

enclosed and comply with AS3000?
Are hydraulic hoses and fittings
appropriately fitted?
Are appropriate PPE used e.g. eye, hearing
and breathing protection, hard hats and
clothing?
Are stop/start including emergency stop
controls within easy access?
Do conveyors comply with AS1755?
Is there adequate working space?
Are lighting levels appropriate in
accordance with AS1680?
Is the working area controlled (from
pedestrians and other traffic)?
Is there a program to regularly inspect and
service the machine?
Have safe systems of work been developed
and implemented?
Are there other associated machines such
as conveyor systems that could create
additional hazards?
Has the plant been modified and its risks
re-assessed?
Are operators and back-ups trained and
competent?
Are emergency systems in place?
Others?
ISSUE SEPTEMBER 07
Rev 00 P A G E xiv
CRITICAL COMPONENTS LIST (CCL)

Based on a designers analysis of the machine, the following items form a list of critical
components:
Item: Safety Critical Risk Control

Tension Rod Spring Stored energy when Guard Supplied for “Stand Alone
compressed Mounting”, designed to contain
stored energy of spring in event of
failure. [It is strongly recommended
that when the machine is mounted
on a track chassis that guarding be
provided the tension rod]
Tension rod designed and
manufactured to give maximum
fatigue life.
Flywheel bolts Retain moving Flywheels Flywheels manufactured from high-
during operation. tensile material and tightened to
correct torque during assembly.
ISSUE SEPTEMBER 07
Rev 00 P A G E xv
EC MACHINERY DIRECTIVE 98/37/EC

CERTIFICATE OF CONFORMITY (Annex IIB)
Report No. :
Machine : Single Toggle Jaw Crusher
Manufacturer : Terex Jaques
Assessment Dates : Not Applicable
Relevant Standards : Essential Health and Safety Requirements, EN 292-1, EN 292-

2, EN 1050, EN 982
The machine identified above has been designed to be capable of conforming to the requirements
of the EC Machinery Directive 98/37/EC (Annex IIA), when properly incorporated into plant
equipment. A Declaration of Incorporation is not issued with the machine.
A CE mark must not be affixed to the machine until it is incorporated, the relevant drive and
safety devices are fitted, and the machine re-assessed for compliance with Annex II A of the EC
Machinery Directive 98/37/EC.
Note: Any significant changes in design or construction of the product or amendments to the
Directive 98/37/EC or standards referenced above may render any certification invalid. The
product liability rests with the manufacturer or his representative.
ISSUE SEPTEMBER 07
Rev 00 P A G E xvi
RISK ASSESSMENT
Date: 2/3/98, Assessor/s: R Lim, M Turner
Section 1: Installation Updated: 30/6/03, Assessor: M.Turner
CONSEQUENCES
POTENTIAL HAZARDS COMMENTS/ACTION/PRIORITY TO ELIMINATE/REDUCE
Public Relations
Environ. Impact
PROBABILITY
Equip. Damage
People Safety
(including sources of potential hazards)
Prod. Losses
RISKS AS FAR AS PRACTICABLE
RISK RANK
1. Crushing hazard from machine falling D 2 3 3 4 3 12=M Ensure adequate lifting capacity of crane. Observe appropriate safe work procedure associated with lifting load. Ensure
during transportation and lifting. adequate supervision and instructions are provided to installation crew. Use lifting lugs where provided.
2. Stability of crusher on concrete foundation. D 2 2 3 4 3 12= M Ensure reinforced concrete foundation is prepared in accordance with Section 2 of this manual and meet the specific
dynamic loading.
3. Stability of crusher and fixtures on steel D 2 2 3 4 3 12= M Ensure steel structure is capable of withstanding the specific dynamic loading of the crusher.
structure.
4. Potential hazards from poor field welding, C 4 4 5 5 5 18 = L Special brackets for attachment of chutes, guards, platforms, etc. should be specified to make these brackets part
arising possibly from - of the component at the time of the original manufacture.
(a) Shrinkage, cracks, tearing from rapid
cooling of weld due to bulk of base
component
(b) Poor control over condition of
welding rods
(c) Poor welding position from restricted
location of brackets
(d) Concentration of stress points on
weld, and causing fixtures to fall.
Probability: A=Common, B = Likely, C = Possible, D = Unlikely, E = Practically Impossible

Consequence: Range 1 – 5, Larger number = Lower Consequences
Risk Rank: (H)igh = 1 – 6, (M)edium = 7 – 15, (L)ow = 16 - 25
ISSUE SEPTEMBER 07
Rev 00 Page xvii
Date: 2/3/98, Assessor/s: R

Lim, M Turner
Section 1: Installation (…continued) Updated: 30/6/03, Assessor: M.Turner
CONSEQUENCES
Environ. Impact
Public Relations
PROBABILITY
Equip. Damage
(including sources of potential hazards) RISKS AS FAR AS PRACTICABLE
People Safety
Prod. Losses
RISK RANK
5. Parts falling from lifting device. D 2 3 3 5 4 12=M Ensure lifting device, cranes have appropriate (SWL) lifting capacity for the load. Safety latches must be fitted to crane
hooks. Review sling methods for each part to be lifted. Use lifting lugs where provided.
6. Pinching points during positioning of parts for C 4 5 5 5 5 18=L Follow safety precautions listed in the manual and/or consult an authorised Jaques person.
assembly.
7. Slipping and falling or bruising from bolt C 3 5 5 4 5 13=M Appropriate hydraulic torque wrench should be used for bolt tightening. Belting with sledge hammer to tighten
tightening. Sprain and strain and flying debris or loosen nuts should be avoided where practicable.
from belting with sledge hammer.
8. Striking by compression spring of tension rod. D 1 3 3 5 3 7=M Tension Rod must be regularly inspected. Guard must be fitted to contain damage from failure of mechanism.
9. In-running nip of pulley drive. D 3 5 5 5 5 17=L Review safety practices to ensure fingers are kept clear of in-running nips during fitting of vee belt (before guards
are fitted).
10. Electrical hazards. D 1 4 5 3 3 7=M Ensure electrical power is isolated where practicable during installation and maintenance.
Ensure the electrical wiring system is effectively earthed.
11. Pinch point between swing jaw and bearing D 3 3 5 3 3 17=L Provide guard rail as part of installation. Ensure guard rail extends at least 1000 mm (40”) above raised platform
housing. to ensure hazard is not within reach.
12. Fall into crusher chamber D 1 1 5 1 2 7=M Provide guard rail as part of installation. Ensure guard rail extends at least 1000 mm (40”) above raised platform,
if the height of any raised platform is such that a person standing on it could fall into the crushing chamber.

Risk Rank: (H)igh = 1 – 6, (M)edium = 7 – 15, (L)ow = 16 – 25
ISSUE SEPTEMBER 07
Rev 00 Page xviii
Section 2: Pre-operational Safety Checks Updated: 30/6/03, Assessor: M.Turner
CONSEQUENCES

Environ. Impact
Public Relations
PROBABILITY
Equip. Damage
People Safety
Prod. Losses
RISK RANK
1. Operator error or unfamiliarity with current D 3 4 4 5 5 17=L Ensure the plant is suitable for the task and copy of Instruction Manual is with the plant. Read and understand
work practices or suitability of plant. manuals before commencing work.
2. Appropriate personal protective equipment and D 4 4 5 5 5 21=L Clothing which might catch or tangle in control levers and mechanical parts is unsuitable and should not be worn. Wear a
clothing. helmet, protective goggles, safety boots, mask, gloves and hearing protection where necessary.
3. Fire and emergency response. D 2 2 3 3 3 12=M Provide a fire extinguisher, first aid box, emergency procedures and telephone numbers. Carry out regular
inspections and report faults and ensure necessary repairs are carried out before commencing work.
4. Slips, trips and falls from poor housekeeping. C 3 5 5 5 5 13=M Ensure floor, steps and hand rails are kept clear of obstacles.
5. Controls and mechanical failure of plant. D 5 1 3 5 5 7=M Carry out pre-operational checks to ensure guards are in place and safety controls are operational.
6. Injury when checking bolts for tightness D 3 5 5 3 5 17=L Use appropriate equipment (torque wrench, etc.) to check fasteners, wear PPE,.

ISSUE SEPTEMBER 07
Rev 00 Page xix
Section 3: Operation Updated: 30/6/03, Assessor: M.Turner
CONSEQUENCES
Environ. Impact
Public Relations
PROBABILITY
Equip. Damage
People Safety
Prod. Losses
RISK RANK
1. Dropping of toggles due to inadequate D 5 2 3 5 5 12=M Ensure tension rod springs are sufficiently tightened in accordance with the instruction manual.
spring tension.
2. Striking by tension rod as a result of breaking D 5 3 3 5 5 17=L As above.

from over-tensioning of springs or fatigue.
Ensure tension rod spring guarding supplied is fitted during operation.
3. In running nip from vee belt drive E 3 5 5 5 5 20=L Ensure fixed guards are fitted to both sides of the vee belt drive.
4. Entanglement from rotating fly wheel. E 1 5 5 2 2 11=M Ensure fixed guards are fitted.
5. Fire from overload on motor from improper D 5 3 4 5 5 17=L Ensure motor thermal overload protection provided.
use.
6. Impact from flying debris. C 3 5 5 5 5 13=M Ensure eye protection and safety helmets are used.
7. Noise. B 4 5 5 4 5 14=M Ensure hearing protection is used.
8. Stop/start controls. - - - - - - - Stop, start and emergency switches should be provided within easy access for operator. Lockable isolation switch
should be provided.
Ensure emergency stops also control associated feeders and machinery’s.

ISSUE SEPTEMBER 07
Rev 00 Page xx
Section 3: Operation (…continued) Updated: 30/6/03, Assessor: M.Turner
CONSEQUENCES
Environ. Impact
Public Relations
PROBABILITY
Equip. Damage
People Safety
Prod. Losses
RISK RANK
9. Blockage by large rocks inside jaw crusher. C 5 4 5 5 5 18=L Stop, start and emergency switches should be provided within easy access for operator. Lockable isolation switch
should be provided.
Ensure emergency stops also control associated feeders and machinery’s.
Do not blast large rocks in crusher. Large rocks should be removed by crane or broken up by other mechanical aid such as
pneumatic jack hammer.
Ensure procedures in place to control size of feed upstream of jaw crusher.
10. Crushing by jaws. D 1 1 5 2 2 7=M Ensure operator access to jaws are appropriately safeguarded, and the crusher is isolated during maintenance.
11. Dust. C 3 5 5 3 4 13=M Ensure appropriate breathing protection PPE is used.

ISSUE SEPTEMBER 07
Rev 00 Page xxi
Section 4: Lubrication Updated: 30/6/03, Assessor: M.Turner
CONSEQUENCES
Public Relations
Environ. Impact
PROBABILITY
Equip. Damage
People Safety
Prod. Losses
RISK RANK
1 Various hazards associated with access to C 3 5 5 4 3 13=M Ensure lubrication is carried out with the crusher stopped.
lubrication points – falling, slipping, etc. Review access to lubrication points. Automatic lubrication system may be provided.
Excess grease (except those on the grease nipple), should be wiped away
2. Application of incorrect lubricants. D 5 3 3 5 5 17=L Ensure containers of lubricant are appropriately labeled and stored in a dust free environment.
Use only lubricants specified in instruction manual.

ISSUE SEPTEMBER 07
Rev 00 Page xxii
Section 5: Maintenance Updated: 30/6/03, Assessor: M.Turner
CONSEQUENCES
Environ. Impact
Public Relations
PROBABILITY
Equip. Damage
People Safety
Prod. Losses
RISK RANK
1. Parts falling from lifting device C 2 4 4 3 5 8=M Review safety practices for removal of specific parts. Use lifting lugs where provided, in some parts where lifting
lugs need to be welded, ensure they are adequate to lift the part. Review slinging procedures for relevant parts. Use
OEM maintenance tools (available separately) for difficult to access components.
Cranes or lifting devices must be capable of lifting the relevant parts. Crane hooks must be fitted with safety latches.
Refer maintenance section of manual for procedures requiring removal and lifting of parts.
2. Hydraulics (CSS Adjustment) D 3 4 5 4 5 17=L Ensure hydraulic pressure is released before working on hydraulic system. Although no high-pressures are expected,
as a precaution carefully disconnect the hydraulic lines during any maintenance.
Ensure hydraulic hoses and fittings are regularly inspected.
3. Electrical hazards D 1 3 4 3 3 7=M Ensure electrical power is isolated where practicable during maintenance.
Ensure effective isolation, lock-out, and tag-out procedures are in place.
4. Lighting D 4 4 5 5 5 21=L Ensure adequate lighting is provided for maintenance of the plant.
5. Inadvertent starting of plant during E 1 2 2 2 2 11=M Ensure electrical power is isolated where practicable during maintenance.
maintenance. Ensure effective isolation, lock-out, and tag-out procedures are in place.
6. Falling from height D 1 3 5 2 2 7=M Ensure surrounding plant has appropriate platforms/steps for safe access where practicable at frequently accessed points.

ISSUE SEPTEMBER 07
Rev 00 Page xxiii
Section 5: Maintenance (…continued) Date: 2/3/98, Assessor/s: R Lim, M Turner
Updated: 30/6/03, Assessor: M.Turner
CONSEQUENCES
Public Relations
Environ. Impact
PROBABILITY
Equip. Damage
People Safety
Prod. Losses
RISK RANK
7. Striking by tension rod as a result of D 1 3 4 3 3 7=M Ensure personnel carrying out tension rod assembly maintenance DO NOT stand in line of axis of spring/tension
breaking from over-tensioning of springs or rod, especially while adjusting spring compressed length.
fatigue, during maintenance with guard Ensure tension rod springs are sufficiently tightened in accordance with the instruction manual.
removed Ensure tension rod spring guarding supplied is fitted during operation.
8. Injury while removing wedge assembly D 3 3 5 3 4 17=L Use OEM maintenance tool to remove wedge assembly, in conjunction with lifting holes in wedge.
from crusher due.
9. Injury while removing toggle seat/spacer D 3 4 5 5 5 17=L Use OEM maintenance tool to remove toggle seat/spacer.
10. Injury while refitting moving jaw/moving C 3 4 5 3 5 13=M Follow procedure in manual, use levers and not fingers to position components.
jaw wedge to Jawholder

ISSUE SEPTEMBER 07
Rev 00 Page xxiv
S E C T I O N 1
Section 1
Technical Description
GENERAL DESCRIPTION
The Jaques/Cedarapids single-toggle jaw crusher is a machine used to reduce rock to a size
suitable for the next stage of processing required. Technically referred to as reciprocating-
pressure breakers, jaw crushers employ beam and short-column loading of two crushing
surfaces set at a small angle, one fixed, and the other moving. The moving crushing surface is
hung on an eccentric drive shaft, and the motion induced crushes material between it and the
fixed crushing surface. This process continues until the material reaches the end of the
crushing chamber, when it is discharged from the machine.
The two crushing surfaces will naturally wear as a result of the crushing action, increasing the
“gap” between the two surfaces, which dictates the final crushed size of the material. This
wear is compensated by moving the two surfaces closer together by means of an hydraulic
system (supplied). This feature also allows the size of the crushed output to be adjusted to suit
varying requirements.
In extreme cases where the crushing forces required exceed the designed capacity, the
machine is protected by a sacrificial component designed to break and isolate the remaining
components from damage.
ISSUE SEPTEMBER 07
Rev 00 Section 1 - Page 1
S E C T I O N 1
DESIGN CRITERIA
Relevant standards together with the combined experience of Terex Jaques were utilised in
the design and manufacture of this machine.
Standards utilized include the following:
AS1554 Grade SP Workmanship & Welding
AS1403 Design of Rotating Steel Shafts
BS7608 Fatigue Design & Assessment of Steel Structures
AS1100 Technical Drawing (except as modified by Jaques

Standard JEP008)
AS1100.201 Appendix Casting Tolerancing

B
MACHINE SPECIFICATION
Whenever the instructions in this manual refer to the left hand or right hand, the ‘hands’ of
the crusher shall be determined by viewing the feed opening from the feed end of the crusher,
ie: fixed jawface end.
A list showing the weights of the various parts and sub-assemblies of the crusher is included
in this manual and should be used as a guide in the selection of the proper size lifting
equipment. Also included are arrangement drawings and the parts list, which should be used
for identification and proper assembly of parts.
Model JW40 AW1726 JW55 AW1749/AW1750

Weight 12000kg/26450lb 23550kg/52000lb
Feed Opening: between side liners 1000mm/39.40” 1400mm/55”
Between Jaws at top (tip to tip) 625mm/24.6” 814mm/32”
Crusher Speed 280 rpm 250 rpm
Direction of Rotation Anti-clockwise viewed from right hand side (top of
flywheel rotates toward Fixed Jaw)
Motor Power (electric) 90 kW/120HP 150kW/200HP
Setting 500 mm Toggle = 55 – 590 mm Toggle = 105 –
160 mm CSS / 2.17” – 225CSS / 4.13” – 8.9”
6.3”
CSS = Closed Side Setting (tip of
fixed to bottom of moving jaws)
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S E C T I O N 1
Model JW40 JW55

Adjustment of Setting
The mechanism has been designed to give toggle block 96mm/3.78” 118mm/4.65”
movement of:
Ratio of change in setting at Jawfaces relative to 1.7:1 1.65:1
movement of the toggle block (nominal):
If is Toggle block moved 10mm, setting will change by: 17mm 16.5mm
Total Setting Adjustment Range: 163mm/6.4” 195mm/7.7”
Wedge Adjustment Cylinder Bore diameter 63.5mm/2.5” 76.2mm/3”
Wedge Adjustment Cylinder Rod diameter 35mm/1.375” 44.45mm/1.75”
Oil Volume Change per mm of CSS change (Piston 8.2cc/0.5ci 13.8cc/0.84ci
side) approximate:
Oil Volume Change per mm of CSS change (Piston Rod 5.7cc/0.35ci 9.1cc/0.56ci
side) approximate:
Design Max Pressure of wedge cylinder 20bar/3000psi 20bar/3000psi
Hydraulic Tension Rod Bore Diameter 101.6mm/4” 101.6mm/4”

Hydraulic Tension Rod Diameter 50.8mm/2” 50.8mm/2”
Oil Volume Change per mm of CSS change (Piston 8.1cc/0.49ci 8.1cc/0.49ci
side) approximate:
Oil Volume Change per mm of CSS change (Piston Rod 6.1cc/0.37ci 6.1cc/0.37ci
side) approximate:
Nominal Working pressure on Rod side of cylinder 70bar/1050psi 75bar/1125psi
Design Max Pressure on Rod side of cylinder 113bar/1700psi 113bar/1700psi
i NOTE:
Any alteration to the closed side setting or stroke which requires new length
toggles or new toggle seats should be referred to Terex Jaques.
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S E C T I O N 1
T A B L E O F W E I G H T S (A P P R O X I M A T E )
Description JW40 JW55
kg. lb. kg. lb.
Main Frame c/w Fixed Jawface, Jawface Wedge and Bolt, Liners, 5537 12204 11193 24670
Backing Plates, Cross Braces, and Misc. Fasteners
Flywheel Sheave including Counterweight 549 1210 1205 2656
Flywheel including Counterweight 627 1382 1262 2781
Swing Jaw c/w Moving Jawface, Jawface Retaining Wedges, Shaft, 4618 10180 8820 19439
Jawholder Protector Plate, Bearing Housings, Bearings, Toggle Seat,
and Misc. Parts
Toggle Block, Toggle Block Spacer, Wedges, Seat, and Hydraulic 270 600 503 1109
Cylinder.
Toggle 193 425 384 846
Hydraulic Tension Rod Assembly 117 260 117 260
Total Crusher Mass 11911 23484

For shipping weights, refer to “shipping weights” located in section 2.
For more Detailed Weights, Refer Jaques Crusher Cross Section Drawing Located in the Spare Parts Section.
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S E C T I O N 2
Section 2
INSTALLATION
Appropriate Personal Protective Equipment (PPE) should be worn while undertaking all
installation related activities.
Eye Protection Head Foot Hearing

Protection Protection Protection
FOUNDATION DESIGN
An installation drawing is included in this manual at the end of this section. This must
be referred to when designing the foundation. Pay particular attention to the clearances
required to easily remove components for maintenance, for which an overhead hoist of
suitable capacity be provided. A list of weights of various parts and sub-assemblies is
included.
The foundation must be structurally sound and designed to suit site conditions in
accordance with statutory requirements. It should allow for maintenance work to be
carried out on the crusher, chutes, and drive in a safe manner. Ensure adequate
clearance is provided between the discharge opening, the chute, and the conveyor so
that material cannot build up and clog the crusher. Clogging could overload the crusher
and cause the toggle to fail.
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S E C T I O N 2
Chutes, guards, and structures which may obstruct ready access, should be designed to
allow for maintenance, and for easy removal with bolted fasteners.
Warning
EQUIPMENT DAMAGE HAZARD

DO NOT WELD to the Crusher except where noted,
to secure the Jawface Backing Plates to the Front
End Frame or Moving Jaw Holder (refer
Maintenance Section).
Welding in certain areas may cause severe damage
to high strength, heat treated steel components.
An allowance of 50 mm (2 inches) between the crusher support feet, and the concrete
foundation is required for grouting.
The foundation bolts are not normally supplied by Jaques unless specifically ordered.
SHIPPING WEIGHTS
The crusher, following workshop testing, maybe disassembled for transport in the
following sections:
Description JW40 JW55

kg. lb. kg. lb.
Crusher – Less Pulley & Flywheel 10624 23415 20883 46026
Flywheel Sheave incl Counterweight 549 1210 1205 2656
Flywheel including Counterweight 627 1382 1262 2781
Miscellaneous Packaging, Tools & Bolts 200 440 200 440
(approx)
Total Crusher Mass 12000 26450 23550 52000
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S E C T I O N 2
Thus the (mobile) lifting equipment used on site for installation should have a minimum
capacity to suit the full mass of the crusher at a radius to suit site access.
Refer to the Installation Drawing, located at the end of this section, for crusher
dimensions.
FRAME
O N MO B ILE C H A SSIS/ FIX ED STEEL STR U C TU R E

1. Check the structure is level prior to installing the crusher on it.
2. Make shims as necessary so that the four mounting points are the same height.
Shims should be made to cover as much of the mounting pad area of the
crusher feet as possible.
3. Carefully lower the crusher onto the structure, using one or two bolts to locate
the machine and recheck the level using the top of the crusher frame as a
reference.
4. Once level, properly fit all four hold-down bolts and tighten securely.
5. Snugs should be made, fitted against the edge of the crusher frame mounting
feet and welded to the support structure (not the crusher) to prevent movement
of the machine relative to the structure.
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S E C T I O N 2
Warning

DO NOT WELD to the Crusher except where noted,
to secure the Jawface Backing Plates to the Front
End Frame or Moving Jaw Holder (refer
Maintenance Section).
Welding in certain areas may cause severe damage
to high strength, heat treated steel components.
O N A C O N C R ETE FO U N D A TIO N
1. For installing on a concrete foundation ensure that the concrete has fully cured
first. Scabble the concrete area where the crusher is to be mounted, and clean
any oil or grease away from concrete.
2. Lift the crusher and thoroughly clean the crusher-mounting feet of loose paint,
scale, rust, oil or grease.
3. Place four suitable wedges on the foundation such that there will be a gap of
approximately 50mm between the crusher base and the foundation, and in a
position where they can be readily removed after the grout has cured.
4. Carefully lower the crusher onto the foundation bolts and structure, taking care
not to damage the threads, and check the level using a spirit level and steel
straight-edge using the top of the crusher frame as a reference. The frame
should be set level in a longitudinal direction but this is not as important as
setting level across the flywheels.
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S E C T I O N 2
5. Tighten the nuts on the foundation bolts evenly, and check that by doing so, the
horizontal level achieved has not been disturbed. Re-level the frame if necessary.
6. A good quality cement type grout or preferably an epoxy grout should be

poured between the crusher and the concrete, thus ensuring that the crusher is
fully supported. Build the wooden framework for grouting around the crusher
base, bracing it against slipping while retaining the liquid grout. Carefully follow
the manufacturer’s instructions regarding the use of the grout paying particular
attention to the cure time.
7. After curing, remove the timber framework and check that the grout has filled
the space entirely, repair if necessary, and then remove the wedges used to level
the crusher.
8. Re-check all four hold-down bolts and ensure they are tightened securely.
FITTING PULLEY AND FLYWHEEL

The pulley and flywheel are generally shipped separate to the crusher assembly, and need
to be refitted to the crusher during installation.
It is important to refit the driven pulley to the side of the crusher to suit the installation.
Check hand of drive required before refitting to crusher.
1. Remove the protective packaging material around the pulley and flywheel
shaft journals.
2. Remove the packaging material from the pulley/flywheel and, ensuring any
shims supplied (if required) between the end of the shaft and the
flywheel/pulley are re-fitted, fit the pulley/flywheel onto the shaft. Ensure
the studs on the end of the shaft pass through the mating holes in the
pulley/flywheel.
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S E C T I O N 2
i HINT:
Check the orientation of the keyway on the shaft, and lift the
pulley/flywheel in such a way as to match the keyway in it
with the shaft keyway.
3. Fit the ten (10) flywheel stud nuts and washers to the studs protruding from
the end of the shaft and through the pulley/flywheel on each side of the
crusher. Tighten each to the torque figure listed on the cross section
drawing, located in the spare parts section of this manual.
i NOTE:
Because these flywheel studs, washers, and nuts form part of

a friction-grip joint, these components must be new, and not
reused from another installation. One used, they must be
discarded and not used again. To ensure this, damage threads
to prevent re-use.
4. Repeat the procedure for the pulley/flywheel on the opposite side of the
crusher.
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S E C T I O N 2
NOTE:
If hand of drive required is different to how it has been ordered

from Terex Jaques, in addition to swapping the flywheel/pulley
handing, the wedge assembly must be reversed and hydraulics must
be swapped from one side of the crusher to the other.
Refer Jaques drawing ‘Setting Adjustment’ located in the spare parts

section.
If swapping the pulley/flywheel, the counterweight locations must

also be repositioned as shown on the Assembly drawing located at
the end of this manual.
Note that the shimming may need to be reassessed. Refer to your

local Terex Jaques dealer for assistance.
EXPOSED SURFACES
After completing the assembly, all exposed threads and machined surfaces should be
covered with grease to prevent rusting.
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S E C T I O N 2
VEE BELT DRIVE

A vee belt drive will operate very successfully for many years if it is installed and
operated correctly. Incorrect installation will reduce the life of the belts considerably.
1. Install the motor onto aligned and level slide rails. The slide rails should be
arranged so that adjustment screws react against the vee belt tension.
2. Ensure pulleys are correctly aligned to one another.
3. Fit the vee belts one at a time by placing them firstly around the smaller
pulley (normally the motor pulley) and then gradually easing them onto the
large pulley. Under no circumstances should vee belts be fitted or removed
with the aid of levers.
4. Before tensioning the drive, locate the vee belt so that the slack is either on
the top or bottom of the drive. Before start-up, adjust the position of the
motor until the belts are just ‘firm’. Upon start-up, a slight sag should appear
on the loose side.
5. Once operation commences, the belts should be tensioned until the slip
ceases to exist when the motor is drawing maximum power. Terex Jaques
recommend the use of a proprietary vee-belt tension tester to ensure the
vee-belts have been fitted correctly.
6. The tension of the belts should be checked frequently during the first two
weeks of operation and adjusted if necessary.
7. A vee belt guard shall be fitted, both to protect personnel and prevent flying
stone from damaging the belts. Guards should be so constructed as to
provide easy access to the belts for maintenance.
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S E C T I O N 2
In most cases the crusher is supplied without such a drive or motor at the
purchaser’s request, and as such this machinery IS NOT equipped with a
guard to prevent accidental contact with the drive mechanism.
The purchaser is responsible for providing and installing any guards which
may be required by Federal, State, or local statutes or regulations.
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S E C T I O N 2
INSTALLATION DRAWING
Refer master schedule.
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S E C T I O N 3
Section 3
OPERATION
Appropriate Personal Protective Equipment (PPE) should be worn while preparing to
operate or operating the crusher.
PREPARING THE CRUSHER

Before starting the crusher for the first time or after a major overhaul, the following
procedure should be adopted.
1. Check all bolts (except the frame and bearing housing bolts) for tightness - see
Maintenance Section, and refer to the torque figures indicated on the general
arrangement drawings located in the spare parts section.
2. Check that there are no objects left in the jaws and no obstruction to the motion
of the Jawholder, toggle or tension rod assembly.
3. Check setting. Adjust if necessary - see Adjustment of Setting.
4. Check that the toggle wedge hydraulics are locked against the check valve.
5. Check that the tension rod hydraulics are sufficiently compressing the spring.
Minimum recommended compression for JW40 is 300mm and JW55 is 280mm.
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S E C T I O N 3
6. Check all guards are in place, and safety tagged as necessary.
RUNNING IN
If the crusher has been reassembled on site or has been standing for some time, it is
advisable to regrease the bearings (see Section 4) and run the crusher empty for at least
two (2) hours to enable the grease to be thoroughly distributed around the bearings.
During this time use a tachometer to check the speed of the crusher flywheel. For speed,
refer installation details. The direction of rotation of the flywheel should be anti-
clockwise when viewed from right hand side of crusher. Initially, the bearings will
probably run at higher temperature than normal. This is quite usual after regreasing and
will continue until excess grease has been dispersed. Under normal conditions the
bearings should not run higher than 27°- 32°C (80°F – 90°F) above ambient
temperature. Slightly higher temperatures due to abnormal crushing and/or weather
conditions are permissible for short periods of time. However, temperatures consistently
higher than 90°C/194°F under normal circumstances are a pointer to probable bearing
trouble. There is also a risk of grease breakdown, and continued use under these
circumstances would certainly then bring about bearing failure.
Listen for knocking noise in the vicinity of the toggle which is synchronised with the
jawholder movement. This noise, if present, is caused by the ends of the toggle knocking
against the seats. If such a noise is heard, it may be that the tension rod spring is too
loose, and the hydraulic pressure in the tension rod cylinder should be increased just
enough to allow the crusher to run without the toggle knock. If the tension rod spring is
too loose the toggle will bump and may drop out of its seats; and if too tight, either the
spring or tension rod may break.
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S E C T I O N 3
Gradual running-in of the crusher is most important - for the initial 20 hour period of
crushing, the crusher motor power draw should be limited to half full load. This
particularly applies where the crusher is worked at small discharge settings. Here the feed
should be regulated to fill only approximately 50% of the crusher chamber and care
should be taken that there is a minimum of dirt and fines in the feed. After the initial
period of working, the crusher may be gradually built up to full capacity over a further
period of approximately 60 hours. Full crushing efficiency is not achieved from the jaws
until about 60-80 hours of crushing. It takes most feed material this length of time to
wear the cast jaw faces to an even surface, which enables the corrugations to grip the
stone much more effectively.
All side liner bolts, fixed jawface wedge bolts, jawface retainer wedge bolts and protector
plate bolts should be checked daily during the initial period of crushing and at regular
periods thereafter.
During the first two weeks of crushing, the tension of the vee belts should be checked
every couple of days with a proprietary vee-belt tension tester. If there is any sign of belt
slip then the belts should be re-tightened until the slip ceases. However, care should be
taken that the belts are not over tensioned.
FEEDING
It is suggested that care should be taken to restrict the amount of dirt and fines in the
feed, particularly with small settings. These fines tend to cause packing in the jaws and
subsequently impose high loadings in the crusher components, particularly the toggle and
toggle wedge mechanism. Ideally all material smaller than the closed side setting should
be removed from the feed before it enters the crusher. This will not only increase the
capacity of the crusher but will also extend the life of the jawfaces.
The feed chute should usually be angled at not less than 45° so that material runs freely
and is directed into the crushing chamber. Chute design should prevent continued
impact of feed material against the head of the moving Jawholder. The material entering
ISSUE SEPTEMBER 07
S E C T I O N 3
the crusher should be small enough in two directions to enter the feed opening without
bridging. Material too large to enter the crusher must not be allowed to crush between
the head of the jawholder and the feed chute. Instead, use appropriate lifting gear (not
blasting) and lift it clear or use a rock breaker to reduce it in size.
To achieve maximum capacity, maintain a uniform flow of dry material from which fines
have been scalped and oversize removed.
CAUTION & WARNING
No blasting must be done on large rocks sitting on or in the crusher.

Blasting in confined spaces is a danger to personnel and equipment, and
must never be done. Serious damage can result, particularly to the shaft
bearings and any such action may result in Terex Jaques warranty on the
machine being withdrawn.
SETTING
The setting of the crusher is measured at the discharge opening of the jawfaces, from the
top of the corrugation on the moving jawface to the valley between the corrugations on
the fixed jawface. The minimum distance between these points when the moving jawface
closes in, is known as the tip to bottom closed side setting (CSS).
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S E C T I O N 3
The crusher must not be operated at closed side settings smaller than that stated in
‘Technical Information’ located in section one (1). Terex Jaques should be consulted
before using smaller settings. Furthermore, crushing conditions where the input power
exceeds the maximum specified in ‘Technical Information’ should be avoided as serious
damage may be caused to the crusher mechanism.
SETTING ADJUSTMENT
(This section should be read in conjunction with the setting adjustment arrangement
drawing located in the spare parts section of this manual)
Adjusting the length of the hydraulic cylinder between the two toggle wedges, using the
hydraulic pump supplied, alters the setting (CSS) between the jaws, as it in-turn moves
the position of the toggle spacer and seat, and therefore the toggle and Jawholder
assembly
The adjustment mechanism is shown on the following illustrations:
Toggle Retracted (Maximum CSS) (P830)
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S E C T I O N 3
Toggle at Mid-Adjustment (P830)
Toggle Extended (Minimum CSS) (P830)
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S E C T I O N 3
WARNING
The adjustment of the crusher’s CSS must only be made while the
machine is stopped, and adequately isolated.
When changing the CSS:
1. Note the compressed length of the spring between the frame and the outer
spring cap (nominally 300 mm).
2. Use the hydraulic controls to either increase or decrease CSS as required.
3. Check the compressed length of the tension rod spring has automatically
compensated (or manually compensate depending on system design) to the
same length as noted in step 1.
4. Run the machine and check that there is no toggle knock. Tighten the tension
rod spring if required to eliminate knock.
IMPORTANT
The compressed length of the tension rod spring measured at step 2 must be reset
prior to re-starting the crusher, as the tension provided by the correctly adjusted
spring holds the crusher assembly together during operation.
While adjusting the setting (CSS), it will be necessary to monitor the compressed
length of the spring. If the CSS is being increased (larger gap between the jawfaces)
the spring’s compressed length can be reset after adjusting the CSS.
However if the CSS is being decreased (smaller gap between jawfaces), it may be
necessary to adjust the compressed length of the spring while adjusting the CSS, to
prevent over-tensioning or other spring damage.
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S E C T I O N 3
5. Check all guards are in place, and safety tagged as necessary, and isolation is removed.
6. Start the crusher.
Refer Technical Information in Section 1 for details on Ratio of change of setting to wedge
adjustment system movement.
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S E C T I O N 4
Section 4
LUBRICATION
The importance of careful and regular applications of the correct lubricant to each
lubrication point cannot be stressed too highly.
lubrication related maintenance.
Eye Protection Head Foot Hearing

Protection Protection Protection
CARE OF LUBRICANTS AND

EQUIPMENT
Keep lubricants in clean well sealed containers and house the containers in a clean dust-
free room.
Mark the type of lubricant and also its use clearly on each container.
Keep lubricating equipment and containers used for handling lubricants clean. Dirty
equipment must be washed carefully in clean petroleum based cleaning agent
(kerosene/paraffin).
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S E C T I O N 4
APPLICATIONS OF LUBRICANTS
All grease nipples must be wiped carefully with a clean rag before applying the grease
gun to them. This is done to prevent dirt, which may have settled on the nipples from
being forced into the bearings with the new charge of grease. It is extremely important
that grit and dust be prevented from contaminating the grease charge, as the grease is
injected directly into the bearing through holes in the outer ring.
After removing the grease gun, it will be found that a light layer of grease is left on top
of the nipple. Do not wipe this excess grease away until before the next application of
grease, as it forms a very effective dust seal for the nipple.
The main and jawholder bearings are more effectively lubricated either at the end of the
day's crushing or after several hours crushing, when the bearings are warm. If the
crusher is stationary when the lubricant is injected, then it should be run for ten minutes
after the application so that the lubricant may be evenly distributed around the bearings.
The quantities given will achieve adequate lubrication for normal working conditions,
however, during the life of the bearings and labyrinths it may be found necessary (due to
prevailing conditions) to increase the amount of grease or decrease the time interval, as
preferred, at the discretion of the site engineer responsible. The aim should be to just
inject enough grease into the system, such that a fresh bead of grease is visible around
the entire circumference of the labyrinths.
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S E C T I O N 4
EQUIVALENT LUBRICANTS
The lubricant recommended for use in the main and jawholder bearings shall be lithium
based multi-purpose, lead-free, extreme pressure grease with improved vibration
resistance, rated to a viscosity of 160 centistokes at 40°C and 15.5 centistokes at 100°C
(742 Saybolt Universal Seconds at 104°F, and 79.3 Saybolt Universal Seconds at 212°F),
and with a worked penetration at 25°C/77°F of 265/295 – typically:
Mobil Mobilux Grease EP2
Shell Alvania EP2
The hydraulic fluid recommended for use in the wedge cylinder and tension rod cylinder
is a mineral hydraulic oil, containing zinc, oxidation and corrosion inhibitors as well as
anti-foam and anti-wear additives, rated to a viscosity of 22 centistokes at 40°C and 4.3
centistokes at 100°C (106.4 Saybolt Universal Seconds at 104°F, and 40.1 Saybolt
Universal Seconds at 212°F) – typically:
Mobil DTE 24 Oil
Shell Tellus Oil 22
The products of companies other than those listed above may be used, provided the
exact equivalent for the above products is obtained.
Responsibility for the use of greases and oils other than those specified rests with the
supplier and user.
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S E C T I O N 4
MANUAL LUBRICATION - JAWHOLDER

AND MAIN BEARINGS
All of the bearings are correctly lubricated before the machine is despatched and
subsequent lubrications should be carried out in accordance with Lubrication
Instructions included in this section.
The grease is fed to the bearings through the grease nipples on the top of the housing.
Add grease amount as specified in table below every 40 hours of operation.
Machine Grease quantity per Grease quantity/brg/40hrs on

bearing on mounting relubrication
JW40 0.8 kg / 1.8 lb 100 gm / 4 oz
JW55 1 kg / 2.2 lb 125 gm / 5 oz
After each application of fresh grease, it will be noticed that the bearings run at a higher
temperature than normal. This is quite usual and continues for a short time until the
grease has been distributed around the bearing.
After replacing the bearings, the voids between the rolling elements should be
thoroughly filled with fresh grease (refer table below). Half of the free space in the
housing should also be filled.
Automatic lubrication of the jawholder and main bearings can be supplied as an optional
extra.
AUTOMATIC LUBRICATION (OPTIONAL)

The standard crusher is supplied with grease nipples fitted to the main and jawholder
bearings for manual lubrication. Automatic lubrication of the Jawholder and Main
Bearings is an available option. If installed, refer to the appropriate appendix section of
the manual.
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S E C T I O N 5
Section 5
MAINTENANCE
PREVENTATIVE MAINTENANCE
The best way to keep the crusher in good operating condition is to adopt a planned program of
inspection and preventative maintenance. It is recommended that a record be kept of the actual
operating hours of the crusher, the inspection intervals, and the maintenance required. A new
crusher should be examined after a relatively short period of operation. The operating time
between subsequent maintenance will vary with the conditions of operation and the economical
maximum period will best be determined by experience.
A systematic inspection and maintenance program will enable the user to determine the overall
wear rate of parts in the crusher and will indicate when worn parts should be replaced before
the major repair job develops.
maintenance.
The checklists on the following pages are offered as a suggested format for preventative
maintenance.
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S E C T I O N 5
IN SPEC TIO N SC H ED U LE & LO G

MACHINE: NOTE: This chart is based on an 8 hour day.
Columns must be signed not ticked
MAINTAINANCE CHECK DATE
DAILY With crusher operating, inspect for loose bolts and parts - tighten where
necessary
Check the vee belts for slip under full load, turning in pulley grooves, wear and
fractures.
Check for any unusual noise when operating which may indicate something is
loose or broken.
Regularly observe ammeter to see that the average current draw is not in excess of
rating shown on motor nameplate
WEEKLY Grease bearings while crusher is warm and running, and check on warmth of
(40 HOURS) bearings.
Check jawface bolts are tight, to ensure there is no movement of jawfaces relative
to the main frame or jawholder.
Inspect jawface wedges for wear and distortion
See that side liner bolts are all secure, to ensure there is no movement of side
liners relative to the main frame
Check lower, middle, and upper side liners for wear
Inspect condition of tension rod. Ensure bolt connecting the tension rod to the
Jawholder is tight, and movement of the spring and outer caps is smooth
Look over the crusher frame for any wear due to spillage of feed material
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Rev 00 SECTION 5 - 2
S E C T I O N 5
MONTHLY Check ends of toggle and toggle seats for wear or cracking. Unusual noises from
(160 HOURS) this area (squeaking, grinding) of the machine, or loss of stroke, may indicate a
problem
Inspect the fixed and moving jawfaces for wear, distortion or growth
Check the fixed jawface to ensure that the growth of the jawfaces is not sufficient
to allow them to contact the sides of the crusher frame, thus causing large
additional stresses at this vital section of the frame
Check tightness of bearing housing bolts
Check tightness of moving jawface retainer bolts
Check fixed jawface wedges for distortion or wear preventing adequate retention
of the jawface
Check moving jawface retaining wedge for distortion or wear preventing
adequate retention of the jawface
QUARTERLY Inspect the tension rod, checking for damage, wear, or cracks.
(480 HOURS)
SIX Inspect bearings using condition monitoring techniques – Terex Jaques

MONTHLY recommend our bearing suppliers for this task.
YEARLY Check the toggle wedges for wear or damage. Terex Jaques recommend taking the
opportunity to replace the hydraulic cylinder seals while the wedge assembly is
removed from the machine for inspection.
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Rev 00 SECTION 5 - 3
S E C T I O N 5
CRUSHER JAWFACES
Lugs on the moving jawface fit into recesses on the front of the jawholder and prevent excessive
side movement.
Experience has shown that most of the wear on the jawfaces is at the bottom of the crushing
chamber where the space between the jawfaces is smallest. This is the main reason for making the
jawfaces reversible.
When corrugations are worn off one end, the jawfaces should be reversed or replaced. When
corrugations are worn down so that they no longer are effective, new jawfaces should be
installed. Flat jawfaces (without corrugations) require much higher forces to break the rock,
resulting in higher power draw and possible overloading of the motor, together with a drop
in throughput.
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MOVING JAWFACE SERVICE

The moving jawface is reversible, but not interchangeable with the fixed jawface. It can be
removed and then replaced without removing the toggle and allowing the jawholder to swing
back, if so desired. However, depending on the setting the crusher is working at and the
extent of the wear on the jawfaces, it may be necessary to fully retract the toggle block to
ensure adequate clearance between the fixed and moving jaw to remove the Jawface.
REMOVAL OF MOVING JAWFACE

Refer to illustrations and description on the following pages.
1. Remove the Jawholder Protector Plate (item 3)
2. Fit suitable wire rope through slots on the sides of

Jawface, and take the weight with crane.
3. Loosen or remove the nut (item 9) on the

Wedgelock bolt (item 5).
4. After providing suitable protection for the threads of the Wedgelock bolt, strike the
exposed end of the bolt to loosen the wedging effect and drive the wedge lock down
behind the jawface.
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5. Loosen or remove the nut (item 9) on the Wedgelock bolt (item 5).
6. After providing suitable protection for the threads of the Wedgelock bolt, strike the
exposed end of the bolt to loosen the wedging effect and drive the wedge lock down
behind the jawface.
7. Strike the ends of the wedges (item 8) to drive them inward behind the jawface. These are
accessible through the holes in the flywheels. The jawface should drop down, releasing
the hook from the toe on the lower end of the jaw holder.
8. Lift moving jawface from the crusher.
WARNING
Take care that the loosened Wedgelock and Wedges do not fall from their location
on the front of the Jawholder as the Jawface is lifted away.
9. Inspect the moving jaw backing plate. De-burr or replace as necessary.
10. Check the jawface location lug on the bottom centre of the Jawholder and build up the
sides of these lugs with hard face welding if excessive wear (more than 5mm/0.2”) is
apparent. As nominal new width of the lug is 200mm (7.875”) on the JW40 and 270mm
(10.63”) on the JW55.
11. Check and inspect the Wedgelock, Bolt and Wedges for wear on the contacting surfaces.
Dress burrs smooth if necessary to ensure free movement. If the wedges have worn
excessively (5mm/0.2”), repair or replace them. Replace the bolt and nut if they are worn
or bent.
REPLACEMENT OF MOVING JAWFACE

1. Clean all debris (stone, dust, sealing compound/foam etc) out of the area on the front of
the jaw holder where the Wedgelock and Wedges fit.
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2. Coat the sliding faces of the Wedgelock and Wedge and the threads of the bolt with ‘anti
seize’.
3. Place the Wedgelock centrally on the Jawholder at the bottom of its adjustment, and
ensure the bolt is installed correctly in the slot. Fit the wedges either side of it, ensuring
they are contacting the Wedgelock.
4. Fit suitable wire rope through slots on the sides of jawface.
Moving Jawface Lifting Lug
5. Lift the Jawface into the crusher and lower it past the end of the Jawholder to enable the
hook on the jawface to engage with the toe of the Jawholder.
6. Lift the moving jawface up to engage the toe and slew it onto the Jawholder ensuring that
it fits over and seats on the wedges at the top.
7. Begin to tighten the nut (item 9) to draw the Wedgelock up and push the Wedges
outward. Ensure the Jawface lifts up and engages properly at the toe. Ensure the Jawface
is fully engaged over the wedges at the top and seated on the backing plate. Complete
tightening the nut to 200Nm (150lbs.ft)
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If the jawface is being reversed, be sure all burrs and ridges on the wedges and backing plates are
removed before refitting is attempted, as the ‘markings’ of the jawfaces will not necessarily be the
same.
FIXED JAW SERVICE

The fixed jawface is reversible, but not interchangeable with the moving jawface, and can be
removed and replaced without removing the toggle and allowing the jawholder to swing back.
However, depending on the setting the crusher is working at and the extent of the wear on the
jawfaces, it may be necessary to fully retract the toggle block wedges to ensure adequate clearance
between the fixed and moving jaw to remove the Jawface.
The fixed Jawface is retained using a wedge arrangement, as illustrated below:
Fixed Jawface Wedge Nut Fixed Jawface
Fixed Jawface Fixed Jawface Wedge Bolt

Wedge Wedge Bolt Tube Spacer
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REMOVAL OF FIXED JAWFACE
Refer to illustrations and description on the following pages.
1. Fit suitable wire rope through slots on the sides of the

fixed jawface and take weight with crane.
Fixed Jawface Lifting Slots
2. Remove the fixed jaw wedge bolt nuts and removed the bolt through the hole in the wedge
on one side.
3. Screw the wedge extraction tools into the threaded hole in each wedge, install the tool
washers and fit the M36 nuts. Tighten the nuts to draw the wedges out of the machine.
4. Push the Jawface away from the frame lift clear with the crane.
5. Inspect the moving jaw backing plate. De-burr or replace as necessary.
6. Check the jawface location lug on the bottom centre of the Front End Frame and build up
the sides of these lugs with hard face welding if excessive wear (more than 5mm/0.2”) is
apparent. As nominal new width of the lug is 200mm (7.875”) on the JW40 and 270mm
(10.63”) on the JW55.
7. Check and inspect the Bolt and Wedges for wear on the contacting surfaces. Dress burrs
smooth or replace if necessary. If the wedges have worn excessively (5mm/0.2”), repair or
replace them. Replace the bolt and nuts if they are worn or bent.
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REPLACEMENT OF FIXED JAWFACE

1. Check the backing plate, welded to the frame, and back of jawfaces for burrs, etc, and
hand dress if necessary.
2. Adjust the position of the nuts at each end of the Fixed Jaw Wedge Bolt so the outer
ends of the Fixed Jaw Wedges are level with the sides of the crusher frame.
3. Lift the jawface into position & pull the jawface back against the frame until it seats over
its full length.
4. Tighten the Fixed Jaw Wedge Bolt Nuts until the wedges are firmly seated against the
crusher frame and the Jawface.
It will be necessary to periodically recheck that the wedges remain firmly seated and are
adequately retaining the fixed jawface in position, as the Jawface will work and change shape over
time. It is recommended this be checked at the commencement of the first day’s crushing, and
again after three days, and a further week of crushing.
Wedge seating should be further checked periodically as the application dictates, but no less
frequently than monthly intervals.
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FIXED AND MOVING JAW BACKING PLATES

The fixed and moving jaw backing plates should be checked every time one or more of the
jawfaces are removed.
Impounding of the profile of the back of the jawface should be expected, but if the backing
plates are so badly damaged that they cannot provide adequate support for the jawface, then they
should be replaced.
REMOVAL
Remove welds holding backing plates by either grinding or oxy torch, do not use arc equipment.
Take care not to damage main frame and/or Jawholder.
Remove backing plates.
Clean up surface of frame and/or Jawholder to leave flat and smooth.
REPLACEMENT
Fit new backing plates and weld as shown on backing plate detail drawing shown at the end of
this section, ensuring they are pushed flat against the machined surfaces of the Jawholder or front
end frame.
Care should be taken to earth arc welding equipment so as not to damage the crusher bearings. If
it is necessary to do any welding on the crusher, the earth wire must not be connected to any
part of the assembly such that current is drawn through the bearings, as rapid bearing failure
could result. The earth wire should be connected directly to the part to be welded.
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NOTE:
When it is necessary to carry out welding on this crusher, as noted in the Maintenance Section,
the earth wire must be connected directly to the part to be welded. Under no circumstances
should welding be performed were it is possible that electrical current can be drawn through
the rolling bearings in the Jawholder or Main Bearing Housings. Rapid bearing failure could
result from this action.
Warning

DO NOT WELD to the Crusher except where noted, to secure the
Jawface Backing Plates to the Front End Frame or Moving Jaw
Holder.
Welding in certain areas may cause severe damage to high strength,
heat treated steel components.
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SIDE LINERS
The side liners are interchangeable and reversible ie: the upper, middle, and lower side liners (or
just upper and lower for JW40) can be fitted to either side of the crushing chamber and can be
turned about their vertical axis. These liners protect the frame around the crushing chamber and
must be kept tight at all times, and replaced before they are worn through to prevent damage to
the frame.
Each liner has tapped bolt holes and is retained in the crusher by a bolt and flat washer, installed
from outside the frame.
Fit the lower side liners first using the bolt and washer. Coat the first 6 threads of each bolt with
Loctite thread locker before installing them. Tighten the fasteners to the torque indicated on the
general arrangement drawing located in the spare parts section of this manual.
Fit the middle and upper side liners and bolts as per the lower side liner (upper liners only for
JW40).
TOGGLE AND TOGGLE SEATS

(This section should be read in conjunction with the setting adjustment arrangement drawing
located in the spare parts section of this manual)
The toggle acts as a pivot for the lower end of the jawholder and also serves as a safety link for
protection of the crusher in the event of tramp iron or other uncrushable objects entering the
crushing chamber or any other occurrence that load the crusher above it’s design load.
Surface deterioration of the toggle which will quickly wear the toggle seats is an indication that the
life of the toggle ends has been reached.
The proper length toggle gives correct contact between the toggle ends and the jawholder and
toggle block toggle seats.
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The use of any toggle length other than those listed in the Machine Specification section of this
manual must be approved by Terex Jaques.
i NOTE
When replacing a worn toggle, it is good practice to renew the toggle seats as worn
seats will adversely affect the ends of the new toggle. It is also important that each
time a new toggle or toggle seats are fitted that the out-of-parallelism of the
mechanism be checked. The total out-of-contact area of the toggle with the toggle
seats will localise the crushing pressures developed and can cause serious damage.
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Item Description
1 Toggle
2 Coverplate – Blank
3&4 Toggle Wedges
5 Hydraulic Hand Pump
6 Rear End Frame
7 Wedge Locking Bolt
Maintenance Tool
8 Clamp Maintenance Tool
9 Toggle Seat
10 Toggle Seat Spacer
11 Extracting Maintenance Tool
12 Wedge Endplates
13 Coverplate – Toggle Adjusting
Toggle/Toggle Seat/Toggle Spacer/Wedge Maintenance Assembly (P843A)
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i NOTE
When replacing a worn toggle, it is good practice to renew the toggle seats as worn
seats will adversely affect the ends of the new toggle. It is also important that each
time a new toggle or toggle seats are fitted that the out-of-parallelism of the
mechanism be checked. The total out-of-contact area of the toggle with the toggle
seats will localise the crushing pressures developed and can cause serious damage.
REMOVAL OF TENSION ROD ASSEMBLY, TOGGLE, TOGGLE SPACER,

AND SEAT
(Read in conjunction with maintenance assembly illustration on previous page.)
WARNING
Before removing the toggle, make sure that the jawholder is at the bottom of its
stroke.
Fit the special maintenance tools:
1. Adequately support the toggle (item 1) from above so that it will not fall when the
jawholder assembly is pulled forward.
2. Remove the dust flap retainer and dust flap.
3. Remove the blank cover plate (item 2) without the hydraulics attached from the side of
the crusher frame to expose the wedges.
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4. Use the hydraulic hand pump (Item 5) or plant hydraulic system to adjust the
position of the wedges (Item 4) until the ends are level, as shown below:
Adjust wedges until wedge ends are flush (P845)
5. Adjust the special wedge locking bolt maintenance tool (Item 7, part number
JW42AY1381) in the tapped hole in the rear end frame (Item 6) of the crusher (above
the wedges) to engage in the wedges and lock them in place.
Note for correct engagement the distance from the top of the rear end frame to the
underside of the bolt head must be 40 mm, as shown below:
Operation Maintenance
Wedge Locking Bolt Maintenance Tool – Positions (P853A)
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6. Fit the special clamp maintenance tool (2-off Item 8) to each side of the front face of
the rear end frame with M12 x 25 long bolts (same bolts that retain the dust flap). These
must be fitted in their innermost slide position to ensure both the toggle seat (Item 9)
and toggle seat spacer (Item 10) are held in position when the toggle (item 1) is
removed.
The tool has slotted mounting holes enabling it to either retain only the toggle seat
spacer (leaving the toggle seat free to enable removal), or both the toggle seat spacer
and toggle seat. Fit the tool so that both are retained, by sliding both toward the
centre of the crusher.
DANGER
Both special maintenance tools must be fitted to retain the toggle seat/toggle
seat spacer and wedges inside the rear end frame BEFORE removing the
toggle. Failure to retain the toggle seat/toggle seat spacer will result in
components falling under gravity from inside the recess in the rear end frame.
Remove the Tension Rod Assembly:

7. Unload the tension rod spring by actuating the plant hydraulic system to completely
release all pressure in the tension rod cylinder. Bleed to make sure there is no pressure.
DANGER
Ensure all hydraulic pressure is bled and isolated from the tension rod cylinder
before any attempt is made to perform work on the tension rod assembly or to
disconnect it from the crusher. Serious injury may occur.
8. Remove the tension rod guard (where fitted to the crusher).
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9. Remove the bolt connecting the tension rod to the Jawholder and lower the tension rod
on its pivots. Note the tension rod can be removed completely or left in the machine if
there is sufficient room to work around it.
Remove the toggle:

10. Using a 5 tonne SWL chain-block or similar, pull the Jawholder Assembly forward until
the fixed and moving jawfaces are touching, and retain securely.
11. Lower and remove the toggle. This will give access to inspect the Toggle Seat and Toggle
Seat Spacer inside the crusher’s rear end frame.
Remove the toggle seat:
i NOTE:
The special wedge locking bolt maintenance tool (step 5) must be in position
to allow adjustment of the tool retaining the toggle seat spacer/toggle seat.
12. Secure the special extracting maintenance tool (Item 11) to the toggle seat (item 9),
and support securely from above.
13. Loosen the special clamp maintenance tool (2-off Item 8) retaining bolts. Free the
toggle seat (Item 9) by sliding the tool outwards. Retighten the bolts.
14. Remove the toggle seat (Item 9) with the special extracting maintenance tool (Item
11)
Remove the toggle seat spacer:

15. Secure the special extracting maintenance tool (Item 11) to the toggle seat spacer (Item
10).
16. Remove the special clamp maintenance tools (Item 8) retaining the toggle seat spacer
(Item 10) in position.
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17. Remove the toggle seat spacer with the special extracting maintenance tool (Item 11).
REPLACEMENT OF TOGGLE, TOGGLE SEAT SPACER, AND

TOGGLE SEATS
1. Reposition the toggle seat spacer (item 10) in the crusher frame using the special
extracting maintenance tool (Item 11).
2. Fit the special clamp maintenance tool (2-off Item 8) in their outer/widest position to
retain the toggle seat spacer (Item 10) in position.
3. Repeat the above procedure with the toggle seat (Item 9), and reposition the special
clamp maintenance tool (2-off Item 8) inwards to retain both the toggle seat (Item 9)
and toggle seat spacer (Item 10)
4. Remove the special extracting maintenance tool (Item 11)
5. Lift toggle up until the toggle end (item 1) slides into the toggle block seat (item 9).
Continue to lift until the other end is in position to slide into the jawholder toggle seat.
6. Slowly ease the jawholder back until the toggle end enters the jawholder toggle seat.
Check that the toggle is properly seated both ends.
7. Remove the special clamp maintenance tool (2-off Item 8) bolted to the front of the
rear end frame retaining the toggle seat (item 9) and toggle seat spacer (item 10) in
position.
8. Bolt the dust flap and retainer to the Jawholder and Rear end frame.
9. Reconnect tension rod assembly to the Jawholder. Re-pressurise the hydraulic system to
the specified pressure for the tension rod. Re-install the guard where fitted.
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10. Adjust the locking bolt maintenance tool retaining the wedges (Item 7) so it is
disengaged from the wedges (refer diagram on page 5-16), and refit cover (Item 2) to side
of crusher.
11. Restart the crusher and check for toggle end ‘knock’, readjust the tension rod spring to
the compression stated on the cross section drawing if necessary.
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REMOVING THE JAWHOLDER ASSEMBLY

To remove the jawholder assembly from the crusher, proceed as follows:
1. Remove the nuts and the C-Washers fastened to the each side main frame to locate the
frame cross braces, and slide both cross braces out the side of the crusher.
One brace is located on the upper rear section of the crusher frame, while the second
runs through a large diameter hole in the Jawholder itself, approximately level with the
upper side liner.
i NOTE:
It may be necessary to rotate the flywheel/pulley so the large diameter holes in

their webs are in-line with the cross braces, to allow the braces to be pulled out
the side of the crusher.
2. Remove toggle and tension rod assembly as outlined on previous pages. Disconnect
wiring to temperature sensors (if fitted). Remove grease lubrication pipework to main
bearing housings and jawholder (if fitted).
3. Loosen the ten (10) flywheel nuts on each side of the crusher. Take weight of a flywheel
and remove the ten (10) nuts, remove flywheel and lift clear of crusher. Repeat for other
flywheel. Being of the ‘nyloc’ type, the nuts are not reusable and must be discarded.
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i NOTE:
The Pulley and Flywheel need only be removed if the work to be performed on the
Jawholder assembly requires it. For example if the Jawholder assembly’s removal is
for storage purposes, the pulley and flywheel can be left in position – removal of the
pulley and flywheel is not a compulsory step for removal of the Jawholder assembly.
4. Attach chain hooks to the two holes on the top of the jawholder protector plate, and
take weight with crane.
5. Remove the bolts fastening the bearing housings to the crusher frame.
i NOTE:
Because these components form part of a friction-grip joint, these bolts, nuts, and
washers must be discarded and not used again. To ensure this, damage threads to
prevent re-use.
6. Carefully lift the assembly out of the frame, guiding the bottom of the jawholder around
the toggle block bracket in the process.
The assembly should then be transported to a workshop for dismantling.
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JAWHOLDER PROTECTOR PLATE

Depending on the size of the feed to the crusher, the occasional large lump may sometimes strike
near the head of the Jawholder. The protector plate will prevent wear and damage to the
jawholder and should be replaced if it becomes excessively warped or worn.
i NOTE:
This task is most easily accomplished during a moving jawface change.
REMOVAL:
Fit eyebolts, sling, and take up the weight of the Jawholder protector plate.
Remove the bolts retaining the Jawholder protector plate to the Jawholder itself.
REPLACEMENT:
Replacement of the Jawholder protector plate is the reverse of the above procedure, noting the
need to tighten the protector plate bolts to the torque shown on the assembly drawing.
TENSION ROD ASSEMBLY

Regularly check the tightness of the tension rod bolt (connecting the tension rod to the
Jawholder) and the general condition of the tension rod pivot pins, bushes and brackets. Too
much compression of spring may cause the tension rod cylinder pins and bushes to wear
prematurely. Too little tension and the assembly may be too loose and come into contact rear
end frame of the crusher causing damage. Check also the eye of the tension rod has not worn out
excessively and that the spring itself is in good condition. A failure of a tension rod can be
dangerous to operating personnel due to high compressive force induced on the spring.
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Erratic sideways motion of the assembly when viewed from the rear can usually be removed by
rotating the spring and re-tightening, but in any case must be rectified to prevent premature
damage or failure of the assembly.
REMOVAL OF THE TENSION ROD ASSEMBLY:

1. Unload the tension rod spring by actuating the plant hydraulic system to completely
release all pressure in the tension rod cylinder. Bleed to make sure there is no pressure.
DANGER
Ensure all hydraulic pressure is bled and isolated from the tension rod cylinder
before any attempt is made to perform work on the tension rod assembly or to
disconnect it from the crusher. Serious injury may occur.
2. Remove the guard (where installed).
3. Remove the bolt connecting the tension rod to the Jawholder and lower the tension rod
on its pivots.
4. Plug the cylinder ports to prevent ingress of dirt or egress of oil.
5. Suitably support the tension rod assembly and remove of the brackets holding the pivot
bushes. Lower the tension rod assembly away from the crusher.
REFITTING THE TENSION ROD ASSEMBLY:

1. Lift the tension rod assembly up under the crusher and locate a pin and bush into one of
the brackets. Fit the second bracket to retain the other bush and pin and tighten the
bolts.
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2. Lift the rod end up to the Jawholder and insert the connecting bolt to the Jawholder.
Note: the cylinder ports may need to be opened to enable the cylinder to be stroked in or
out to align the hole in the rod eye with the holes in the jaw holder.
3. Use the plant hydraulic system to compress the tension rod spring. Initial compressed
length should be approx. 300mm/11.8” for the JW40 and 280mm/11” for JW55 though
this may need to be altered when the crusher is started to remove toggle ‘knock’.
4. Refit the guards (where installed).
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REMOVAL OF BEARINGS
The jawholder assembly should be removed from the frame (see previous instructions) and set up
in a clean, well equipped workshop. It is recommended that the frame bearings be removed using
oil injection equipment which is available from bearing manufacturers and a hydraulic nut (Terex
Jaques shop tool).
Refer to Terex Jaques drawing “Arrangement of Hydraulic Mounting Equipment”, located at the
end of this section.
REMOVAL OF MAIN BEARINGS

1. Undo bolts and remove outer covers and outer seals.
2. Screw the hydraulic nut onto withdrawal sleeve and use pump type oil injector with
suitable high pressure steel capillary tube and end fittings to withdraw the sleeve.
Alternatively, an ordinary withdrawal nut may be used; however its threads and the end
face should be lubricated. The nut should then be screwed onto the withdrawal sleeve
and tightened against the inner race of the bearing using an bearing impact spanner or a
hammer and steel dolly so that withdrawal sleeve is forced out.
3. Remove the bearing housings and main bearings from the shaft along with the fixed and
floating inner covers and seals.
4. Tap the bearing out of the housing using a hardwood or brass dolly.
REMOVAL OF JAWHOLDER BEARINGS

1. Remove the jawholder seal, undo the set screws and remove the jawholder cover seal
using the jacking holes provided if necessary.
2. Remove the eccentric shaft and jawholder bearings from the jawholder with the aid of a
press or a block and tackle. Alternatively, lightly ramming the end of the shaft will also
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remove it. A soft dolly such as timber or white metal should be used to protect the end
of the shaft. The end remote from the ramming should be supported in a sling to ensure
the bearings slide out squarely and do not jam, and once point “X” (as indicated below)
on the shaft is visible, fit a second sling to support the shaft as the second bearing is
freed from the Jawholder.
Remove The Eccentric Shaft (P846A)
3. Remove the bearing using a press or a suitably proportioned pulling tool. It may be found
easier if the bearing is worn out, to remove the outer ring, the rollers and the cage, and
expand the inner ring with heat so that it can be freed.
INSPECTION OF BEARINGS
When bearings are removed from a machine, they should be thoroughly cleaned and
inspected, even if nothing abnormal has been noticed and the reason for dismantling the
machine has nothing to do with the bearings. The most common and generally most suitable
cleaning agent to use is a clean petroleum based cleaning agent (kerosene/paraffin) or white
spirit.
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Carry out inspections methodically. Take one bearing at a time and follow a definite system.
Begin by examining the outer cylindrical surface, side faces and inside surfaces of the outer
ring. Then swivel the outer ring away and examine each roller carefully, followed by the cage.
Remove a few of the rollers and examine the inner ring for defects.
FAILURE OF BEARINGS
The failure of a roller bearing will be obvious to the operator, because the operational sound of
the crusher will change considerably. The change of the sound is obvious if the crusher is running
empty, although the exact location or the nature of the failure cannot be determined in this way.
Overheating of a bearing also indicates the possibility of bearing trouble, and unless the
overheating has resulted from recent lubrication, the bearing should be removed from the
crusher and inspected closely for visible defects.
Listed below are a number of visible causes of bearing failure.
1. Rust on the rollers or raceways/tracks.
2. Overheating causes distortion to the bearing components and is obvious by the

discolouration it produces on the components.
3. Cracking of the outer or inner rings of the bearing.
4. Indentations in the roller or rings.
5. Surface damage such as flaking, smearing and impregnations of swarf or other foreign
materials.
PRECAUTIONS
1. Too much emphasis cannot be placed on cleanliness when handling, inspecting or fitting
roller bearings. Bearings should be thoroughly washed in clean petroleum based cleaning
agent (kerosene/paraffin) or white spirit before fitting, except in the case of new
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bearings, which may be fitted direct from their containers, providing they are not dirtied
in any way. Fitting should always be done in a clean dust-free environment.
2. Before fitting a new bearing, its serial number should be checked against that of the
bearing which was removed. This number is stamped on the side face of the outer ring.
3. If it is necessary to do any welding on the crusher, the earth wire must not be connected
to any part of the jawholder assembly such that current is drawn through the bearings, as
rapid bearing failure could result. The earth wire should be connected directly to the part
to be welded.
NOTE:
When it is necessary to carry out welding on this crusher, as noted in the

Maintenance Section, the earth wire must be connected directly to the part to be
welded. Under no circumstances should welding be performed were it is possible
that electrical current can be drawn through the rolling bearings in the Jawholder or
Main Bearing Housings. Rapid bearing failure could result from this action.
Warning

DO NOT WELD to the Crusher Main Frame except where noted, to
secure the Jawface Backing Plates the Front End Frame or Moving Jaw
Holder.
Welding in certain areas may cause severe damage to high strength,
heat treated steel components.
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OVERHEATING OF BEARINGS
Under normal conditions, the bearings should not run higher than 27° - 32°C (80°F – 90°F)
above ambient temperature. Slightly higher temperatures, due to abnormal crushing and/or
weather conditions, are permissible for short periods of time. However, temperatures consistently
higher than 90°C (194°F) under normal circumstances are a pointer to probable bearing trouble.
There is also a risk of grease breakdown, and continued use under these circumstances would
certainly then bring about bearing failure. The temperature of a bearing may be checked by
removing the outer grease nipples (taking care to thoroughly clean around them), and then
inserting a bulb thermometer or thermocouple probe. (An alarm is sounded when the
temperature exceeds 90°C. (194°F) if monitoring equipment has been supplied).
Overheating could be caused by the following:
1. Excessive Grease.
After application of fresh grease, the temperature of the bearings may rise for a short time, until
the grease has been distributed evenly around the bearing.
If, however, excessive grease is injected, the bearing may run at a temperature above the
recommended maximum for considerable period, and failure may result. The excessive grease can
only be removed by dismantling the jawholder shaft assembly, however it may purge through the
labyrinths over a period of time, but close monitoring of the bearing temperatures is essential
until they stabilise.
2. Incorrect Lubricant or Contaminated Lubricant.
Lubricant other than that specified in the Lubricant Section, could cause overheating, even if
injected in the correct quantity. In particular, molybdenum based greases should not be used
under any circumstances – lithium based greases with EP additives are they only type
recommended – refer lubrication section for recommendations.
3. Toggle ends not parallel.
ISSUE SEPTEMBER 07
S E C T I O N 5
If the toggle ends are not parallel, the thrust loads will be transmitted more to one bearing than
the other and cause overheating. In cases such as this, the toggle ends and pads must be refitted
to obtain correct seating along the full length.
4. Frame Bearings Incorrectly Mounted
If bearing withdrawal sleeves are driven up too tightly, the working clearance will be reduced and
cause the bearing to become overheated. Conversely, the bearings may be heated excessively if
the withdrawal sleeves become loose and revolve around the shaft. In both of these cases, the
bearings must be dismantled and refitted, paying particular attention to obtaining the correct
working clearance.
5. Failure of Bearing
Overheating may be caused by the failure of a bearing, and unless the overheating has resulted
from recent excessive greasing, the bearing should be removed and inspected for the faults listed
previously.
MOUNTING OF BEARINGS
Before reassembly, wash the eccentric shaft using clean petroleum based cleaning agent
(kerosene/paraffin) and inspect the surfaces for defects. Small imperfections such as burrs may
be removed by lightly rubbing with fine file, and dressing with fine emery cloth, however take
care not to destroy the form of the seating. If filing is necessary, be sure to clean the shaft once
again before commencing assembly.
PRECAUTIONS
Before fitting new bearings, all persons involved should be familiar with the work to be done.
The cross section through the shaft assembly should be familiar to all concerned and the
necessary equipment must be on hand, including a hydraulic nut.
ISSUE SEPTEMBER 07
S E C T I O N 5
The fitting of bearings should be done in a clean, dust-free environment. Cleanliness is extremely
important and all parts, except new bearings, must be thoroughly washed in a clean petroleum
based cleaning agent (kerosene/paraffin) before assembly.
MOUNTING OF JAWHOLDER BEARINGS
i NOTE:
If there are any doubts about the condition or size of the shaft journal or bearing
bores in the Jawholder, contact Terex Jaques.
1. Fit the grease baffles on the shaft, ensuring they are located on the shaft shoulders.
2. Remove the new jawholder bearings from their packages, check the bearing number
against the old ones, and slip adjustable lifting slings around them.
Adjustable Lifting Sling (P849)
ISSUE SEPTEMBER 07
S E C T I O N 5
3. Using a suitable “Induction” bearing heater (available from bearing suppliers), heat the
jawholder bearing until a minimum of 0.05mm/0.002” (bearing to journal clearance is
achieved, and then fit the bearing to the shaft. Fit the other jawholder bearing in the same
manner.
i NOTE:
Alternatively, bearings may be heated in a large bath of soluble oil.
4. Thoroughly clean out the jawholder bore and inspect for burrs which may have been
caused during dismantling. Remove any imperfections by rubbing with fine emery cloth
and then clean out the bore again with clean petroleum based cleaning agent
(kerosene/paraffin).
5. When the bearings are cool, pack grease into each bearing cage until they are filled flush
with their outer faces.
6. Preheat Jawholder to 40°C (104°F). Smear the Jawholder bore with light oil, balance the
shaft horizontally, and enter it into the Jawholder. Take care to protect the shaft by using
appropriate soft slings to ensure no damage to the shaft.
Slide Jawholder shaft bearing assembly into Jawholder (P850A)
ISSUE SEPTEMBER 07
S E C T I O N 5
7. Tap the outer ring of the leading bearing into the jawholder, using a hardwood dolly. Do
not use a lead hammer because small lead particles may enter the bearing and cause failure.
Tap bearing into Jawholder (P851)
8. Push the rest of the shaft into the jawholder and again tap home the bearing.
Alternatively, the shaft may be inserted with the aid of either a hydraulic jack or a block
and tackle. Ramming the shaft into the jawholder is also acceptable, providing extreme
forces are not used. Ensure that the bearings are positioned below the jawholder outer
face so that they will not foul jawholder cover seal.
9. Fit the jawholder covers and bolts, tightening the latter evenly around the pitch circle to
the torque indicated on the cross section drawing.
10. Pack the labyrinth of the jawholder covers with the recommended grease for bearings,
and fit the jawholder outer labyrinth seal.
11. Pack the labyrinth of the frame bearing main outer labyrinth seals with bearing grease.
ISSUE SEPTEMBER 07
S E C T I O N 5
MOUNTING OF FRAME BEARINGS

Locate one of the main bearing covers, and mount it on the flange side of the bearing housing.
Push the bolts through from the inside, so the threaded end would be pointing outward, toward
the pulley/flywheel.
Insert a fixing ring into the housing and push it against the inside of the bearing cover.
8. Remove the spherical roller bearing from its wrappings and check the bearing
number against the old one. Measure the roller clearance by inserting the feeler gauge
between the top roller and the outer ring at the highest point, with the bearing
standing vertically by itself. The rollers must be aligned correctly by being pressed
lightly against the inner guide ring. Record the clearances with respect to the bearing
from which they were obtained.
Measure & Record Clearances (P852)
9. Swivel the outer race of the bearing away and inspect the inside of the bearing to
ensure it is clean. Pack the rollers and cage with grease but leave a section 100mm (4”)
long free from grease.
10. Slide the bearing into the bearing housing and keep the ungreased section at the
bottom (adjacent to the flange).
ISSUE SEPTEMBER 07
S E C T I O N 5
11. Pack the outside of the labyrinth with grease then position the bearing, housing and
cover on the shaft hard up against the labyrinth seal. Slide the withdrawal sleeve into
the bearing (threaded end out outward).
12. Arrange the Mounting Barrel on the shaft with the narrow end against the threaded
end of the withdrawal sleeve. Locate the Hydraulic Nut on the End Retainer and
insert the bolts and washers to attach it to the shaft with the Nut facing the Mounting
Barrel. Refer to “Arrangement of Hydraulic Mounting Equipment”, located at the end
of this section.
i NOTE:
The mounting barrel and retainer are special tools and are not supplied with the
crusher as standard equipment. However, they can be supplied as an optional extra.
8. As the bolts are tightened in an even pattern, resistance will be felt as the withdrawal
sleeve is forced into the bore of the bearing.
9. Check the internal clearance again at the bottom roller with the outer ring of the bearing
hanging (unsupported) on the shaft. Record also the distance the hydraulic nut (and hence
withdrawal sleeve) is away from the inner race of the bearing.
10. Connect oil injection equipment to the hydraulic nut and then pump the sleeve into the
bearing. Determine the reduction in clearance of the ungreased rollers at the bottom of
the bearing and the amount the withdrawal sleeve has been driven up. Check these
dimensions against the tolerance ranges specified in the drawing “Arrangement of
Hydraulic Mounting Equipment”. Aim to achieve a reduction in clearance of rollers equal
to the mean of the range specified, and also check that the actual clearance is greater than
the minimum roller clearance stated.
ISSUE SEPTEMBER 07
S E C T I O N 5
11. Insert a second fixing ring into the housing and push it against the outer race of the
bearing.
12. Locate a second main bearing cover, fit it onto the bearing housing over the exposed
threaded ends of the bolts, and fit the washers and nuts. Tighten to the torque indicated
on the bearing assembly drawings, located in the spare parts section.
13. Using a depth micrometer, measure the distance from the end of the shaft to the outer
face of the withdrawal sleeve.
(P840)
14. Using a depth micrometer, measure the depth of the bore in the flywheel/pulley
(Measurement B).
(P141)
13. Measure the thickness of the outer labyrinth seal (Measurement C).
ISSUE SEPTEMBER 07
S E C T I O N 5
(P842)
Nominal Measurements
Model ‘A’ Shaft ‘B’ Flywheel/Pulley ‘C’ Seal
JW40 100.14mm/3.043” 85mm/3.346” 15.1mm/0.594”
JW55 139.75mm/5.502” 130mm/5.118” 8.95mm/0.352”
14. Calculate the required shim thickness using the following formula:
Shim Thickness = A – (B+C).
Example using the nominal values for JW40
Shim Thickness = 100.14 – (85+15.1) = 0.04mm (0.0015”)
Note: If the result of the calculation is positive – as above, Shims are to be installed between
the outer face of the withdrawal sleeve and the labyrinth seal. If the result if the calculation is
negative, then the clearance is actually present between the end of the shaft and the inside
of the Flywheel/Pulley and Shims must be installed here instead. Tolerances are generally
such that Shim calculations will result in shims being required between the sleeve and seal.
Suitable shims are available from Terex Jaques.
15. If the Shims of the required thickness are to be installed between the withdrawal sleeve
and the labyrinth seal, install them now against the outer face of the withdrawal sleeve, if
not go to step 18.
ISSUE SEPTEMBER 07
S E C T I O N 5
16. Pack the labyrinth of the main bearing housing cover with the recommended grease for
bearings and fit the outer labyrinth seal.
17. Install the key into the shaft for the Flywheel or Pulley.
18. If the Shims of the required thickness are to be installed between the end of shaft and
Flywheel/Pulley install them now over the studs and against the end of the shaft.
19. Fit the Pulley/Flywheel, washers, and bolts. Torque to the values shown on the cross
section drawing.
20. Repeat the above procedure for the other bearing assembly (the floating bearing), noting
that there are no fixing rings between the bearing and covers.
REFITTING THE JAWHOLDER ASSEMBLY

It is advisable to place the toggle in position under the crusher before the jawholder assembly is
placed in the frame as the toggle must be assembled by lifting up from underneath the crusher.
1. Clean the frame main bearing recesses and all machined surfaces with a solvent cleaner.
The joint between the bearing housings and side plates is “friction grip”. DO NOT use
anti-fret compound.
2. Hoist the jawholder assembly into the frame, passing the lifting tackle through the lifting
holes provided on top of the Jawholder protector plate. The location of these holes are
such that the bottom of the jawholder swings without fouling the rear end frame. If the
‘tilt’ angle is not sufficient, lifting tackle must be arranged to provide the necessary lift at
the bottom end when the whole assembly is suspended.
3. Lower the jawholder assembly until the main bearing housings are seated firmly in the
frame. Fit bolts and washers between the main bearing housing and the crusher frame,
and tighten.
ISSUE SEPTEMBER 07
S E C T I O N 5
i IMPORTANT
New fasteners must be used between the bearing housings and crusher frame. Do
not re-use fasteners, because as these components formed part of a friction-grip
joint, these bolts, and washers must be discarded and not used again.
4. Using a chain-block or similar, pull the Jawholder Assembly forward until the fixed and
moving jawfaces are touching, and retain securely.
5. Lift the toggle until upper end slides into the lower toggle seat. Continue to lift until the
other end is in position to slide into the jawholder toggle seat.
6. Slowly ease the jawholder back until the toggle end enters the jawholder toggle seat. Check
that the toggle is properly seated both ends.
7. Bolt the dust flap and retainer to the jawholder.
8. Install the Tension Rod Assembly as previously described.
9. Read through the Operating Section and follow relevant instructions for putting the
crusher back into service, noting to check for toggle end ‘knock’ and the need to readjust
the tension rod spring if necessary.
ISSUE SEPTEMBER 07
S E C T I O N 5
TOGGLE WEDGES
(This section should be read in conjunction with the setting adjustment arrangement
drawing located in the spare parts section of this manual)
The toggle wedge assembly consists of two toggle wedges, hydraulic cylinder, and associated
hoses, requires minimal maintenance, and cannot be maintained while installed in the machine.
Toggle Adjustment Mechanism (P830)
ISSUE SEPTEMBER 07
S E C T I O N 5
Item Description
1 Toggle
2 Coverplate – Blank
3&4 Toggle Wedges
5 Hydraulic Hand Pump
6 Rear End Frame
7 Wedge Locking Bolt
Maintenance Tool
8 Clamp Maintenance Tool
9 Toggle Seat
10 Toggle Seat Spacer
11 Extracting Maintenance Tool
12 Wedge Endplates
13 Coverplate – Toggle Adjusting
Toggle/Toggle Seat/Toggle Spacer/Wedge Maintenance Assembly (P843A)
ISSUE SEPTEMBER 07
S E C T I O N 5
REMOVAL OF THE WEDGE ASSEMBLY
(Read in conjunction with maintenance assembly illustration on previous page.)
WARNING
Before removing the toggle, make sure that the jawholder is at the bottom of its
stroke.
Fit the special maintenance tools:

1. Adequately support the toggle (item 1) from above so that it will not fall when the
jawholder assembly is pulled forward.
2. Remove the dust flap retainer and dust flap.
3. Remove the blank cover plate (item 2) without the hydraulics attached from the side of the
crusher frame to expose the wedges (item 3 & 4).
4. Use the plant hydraulics (or hand pump if installed) to adjust the position of the wedges
(items 3 & 4) until the ends of the two are level, as shown below:
Adjust wedges until wedge ends are flush (P845)
ISSUE SEPTEMBER 07
S E C T I O N 5
DANGER
Ensure all hydraulic pressure is bled and isolated from the wedge hydraulic
cylinder before any attempt is made to perform further work on the hydraulics
and wedge assembly or to disconnect it from the crusher. Serious injury may
occur.
5. Remove the cover plate (item 13) from the other side of the crusher (with the hydraulics
attached), disconnect the hydraulic hoses, and fit the special wedge endplate (item 12)
maintenance tool to both ends of the wedges.
6. Fit the special clamp maintenance tool (2-off item 8) to each side of the front of the
crusher’s rear end frame. These must be fitted in their innermost slide position to ensure
both toggle seat (item 9) and toggle seat spacer (Item 10) are held in position when the
toggle is removed.
WARNING
Both special maintenance tools must be fitted to retain the toggle seat/toggle
seat spacer and wedges inside the rear end frame BEFORE removing the
toggle. Failure to retain the toggle seat/toggle seat spacer will result in
components falling under gravity from inside the recess in the rear end frame.
ISSUE SEPTEMBER 07
S E C T I O N 5
Remove the Tension Rod Assembly:

7. Remove the assembly as previously described in this manual.
Remove the toggle:

8. Using a chain-block or similar, pull the Jawholder Assembly forward until the fixed and
moving jawfaces are touching, and retain securely.
9. Lower and remove the toggle. This gives access to inspect the Toggle Seat and Toggle Seat
Spacer inside the crusher’s rear end frame.
Remove the wedge assembly:

10. Using a 5 tonne SWL chain-block or similar attached to the special wedge endplate
maintenance tool (Item 12), pull the wedge assembly out until the M20 x 2.5 lifting holes in
the top of the wedges are accessible.
Lifting of Wedges (P844)
ISSUE SEPTEMBER 07
S E C T I O N 5
i NOTE:
If Wedges are jammed, back off both special clamp (item 8) retaining bolts to
allow free movement.
11. Fit suitable lifting equipment to the lifting holes, pull the wedge assembly from the crusher,
and lift clear.
With the wedge assembly out of the machine, the opportunity should be taken to inspect the
wedge tapered faces, hydraulic cylinder, nipples, and hoses for damage or excessive wear, or
evidence of leakage.
On a flat surface, remove the special wedge endplate maintenance tool (Item 12) from
both ends of the wedge assembly, and slide the wedges apart to gain access to these
components.
Replacement cylinder seal kit and pump cartridge details are listed in the spare parts section
of this manual.
REASSEMBLY OF THE WEDGE ASSEMBLY

Reassembly is the reverse of the above procedure, taking care to:
1. Assemble the wedge parts in the same orientation as they were withdrawn from the crusher,
specifically so the hoses exit the assembly in-line with the bulkhead nipples on the cover plate.
ISSUE SEPTEMBER 07
S E C T I O N 5
i NOTE:
An incorrectly assembled wedge with the hoses not exiting in-line with the bulkhead
nipples on the cover plate will result in the wedge assembly fouling the hoses and
nipples during operation – refer hydraulic arrangement drawing located in the spare
parts section of this manual.
2. Remove the special clamps (2-off item 8) after the toggle (item 1) has been correctly fitted.
3. Remove the special wedge endplates (2-off item 12) prior to reconnecting hydraulic hoses
to the nipples in the cover plate.
4. Prime the hydraulic system:
5. Ensure the hydraulic system has sufficient oil. Reservoirs should be filled to the maximum
operating level marks.
6. Extend the cylinder fully to increase the setting of the crusher
7. Retract the cylinder as far as it will go without touching the moving jaw and fixed jaw
together. The hydraulic cylinder should now be full of oil.
8. Check and top up the hydraulic reservoir as required.
i NOTE:
It should not be necessary to ‘bleed’ the hydraulic system, as excess air in the system
will escape via the filler/breather as the system is operated.
9. Reset the tension rod spring to the correct compressed length.
ISSUE SEPTEMBER 07
S E C T I O N 5
An arrangement drawing of the hydraulic system used to actuate this mechanism is

located in the spare-parts section of this manual.
ISSUE SEPTEMBER 07

Jaques JW40 Manual - ENGLISH

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Jaques JW40 Manual - ENGLISH

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I N S T A L L A T I O N , M A I N T E N A N C E

J-1160 ENGLISH JAQUES

Single Toggle Jaw Crusher

MODEL No: JW40/JW55

SERIAL No: XXXXXX

FEED OPENING: 1000 x 625/1400 x 814

39.4” x 24.6”/55” x 32”

MASTER SCHEDULE: N/A

MACHINE SCHEDULE: AW1726/AW1749/

ISSUED: September 2007

Section 1 - Technical Description

Vee Belt Drive________________________________________________________ 2 - 8

Refitting Tension Rod Assembly _________________________________ 5 - 27

Section 6 - Spare Parts

USE OF THIS MANUAL

STOP ACCIDENTS BEFORE THEY STOP YOU!

• Be alert for possible hazards before they cause trouble.

Equipment not properly prepared for operation is unsafe equipment.

Danger denotes a particular hazardous or hazardous conditions that is

Warning denotes a hazard or hazardous conditions that is not likely to be

This machine is built to the latest technology and is safe to operate.

Before initial operations, the operator of the machine is obliged to check

Eye Protection Head Protection Foot Protection Hearing Protection

It is forbidden to stand under suspended loads.

Electrical connections and work on the machine’s electrical equipment may

Unauthorised modification and changes to the machine carried out by the

The electrical connection of the drives must be sufficiently protected.

WORKING ENVIRONMENT (SITE) CHECKLIST

Work to and follow your Job Safety Analysis (J.S.A.)

Are electrical wiring appropriately

CRITICAL COMPONENTS LIST (CCL)

Item: Safety Critical Risk Control

EC MACHINERY DIRECTIVE 98/37/EC

Machine : Single Toggle Jaw Crusher

Manufacturer : Terex Jaques

Assessment Dates : Not Applicable

Relevant Standards : Essential Health and Safety Requirements, EN 292-1, EN 292-

Section 1: Installation Updated: 30/6/03, Assessor: M.Turner

POTENTIAL HAZARDS COMMENTS/ACTION/PRIORITY TO ELIMINATE/REDUCE

Probability: A=Common, B = Likely, C = Possible, D = Unlikely, E = Practically Impossible

Date: 2/3/98, Assessor/s: R

POTENTIAL HAZARDS COMMENTS/ACTION/PRIORITY TO ELIMINATE/REDUCE

Probability: A=Common, B = Likely, C = Possible, D = Unlikely, E = Practically Impossible

Date: 2/3/98, Assessor/s: R Lim, M Turner

Section 2: Pre-operational Safety Checks Updated: 30/6/03, Assessor: M.Turner

POTENTIAL HAZARDS COMMENTS/ACTION/PRIORITY TO ELIMINATE/REDUCE

Probability: A=Common, B = Likely, C = Possible, D = Unlikely, E = Practically Impossible

Date: 2/3/98, Assessor/s: R Lim, M Turner

Section 3: Operation Updated: 30/6/03, Assessor: M.Turner

POTENTIAL HAZARDS COMMENTS/ACTION/PRIORITY TO ELIMINATE/REDUCE

2. Striking by tension rod as a result of breaking D 5 3 3 5 5 17=L As above.

7. Noise. B 4 5 5 4 5 14=M Ensure hearing protection is used.

Probability: A=Common, B = Likely, C = Possible, D = Unlikely, E = Practically Impossible

Date: 2/3/98, Assessor/s: R Lim, M Turner

Section 3: Operation (…continued) Updated: 30/6/03, Assessor: M.Turner

POTENTIAL HAZARDS COMMENTS/ACTION/PRIORITY TO ELIMINATE/REDUCE

11. Dust. C 3 5 5 3 4 13=M Ensure appropriate breathing protection PPE is used.

Probability: A=Common, B = Likely, C = Possible, D = Unlikely, E = Practically Impossible

Date: 2/3/98, Assessor/s: R Lim, M Turner

Section 4: Lubrication Updated: 30/6/03, Assessor: M.Turner

POTENTIAL HAZARDS COMMENTS/ACTION/PRIORITY TO ELIMINATE/REDUCE

Probability: A=Common, B = Likely, C = Possible, D = Unlikely, E = Practically Impossible

Date: 2/3/98, Assessor/s: R Lim, M Turner

Section 5: Maintenance Updated: 30/6/03, Assessor: M.Turner