Operation 5

Table of Contents
5 Operation
5.1 Daily Plant Inspection Before Startup ............................................................ 5-2
5.2 Normal Plant Operation .................................................................................. 5-3
5.3 Plant Start-Up Procedure ............................................................................... 5-4
5.4 Loading the Hooper ........................................................................................ 5-7
5.5 Glossary of Jaw Crusher parts ....................................................................... 5-8
5.6 Preparing Crusher .......................................................................................... 5-9
5.7 Operator Panel with Feeder speed Display ................................................. 5-16
5.8 Operator Panel with no Feeder speed Display ............................................ 5-17
5.9 End of Shift or Workday ............................................................................... 5-18

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5 Operations

5.1 Daily Plant Inspection Before Startup

Prior to starting the plant each day or shift, check the following items. After completing
the pre start-up inspection, you can start the plant:

NOTICE
Do all pre-startup and operation procedures in accordance with the applicable
individual component operation and maintenance manuals. Follow the start-up
sequence exactly. Failure to comply with this notice could result in equipment
damage.

WARNING
Always wear eye, head, hand, foot, and hearing personal protective equipment
(PPE).
Additional PPE may be required as needed such as a respirator or reflective vest.
Failure to comply with these safety messages could result in death or serious
injury.
Prior to starting the plant each day or shift, check the following items:
• Make sure that all safety signs are in place and readable.
• Make sure that all guards are in place.
• Make sure that the jaw crusher and feeder are free of material.
• Check the oil level in the feeder.
• Clean up any spilled material on or around the plant.
• Remove any equipment and tools that are hazardous to plant operation from the
immediate plant area.
• Inspect the feeder liners to determine if holes have worn through. Replace, as
needed, following instructions in your feeder manual.
• Inspect plant components for damage or wear.
• Record any pertinent observations about the system in your plant log book

5.2 Blocked Crusher Operation

The clearing of blocked crushers should be given considerable thought prior to
attempting to unblock a crusher. These procedures should be considered under risk

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assessment review for the implementation of a procedure of safe working practice for
this operation.
There is a document entitled ‘Clearing Blocked Crushers’ available from the British
Aggregate Construction Materials Industries (BACMI) which gives more details about
this and covers in more detail risk assessment areas. Tramp metal is a serious problem
when it enters a crusher as this can cause more problems than oversize or hard stone.
When an overload occurs and the crusher continues to run, the plant siren will sound,
the feeder will stop and a fault message is displayed on the panel screen together with
acknowledge alarm. This indicates that the crusher moving jaw has automatically
opened sufficiently to release material from the jaw onto the product conveyor, when
excessive crushing pressure has been sensed. This may operate until the jaw is fully
open.
The operator must react to this immediately. The feeder will stop, followed by slowing
and stopping of the product conveyor. Before proceeding further, follow all the safety
warnings and procedures. Check if the crushing chamber is empty and inspect the
product conveyor to see if material is still falling from the underside of the crusher. Listen
for the sound of material being crushed or alarm if necessary.
Acknowledge the alarm and press the crusher stop button to stop the crusher, wait until
the crusher has stopped.

WARNING
The Automatic Overload Release system, after operating, can retain hydraulic
pressure in the system after the plant has stopped. Check the main control screen
to view the current pressure. To release any pressure fully open the jaw, in case
for any other information requires, contact Terex.
Now select the manual mode from the panel and lockout the plant before climbing to the
maintenance platform to confirm the crusher blockage and check whether it is possible
to remove the blocked material by simply opening the jaw to the maximum.
Before proceeding further, first make sure that all the material on the product conveyer
should be cleared off the belt. Now open the jaw and release pressure on the blockage
and thus evacuate from the crusher jaws. The product and dirt conveyers can be started
and stopped if required to assist in clearing a blockage.
If it is not possible to remove the blocked material by opening the jaw to the maximum, it
may be possible to reduce the material size to release it by using the jaw hydraulic
pressure with the crusher static. Press and hold the jaw in button to apply pressure on
the material and break it up and press jaw out of release it from the jaws.
Repeat this process if necessary to clear the jaws. if the process is successful, manually
start the crusher and check for the functioning.

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5.3 Plant Start-Up Procedure

5.3.1 Pre-Run Check

WARNING
Terex cannot overemphasize the need to ensure that all safety aspects are
checked before starting the machine.
• Ensure that the plant is fully ‘Set Up’ in accordance with Section Set up and ready to
operate.
• Check that the rushing chamber are empty of material.
• Ensure that all guards are in position and secure and that other personnel are clear of
the plant.
• Before the machine can be run normally, the direction of the electric motor must be
checked.
• First, note the required direction of the hydraulic pumps, usually indicated on the
pump housing. If unsure, contact Terex for advice.
• Ensure all circuit breakers are in the ON position and that the Isolator switch on the
machine Power unit is locked in the OFF position.
• Ensure all Emergency Stop buttons are released and that it is safe to start the
machine.
• Switch on the Main Panel 3P Isolator switch.
• Press the Emergency Reset Button on the main control panel. Providing the
emergency stop circuit is healthy, the green Emergency Stop Healthy Lamp will
illuminate.
• Next Press the Pre-Start button. This will cause the siren and beacon to activate.
• After 7 seconds the, Pre-Start lamp will illuminate indicating it is clear to start the
plant.
• Start the Hydraulic power pack.
• Next press Electric Motor Start button followed by Electric Motor Stop button in quick
succession. Check that Electric Motor is running in the correct direction.
• If the electric motor is running in the wrong direction, swap 2 of the supply cable
phases.
• Do not swap the motor connections in the main control panel as these are tested
before leaving the factory.
• Once the motors are running the correct direction the plant can be started as follows

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NOTICE
Do not leave Motor running while checking the direction. Simply ‘Pulse’ the motor
as described. Failure to follow these directions may result in damage to the
motors and / or pumps.
• The plant Electric Motor drives the Crusher crusher directly through a vee belt drive
system

NOTICE
During operation, motors have live or moving parts. Therefore, removal of
electrical or mechanical guards, improper use, or inadequate maintenance may
cause serious damage to persons or property.
5.3.2 Normal Start Procedure

• Ensure all circuit breakers are in the ON position and that the Isolator switch on the
machine Power unit is locked in the OFF position.
• Ensure all Emergency Stop buttons are released and that it is safe to start the
machine.
• Switch on the Main Panel 3P Isolator switch.
• Make sure that Auto mode and Test mode should be off.
• Switch Test / Manual selector switch to MANUAL mode.
• Press the Emergency Reset Button on the operator panel that it is safe to start the
machine. Providing the emergency stop circuit is healthy, the green Emergency Stop
Healthy Lamp will illuminate.
• Next Press the Pre-Start button (refer the operator panel details). This will cause the
siren and beacon to activate.
• After 7 seconds the, Pre-Start lamp will illuminate indicating it is clear to start the plant

NOTICE
If the Main Motors & hydraulic pump motor are not started within 30 seconds of
the Pre-Start lamp illuminating, The Pre-Start sequence will reset and will need to
be repeated in order to start the plant.

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• Start the electric motor for the power pack (PLC controlled).
• Press Motor Start button. The Main contactor and Star contactors will energise. After
aprox. 5 seconds, the Star contactor will disengage and the Delta contactor will
energise. This will cause the Motor Run Lamp to illuminate.
• Once the Electric motor is running, the plant items can be started using the button
provided on the Panel. For more details related to the buttons, see the Panel
illustration.
• Now start the crusher but before starting make sure that the feeding chute should be
empty.
• Start the Dirt conveyer C1 by pressing the Dirt conveyer button provided on the
operating panel of the crusher.
• Now start the magnetic detector if fitted.
• Now start the conveyer C3 by pressing the conveyer C3 start button.
• After a delay of 3 seconds, now start the Product conveyer C2 by pressing the
Product conveyer start button provided on the panel.
• Raise the safety grid on the crusher feed chute with suitable lifting equipment and
insert the two pins. Always operate the plant with the safety grid in the raised position
and allow it to be free to lift, should any large mater ail be present.
• Before start the vibrating grizzly feeder, have a delay of 3 seconds and then start the
vibrating grizzly feeder using the Feeder start button from the panel.
• Before loading the plant, once check the diagnosis screen and check if any fault is
available or not. If any fault is present than do not load the plant until the fault
disappeared.
5.3.3 Normal Stop Procedure

• Before stopping the plant, make sure that the feed supply to the feeder stopped.
Empty the feeding chute before stopping the plant.
• Stop the vibrating grizzly feeder using the feeder stop button from the panel.
• After a delay of the 5 seconds, stop the crusher motor but ensure that there is no
further supply of the material to be crushed.
• After a delay of the 5 seconds, stop the Product conveyer C2 by pressing the Product
conveyer stop button provided on the panel.
• Ensure that the material should be cleared off the belt before stopping the conveyers.
• Stop the magnetic detector if fitted.
• After a delay of the 5 seconds, stop the Dirt conveyer C1 by pressing the Dirt
conveyer stop button provided on the panel.

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• Now, stop the C3 conveyer by pressing the C3 conveyer stop button provided on the
panel.
• Now reset all the emergency stop button and make all the circuit breaker on off
position and isolator switch also.
• Now lock out the machine.

5.4 Loading the Hooper

• Observe all safety warnings and notices.
• Make sure all the personnel are clear of the plant.
• Material for crushing must be within the sizes as specified in the crusher capacity
specification.
• Material for crushing must be fed on to the base plate of the hopper as it is designed
for loading purpose.
• This method will allow feed material to pass over the feeder bars gradually to allow
them to function correctly.
• The feed bucket should pass as close as possible to the hopper top edge, just
clearing the sides or end of the hopper.
• Empty the bucket to drop material the minimum height into the hopper base plate.
• Do not drop material on to the feeder bars as they are not designed for impact of
material from a great height.
• Load the material into the hopper at a rate the feeder and crusher can work efficiently.
• Set the feeder speed such that material is fed evenly and does not build up.
• Do not feed excess material into the hopper.

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5.5 Glossary of Jaw Crusher parts

BALANCED FLYWHEEL
AND PULLEY

FEED ENTRY
PROTECTION

BOLTED SIDE PLATES

FIXED JAW NO BOLTED
WEDGE
RETENTION CAST SWING JAW
HOLDER

C.S.S.WEDGE
ADJUSTMENT

CAST END
FRAMES

DISCHARGE PROTECTION

REPLACEABLE
LINER

SIDE
PLATE
TOGGLE

HYDRAULIC
ADJUSTING
CYLINDER

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5.6 Preparing Crusher

Before starting the crusher for the first time or after a major overhaul, the following
procedure should be adopted.
• Check all bolts (except the frame and bearing housing bolts) for tightness.
• Check that there are no objects left in the jaws and no obstruction to the motion of the
jaw holder or toggle.
• Check setting. Adjust if necessary - see Adjustment of Setting.
• Check that the toggle wedge hydraulics are locked against the check valve (JW42
only).
• If fitted, check that the automatic grease system has been primed and is set to run.
• If fitted, check that Bearing temperature monitoring is set to alarm at 90 C / 194°F
• Check all guards are in place, and safety tagged as necessary.
5.6.1 MOTORISED HYDRAULIC ADJUSTMENT SYSTEM

Description of Functions
System Activate:
• Enables Crush mode or Adjust mode. If the System Activate is turned off all outputs
are turned off, therefore the electric motor stops.
Crush Mode:
• Crush mode is on and Adjust mode is disabled.
• Tension Cylinder is charged to the predetermined tension setting (55Bar).
Adjust Mode:
• Adjust mode is active if the crusher is off.
• Tension Cylinder charge reduces to predetermined tension (45 Bar).
• The "Increase" (Increase_Gap) or "Decrease (Decrease_Gap)" switches are used to
adjust to the desired position of the jaw.
• When Pressure is Low, then power pack RUN output starts the PowerPack motor and
loads the pump.
• When Pressure is High , then pump unloads and stops the PowerPack motor.
Emergency Stop:
• Stops all functions
5.6.2 Operation

Ensure the unit is both hydraulically and electrically connected and fill the reservoir filled

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with oil. Turn the selector switch to “Crush Mode”. Test the system for the correct
direction of rotation turning the “System Activate” switch on and off (bump) which will
cause the pump motor to run briefly. Direction of rotation is to be counter clockwise
looking at the fan end of the motor.
With the correct direction of rotation established, start the system by turning the “System
Activate” switch to the on position; the pump will start and run for 30 seconds to fill the
Tension cylinder with oil. Should the initial fill take longer than 30 seconds it will be
necessary to turn the “System Activate” switch off and on again to reset the 30 second
timer. Once the system is full and purged of air, the tension cylinder will pressurize to 55
bar and the pump motor will shut down automatically. Should the pressure in the tension
cylinder fall back to 45 bar, indicating a lower tension, the system will start the pump
motor up automatically and recharge the tension cylinder back to the desired pressure
of 55 bar. During operation of the crusher the system may occasionally cycle between
55 bar and 45 bar to keep the desired tension on the toggle plate.
To set the Crusher's CSS (Close Side Setting) switch the mode switch to “Adjust Mode”.
Then using the “CSS Increase” or “CSS Decrease” switches adjust to the desired CSS.
These are spring returned switches and need to be held on, to keep the electric motor
running and enable the adjustment. Operating these switches will firstly reduce the
tension on the toggle plate to 20 bar and allow adjustment of the CSS. In the “Adjust
Mode” the crusher must be off. A wiring interlock from the crusher control is provided to
ensure that the CSS can not be set while the crusher is running. Conversely if the mode
switch is set to “Adjust Mode” switch, the interlock should shut down the crusher main
drive motor.
5.6.3 RUNNING IN

If the crusher has been reassembled on site or has been standing for some time, it is
advisable to regrease the bearings 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 jaw
holder movement. This noise, if present, is caused by the ends of the toggle knocking

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against the seats. If such a noise is heard, it may be that the tension rod spring is too
loose, and the tension rod nut should be tightened 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.

NOTICE
When the hydraulic tension rod and adjustment system is installed, the tension
rod should not knock, as the spring pressure is maintained. If there is knocking,
ensure the system is operative and check that pressure is present (view the
pressure gauge inside the cabinet). If knocking is still present, contact Terex
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 jaw face wedge bolts, jaw face retainer wedge bolts and
protector plate bolts should be checked daily during the initial period of crushing and at
regular periods thereafter. The Moving Jaw face Retainer bolts are fitted with neoprene
washers to enable the part to be held tight and yet allow for slight misalignment of
bolting faces, and growth. Excessive tightening will destroy the buffer effect, therefore
compress only to the amount shown on the general arrangement drawing.
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.
5.6.3 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 jaw faces.
The feed chute should usually be angled at not less than 45 so that material runs freely

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 5 Operation

and is directed into the crushing chamber. Chute design should prevent continued
impact of feed material against the head of the moving jaw holder. The material entering
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 jaw holder and the feed chute. Instead, using appropriate lifting gear
(and not blasting), it must be lifted clear and reduced in size.
To achieve maximum capacity, maintain a uniform flow of dry material from which fines
have been scalped and oversize removed.

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 Jaques warranty on the machine being withdrawn.
5.6.4 SETTING

The setting of the crusher is measured at the discharge opening of the jaw faces, from
the top of the corrugation on the moving jaw face to the valley between the corrugations
on the fixed jaw face. The minimum distance between these points when the moving jaw
face closes in, is known as the tip to bottom closed side setting (CSS).
The crusher must not be operated at closed side settings smaller than that stated in
'Technical Information' located in section one (1). 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.
5.6.5 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 Jaw holder
assembly The adjustment mechanism is shown on the following illustrations:

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Operation 5

Toggle Extended (Minimum CSS)

Toggle Extended (Minimum CSS) (P830)

Toggle Extended (Mid CSS)

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 5 Operation

Toggle Extended (Mini mu mC SS)

(MOTORISED HYDRAULIC ADJUSTMENT)

NOTICE
The crusher must not be running during the Setting Adjustment. This is to
prevent the toggle falling out when the hydraulic tension rod pressure is released.
Interlocks (described earlier) must prevent this.
To change the CSS:
• Ensure Crusher main drive motor is turned off.
• Ensure the 'System Activate' switch is ON.
• Turn the selector switch to 'Adjust Mode'.
• Adjust the setting: To increase the setting turn the 'CSS Increase' switch for as long as
required to achieve the desired setting; to decrease the setting turn the 'CSS
Decrease' switch for as long as required to achieve the desired setting.
• Once the setting is correct, turn the selector switch to 'Crush Mode'
• Crusher may now be restarted for operation.
The hydraulic Tension Rod will depressurize during the adjustment process and re-
pressurize once the adjust switch is released.

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NOTICE
Observe the crushing chamber whilst performing setting adjustments. Setting
changes are relatively quick and over adjustment is possible.
The Crusher stops on the 'Open Side' so the observed setting in the chamber will
by the CSS plus the stroke at the toe of the moving jaw. Stroke may vary slightly
between crusher models and throughout the range of setting adjustment,
however approximate CSS may be taken as OSS minus 30 to 35mm in most
cases.

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5.7 Operator Panel with Feeder speed Display

DEVICE

P/N

PB2/L4 Pre-start
PB4/L5 Product Conveyer start
PB6/L7 Crusher start
PB8/L9 Dirt Conveyer start
PB10/L11 Feeder start
PB12/L13 Conveyer C3 start
PB1/L3 Emergency stop reset
PB3/L6 Product Conveyer stop
PB5/L8 Crusher stop
PB7/L10 Dirt Conveyer stop
PB9/L12 Feeder stop
PB11/L14 Conveyer C3 stop
PB13 Power pack activation
L2 Test mode selected
S1 Test / Off / Manual select
L3 Manual mode selected
S2 Crusher off / Adjust on
S3 CSS increase
S4 CSS decrease
L15 Power Pack run lamp
L16 Power Pack trip lamp

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Operation 5

5.8 Operator Panel with no Feeder speed Display

DEVICE

P/N

PB2/L4 Pre-start
PB4/L5 Product Conveyer start
PB6/L7 Crusher start
PB8/L9 Dirt Conveyer start
PB10/L11 Feeder start
PB12/L13 Conveyer C3 start
PB1/L3 Emergency stop reset
PB3/L6 Product Conveyer stop
PB5/L8 Crusher stop
PB7/L10 Dirt Conveyer stop
PB9/L12 Feeder stop
PB11/L14 Conveyer C3 stop
PB13 Power pack activation
L2 Test mode selected
S1 Test / Off / Manual select
L3 Manual mode selected
S2 Crusher off / Adjust on
S3 CSS increase
S4 CSS decrease
L15 Power Pack run lamp
L16 Power Pack trip lamp

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5.9 End of Shift or Workday

Always clear plant of material. Make sure that the crusher is empty at the next startup,
stop all infeed and watch the plant run until the last of the material has been cycled
through and discharged. Then shut down plant.
Shut down plant components in opposite order from the startup sequence, beginning
with the point of feed and ending with the discharge conveyor.
Check the tension on any drive belts, including crusher and feeder drive belts.

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Maintenance 6

Table of Contents
6 Maintenance
6.1 Safety Information .......................................................................................... 6-2
6.2 General Information ....................................................................................... 6-3
6.3 Maintenance Schedule ................................................................................... 6-4
(1) Regular Maintenance ............................................................................. 6-4
(2) Daily, Weekly and Monthly Checks ....................................................... 6-4
(3) Daily Checks .......................................................................................... 6-5
(4) Weekly Checks ...................................................................................... 6-5
(5) Monthly Checks ..................................................................................... 6-6
6.4 Replacing Wear Parts .................................................................................... 6-6
6.5 Maintaining Jaw Crusher ................................................................................ 6-6
(1) Jaw Crusher Maintenance Access Points ............................................. 6-7
(2) Servicing Jaw Crusher Tension Rods .................................................... 6-9
(3) Servicing Jaw Crusher Drive Belt ........................................................ 6-10
6.6 Maintaining Feeder ...................................................................................... 6-11
6.7 Maintaining Bypass Chute ........................................................................... 6-11
6.8 Maintaining Conveyor Components ............................................................. 6-11
(1) Adjusting Conveyor Belt ...................................................................... 6-11
(2) Tensioning Conveyor Belts .................................................................. 6-12
(3) Adjusting Conveyor Belt Tracking ........................................................ 6-13
(4) Adjusting Conveyor Return Roller Nip Guards .................................... 6-14
(5) Tightening Conveyor Bearing Collars .................................................. 6-15
(6) Tightening Conveyor Bushing Bolts ..................................................... 6-15
6.9 Lubrication .................................................................................................... 6-16
6.10 Lubricating Stored Equipment .................................................................... 6-17
6.11 Grease Points ............................................................................................ 6-17
6.12 Checking Conveyor Gear Box Oil Levels ................................................... 6-18

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 6 Maintenance

6 Maintenance

6.1 Safety Information

Maintenance procedures in this manual must be carried out only by trained and
competent personnel. Contact your supervisor if training is required. More complex
machine service procedures not covered in this manual must only be carried out by
trained personnel. Please contact your supervisor, local dealer, or Terex for task
specific training.
As part of periodic maintenance, inspect the plant for any missing or damaged parts. For
example, replace or repair any damaged guards or handrails. Replace any missing or
damaged safety signs. Check conveyor drive belts for proper belt tension.
Most maintenance can be performed from maintenance platforms In the event it cannot,
use personnel lift or ladder to gain access to maintenance work area.
Keep operator safety in mind at all times. For added maintenance procedures refer to
either the JW42 Jaw Crusher Operations Manual.

WARNING
Always wear eye, head, hand, foot, and hearing personal protective equipment
(PPE).
Additional PPE may be required as needed such as a respirator or reflective vest.
When appropriate, implement the lockout and tagout procedure prior to carrying
out maintenance or adjustments to the machine. Isolate the electrical supply.
Refer to the Safety Section earlier in this manual for the proper Lockout and
Tagout procedure.
Make sure that the lifting device has adequate capacity when moving plant
components. Reference Drawing (MTJ1175*Shipping Container Layout) for all
weights. Please contact the factory if you are missing this drawing.
The system may contain high voltage electrical equipment. Any maintenance
electrical equipment on or replacement of electrical equipment should only be
undertaken by suitably trained and competent electrical technicians.
Falling hazard. Do not climb onto the machine. Always use the walkways and
platforms provided.

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Maintenance 6

Use the correct tools and appliances.

Understand service procedures before doing any work.
Keep the area clean and dry.
Never lubricate, clean, service or adjust machine while it is moving.
Keep hands, feet and clothing clear of power driven parts and in-running nip
points.
Disengage all the power and operate controls to relieve pressure.
Allow the machinery to cool.
Securely support any machine elements that must be raised for service work.
Keep all parts in good condition and properly installed. Attend to damage
immediately. Replace worn or broken parts.
Remove any build up of stones, dust, grease, oil or other debris from the
machine.
When performing maintenance tasks, always observe the local site safety rules as well
as those provided in safety sections of this manual.

PRIOR TO ANY MAINTENANCE:

• Observe the all safety advice given, as appropriate to the task in hand.
• Read the appropriate manual literature relevant to the operation in hand. Carry out a
risk assessment for all maintenance operations; have suitable lifting gear available for
the weights involved and all necessary tools/equipment ready for the tasks in hand
before starting work. Terex Service Department is available for advice when required.
• The machinery should be completely emptied of material i.e. stone.
• Keep clear of moving parts when trying to identify or isolate any unusual noises whilst
the machine is running.
• Fit dismantled parts in the same location from which they were removed.
• Make sure that the area surrounding the maintenance site is clear of any obstructions.
• If arc welding work is involved in any maintenance operation, make sure that the
current does not pass through any bearings. The machinery must be fully isolated
prior to any welding work.
• Implement a lockout and tagout procedure to isolate any power sources to the plant.

6.2 General Information

The arduous task of continuously crushing stone and the generally harsh environment in
which the plant has to operate calls for reasonable care and consideration to be taken to
keep the machine in good order.

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Machinery breakdown caused by insufficient or improper maintenance will cause high

repair costs and long term standstill. Therefore, regular maintenance is imperative.
In addition to several other factors, the reliability and life of the crusher depends on
regular and proper maintenance.
The following section contains maintenance instructions as well as service schedules for
normal operating conditions.
The type of lubrication oil and hydraulic fluids for the some parts are dependent upon
the ambient operating temperature. Temperatures shown are defined as a daily ambient
temperatures which are consistently below the figure stated or a daily ambient
temperatures which are consistently above the figure stated.

6.3 Maintenance Schedule

Routine checks/replenishment/changes of lubricants, oils, etc. must be carried out to the
plant machinery in accordance with the lubrication and servicing schedule in order to
maintain efficiency.

(1) Regular Maintenance

NOTICE
Failure to carry out scheduled maintenance or exercise due care may invalidate
any warranty that may apply.
It is important that a strict routine of regular servicing is undertaken from the start
of operation of the plant. Keep records of all servicing and maintenance.
It is most important to keep the oil lubrication system in good order by only using
an approved lubricant of the correct grade for the prevailing conditions, changing
at the appropriate intervals and observing the filter change schedule using only
the correct pattern of replacement part.
Make sure that all the various lubrication system protection devices, as detailed
on the wiring diagram, are operating correctly.
Make sure that frequent checks are made for wear to the manganese liners and
other wearing surfaces so that replacement can be made before any damage to
other components of the crusher is sustained.
Regularly check the wedge pressure to avoid damage to the machine and to
obtain the best performance from the crusher.

(2) Daily, Weekly and Monthly Checks

All hours stated are working hours for the component concerned.

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Schedules are based on the plant operating 8 hours a day and 40 hours a week.
• Monthly = 160 hours
• Annually = 2000 hours
Adjust schedule to suit actual operating hours.

WARNING
It is imperative that the operator carries out regular and diligent checks before
operating the plant especially with operational safety in mind including, but not
limited to, those listed below.
Additionally, the operator should always consider what particular safety hazards
could occur at specific operating sites and take steps to eliminate them before
commencing work.

(3) Daily Checks

PROCEDURE
1. Check that all guarding is complete and properly secured prior to start up.
2. Check that safety signs are present and readable.
3. Check that all the plant emergency stop buttons are operative.
4. Carry out a general inspection of the machinery to check that nothing is out of place
or damaged so as to cause a safety hazard.
5. Carry out the daily lubrication and servicing Schedule.
6. Check for loose fixings and rectify. Check the security of nuts and bolts on the plant.

(4) Weekly Checks

PROCEDURE
1. Perform all checks on the daily check list.
2. Carry out the weekly lubrication and servicing schedule.
3. Check the area in and around the crusher for build-up of material. Clean out as
necessary.
4. Check drive belts for damage, wear and fraying.
5. Clean away dust, dirt and grit from maintenance platforms and any moving parts.
6. Check conveyor belts for damage and fraying.

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(5) Monthly Checks

PROCEDURE
1. Perform all checks on the daily and weekly check list.
2. Lubricate and service to the monthly requirements also attending to the longer
interval requirements as necessary.
3. Visually examine the plant for wear and damage. Renew parts as necessary.
4. Check all drive belts are at the correct tension.

6.4 Replacing Wear Parts

The wear parts on the plant must be replaced periodically to maintain optimal
performance and output. The length of time a wear part can be used depends on the
operating conditions and the material being processed.
Equipment settings, material flow rate, and quality of product output are the best guides
for determining when to replace wear parts. Refer to your Terex JW42 Jaw Crusher
Operations Manual or instructions on how and when to replace wear parts.
Periodically check conveyor belts, chutes, rubber skirts, jaw dies, and the feed box for
holes, tears, or excessive wear. An unusual pile of product next to the equipment is an
obvious clue that some adjustment or replacement is needed at the next shutdown.
Keeping a log of conditions, downtime, repairs, replacements and other maintenance
work can help identify patterns of wear and saves money by allowing you to plan
preventive maintenance during normal shutdown time.

6.5 Maintaining Jaw Crusher

DANGER
Make sure to lockout/tagout all plant power sources prior to performing any jaw
crusher maintenance. See Section 2 - Safety earlier in this manual for proper
lockout/tagout procedures.

WARNING
When removing any crusher component, such as jaw dies, make sure that the
lifting equipment has adequate capacity. Never stand under a suspended load.
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

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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. The economical maximum period will best be determined by
experience.
An inspection and maintenance program will allow the operator to determine the overall
wear rate of parts in the crusher and will indicate when worn parts should be replaced
before a major failure develops.
For complete information on maintaining the jaw crusher, refer to your Terex JW42 Jaw
Crusher Operations Manual.

6.6 Maintaining Feeder

Contact your Terex MPS distributor or service department for information on performing
complex feeder maintenance tasks.
For information on performing more common maintenance tasks, please consult your
Terex Simplicity Feeder Operations Manual.

6.7 Maintaining Bypass Chute

Generally, the only maintenance required on the plant bypass chute is to inspect for
wear, replace any worn liners or repair damaged chutework. Inspect the chute liners and
the chute curtains regularly for excessive wear. Repair or replace as required.
The majority of chute maintenance procedures can be done without actually entering
the chute, which should be avoided. Refer to the Section 2. Safety earlier in this manual
for specific safety hazards related to working in or near the bypass chute.

6.8 Maintaining Conveyor Components

During normal operation, the troughing and return idlers and the head and tail pulleys,
require minimal maintenance. Inspect conveyor idlers and pulleys regularly for material
buildup and wear. Typical conveyor maintenance includes regular adjustment and
periodic replacement of idlers, pulleys and drive components. Maintaining proper belt
alignment, tension and tracking extends the life of conveyor components.
Watch the condition of the belt wipers. Keep the wipers tight and centered on the belts.
This plant utilizes standard V-Belt drive arrangements requiring periodic inspections for
proper belt tension.
For added information on conveyor components, including maintenance procedures,
please contact the Terex Mineral Processing Systems (MPS) Service Department at
1-800-821-5600.

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(1) Adjusting Conveyor Belt

The conveyor belts are adjusted at the factory so they “track true”. That is, the belt runs
straight without rubbing any part of the conveyor frame.
When the plant arrives at the job site, the tracking might not be true due to product
loading, vibration during travel, or belt stretch. As the belt wears in, or product loading
changes, you might need to adjust the belt to keep it centered in the conveyor frame.
A properly adjusted belt provides excellent service over a long operating life. If possible,
make adjustments to the conveyor belt when it is empty.
A properly adjusted conveyor belt has the following characteristics:
• Carries product load in the center of the belt,
• Rides and fits smoothly on the idlers ((Ref: Figure 6.1)
• Runs straight in the frame,
• Accurately delivers product to the discharge or head end
• Has a slight “belly” (droop or sag) in the return loop
• Does not slip at the pulleys

Belt
Return Idler
Head Pulley

Troughing
Roll/Idler Pillow
Block
Tail Pulley

Take-Up Take-Up Bearing

Figure 6.1 Typical Conveyor Components

(2) Tensioning Conveyor Belts

WARNING
Stop the conveyor and lock out power before making any adjustments to a

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conveyor. Failure to do so could result in death or serious injury.

NOTICE
Using belt dressing on conveyor belt could result in conveyor damage. If head
pulley slips increase belt tension to prevent belt slippage.
(a) Belt Too Tight
Overtightening increases the conveyor motor's amperage draw, wasting energy and
raising the cost of operation.
When the belt is too tight, it begins to lift above the troughing rolls even when the belt is
fully loaded. This reduces the amount of product the belt can carry, and strains the
fasteners and lacing on the belt.
A quick way to determine if this condition exists is to examine the return loop. If the belt
is too tight, the return loop on the underside of the conveyor does not have enough
“belly” across the belt.
(b) Belt Too Loose
If the belt is too loose, the pulleys can slip. This reduces product-carrying capability and
causes rapid belt wear.
Adjust the belt tension at the wing (tail) pulley by turning the nuts on the end of each
take up in the direction required, moving the take-up bearings (Ref: Figure 6.2). Adjust
each side the same amount.
The take-ups must provide a belt tension great enough to prevent belt slippage on the
head pulley and must keep the tail pulley at right angles to the direction of belt travel.
This is usually the only adjustment required.

(3) Adjusting Conveyor Belt Tracking

WARNING
Stop the conveyor and lock out power before making any adjustments to a
conveyor. Failure to do so could result in death or serious injury.
The following conditions can cause the belt to track to one side.
• The conveyor is not level. Solution: level the conveyor.
• The belt ends are not square or are not spliced properly. Solution: correct the splice or
replace the belt.) Factory-installed belts are square and properly spliced.
• The belt material has significant defects or is badly worn. Solution: replace the belt.
• One or more troughing rolls or return idlers are jammed and do not turn freely.
Solution: remove material buildup from rollers. If bearings are frozen, replace them.
• One or more troughing rolls or return idlers are not square with the conveyor

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centerline. Solution: adjust the misaligned rolls or idlers.

Before attempting to change the angle of the troughing rolls or return idlers, make sure
the plant is level. Check and correct, if necessary, the belt splice and remove any
product buildup. If the belt still does not track true, adjust the angle of the troughing rolls
or return idlers as follows (Ref: Figure 6.3):
1) The belt moves to the side that contacts the return idler first. You may need to adjust
several idlers, depending on how far the belt is out of alignment. Start with the return
idler closest to the head pulley and work toward the tail pulley until the belt runs true.
Loosen the bolt on the problem side of the first return idler. Move it forward or backward,
as required, in the slotted bolt hole.
Each idler can be moved a maximum of about 0.5 in. (13 mm) on each side. To increase
the amount of adjustment on a single idler, move the other side in the opposite direction.
Be sure to retighten all the bolts. See Appendix A for standard torque values.
2) When the conveyor belt runs to one side of the frame in a local area, you can make
more adjustments by moving the troughing rolls (also called troughing idlers) forward or
backward in the slotted bolt holes. The belt moves to the side where it touches first.
Move only the troughing rolls in that particular area.
Occasionally, it may be necessary to shim the head pulley (the pulley without take-ups,
usually at the upper, or discharge end) to get true alignment.

2 D

A B 5

C C 3
E

1. Level frame crosswise. 2. Square tail pulley. 3. Check belt splice

for squareness. 4. Square all troughing and return rolls 5. Adjust individual troughing or
return rolls as needed. Important: For run-out at “D” adjust preceding roll “E”.

Figure 6.2 Conveyor Belt Training

(4) Adjusting Conveyor Return Roller Nip Guards

Procedure
1. Loosen bolts on nip guard.

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2. Adjust for .25” (6.35 mm) clearance between the guard and the return roller and the
guard and belt (Ref: Figure 6.3).
3. May need to reposition return roller for horizontal adjustment.
4. Tighten bolts to secure in place.

.25” (6.35 mm)

.25” (6.35 mm)
Clearance
Clearance

Figure 6.3 Conveyor Return Roller Nip Guard Adjustment

(5) Tightening Conveyor Bearing Collars

Some conveyor bearings may have self-locking collars (Ref: Figure 6.4). Check
bearings periodically to assure a tight shaft fit. To tighten, turn the collar in the direction
of shaft rotation using a lightweight hammer and punch inserted in the hole, as shown.
After locking the collar to the shaft, tighten the setscrew to the recommended torque
value shown in Appendix A, Torque Specification charts.

Setscrew

Figure 6.4 Tightening Bearing Collar

(6) Tightening Conveyor Bushing Bolts

Periodically check the tightness of the conveyor bushing bolts (Ref: Figure 6.6). These

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can loosen during transport or use. If the pulley moves on the shaft, it could cause the
belt not to track, possibly even damaging the pulley, shaft, or conveyor frame. Make
sure that these bolts are torqued (dry-fastener torque) to the following specifications.
Figure 6.5 Hub Model Flange Diameter and Bolt Torque
Hub Model Flange Diameter Bolt Torque
(Inches) (ft lbs)
XT25 4-7/16” 29
XT30 5-5/16” 46
XT35 6-5/16” 70
XT40 7-1/8” 100

Periodically check the bolt

tightness on the pulley bushings

Figure 6.6 Check Conveyor Pulley Bushings

6.9 Lubrication

WARNING
Never attempt to lubricate or maintain the crusher until flywheels are stopped and
machine power is locked out.
The greatest single factor governing the life and efficiency of any piece of machinery,
where friction is encountered, is proper lubrication. While it is generally known that
insufficient lubrication will enable friction to reduce the efficiency and service life of key
parts, it is also true that the presence of too large a quantity of grease in a bearing
housing usually results in high operating temperatures and subsequent loss of
efficiency.
Cleanliness in the handling of lubricants, fittings, grease guns and the openings and
plugs of housings is of vital importance. Foreign substances contaminate lubricant. Be
sure that all fittings and openings are thoroughly cleaned of all foreign substances
before starting to inject lubricant. In using the grease gun always see that the gun

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makes proper contact with the cleaned fittings and that the nozzle has not been allowed
to touch unclean surfaces.
After removing the grease gun, there will a light layer of grease left on top of the nipple.
Do not wipe this excess grease away until just before the next application of grease. It
forms a very effective dust seal for the nipple.

6.10 Lubricating Stored Equipment

Idle equipment whether new or used; must be turned over at least every 30 days either
by power or hand to redistribute the lubricant. Rotating the bearing assemblies
periodically redistributes lubricant on all surfaces of the bearing.
Failure to rotate bearings when crusher is idle will permit lubricant to drain to the bottom
of the bearing assembly. Moisture from condensation could collect and set up a
chemical reaction in the bearing assemblies know as corrosive staining. These stained
areas are a positive point for premature bearing failures, as flaking will start at these
points when the equipment is put back into operation

6.11 Grease Points

NOTICE
To deliver the specified quantity of grease to shaft bearings, determine the
amount of grease the gun will deliver with each “pump”. Do not grease or assume
an amount. Check the greasing equipment used regularly.
Do not mix greases. The blend can have a lower specification than an individual
grease and can lead to premature bearing failure. Regular lubrication of the plant
in accordance with the Lubrication and Servicing Schedule is essential.
To prevent contamination of the grease lines, all grease nipples must be wiped
with a clean rag prior to applying the grease gun.
Failure to comply with these notices could result in equipment damage.
If a seal on a bearing breaks, or the bearing is otherwise damaged, replace it as soon as
possible. Grease the bearing more frequently until the next scheduled shutdown when
bearing or seal replacement can be performed.
Bearings that are not factory sealed should be greased as needed until grease zerks
show excess. This plant is equipped with grease extension hoses allowing all grease
points to be serviced from platforms or at ground level.
(a) Jaw Crusher Grease Points
The jaw crusher can be remotely greased at two locations. For information on greasing
the Terex JW42 jaw crusher, please consult your Terex Jaw Crusher Operations
Manual.

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(b) Undercrusher Conveyor Grease Points

The undercrusher conveyor needs to be periodically greased in two locations on both
conveyor sides (Ref: Figure 6.14).

Figure 6.7 Undercrusher Conveyor Grease Points (Both Sides)

6.12 Checking Conveyor Gear Box Oil Levels

The proper oil level must be maintained at all times. Inspect frequently with the unit not
running. Remove level plug to check oil level. Allow sufficient time for oil to cool and
entrapped air to settle out of oil before inspecting.
If low, add the proper type and viscosity of lubricant through one of the upper openings
until it comes out of the oil level hole. Replace the oil level plug securely.

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NOTICE
Angle must not exceed 20º for accurate oil level indication. Adjust or disconnect
torque arm to allow for accurate reading. Fill speed reducer with appropriate gear
oil. Failure to comply with this notice could request in equipment damage.

2 1

Figure 6.8 Gear Reducer Oil Check Angle

1. Breather 2. Oil Level Plug 3. Drain 4. Plug

After an initial operation of about two weeks, the oil should be changed. If desired, this
oil may be filtered and reused. Very often, small metal particles will show up in the oil
due to the wearing in process. After the initial break in period, the lubricant should be
drained, magnetic drain plug cleaned, gear case flushed and refilled annually under
average industrial conditions.
More frequent oil changes are recommended when operating continuously or at high
temperatures or under conditions of extreme dirt or dust. Under these extreme operating
conditions, the oil should be changed every three (3) months.

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