1. PAINPOINT DRIVEN OPENING

Are escalating maintenance costs and unplanned downtime eroding your aggregate production margins? Inconsistent feed size, abrasive materials, and the relentless demand for higher throughput create a cascade of operational challenges for plant managers. These issues directly impact your bottom line: excessive wear part replacement, costly hourly labor for adjustments, and production shortfalls that delay project timelines and contract fulfillment.

Are you currently managing:
Premature Wear Failure: Are you replacing liners, mantles, or jaws more frequently than the OEM projected lifespan, leading to high consumable costs and frequent stoppages?
Throughput Bottlenecks: Is your current crushing circuit unable to process peak feed volumes or handle varying material hardness without causing downstream delays?
Product Quality Inconsistency: Are you facing challenges in maintaining a consistent product gradation, leading to rejected loads or the need for reprocessing?
High Operational Complexity: Does your equipment require constant manual monitoring and adjustment to maintain performance, tying up skilled labor?

A robust primary crushing station is the foundation of any efficient operation. The right jaw crusher must not only withstand punishment but also optimize the entire flow of material to your secondary and tertiary circuits.

2. PRODUCT OVERVIEW: HEAVYDUTY JAW CRUSHER

This product is a stationary heavyduty jaw crusher engineered for primary crushing applications in quarrying, mining, and largescale construction recycling. It is designed to accept large feed material (up to 1200mm) and reduce it to a consistent, manageable size for subsequent processing stages.

Operational Workflow:
1. Feed Intake: Large shot rock or runofquarry material is loaded into the vibratory grizzly feeder, which bypasses subsize material and directs only oversize to the crusher.
2. Crushing Action: Material enters the aggressive crushing chamber where a steep nip angle and high inertia elliptical jaw motion apply compressive force to break rock.
3. Discharge & Clearance: Crushed material exits through a hydraulically adjustable closed side setting (CSS), ensuring precise control over final product size. An automatic toggle tensioning and clearing system protects the unit from tramp metal.

Application Scope & Limitations:
Scope: Ideal for hard rock (granite, basalt), abrasive ores, and reinforced concrete demolition debris. Serves as the primary reduction unit in fixed plant configurations.
Limitations: Not designed for wet, sticky materials without prior scalping. Requires a stable concrete foundation and significant upfront capital investment compared to mobile units.

3. CORE FEATURES

Deep Crushing Chamber & Aggressive Nip Angle | Technical Basis: Kinematic geometry of moving jaw | Operational Benefit: Increased capacity per stroke and reduced bridging; draws material into the crushing zone effectively | ROI Impact: Higher throughput with same footprint reduces costperton; fewer operator interventions for clearing

Hydraulic Toggle Adjustment System | Technical Basis: Dualacting hydraulic cylinders replace traditional mechanical toggle plates | Operational Benefit: Enables remote adjustment of CSS for product sizing and provides automatic uncrushable release in seconds | ROI Impact: Eliminates manual shim adjustments, saving hours of downtime; prevents major damage from tramp metal

HeavyDuty Fabricated Steel Frame | Technical Basis: Stressrelieved steel plate construction with finite element analysis (FEA) optimization | Operational Benefit: Provides exceptional structural integrity under high cyclic loads, minimizing frame fatigue and alignment issues | ROI Impact: Extends operational life of core structure beyond 20+ years under normal conditions

WedgeLock Jaw Die Retention System | Technical Basis: Mechanically locked wedges secure jaw plates without backing resin | Operational Benefit: Allows fast, safe die changes with standard tools; eliminates hazardous resin heating/pouring | ROI Impact: Reduces liner changeout time by up to 50%, increasing plant availability

Integrated Motor Base & Belt Guard | Technical Basis: Unified baseplate design incorporating crusher, drive motor, and sheaves | Operational Benefit: Ensures permanent Vbelt alignment; reduces vibration transmission; enhances overall site safety | ROI Impact: Prolongs belt life by up to 30% and reduces maintenance checks

Centralized Greasing Point | Technical Basis: Labyrinth seal protection fed from a singlepoint manifold | Operational Benefit: Allows complete bearing lubrication in under 10 minutes from ground level during routine stops | ROI Impact: Standardizes preventive maintenance, ensuring bearing longevity and preventing costly failures

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard | This Jaw Crusher Solution | Advantage (% improvement) |
| : | : | : | : |
| Liner ChangeOut Time (Jaw Dies) | 1216 hours (mechanical shims/resin) | 68 hours (hydraulic wedge system) | 50% faster |
| Total Cost of Ownership (5year estimate) Based on Wear Parts & Downtime| Baseline (100%)| Estimated 1525% reduction| Up to 25% lower |
| Throughput Capacity (Hard Granite) at Same CSS| Baseline (100%)| +1015% due to chamber geometry & kinematics| Up to 15% higher |
| Bearing Life Expectancy Under Peak Load| ~12,000 hours with optimal greasing| ~16,000 hours with forcedfeed lubrication & alignment| ~33% longer |

5. TECHNICAL SPECIFICATIONS

Model Designation: JC1208HD
Feed Opening: 1200mm x 800mm
Maximum Feed Size: 1000mm lump
Recommended Closed Side Setting Range: 150mm 250mm
Capacity Range (Varies by Material): 450 750 MTPH
Drive Power Requirement: 150 kW (200 HP) electric motor
Crusher Weight (excluding motor & base): Approximately 48,000 kg
Key Material Specifications: Main frame – ASTM A36 Steel; Jaw dies – AR400 manganese steel; Shaft – forged alloy steel EN24.
Physical Dimensions (L x W x H): ~4.2m x 3.8m x 3.5m
Environmental Operating Range: Designed for ambient temperatures from 20°C to +45°C.

6. APPLICATION SCENARIOS

Granite Quarry Expansion Project

Challenge: An existing quarry needed to increase primary circuit output by over 30% without expanding its primary crusher footprint or foundation.
Solution Implementation of our JC1208HD jaw crusher with its deepchamber design replaced an older model of similar physical size.
Results Throughput increased by an average of 35%. The hydraulic toggle system allowed quick daily CSS checks without stopping production entirely.

Urban Construction & Demolition Recycling Hub

Challenge Processing heavily reinforced concrete foundations produced excessive tramp metal incidents causing weekly shutdowns on their previous crusher.
Solution A JC1208HD was installed with its automatic hydraulic release system set at a conservative pressure threshold.
Results The system activated seven times in the first month releasing rebar bundles each event resulted in less than two minutes of downtime compared to previous halfday repairs No major component damage was sustained

7 COMMERCIAL CONSIDERATIONS

Equipment pricing is structured into three standard tiers based on configuration:

1. Base Unit Tier Includes crusher fabricated base motor sheaves vbelts guards Standard manganese jaw dies are quoted separately as wear parts
2 Premium Package Tier Base unit plus automated grease system hydraulic power pack for toggle adjustment spare part starter kit Discounted wear parts contract available
3 Turnkey Skid Tier Crusher preassembled on a heavyduty transportable skid including feeder scalping screen walkways access platforms Requires site connection only Financing Options Capital lease operating lease or loan structures can be arranged through partners Typical terms range from months Service Packages Annual inspection packages extended warranty on major components guaranteed wear part performance rates are offered Optional Features Dust suppression spray systems special alloy liners remote monitoring telematics package

8 FAQ

What power supply is required for this jaw crusher? The unit requires a kV AC supply suitable for a kW motor Variable frequency drives can be accommodated but must be specified at order

Can this crusher handle slag or other abrasive materials? Yes but we recommend specifying our Xtralloy premium manganese liners which field data shows can improve wear life by over in highly abrasive applications compared to standard manganese

What is the lead time from order to shipment? For standard configurations lead time is typically weeks Custom configurations may require additional engineering time

Do you provide installation supervision? Yes we offer technical commissioning support This service includes foundation drawing verification initial startup supervision operator training documentation handover

Are your machines compatible with existing conveyor systems? Our engineering team can review your existing discharge height conveyor specifications We provide detailed interface drawings as part of our predelivery documentation