1. PAINPOINT DRIVEN OPENING

Are escalating operational costs and unpredictable downtime eroding your aggregate production margins? For plant managers and engineering contractors, the core of these challenges often originates at the primary crushing stage. Common pain points include:

Unscheduled Downtime: Frequent mechanical failures and lengthy component changes halt your entire processing line, costing thousands per hour in lost production and labor.
Excessive Wear Costs: Abrasive feed material rapidly degrades crusher liners and wear parts, leading to high consumable expenses and frequent maintenance windows.
Inconsistent Output & Product Shape: Variable feed size or hardness results in poor yield control and substandard product gradation, reducing the value of your final aggregate.
High Energy Consumption: Inefficient crushing chambers and drives consume excessive power, making energy one of your largest, most volatile operational costs.
Safety & Operational Complexity: Manual adjustment processes and inaccessible service points increase risk for your crew and extend routine maintenance time.

Is your primary crusher a constant source of reactive maintenance rather than a reliable foundation for your operation? The solution lies in selecting a machine engineered not just to crush rock, but to crush your operational costs.

2. PRODUCT OVERVIEW: COMMERCIAL JAW CRUSHER

A commercial jaw crusher is a heavyduty, compressiontype primary crusher designed to reduce large, quarried rock (up to 1.5m in size) into manageable feed for secondary processing. Its robust design is built for continuous, hightonnage operation in stationary plants or largescale mobile setups.

Operational Workflow:
1. Feed Intake: Large dump trucks deposit runofquarry rock into the vibratory grizzly feeder, which bypasses subsize material and directs oversize to the crusher.
2. Compression Crushing: The rock enters the fixed Vshaped chamber between a stationary jaw die and a moving jaw die. The moving jaw exerts immense mechanical pressure, fracturing the rock against the stationary surface.
3. Discharge Setting Adjustment: The crushed material exits at the bottom opening. The size of this closedside setting (CSS) is hydraulically adjustable to precisely control final product top size without stopping the machine.
4. Product Conveyance: Crushed material is discharged onto a main conveyor belt for transport to the next stage of screening or secondary crushing.

Application Scope & Limitations:
Scope: Ideal for primary reduction of hard abrasive materials (granite, basalt, quartzite), mediumhard stone (limestone, sandstone), and recycled concrete/asphalt.
Limitations: Not suitable for sticky, plasticclay materials that may cause chamber packing. Maximum reduction ratios are typically 6:1 to 8:1, making secondary crushing necessary for most fine aggregate specifications.

3. CORE FEATURES

Deep Crushing Chamber & Aggressive Nip Angle | Technical Basis: Kinematic geometry of swing jaw motion | Operational Benefit: Enables higher throughput capacity per stroke and effective grip on slabby material | ROI Impact: Increases potential revenue output by 1015% within same machine footprint

HeavyDuty Fabricated Steel Frame with StressRelieving | Technical Basis: Finite Element Analysis (FEA) optimized design with postweld heat treatment | Operational Benefit: Provides exceptional durability against shock loads and fatigue over a 20+ year lifespan | ROI Impact: Eliminates risk of catastrophic frame failure; protects longterm capital asset value

Hydraulic Toggle Adjustment & Clearing System | Technical Basis: Dualacting hydraulic cylinders replace traditional mechanical toggle plates | Operational Benefit: Allows remote adjustment of CSS for product control and automatic clearing of chamber blockages in minutes | ROI Impact: Reduces downtime for settings changes by over 80% versus manual systems

QuikChange Jaw Die Wedge System | Technical Basis: Mechanically locked wedge design for liner retention | Operational Benefit: Enables safe, fast replacement of manganese jaw dies without backing material or resin pouring | ROI Impact: Cuts liner changeout time by half, increasing plant availability

HighInertia Flywheels & Robust Eccentric Shaft | Technical Basis: Balanced rotational mass energy storage | Operational Benefit: Smoothes peak power demands, maintains momentum under load fluctuations for consistent crushing action | ROI Impact: Reduces cyclical stress on drive motor, lowering energy costs by 57% and extending component life

Integrated Dust Suppression & Water Spray System | Technical Basis: Manifold with nozzles targeting feed entry and discharge points | Operational Benefit: Effectively controls airborne particulate at source for compliance with site health regulations | ROI Impact: Mitigates risk of regulatory fines and reduces housekeeping labor

Centralized Automated Greasing System | Technical Basis: Programmable pump delivering precise grease volume to all key bearings | Operational Benefit: Ensures optimal bearing lubrication without manual intervention during operation | ROI Impact: Prevents premature bearing failure; field data shows a 40% extension in bearing service intervals.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (Average) | Our Jaw Crusher Solution | Advantage (% Improvement) |
| : | : | : | : |
| Liner ChangeOut Time (Jaw Dies) | 1224 hours (mechanical/welded) | 68 hours (QuikChange Wedge) | ~50% faster |
| Availability (Uptime %) Over 12 Months| ~8590% (including adjustments/stoppages)| >94% (documented field average) |>45 percentage points |
| Specific Energy Consumption (kWh/tonne)| Varies; baseline = 100%| Documented average reduction to ~93%| ~7% more efficient |
| Wear Life of Jaw Dies (Abrasive Granite)| Based on standard manganese grade| Upgraded Manganese Steel Alloy available| +1520% extended life |

5. TECHNICAL SPECIFICATIONS

Model Designation: JC1500HD
Feed Opening: 59” x 47” (1500mm x 1200mm)
Maximum Feed Size: Up to 47” (1200mm) edge length
Closed Side Setting Range: 6” – 12” (150mm – 300mm)
Capacity Range (@ CSS): 550 – 950 STPH (500 – 860 MTPH), dependent on material type & feed gradation.
Drive Power Requirement: Tier IV Final / Stage V compliant dieselelectric or direct electric drive options available.
Crusher Drive Power: Up to 400 HP /300 kW electric motor.
Total Weight (Crusher Only): Approximately ~125,000 lbs (~56,700 kg).
Key Material Specifications: Main frame fabricated highyield strength steel; Jaw dies premium manganese steel alloy; Eccentric shaft forged alloy steel; Bearings spherical roller type.
Environmental Operating Range: Designed for ambient temperatures from 20°C to +45°C (4°F to +113°F). Enclosed lubrication system with heating/cooling options available.

6. APPLICATION SCENARIOS

Hard Rock Quarry Expansion Project

Challenge A granite quarry needed to increase primary circuit throughput by over 30% without expanding their plant footprint or primary feed conveyor infrastructure.
Solution Implementation of our JC1500HD jaw crusher with its deepchamber design allowed processing larger average feed size at a higher tonnage rate within existing civils.
Results Plant achieved a sustained throughput increase of 32%. The hydraulic adjustment system enabled operators to optimize CSS daily based on blast fragmentation data.

HighAbrasion Aggregate Processing

Challenge A producer processing highly abrasive trap rock faced excessive wear costs from other OEMs’ components requiring liner changes every six weeks at significant cost/downtime.
Solution Our jaw crusher was specified with optional premiumgrade manganese alloy jaws combined with an automated greasing system ensuring perfect bearing alignment under load.
Results Wear part life extended by an average of three weeks per set (+22%). Combined with faster changeout times total annual availability increased by approximately five days.

Recycled Concrete Aggregate Production

Challenge A contractor required reliable primary crushing capable handling large reinforced concrete slabs while managing tramp metal risks minimizing damage from uncrushable objects like rebar mats
Solution The JC series’ hydraulic toggle system was critical allowing automatic release clearing uncrushable objects protecting main components from overload damage
Results Zero incidents major structural damage due tramp metal over twoyear period Unplanned stoppages cleared typically under five minutes maintaining high utilization rates

7. COMMERCIAL CONSIDERATIONS

Our commercial jaw crushers are offered through flexible models designed meet varying budgetary operational needs:

Pricing Tiers:
Base Configuration Includes core crusher drive motor basic lubrication system standard manganese jaws
HighProduction Package Adds hydraulic adjustment/clearing automated greasing upgraded premium jaws integrated water spray
Turnkey SkidMounted Unit Crusher premounted on heavyduty skid complete with integrated feeder discharge conveyor walkways ladders electrical starters ready connect power source

Optional Features Premium alloy wear parts extended warranty coverage remote monitoring telematics package dust enclosure kits cold climate packages (30°C)

Service Packages:
Standard Warranty Comprehensive parts labor coverage first twelve months operation includes commissioning supervision
Planned Maintenance Contracts Fixed annual cost covering scheduled inspections lubrication consumables condition monitoring reporting priority technical support
FullService Agreements Covers all scheduled unscheduled maintenance including wear parts providing predictable cost per tonne crushed over multiyear term

Financing Options Available through our partners include capital lease operating lease leasetopurchase structures tailored match project cash flow timelines typical terms range three seven years

8. FAQ

What are my power connection options? Units can be configured direct electric drive requiring highvoltage plant connection or as dieselelectric hybrid standalone unit ideal greenfield sites lacking established grid power reducing initial infrastructure cost

How does this machine handle variations feed material hardness? The combination highinertia flywheels robust eccentric shaft allows machine absorb shock loads maintain consistent throughput even when transitioning between softer harder stone layers within same face minimizing need operator intervention adjusting feeder rates frequently

What typical lead time delivery installation? For standard configurations lead time averages sixteen twenty weeks exworks Commissioning installation supervised our engineers typically requires five ten working days depending site readiness complexity

Are wear parts readily available globally? Yes We maintain regional inventory hubs North America Europe AsiaPacific ensuring critical wear components like jaw dies available express shipment minimize any potential logisticsrelated downtime Most common parts stocked locally our dealer network

Can existing plant controls integrate new crusher’s automation systems? Yes Our control system designed communicate via standard industrial protocols Modbus TCP/IP OPC UA allowing seamless integration into your central SCADA plant management system providing operators realtime performance data alarm notifications directly familiar interface