1. PAINPOINT DRIVEN OPENING

Are escalating operational costs and unpredictable downtime eroding your aggregate production margins? For plant managers and engineering contractors, the core challenges in primary crushing often manifest in three critical areas:

Unscheduled Downtime: Frequent mechanical failures, particularly in bearings and frames under shock loads, halt entire processing lines. Industry data indicates an average of 1520% production loss can be attributed to crusherrelated stoppages.
Rising Cost Per Ton: Premature wear part replacement, high energy consumption from inefficient crushing chambers, and excessive maintenance labor directly increase your cost per ton of finished aggregate.
Inconsistent Output & Product Shape: An inability to adapt to variable feed materials leads to poor product gradation and suboptimal yield of highvalue chips, impacting downstream process efficiency and final product marketability.

Is your primary crushing station a source of constant concern rather than a pillar of reliability? The solution requires equipment engineered not just for peak performance, but for sustained operational integrity under continuous punishment.

2. PRODUCT OVERVIEW

The Certified Top Ten Jaw Crusher is a heavyduty, singletoggle primary crusher engineered for the first stage of size reduction in quarrying, mining, and demolition recycling applications. Its design focuses on delivering maximum productivity with minimum operational risk.

Operational Workflow:
1. Feed Intake: Large runofmine material (up to 80% of crusher gape) is loaded into the vibrating grizzly feeder (optional), which bypasses fines to increase effective capacity.
2. Crushing Cycle: The robust singletoggle mechanism drives a moving jaw in an elliptical motion against a fixed jaw, applying compressive force to fracture the rock.
3. Discharge & Setting Adjustment: Crushed material exits through the bottom discharge opening. The closedside setting (CSS) is hydraulically adjustable for rapid product size changes without manual shim manipulation.

Application Scope: Ideal for processing hard abrasive materials like granite, basalt, and iron ore as a stationary or mobile primary unit. Limitations include processing highly plastic or claybound materials without prior screening/scalping.

3. CORE FEATURES

HEAVYDUTY WELDED FRAME | Technical Basis: Finite Element Analysis (FEA) optimized highgrade steel fabrication | Operational Benefit: Eliminates stress cracking under high cyclic loads, ensuring longterm structural integrity | ROI Impact: Reduces risk of catastrophic frame failure, extending machine service life beyond 20+ years with proper maintenance

HYDRAULIC TOGGLE ADJUSTMENT SYSTEM | Technical Basis: Integrated hydraulic cylinder for tensioning and setting adjustment | Operational Benefit: Enables safe, remote CSS adjustment in minutes versus hours required for manual shim systems | ROI Impact: Minimizes nonproductive downtime for product changes by up to 90%, increasing plant flexibility

OPTIMIZED CRUSHING CHAMBER PROFILE | Technical Basis: Deep symmetrical chamber design based on kinematic dynamics simulation | Operational Benefit: Promotes interparticle crushing, increases throughput by 1015%, and produces a more cubical product shape | ROI Impact: Higher yield of premiumgrade aggregate and reduced recirculating load lowers cost per ton

DUALPATH LUBRICATION SYSTEM | Technical Basis: Independent grease lines to swing jaw bearings and central automatic lubrication option | Operational Benefit: Ensures positive lubrication to critical wear points under all operating angles and conditions | ROI Impact: Extends bearing service life by an average of 35%, reducing spare parts inventory cost

REVERSIBLE MANGANESE JAW DIES | Technical Basis: Highstrength alloy steel jaws with multiple tooth profiles available | Operational Benefit: Allows rotation/swap of dies to utilize full wear material, increasing utilization by nearly 100% | ROI Impact: Directly reduces wear part expenditure by optimizing consumable usage

INTEGRATED MOTOR BASE & BELT GUARD | Technical Basis: Unified chassis design incorporating drive motor mounting and OSHAcompliant guarding | Operational Benefit: Simplifies installation, enhances site safety, and protects drive components from debris | ROI Impact: Reduces installation time/cost by approximately 25% and mitigates safetyrelated incident risk

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard Average | Certified Top Ten Jaw Crusher Solution | Advantage (% Improvement) |
| : | : | : | : |
| Availability (Uptime) | 8892% per annum| >95% per annum (documented) |> 4% improvement |
| Wear Life (Jaw Dies Abrasive Rock) | 120,000 150,000 tons| 180,000 220,000 tons |> +40% improvement |
| Energy Efficiency (kWh/ton) Varies by material| Baseline = 100%| Documented reduction to ~87% of baseline |>13% improvement |
| CSS Adjustment Time (Mechanical to Hydraulic)| 24 hours| ~95% improvement |
| Noise Emission at 1 Meter| ~110 dBA| Significant reduction for permit compliance |

5. TECHNICAL SPECIFICATIONS

Model Range Capacity: From 200 MTPH to over 1,200 MTPH, dependent on feed material density and crushability.
Feed Opening Range: From 800mm x 500mm up to 1500mm x 1200mm.
Power Requirement: Electric motor drives from 75 kW up to 200 kW; configured for standard industrial voltages (400V/50Hz or 480V/60Hz).
Material Specifications: Main frame constructed from S355J2+ grade steel; jaw dies from Mn18Cr2 or Mn22Cr2 alloy; shaft from forged 42CrMo4 steel.
Physical Dimensions (Typical Model): Approximate footprint of 4m (L) x 3m (W) x 3m (H); weight approx. 28 metric tons.
Environmental Operating Range: Designed for ambient temperatures from 20°C to +45°C; dust and weatherprotected bearings and electricals.

\Throughput capacities are based on standard crushed granite with bulk density of 1.6 t/m³.

6. APPLICATION SCENARIOS

Granite Quarry Expansion Project

Challenge A contractor needed to increase primary crushing capacity by 40% within a fixed plant footprint while maintaining strict product shape specifications for asphalt chips.
Solution Installation of one Certified Top Ten Jaw Crusher with an optimized deepchamber profile replaced two older units.
Results Throughput increased by 45%. Product cubicity improved by 18%, enhancing downstream screening efficiency. The singleunit solution reduced planned maintenance hours by 30%.

Urban Demolition Waste Recycling

Challenge A recycling plant faced excessive downtime due to uncrushable metals entering the chamber from mixed C&D waste feeds.
Solution Implementation of the Certified Top Ten Jaw Crusher equipped with an automatic hydraulic toggle release system.
Results The system automatically releases tramp metal within seconds without stopping the feed conveyor or causing damage. This reduced uncrushablerelated stoppages by over 95%, protecting downstream equipment.

7. COMMERCIAL CONSIDERATIONS

Pricing Tiers: Configured across three tiers—Base Configuration (core crusher only), PlantReady Configuration (with motor base/vbelts/guards), Turnkey Skid Package (fully mounted with feeder/discharge conveyor).
Optional Features: Automatic Greasing System (AGS), Hydraulic Jacking Legs for liner changes, Wear Monitoring Systems via IoT sensors (subscription service), Sound Abatement Enclosures.
Service Packages: Choose from Bronze (parts only) , Silver (parts + scheduled maintenance) , or Gold (full coverage including wear parts & field service) annual support agreements.
Financing Options: Available through partner institutions including equipment leasing (3660 months), rentaltoown programs tailored for projectbased work.

8. FAQ

Q1 Is this jaw crusher compatible with my existing secondary cone crusher setup?
A1 Yes. Its deepchamber design promotes interparticle crushing which produces a wellgraded feed ideal for secondary cone crushers. Our engineering team can review your current flow sheet to ensure optimal feed size distribution matching.

Q2 What is the expected impact on my overall plant energy consumption?
A2 Field data shows that due to its optimized kinematics and efficient drive design this jaw crusher typically operates at 8792% of the energy draw compared to older generation units performing the same task reducing overall plant load

Q3 How does the warranty structure work?
A3 We offer a standard 24month / 5，000 operating hour warranty on all major structural components against defects A separate warranty applies to wear parts based on consumed tonnage thresholds

Q4 What training is provided for our operations team?
A4 Every delivery includes comprehensive onsite operational training covering safe startup/shutdown procedures daily checks CSS adjustment troubleshooting basic fault codes Maintenance training modules are available as part of our service packages

Q5 Can you provide performance guarantees?
A5 Yes Performance guarantees for throughput power consumption and wear life are contractually provided based on certified thirdparty testing results using your specified sample material prior purchase