A jaw crusher is a primary crushing machine used in various industries for breaking down large rocks into smaller, more manageable sizes. It is a key piece of equipment in crushing operations, playing a crucial role in the initial stages of material processing. Jaw crushers are designed to handle a wide range of materials, from hard rock to softer substances, making them versatile tools in industries such as mining, construction, and demolition.
- Description
- Specifications
- Installation
- Maintenance
- Replacement Parts
- Q&A
- Advantages and Disadvantages
- Applications
- Downloads
- Drawings
Description
Introduction to Jaw Crusher
A jaw crusher is a powerful machine used to break down large rocks and materials. It consists of two main components: a fixed jaw and a movable jaw. These components form a V-shaped chamber that allows for efficient crushing. The movable jaw exerts force on the material, pressing it against the fixed jaw. This action reduces the size of the material, making it more suitable for further processing. The crushing process is integral to industries like mining, construction, and recycling. By efficiently reducing large materials into smaller, more manageable pieces, jaw crushers help ensure that further processing, such as sorting or refining, can occur more easily.
Components of a Jaw Crusher
The fixed jaw serves as a stationary component in the jaw crusher’s design. It is designed to remain in place while the movable jaw moves back and forth. This fixed jaw provides a surface where the material is crushed. On the other hand, the movable jaw is attached to a swinging mechanism. It moves in a back-and-forth motion, applying pressure to crush the material against the fixed jaw. The movable jaw plays a key role in reducing the size of the material. This design makes the jaw crusher highly effective at compressing and breaking down the hardest materials.
The Role of the Toggle Plate and Eccentric Shaft
A toggle plate connects the movable jaw to the rest of the crusher’s structure. It ensures the proper movement of the jaw during the crushing process. The toggle plate also helps in maintaining the jaw’s position during operation. The eccentric shaft is another crucial part of a jaw crusher. It is responsible for the rotation of the movable jaw. By converting input power into a crushing motion, the eccentric shaft enables the effective breakdown of material. The constant motion of the eccentric shaft ensures that the material is repeatedly compressed and crushed until it reaches the desired size.
Importance of Bearings and Flywheel
Bearings in the jaw crusher support the movable jaw, minimizing friction during operation. These bearings contribute to the smooth movement of the jaw, increasing the machine’s efficiency. The flywheel is another important component. This heavy wheel stores energy and smoothens the crushing process. It helps maintain a consistent speed and momentum, ensuring efficient operation throughout the crushing cycle. The flywheel also plays a role in balancing the forces exerted on the machine during operation, reducing strain on other parts and improving the overall reliability of the system.
Function of the Adjustment Mechanism
An adjustment mechanism is used to modify the size of the crushed material. This mechanism can be manual or hydraulic, depending on the design of the crusher. By adjusting the mechanism, operators can control the size of the output material, ensuring it meets specific requirements. This adjustability is important for industries that require different sized material outputs, as it allows for flexibility in the crushing process. Adjusting the discharge opening provides an effective way to fine-tune the final product to ensure it fits the needs of various applications.
How Jaw Crushers Work
The primary purpose of a jaw crusher is to reduce the size of large rocks or materials. This reduction is achieved through a crushing mechanism where the movable jaw moves back and forth. As it moves, the movable jaw exerts pressure on the material, breaking it down against the fixed jaw. This action creates smaller pieces that can be processed further. The crushing action in the jaw crusher allows for the efficient reduction of even the toughest materials. It is particularly useful in primary crushing stages where larger pieces of material must be broken down into manageable sizes.
The Significance of Feed and Discharge Openings
The size of the material that enters the jaw crusher is determined by the feed opening. Larger rocks need to be broken down before entering the chamber. The feed opening ensures that only appropriately sized material enters the crushing chamber. Once the material is in the chamber, the movable jaw works to crush it against the fixed jaw. The feed opening design is essential for ensuring efficient material flow and optimizing the crushing process.
The discharge opening is a vital aspect of a jaw crusher’s functionality. It controls the size of the material that exits the machine after being crushed. By adjusting the discharge opening, operators can ensure the final product has the desired dimensions. Customizing the size of the output material allows jaw crushers to meet the specific needs of various industries. Proper management of both the feed and discharge openings ensures that the jaw crusher operates efficiently, maximizing its capacity and performance.
Jaw Crushers, Maximizing Efficiency and Capacity
Efficiency and capacity are key factors in the design of jaw crushers. These machines are designed to maximize both aspects. They continuously crush incoming material while maintaining a consistent output size. This ensures high productivity in operations that require the constant processing of large quantities of material. Jaw crushers are designed to handle a wide range of material types, from softer materials like limestone to harder materials such as granite. This versatility ensures that they are suitable for a wide variety of industries and applications.
Applications of Jaw Crushers
Jaw crushers are widely used in mining operations to crush hard rock ores. These ores are then further processed to extract valuable minerals and metals. In construction, jaw crushers are used to process construction debris and materials like concrete. These materials are crushed and recycled for reuse in new projects. The demolition industry also benefits from jaw crushers, which are used to break down structures and concrete into manageable pieces. Jaw crushers have become essential in urban demolition projects, where large amounts of concrete and steel need to be broken down.
Jaw Crushers in the Quarrying Industry
The quarrying industry relies heavily on jaw crushers to process large rocks and stones. These materials are extracted from quarries and then crushed into smaller sizes for construction and other purposes. Jaw crushers are also essential in the recycling industry. They crush and process materials such as concrete, asphalt, and demolition waste. These materials are then reused, reducing the need for new raw materials and minimizing environmental impact. The role of jaw crushers in recycling has become increasingly important as sustainability becomes a central focus in many industries.
Key Features of Jaw Crushers
Jaw crushers offer numerous features that enhance their functionality. The robust design and construction allow them to withstand heavy-duty use in demanding environments. Additionally, the simple mechanism ensures ease of operation and maintenance. These features make jaw crushers highly reliable and suitable for various industrial applications. Their simple design reduces the need for extensive training for operators and minimizes downtime, making them an efficient choice for many industries.
Another significant feature is the adjustability of the output size. By controlling the discharge opening, operators can adjust the final product’s size to meet specific needs. This flexibility is crucial for applications requiring a wide range of material sizes. Jaw crushers provide this adjustability while maintaining the machine’s overall performance and efficiency.
Moreover, jaw crushers often feature a flywheel that stores energy. This helps smoothen the crushing process by maintaining a consistent speed. The flywheel also minimizes energy loss during operation, increasing overall efficiency. The combination of energy storage and smooth operation enhances the performance of jaw crushers, especially in high-output applications.
Benefits of Using Jaw Crushers
One of the key advantages of the crushers are their versatility. They are capable of handling a wide range of materials, making them indispensable in various industries. Whether for mining, construction, or recycling, jaw crushers are adaptable to different materials and tasks. This versatility allows companies to use the same machine for multiple purposes, maximizing its utility and reducing the need for additional equipment.
Durability and Efficiency of Jaw Crushers
Another benefit is the efficiency of jaw crushers. They are designed to crush large rocks and materials in a single pass, significantly reducing material size. This single-pass crushing is both time and cost-efficient, allowing for quicker operations. Jaw crushers are also highly durable machines. Their robust construction ensures that they can withstand heavy-duty use in demanding environments. This durability guarantees long-term reliability and reduces the need for frequent maintenance. Their longevity makes jaw crushers a wise investment for companies in need of reliable crushing solutions.
The Advantage of Adjustable Output Size
Adjustability is another advantage of jaw crushers. The ability to modify the size of the crushed material makes them highly customizable. Whether the application requires smaller or larger pieces, the adjustment mechanism ensures the desired outcome. This flexibility makes jaw crushers a valuable tool in various applications, from mining to recycling. Operators can fine-tune the machine to meet specific project requirements, improving efficiency and output consistency.
Cost-Effectiveness of Jaw Crushers
Jaw crushers are also known for their cost-effectiveness. They provide a high level of productivity while keeping maintenance costs low. Their simple design and robust construction contribute to lower operational costs over time. The combination of low maintenance and high efficiency makes jaw crushers an excellent investment for companies involved in material processing. This cost-effectiveness ensures that businesses can achieve their production goals without exceeding budgetary constraints.
Conclusion
In conclusion, jaw crushers are essential machines in industries that require material reduction. Their simple yet effective design allows for the efficient breaking down of large rocks into smaller, more manageable sizes. With components such as the fixed jaw, movable jaw, eccentric shaft, and flywheel, the jaw crusher performs its primary function of size reduction efficiently. These machines play a crucial role in mining, construction, demolition, quarrying, and recycling industries.
The versatility, efficiency, and durability of jaw crushers make them indispensable tools for various applications. Their ability to adjust the size of the crushed material and handle different materials ensures that they remain a vital part of industrial operations. Whether for primary crushing or material recycling, jaw crushers continue to be reliable and cost-effective solutions for breaking down large rocks and materials.
Also check out “Hammer mills“, “Fine Jaw Crushers“
Specifications
Capacity: 1-1120 tph
Feeding Size: <1200mm
Output Size: 10-360mm
| Model | Feeding Size(mm) | Max Feeding Size(mm) | Discharging Range Size(mm) | Capacity (t/h) | Motor Power(kw) | Weight(t) | Overall Dimension (LxWxH)(mm) |
| PE-150*250 | 150*250 | 130 | 10-60 | 3-15 | 5.5 | 2.2 | 1000x1450x900 |
| PE-250*400 | 250*400 | 210 | 20-80 | 5-20 | 15 | 2.8 | 1450x1315x1296 |
| PE-400*600 | 400*600 | 340 | 40-100 | 16-60 | 30 | 6.65 | 1565x1732x1586 |
| PE-500*750 | 500*750 | 425 | 50-100 | 40-110 | 55 | 11.73 | 1890x1916x1870 |
| PE-600*900 | 600*900 | 500 | 65-180 | 80-180 | 55-75 | 16.13 | 2305x1840x2298 |
| PE-750*1060 | 750*1060 | 630 | 80-180 | 110-320 | 90-110 | 28 | 2450x2472x2840 |
| PE-800*1060 | 800*1060 | 680 | 100-200 | 140-340 | 90-110 | 30 | 2610x2556x2800 |
| PE-870*1060 | 870*1060 | 750 | 170-270 | 180-360 | 90-110 | 31.22 | 2660x2556x2800 |
| PE-900*1060 | 900*1060 | 780 | 200-290 | 200-380 | 90-110 | 31 | 2690x2556x2800 |
| PE-900*1200 | 900*1200 | 780 | 95-225 | 220-450 | 110-132 | 49 | 3335x3182x3025 |
| PE-1000*1200 | 1000*1200 | 850 | 195-280 | 280-550 | 110-132 | 51 | 3435x3182x3025 |
| PE-1200*1500 | 1200*1500 | 1020 | 150-300 | 400-800 | 160-220 | 100.9 | 4200x3732x3843 |
| PE-1500*1800 | 1500*1800 | 1200 | 210-360 | 525-1120 | 280-335 | 132 | 5100x4700x4300 |
| PEX-150*250 | 150*250 | 125 | 10-40 | 1-3 | 5.5 | 2 | 896x745x935 |
| PEX-150*750 | 150*750 | 120 | 18-48 | 8-25 | 15 | 3.5 | 1380x1658x1025 |
| PEX-250*750 | 250*750 | 210 | 25-60 | 13-35 | 30 | 4.96 | 1545x1667x1330 |
| PEX-250*1000 | 250*1000 | 210 | 25-60 | 16-52 | 30-37 | 6.5 | 1530x1992x1380 |
| PEX-250*1200 | 250*1200 | 210 | 25-60 | 20-61 | 37-45 | 8.52 | 1900x2192x1430 |
| PEX-300*1300 | 300*1300 | 250 | 20-90 | 25-95 | 55-75 | 12.6 | 1750x2320x1724 |
| PEX-350*1200 | 350*1200 | 300 | 70-140 | 25-120 | 75 | 12.35 | 2162x2220x1723 |
Installation
Jaw Crusher Installation Instructions
Introduction: Proper installation of a jaw crusher is essential for ensuring its optimal performance and longevity. Follow these steps to install your jaw crusher safely and effectively.
1. Site Preparation
- Location: Choose a solid, level foundation with enough space for the crusher and easy access for maintenance.
- Space Requirements: Ensure there is adequate space around the crusher for operation, including access for unloading, maintenance, and future adjustments.
- Electrical and Water Supply: Make sure the site has a proper electrical connection and, if necessary, a water supply for cooling.
2. Foundation Setup
- Foundation Base: Build a robust concrete base capable of supporting the weight and vibrations of the jaw crusher. The base should be level and flat to prevent misalignment.
- Anchor Bolts: Install anchor bolts on the concrete foundation to secure the jaw crusher in place. Ensure they are placed in the foundation according to the jaw crusher’s design specifications.
3. Assembling the Crusher Components
- Fixed Jaw: Place the fixed jaw securely on the foundation. It should be attached according to the manufacturer’s guidelines, ensuring it is stable and properly aligned.
- Movable Jaw: Position the movable jaw within the frame, ensuring that it is correctly aligned with the fixed jaw.
- Toggle Plate and Bearings: Install the toggle plate and bearings, making sure they are properly aligned and lubricated.
- Flywheel and Eccentric Shaft: Attach the flywheel and eccentric shaft to the movable jaw. Ensure the eccentric shaft is positioned and aligned to facilitate smooth jaw movement.
4. Connecting the Power Source
- Electric Motor: Install the electric motor on the machine frame. Ensure that it is properly aligned with the crusher’s drive system.
- V-belt and Pulley System: Connect the V-belt system to the flywheel, ensuring the belts are tensioned correctly. Double-check the pulley sizes and their alignment to prevent unnecessary wear.
5. Installing the Adjustment Mechanism
- Adjustment Mechanism: Install the mechanism that will adjust the discharge opening size. This could be a manual or hydraulic system, depending on the model.
- Check Alignment: Ensure the adjustment mechanism is properly aligned with the jaw crusher’s moving parts.
6. Lubrication and Cooling Systems
- Lubrication: Fill the bearings, eccentric shaft, and other moving parts with the recommended lubricant. Regular lubrication ensures smooth movement and reduces friction.
- Cooling System: If your jaw crusher requires a cooling system, install the necessary piping and cooling apparatus to maintain optimal operating temperatures.
7. Testing and Calibration
- Test Run: Before starting full operations, run the jaw crusher without material to check for any irregular sounds or vibrations. Listen for any signs of misalignment or improper installation.
- Adjustments: Make necessary adjustments to the jaw alignment, motor tension, or lubrication to ensure smooth operation.
- Final Check: Verify all bolts, nuts, and mechanical connections are securely fastened. Ensure there are no loose parts that could interfere with the crusher’s operation.
8. Safety Check
- Safety Guards: Install all necessary safety guards and shields around moving parts of the jaw crusher to prevent accidental injuries.
- Emergency Stop: Ensure the emergency stop function is fully operational and easily accessible.
- Personnel Training: Train operators on the proper startup, operation, and shutdown procedures.
9. Final Inspection and Commissioning
- Check for Proper Alignment: Verify the crusher jaws and movable parts are properly aligned and are not experiencing undue wear.
- Material Feeding Test: Start feeding material into the crusher in small amounts, gradually increasing the load to ensure the system operates correctly and efficiently.
- Monitor Performance: Continuously monitor the jaw crusher’s performance during its initial operation to ensure everything is functioning as expected.
10. Routine Maintenance
- After installation, set up a regular maintenance schedule to ensure the jaw crusher operates at peak performance. Check the jaw alignment, lubrication, and wear parts frequently to prevent downtime and ensure long-term reliability.
Conclusion: Proper installation is crucial for maximizing the efficiency and lifespan of your jaw crusher. By following these steps carefully, you ensure that the equipment operates smoothly and safely. Always refer to the manufacturer’s manual for specific installation details and recommendations.
Maintenance
Correct Operation of Jaw Crusher
A jaw crusher, as one of the modern crushing equipment, has a great crushing capacity and wide application. Generally, working as a medium crusher, it is a standard crushing machine for the mining process and aggregate processing, quarry plant, etc. The correct operation directly affects the jaw crusher’s working effect and service life. The summary of correct operation matters needing attention is as follows.
Central parts of the jaw crusher have the frame, eccentric shaft, belt, freewheel, moving jaw plate, side guard, elbow plate, the back seat of elbow plate, adjusting screw, reset spring, and fixed jaw plate.
No load startup
The crusher needs to start up when no loading, and after running for a while, gradually increase ore feeding. If the crusher makes an unusual sound, it should stop running, find out the reasons.
Blocking
Sometimes, a large size rock plugs up the feeder mouth, in the event of a lock, rolling over the large stone makes the feeder mouth free at first. If blocking in the crusher chamber, it should stop feeding until the chamber is clear. For Your Attention, it is strict that use specialized tools to clear the obstruction instead of using a hand.
Feeding
It is essential that keep a steady status of material feeding and processing; the crusher chamber cannot be allowed to be filled with stone material, meanwhile, prevent irrelevant objects such as a drill, and shovel from entering the crusher.
Lubrication
Lubricating oil helps the smooth and efficient operation of the machine. What’s more, the eccentric bearing temperature cannot exceed 600 °c.
Maintenance and repair
Check the wear of the discharge mouth regularly, and adjust the size of the discharge port in time according to the wear condition. Besides, replace the worn parts on time.
Replacement Parts
Jaw Crusher Parts
Flywheel, pitman, hydraulic cylinder, toggle plate, eccentric shaft, fixed jaw, moving jaw, etc.
Jaw Crusher Working Principle
Motor drive belt and pulley, the eccentric shaft pushes the movable jaw against the fixed jaw, generates the crushing action, and compresses the material to the desired size. The crushed materials are discharged from the discharge port, and the bottom gap of the crusher controls the discharge particle size.
Jaw Crusher Manufacturer
Manufactures various types of rock crushing machines that are designated with the maximum efficiency, safety, and productivity for mining, aggregates, crushed stone production applications, and alternatives for jaw crushers. The jaw crusher machine is for sale, contact us to get the best jaw crusher price.
Jaw Crusher Price
Do you need a single jaw stone crusher or crushing plant? The price is determined by the crushing material, capacity. You may interested in the Jaw crusher specification and cost, how to select a jaw crusher? What is the difference between a jaw crusher and an impact crusher? What jaw crusher spare parts do we supply? Just contact us, engineer answer online.
Q&A
Crushing Material
Granite, dolomite, river pebbles, quartz, calcite, and other materials.
Correct Operation of Jaw Crusher
A jaw crusher, as one of the modern crushing equipment, has a great crushing capacity and wide application. Generally, working as a medium crusher, it is a standard crushing machine for the mining process and aggregate processing, quarry plant, etc. The correct operation directly affects the jaw crusher’s working effect and service life. The summary of correct operation matters needing attention is as follows.
Central parts of the jaw crusher have the frame, eccentric shaft, belt, freewheel, moving jaw plate, side guard, elbow plate, the back seat of elbow plate, adjusting screw, reset spring, and fixed jaw plate.
No load startup
The crusher needs to start up when no loading, and after running for a while, gradually increase ore feeding. If the crusher makes an unusual sound, it should stop running, find out the reasons.
Blocking
Sometimes, a large size rock plugs up the feeder mouth, in the event of a lock, rolling over the large stone makes the feeder mouth free at first. If blocking in the crusher chamber, it should stop feeding until the chamber is clear. For Your Attention, it is strict that use specialized tools to clear the obstruction instead of using a hand.
Feeding
It is essential that keep a steady status of material feeding and processing; the crusher chamber cannot be allowed to be filled with stone material, meanwhile, prevent irrelevant objects such as a drill, and shovels from entering the crusher.
Lubrication
Lubricating oil helps the smooth and efficient operation of the machine. What’s more, the eccentric bearing temperature cannot exceed 600 °c.
Maintenance and repair
Check the wear of the discharge mouth regularly, and adjust the size of the discharge port in time according to the wear condition. Besides, replace the worn parts on time.
Advantages and Disadvantages
What’s a Jaw Crusher?
A jaw crusher is a compression-type crusher, usually used as a primary crusher set at the front of the ore or rock-crushing plant to reduce hard rock size. Jaw rock crushers commonly double-toggle jaw crushers, are composed of a fixed jaw and a moving jaw. The discharging stone particle size can be controlled by changing the discharge port. Owing to its high crushing capacity and hard material efficiency, jaw crushers are a good alternative to primary gyratory crushers.
How Many Types of Jaw Crushers?
Single toggle jaw crushers and double toggle jaw crushers; industrial jaw crushers and laboratory small jaw crushers; diesel engine jaw crushers; hydraulic jaw crushers; stationary, mobile jaw crushers, track mounted jaw crushers; jaw crushers.
What’s The Jaw Crusher’s Size and Capacity?
The size of a jaw crusher is determined by the rectangular or square opening (feeding port) at the top of the jaws. The sheet below shows different gaps for coarse and fine crushing applications, Jaw Crusher (coarse crushing), and Jaw Crusher (fine crushing).
Jaw Crusher Plant
JXSC can design a reasonable jaw crusher plant depending on your application requirements.
Applications
Application
Jaw crushers are mainly used at the primary stage to reduce hard and brittle material size for the next crushing stages, widely applied in the mining, road aggregate, quarry, sand, and gravel industries.
