KPI-JCI Crusher Reduces Maintenance; Increases Energy, Performance

KPI-JCI, Astec 3055-Vanguard-Jaw-Crusher

KPI-JCI and Astec Mobile Screens made significant changes to its new generation Vanguard Jaw Crusher that are designed to reduce producer maintenance and increase energy and performance.

The Vanguard Jaw Crusher features replaceable wear parts to protect producers’ investment in their equipment. Without proper protection, high wear areas of a machine can significantly reduce its lifespan.

The Vanguard Jaw Crusher’s replaceable jaw die seats and replaceable barrel protector plate are two enhancements that decrease producers’ exposure to costs inflicted by everyday wear and tear of normal use, according to Ron Griess, product manager for KPI-JCI and Astec Mobile Screens.

In addition to replaceable wear parts and the new tramp-iron relief system, the new generation Vanguard Jaw Crusher provides simpler maintenance with its jaw die wedges. In the new design, jaw die retention wedges hold the jaw die in place, providing easy access to the jaw die and efficient removal and replacement.

In addition, the new design contains lifting holes on all Vanguard jaw dies so lifting lugs are no longer required to be welded. These advancements yield less downtime between jaw die replacement and other maintenance intervals, Griess said.

Another significant change to the Vanguard Jaw Crusher is the elimination of the manual shim adjustment method to change the crusher’s closed side setting. Unlike competitors who still use traditional shim plates to adjust the closed side setting, the Vanguard Jaw Crusher utilizes hydraulic cylinders.

“This new design employs an optional hydraulic tramp iron relief system, which enables adjusting the closed-side-setting while providing overload protection from uncrushable events,” Griess said. “Allowing this convenience for producers allows them to be more successful in their operations by reducing downtime.”

The new design components – including increased stroke, toggle angle and flywheel inertia – also enable producers to achieve increased performance, Griess said. The five largest Vanguard Jaw Crushers crush with a 1½-in. stroke, which opens up wider and compresses material more, allowing aggregate to get crushed and through the jaw faster. The Vanguard Jaw 3055 and the 3144 are the only jaw crushers in their class with a 1½-in. stroke.

Additionally, the Vanguard Jaw Crusher’s aggressive toggle plate angle gives more movement to the bottom of the pitman, resulting in more crushing per stroke. Its flywheel inertia allows the crusher to function while reducing energy input. By using large, dynamically balanced flywheels, peak horsepower requirements are reduced, yielding greater efficiencies and fewer fuel costs.

“With the increased energy and performance, producers can expect the Vanguard Jaw Crusher to deliver up to 25 percent more tons per hour than comparable jaw crushers,” Griess said.

Components such as the common flinger collar, stress-relieved base frame and machined saddle work together to increase the lifespan of the machine. The Vanguard Jaw Crusher uses the common flinger collar between the saddle block bearing and the pitman bearing. Using the same collar allows the bearings to be located closer together, greatly reducing the shaft deflection – and therefore the bending stresses – due to the rotation of an eccentric shaft.

“Because the stresses are reduced, the Vanguard Jaw Crusher is able to use a smaller eccentric shaft than competitors without sacrificing bearing life,” Griess said. “The smaller eccentric shaft of the Vanguard Jaw Crusher is a superior design over competitive models, which are unable to control shaft deflection, causing them to resort to a bigger shaft and bearings.”

Track and wheel configurations on the new generation Vanguard Jaw Crusher allow producers to function efficiently and economically in tighter jobsites to process new alternative materials like recycled aggregate and slag, Griess said. This flexibility allows producers and dealers to penetrate any market.


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