CRUSHING

MATERIAL SIZING SOLUTIONS

ROCK ON

1.

M M M M M M M M M M

TABLE OF CONTENTS

VANGUARD JAW . . . . . . . . . . . . . . . . . . . . . . . . 3
LEGENDARY JAW. . . . . . . . . . . . . . . . . . . . . . . . 5
KODIAK CONE . . . . . . . . . . . . . . . . . . . . . . . . 7
LS CONE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
ANDREAS HSI . . . . . . . . . . . . . . . . . . . . . . . . 11
NEW HOLLAND HSI . . . . . . . . . . . . . . . . . . . . 13
VSI. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
PLANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
SUPPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
TOTAL SOLUTION . . . . . . . . . . . . . . . . . . . . . . 21

RELIABLE AND PRODUCTIVE

KPI-JCI is Your One Source for a complete

line of dependable, productive and
innovative crushing equipment. From
initial plant design through the entire
operational life of your equipment,
KPI-JCI stands with you and ensures
your operation is always running at its
best. Trust KPI-JCI to deliver solutions
which meet your exact needs in any
application from hard rock to recycling.
Ready for serious crushing results?
KPI-JCI is rock-solid. Rock On.

2.

PRODUCTION CAP

VANGUARD

EASY TO USE RETENTION SYSTEM SPEEDS UP

JAW DIE REPLACEMENT

INNOVATIVE CRUSHER DESIGN PRODUCES

UNMATCHED CAPACITY

FLY WHEEL DESIGN REDUCES HORSEPOWER

REQUIREMENTS, INCREASES PROFITS

CAPABILITIES

HYDRAULIC DUAL WEDGE SYSTEM DELIVERS

QUICK CLOSED SIDE SETTING ADJUSTMENTS

3.

PACITIES UP TO 816 TPH

Our new generation of jaw crushers,

closed side setting adjustment.

the Vanguard Series provides innovative,

The Vanguard Series offers you

time-saving and user-friendly features

a feed opening up to 44 x 50 in size.

to meet the demanding productivity

Lighter, stronger and ever-more

of the crushing industry. Replaceable

productive, Vanguard Series Jaw

wear tips protect the crusher base

Crushers never quit. Ready to get

and pitman while dynamically-balanced

serious about crushing? Get

fly wheels deliver smooth, consistent

KPI-JCI and Rock On with

operation. Change product size in no

rock-solid productivity.

time with our hydraulic dual-wedge

Self-Aligning Spherical
Roller Bearings

Forged Eccentric Shaft

Unique, efficient bearing assembly

provides added strength and reliable,
long-term service.

Provides a full 1 inches

of stroke-increasing productivity.

Barrel Protector Plate

Single Side Plate

Base Construction

Guards against costly

pitman damage

Welded and machined for true

alignment and long life.

Jaw Die Retention Wedge

Simply retains the stationary
jaw die without the use
of problematic key
and heal plates.

Hydraulic Dual
Wedge System

Side Base Wear Liners

Provides quicker CSS

adjustment
by eliminating
cumbersome shims.

Three piece design allows

for replacement of high
wear liners separately.

Lower Retaining Lips

Replaceable manganese
retention bars protect the
pitman and crusher base
from costly damage.

Toggle Seats
Machined to ensure proper fit and
alignment reducing excessive wear.
Model

Capacity
Up To

Jaw Opening

Weight

(in/mm)

(lbs/kg)

(tph/mtph)

2640

26 / 660

29,500 / 13,393

240 / 218

2650

26 / 660

32,000 / 14,528

282 / 256

3055

30 / 762

50,000 / 22,700

528 / 479

3144

31 / 787

44,520 / 20,194

426 / 386

3165

31 / 787

56,000 / 25,402

692 / 628

3352

33 / 838

85,500 / 29,555

553 / 502

4450

44 / 1118

101,900 / 46,221

816 / 740

Based on material weighing 2,700 lbs per cubic yard. Capacity may vary with the material
characteristics.
Larger settings may be obtained with other than standard toggle plate consult factory.

4.

PRODUCTION CAP

LEGENDARY

STRONG SIMPLE DESIGN DELIVERS

MAXIMUM DURABILITY AND LONG LIFE

EXCELS IN A WIDE RANGE OF APPLICATIONS

INDUSTRYS LARGEST ECCENTRIC SHAFT

BEARINGS PROVIDE RELIABLE PERFORMANCE

CAPABILITIES

MULTIPLE STYLES OF JAW DIES ARE AVAILABLE

FOR EACH MODEL

5.

PACITIES UP TO 875 TPH

Proven performers, Legendary Series

perfect for smaller jobs, but the

Jaw Crushers have set the standard

Legendary Series can handle all

of durability since the 1930s.

crushing needs with models up to

Extraordinary bearing life ensures

42 x 48. For durable, consistent

years of reliable operation, delivering

performance and yields up to 875 TPH,

consistent performance with reduced

Legendary Series Jaw Crushers will

downtime and low maintenance costs.

never let you down. Ready to get

The entry-level size of 15 x 24 is

serious about crushing? Get KPI-JCI

and Rock On with rock-solid durability.

Spherical Roller Bearings

Unique,efficient bearing
assembly provides added
strength and reliable,
long-term service.

Barrel Protector Plate

Guards against costly pitman damage.

Forged
Eccentric Shaft
Precision machined,our forged
steel eccentric shafts provide
an exact fit producing
extended bearing and
shaft life.

Single Side Plate

Base Construction

Reversible
JawDies

Welded and machined for true

alignment and long life.

Maximizing life,
decreasing costs
and increasing
profitability.

Toggle Plate

Toggle Seats

Available in multiple sizes for application

versatility. Machined to ensure maximum life.

Machined to ensure proper fit and

alignment,reducing excessive wear.
Weight

Capacity Up To

(in/mm)

(lbs/kg)

(tph/mpth)

1047
1524
1536

10 / 254
15 / 381
15 / 381

16,940 / 7,700
11,500 / 5,221
17,500 / 7,945

89 / 81
72 / 65
136 / 123

1654

16 / 406

30,690 / 13,933

204 / 185

2036
2148
2436
2854
3042
3546
4248

20 / 508
21 / 533
24 / 610
28 / 711
30 / 762
35 / 889
42 / 1067

21,000 / 9,525
32,000 / 14, 528
29,500 / 13,393
51,000 / 23,154
43,500 / 19,749
75,500 / 34,277
102,000 / 46,266

187 / 171
248 / 248
273 / 225
282 / 256
357 / 324
522 / 473
875 / 794

Model

Jaw Opening

Based on material weighing 2,700 lbs. per cubic yard. Capacity may vary with the material
characteristics.
Larger settings may be obtained with other than standard toggle plate consult factory.

6.

PRODUCTION CAPA

KODIAK

M
M

HIGHER CRUSHING EFFICIENCY WHICH

REDUCES RECIRCULATING LOADS

M
7.

MEETS COARSE AND FINE CRUSHING

APPLICATION REQUIREMENTS

ROBUST STATE-OF-THE-ART DESIGN FOR

LONGEVITY AND REDUCED OWNERSHIP COSTS.

CAPABILITIES

ON-THE-FLY ADJUSTABILITY FOR EASY

OPERATION

ACITIES UP TO 625 TPH

Using the latest technology and an

operation without sacrificing

advanced crushing chamber, Kodiak

production. Equipped with our

Series Cone Crushers offer the

advanced tramp-iron relief system,

most innovative performance

dual-acting cylinders provide

features to date, delivering highly

increased protection without the

efficient crushing in secondary to

need for accumulators. For innovative

finish stages. Our patented features,

performance with yields up to 625 TPH,

such as our internally located

Kodiak Series Cone Crushers lead

counterweights and remote-adjust

the pack. Ready to get serious about

CSS motors, provide ease of

cone crushing? Get KPI-JCI and Rock

On with rock-solid efficiency.

Thread Locking Ring

Tramp Iron Relief System

360 degree ring replaces

individual cylinders and acts
as a single piston,providing
a low maintenance,leak-free
operation while preventing
bowl creep.

Eliminates all maintenance costs

associated with accumulators
through pressure relief valves that
act as a latch and generate
minimal back pressure build-up
during an event.

Internal Counterweights

Brass Thread Inserts

Are fully protected which

eliminates the need to replace
worn counterweights while
maintaining true balance
for life.

Segmented threads are field

replaceable. Resists galling and
welding for reduced downtime and
increased profitability.

Cone Brake

Roller Bearings

The anti-spin feature reduces

manganese wear cost while
minimizing projectiles for
improved safety.

Model

A precision design that

generates higher efficiencies,
reducing re-circulating loads
and operating temperatures.
Highly tolerant of climate and
temperature fluctuations.

Head Diameter

Weight

Capacity Up To

(in/mm)

(lbs/kg)

(tph/mtph)

K200

40 / 1016

33,500 / 15,196

385 / 349

K300

45 / 1143

45,500 / 20,639

460 / 417

K400

54 / 1372

58,600 / 26,580

625 / 567

8.

PRODUCTION CAPA

LS

PROVEN DESIGN REFINED OVER THREE

DECADES ENSURES RELIABILITY AND LONGEVITY

ANTI-FRICTION BEARINGS HOLD TOLERANCES FOR

RELIABLE PERFORMANCE THROUGH THEIR LIFE

TWO-PIECE CONE HEAD DESIGN WITH HIGH

STRENGTH SHAFTING

CAPABILITIES

QUICK AND EASY LOW COST MANUAL

CSS ADJUSTMENT

9.

ACITIES UP TO 480 TPH

LSSeries
SeriesRoller-Bearing
roller-bearing cone
LS
Cone

crusher compares to the LS Series

crushers are well-proven to deliver

Crushers

reputation earned by years of reliable

reliableperformance
performancefor
formost
mostany
any
reliable

production. For reduced operating

aggregateand
andmining
miningapplication.
application.
aggregate

costs, extended life and unmatched

Fromsand
sandand
andgravel
gravelto
toshot
shotrock,
rock,LS
LS
From

reliability, JCI LS Series Cone

Series Cone
cone crushers
Series
Crushersoffer
offersecondary,

Crushers are the dependable choice.

tertiary and
quaternary
reduction
secondary,
tertiary
and quaternary

Ready to get serious about crushing?

performance
in both stationary
reduction
performance
in both and

Get KPI-JCI and Rock On with

portable configurations.
stationary
and portable No other

rock-solid reliability.

configurations. No other cone

Closed Side Setting Adjustment

Tramp Iron Relief System

The simple shim design

reduces maintenance costs
and provides a secure
adjustment.

Entire beam supports all relief

cylinders and accumulators and
can be lifted off in a single piece
for reduced downtime
during maintenance.

Frame Design

Two-Piece Cone

Utilizing a shrink-fit design,

our built-in center section design
resists stresses and cracking
for a longer service life.

Our design resists stresses and

cracking for long service life.

Roller Bearings
A precision design that
generates higher efficiencies,
reducing re-circulating loads
and operating temperatures.
Highly tolerant of climate and
temperature fluctuations.

Cone Brake
The anti-spin feature reduces
manganese wear cost while
minimizing projectiles for
improved safety.

Model

Head Diameter

Weight

Capacity Up To

1200LS

(in/mm)
45 / 1143

(lbs/kg)
30,850 / 13,993

(tph/mtph)
385 / 349

1400LS

54 / 1372

43,765 / 19,852

480 / 435

10.

PRODUCTION CAPA

ANDREAS

DUAL APRONS ADJUST INDEPENDENTLY TO

PROVIDE MAXIMUM APPLICATION FLEXIBILITY

INNOVATIVE, MAXIMUM PRODUCTION

ROTOR (MPR) DESIGN

REPLACEABLE LINERS PROTECT ENTIRE

CRUSHING CHAMBER

CAPABILITIES

BLOW BAR OPTIONS TO MEET SPECIFIC

APPLICATION REQUIREMENTS

11.

ACITIES UP TO 450 TPH

Accommodating two, three or four

crusher chamber, maintenance is a

blow bar configurations, Andreas Series

snap. For effective impact crushing in

HSI Crushers offer the adaptability

numerous applications and production

required to meet the fast-changing

rates up to 450 TPH, Andreas Series

aggregate markets. Equipped with

HSI Crushers meet your needs.

our Maximum Performance Rotor,

Ready to get serious about impact

operators gain the flexibility of an open

crushing? Get KPI-JCI and Rock On

configuration with the mass of a solid

with rock-solid adaptability.

design. And with the easy-access

Feed Opening

Dual Aprons

Provides optimal material

transition and is well-suited
for aggregate and
recycling applications.

Adjust independently
from each other providing
maximum application
flexibility.

MPR Rotor
Our Maximum Performance
Rotor provides the rugged
performance characteristics
of a solid rotor with the
accessibility of a
segmented rotor.

Apron Wear Tips

These replacement bars
extend the life of the apron
by offering increased
protection.
Less down time.

Crusher Housing

Wear Liners

Hydraulically opens over

center for safe and easy
maintenance access.

Model

Bolt-on design eliminates costly

downtime associated with damage
caused by unprotected surfaces.

Rotor (Diameter-Width)

Weight

Capacity Up To

(in/mm)

(lbs/kg)

(tph/mtph)
200 / 181

4233

42 / 1069 - 33 / 828

23,300 / 10,569

4240

42 / 1069 - 40 / 1016

24,500 / 11,113

250 / 227

4250

42 / 1069 - 50 / 1269

28,200 / 12,792

300 / 272

5260

52 / 1320 - 60 / 1523

39,000 / 17,591

450 / 408

12.

PRODUCTION CAP

NEW HOLLAND

SOLID ROTOR PROVIDES RELIABLE,

LONG-TERM PERFORMANCE

EASILY ADJUSTABLE IMPACT BARS PROVIDE

QUICK SETTING CHANGES

BUILT TO EXCEL IN MULTIPLE AGGREGATE

AND RECYCLE APPLICATIONS

CAPABILITIES

BLOW BAR OPTIONS TO MEET SPECIFIC

APPLICATION REQUIREMENTS

13.

PACITIES UP TO 1019 TPH

With over 40 years of field-proven

Available in either stationary or

results, New Holland Series HSI

portable configurations, New Holland

Crushers consistently provide

Series HSI Crushers easily fit right

profitable impact performance in

in to your operation. For solid

models with feed openings ranging

performance that increases your

from 38 x 50 to 60 x 64. The solid

profit, New Holland Series HSI

rotor design makes quick work of any

Crushers have you covered. Ready to

hard rock application, but also performs

get serious about impact crushing?

with equal perfection in asphalt and

Get KPI-JCI and Rock On with

concrete recycling operations.

rock-solid profitability.

Impact Bar Sleeves

Wear Liners
Bolt-on design eliminates
costly downtime associated
with damage caused by
unprotected surfaces.

Wear-resistant manganese
sleeves offer protection
against abrasive wear
providing less downtime.

Adjustable Impact Bar

Feed Lip

A highly adjustable design

that provides optimum
flexibility in producing
multiple material sizes.

Fully replaceable,
it protects the unit
from feed material
wear and damage.

Shear Assembly

Feed Release

Protects the rotor assembly

and crusher from damage
when an uncrushable enters
the chamber.

Model

Rotor (Diameter-Width)
(in/mm)

Hydraulically relieves
bridge-overs while
crusher is operating.

Weight
(lbs/kg)

Capacity Up To
(tph/mtph)

3850

38 / 965 - 50 / 1270

40,900 / 18,552

450 / 408

4654

46 / 1168 - 54 / 1372

50,950 / 23,110

750 / 680

6064

64 / 1626 - 60 / 1524

88,600 / 40,188

1019 / 924

14.

PRODUCTION CAP

IMPACT

AUTOGENOUS CONFIGURATION PRODUCES

MORE SPEC MATERIAL IN A SINGLE PASS

EFFICIENT DESIGN DECREASES HORSEPOWER

REQUIREMENTS

REVERSIBLE, REPLACEABLE AND ADJUSTABLE

WEAR PARTS REDUCE OPERATING COSTS

CAPABILITIES

MULTIPLE SHOE TABLE AND ROTOR

CONFIGURATIONS ARE EASILY
INTERCHANGEABLE

15.

PACITIES UP TO 500 TPH

For precision-demanding applications,

stringent material specs. With

KPI-JCI VSI Crushers deliver a highly

production rates up to 500 TPH,

consistent end product through its

KPI-JCI VSI Crushers are available in

efficient and versatile crushing design.

both stationary and portable

Capable of running in standard,

configurations, with several power

semi-autogenous and fully autogenous

options to fit your exact need. Ready to

configurations, our models 1500,

get serious about impact crushing?

2500, 4500, 82 and 120 VSI Crushers

Get KPI-JCI and Rock On with

deliver products meeting the most

rock-solid versatility.

Feed Tube

Crushing Configurations

Externally adjustable,our
heavy-duty tube compensates for
excessive wear normally experienced
by other non adjustable systems.

Multiple configurations are

available to meet all your
abrasive and non-abrasive
application needs.
Standard,Semi-Autogenous
and Fully Autogenous
configurations with quick
and easy anvil replacement.

Crusher Access Lid

Optional hydra-arm
lifts the crusher lid for
360 degrees of safe
and efficient crusher
maintenance,reducing
downtime,maximizing
profitability.

Wear Liners
Eliminates costly
downtime associated
with damage caused by
unprotected surfaces.
Bolts on and requires
no balancing.

Lube System
The oil flow and
temperature is monitored
for fail safe operation
utilizing common diesel
engine oil

Standard

Fully-Autogenous

Table/Rotor
The accelerator is bolted directly to the flywheel
and is interchangeable within the same crusher.

Model

Tub/Main Frame

Welded steel mainframe and tub assemblies provide

proper internal clearances,pedal support and
integral drive tunnel.

Feed Tube Diameter

Weight

(in/mm)

(lbs/kg)

Capacity Up To
(tph/mtph)

1500

8 . 5 / 216

13,200 / 6,000

150 / 136
300 / 272

2500

11 . 4 / 290

18,000 / 8,182

82

14 / 356

24,000 / 11,000

400 / 363

4500

16 / 406

29,600 / 13,320

500 / 453

120

18 / 457

32,100/ 14,595

500 / 453

16.

ROCK ON

CAPABILITIES

PLANTS ARE DESIGNED TO MEET YOUR EXACT

SPECIFICATIONS

QUALITY IS GUARANTEED WITH AN INDUSTRY

LEADING WARRANTY PROGRAM FROM KPI-JCI

MULTIPLE PORTABLE AND STATIONARY

CONFIGURATIONS AVAILABLE FOR MOST UNITS

ALL NECESSARY COMPONENTS AND RESOURCES

PROVIDED THROUGH YOUR ONE SOURCE DEALER

17.

PORTABLE AND STATIONARY CONFIGURATIONS

KPI-JCI is Your One Source for

complete crushing flexibility. From a
large stationary primary, to portable
quaternary, KPI-JCI Crushers excel
in most any application. For extreme
portable performance, the revolutionary
Fast Pack Rapid-Deployment
Crushing and Screening Systems
can deliver up to 500 TPH of immediate
aggregate production.

With plants available in both open and

closed-circuit configurations, as well
as several track-mounted options,
our crushing solutions can improve
the efficiency of any rock or recycling
operation. KPI-JCI can design, build
and erect a complete turnkey system
to meet your precise application
needs, with factory-trained local
technicians to ensure satisfaction for
the life of your plant. Ready to get
serious crushing results? Get KPI-JCI
and Rock On with rock-solid flexibility.

18.

ROCK ON

CAPABILITIES

LOCAL APPLICATION SUPPORT 24/7

M M

LOCAL SERVICE SUPPORT 24/7

LOCAL OFF-THE-SHELF PARTS SUPPORT 24/7

19.

LOCAL EQUIPMENT INVENTORIES FOR

RENT AND PURCHASE

LOCAL, AVAILABLE AND KNOWLEDGEABLE

KPI-JCI crushing equipment is

supported by Your One Source local
KPI-JCI Crushing & Screening Dealer.
Equipped with factory-trained
technicians, aggregate specialists
and off-the-shelf parts support,
your local dealer is prepared to help
you maximize your capability. Rock On
with increased uptime and decreased
costscontact your local KPI-JCI
dealer today, or visit www.kpijci.com
to find the dealer nearest you!

20.

YOUR ONE SOURCE

21.

MEETING YOUR EVERY NEED

KPI-JCI continues to lead the industry

with tomorrows technology...delivering
the right equipment and systems today
to meet your application and production
needs of tomorrow.
From concept to production, we offer
you the most experienced team in the
industry, ready to make your buying
decision simple and easy.
With a worldwide product support
group, Your One Source dealer offers
you after-the-sale support thats
available and dependable. From parts to
repair, you can count on fast response
by trained technicians. From innovative
products to world -class support,
KPI-JCI and its distributors offer you
simple and profitable solutions that
meet all your objectives...PROFITABLY!

22.

NOTE: SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE

Rev. 2 12/6/07

Because KOLBERG-PIONEER, INC., and JCI may use in its catalog & literature, field photographs of its products which may have been modified by the owners, products furnished by
KOLBERG-PIONEER, INC., and JCI may not necessarily be as illustrated therein. Also continuous design progress makes it necessary that specifications be subject to change without
notice. All sales of the products of KOLBERG-PIONEER, INC., and JCI are subject to the provisions of its standard warranty. KOLBERG-PIONEER, INC., and JCI does not warrant or
represent that its products meet any federal, state, or local statutes, codes, ordinances, rules, standards or other regulations, including OSHA and MSHA, covering safety pollution,
electrical, wiring, etc. Compliance with these statutes and regulations is the responsibility of the user and will be dependent upon the area and the use to which the product is put by
the user. In some photographs, guards may have been removed for illustrative purposes only. This equipment should not be operated without all guards attached in their normal position. Placement of guards and other safety equipment is often dependent upon the area and the use to which the product is put. A safety study should be made by the user of the application, and, if required, additional guards, warning signs and other safety devices should be installed by the user, wherever appropriate before operating the products.