1. PAINPOINT DRIVEN OPENING

Are escalating operational costs and unpredictable downtime eroding your primary crushing circuit's profitability? For plant managers and engineering contractors, the primary crushing stage is a critical bottleneck where inefficiencies cascade through the entire processing line. Common challenges include:
Excessive Downtime for Maintenance: Frequent liner changes and unexpected mechanical failures halt production, costing thousands per hour in lost throughput.
High Wear Part Consumption: Aggressive or abrasive feed material leads to premature jaw plate wear, driving up your costperton and creating inventory management headaches.
Inconsistent Product Gradation: Fluctuations in feed size or hardness result in an uneven discharge product, placing stress on downstream screening and secondary crushers.
Rigid Setup Limitations: Fixed jaw crushers cannot adapt to changing project demands or feed characteristics, locking you into a single operational profile.

How do you secure consistent throughput while controlling maintenance costs and adapting to variable feed conditions? The solution requires a robust design focused on durability, serviceability, and sustained performance.

2. PRODUCT OVERVIEW

The Bulk JC5000 is a highcapacity, singletoggle jaw crusher engineered for primary crushing in demanding mining, quarrying, and largescale construction applications. It processes runofmine rock, blasted quarry stone, and demolition concrete into a consistent, coarse aggregate.

Operational Workflow:
1. Feed Intake: Oversized material (up to 1300mm) is directed into the deep crushing chamber by vibrating grizzly feeders.
2. Compression Crushing: The elliptical motion of the single toggle forces the movable jaw against the fixed jaw, applying compressive force to fracture the rock.
3. Discharge & Clearance: Crushed material exits through the bottom discharge opening (CSS), with the aggressive stroke ensuring efficient clearing even under high load.

Application Scope: Ideal for hard rock (granite, basalt), abrasive ores, and recycled concrete with strengths up to 400 MPa. It serves as the primary workhorse in stationary plants and large mobile tracked setups.

Limitations: Not designed for wet, sticky materials that may cause chamber packing without proper feed conditioning. For ultrafine output (<50mm), secondary or tertiary crushing stages are required.

3. CORE FEATURES

Deep Chamber Design | Technical Basis: Optimized nip angle and long linear crushing path | Operational Benefit: Enables higher volume intake per cycle and reduces bridging risks | ROI Impact: Increases potential throughput by up to 15% versus shallower chambers of similar inlet size

Hydraulic Toggle Adjustment System | Technical Basis: Replaceable hydraulic cylinder for tensioning & overload release | Operational Benefit: Allows remote CSS adjustment under load and protects against tramp metal damage | ROI Impact: Reduces unplanned downtime by an average of 30 hours annually related to tramp iron incidents

HeavyDuty Roller Bearing Assembly | Technical Basis: Spherical selfaligning roller bearings on main shaft | Operational Benefit: Supports higher radial loads and operates at lower temperatures than bronze bushings | ROI Impact: Extends bearing service life by approximately 40%, lowering part replacement frequency

BoltOn Wear Liners | Technical Basis: Modular manganese steel liners on frame sides | Operational Benefit: Protects crusher frame from abrasion; replaced independently of jaw dies | ROI Impact: Preserves structural integrity of main frame for decades, avoiding capital replacement costs

Centralized Greasing Points | Technical Basis: Automated or manual greasing lines routed to all major bearings | Operational Benefit: Enables safe, routine lubrication without direct operator access to moving parts | ROI Impact: Standardizes preventive maintenance, reducing lubricationrelated failures by over 80%

Reinforced Swing Jaw Design | Technical Basis: Finite Element Analysis (FEA) optimized cast steel structure with thick ribs | Operational Benefit: Provides maximum fatigue resistance under cyclic loading stresses | ROI Impact: Minimizes risk of catastrophic jaw failure, ensuring multiyear structural service life

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (Comparable Class) | Bulk JC5000 Solution | Advantage (% Improvement) |
| : | : | : | : |
| Average Jaw Plate Life (Abrasive Granite) | ~180,000 MTONs per set (Standard Mn18) | ~250,000 MTONs per set (Premium Mn22) +38% |
| Time for CSS Adjustment / Liner Turnover| 46 hours (manual shim adjustment) 900 TPH in field trials| >6% Higher Output |

5. TECHNICAL SPECIFICATIONS

Feed Opening: 1300mm x 1000mm (51" x 40")
Maximum Feed Size: Up to 1100mm edge length
Closed Side Setting (CSS) Range: 150mm 300mm
Capacity Range: Up to 950 tonnes per hour (dependent on feed material & CSS)
Drive Power Requirement: 132 kW Electric Motor
Total Weight (Crusher Only): Approximately 62 tonnes
Key Material Specifications:
Main Frame: Fabricated heavyduty steel plate
Swing Jaw & Fixed Jaw Dies: Premium Manganese Steel
Eccentric Shaft: Forged alloy steel
Operating Temperature Range: 30°C to +45°C with appropriate lubricants
Dimensions (L x W x H): ~4m x 3m x 3m

6. APPLICATION SCENARIOS

Hard Rock Quarry Expansion Challenge:

A granite quarry needed to increase primary circuit output by 25% without expanding its plant footprint or secondary crushing line.

Solution:

Two older jaw crushers were replaced with a single Bulk JC5000 unit configured with a wider CSS to produce optimal feed for existing cone crushers.

Results:

Throughput increased by 28%. The consistent product gradation reduced cycling in downstream cones. Combined with longer wear life on jaw plates,the change lowered costpertonne by an estimated 18%.

LargeScale Mineral Processing Plant Challenge:

An iron ore operation faced excessive unplanned downtime due to tramp steel damaging its primary crusher,losing an average of $15k per incident.

Solution:

Implementation of the Bulk JC5000 with its hydraulic toggle system for automatic overload protection.

Results:

Field data shows three overload events were safely cleared without shutdown in one quarter.Planned maintenance intervals are now reliably met,directly saving over $60k in avoided downtime within six months.

7. COMMERCIAL CONSIDERATIONS

The Bulk JC5000 is positioned as a capital investment for operations focused on longterm total cost of ownership reduction.

Base Equipment Pricing Tier: Includes crusher,motor mounts,and drive sheaves.Competitively structured against equivalent OEM offerings.
Optional Features & Packages:

Performance Package: Includes automated grease system,motor starter,and wear part monitoring sensors.
QuickChange Package: Features hydraulic assist tools for jaw die replacement.
Modular Frame Guarding: Preassembled safety guards for faster installation.

Service Agreements:

1Year OnSite Warranty with factory commissioning support.
3Year /5Year Extended Protection Plans covering major components.
Scheduled Inspection Programs managed via predictive maintenance software.

Financing options include equipment leasing through partners,tailored rentaltoown structures for projectbased work,and fleet upgrade programs involving tradeins of legacy equipment.

8.FAQ

Q1:What is the compatibility of the Bulk JC5000 with my existing vibrating grizzly feeder and discharge conveyor?
A1:The JC5000 is designed to standard industry mounting footprints.Its feed height and discharge trajectory can be engineered during quotation to match your current layout.Engineering support is provided for integration reviews.

Q2:What is the expected operational impact during liner changeouts?
A2:The design prioritizes service access.Field reports indicate a full set of jaw dies can be changed by a threeperson crew in one shift,a significant reduction compared to older designs requiring torch work or complex dismantling.

Q3:What commercial terms are available beyond upfront purchase?
A3.We offer several models including straight capital sale,fixedterm lease financing,and certified refurbished units from our rebuild program.Each has distinct cash flow implications we can detail based on your procurement process.

Q4:What power supply infrastructure is required?
A4.The unit requires a dedicated supply compatible with its 132 kW motor.Full electrical schematics,suggested protection devices,and softstart recommendations are provided ahead of installation.A dieselhydraulic drive option exists for remote sites lacking grid power.

Q5:What training is provided for our maintenance team?
A5.Comprehensive training modules are included,covershing safe operation,routine maintenance procedures,and basic troubleshooting.This can be delivered onsite during commissioning or at our regional technical centers.Documentation includes detailed parts manuals and taskspecific videos