1. PAINPOINT DRIVEN OPENING

Are unplanned maintenance shutdowns and inconsistent final product quality eroding your aggregate production margins? Managing a primary crushing station presents distinct challenges that directly impact your bottom line. Common operational hurdles include:

Excessive Downtime for Liner Changes: Traditional designs require lengthy, laborintensive processes to access and replace worn manganese, halting your entire feed line for 812 hours or more.
Uncontrolled Feed and Bridging: Inconsistent feed from haul trucks or surge piles leads to uneven chamber loading, causing premature wear, potential damage from tramp metal, and costly bridging incidents.
Poor Product Shape & High Fines Generation: An improperly configured chamber or worn liners produces an excess of flaky material and fines, reducing the yield of valuable, spec aggregate and increasing waste.
High Operational & Maintenance Costs: Rising expenses for energy consumption, liner replacement labor, and component repairs directly compress profit margins on every ton processed.

How can you achieve higher throughput with greater reliability while controlling the total cost of ownership for your primary crushing stage? The solution lies in selecting a certified stone crusher machine engineered to address these specific industrial pain points.

2. PRODUCT OVERVIEW

This certified stone crusher machine is a heavyduty, primary jaw crusher engineered for the first stage of size reduction in quarrying, mining, and demolition recycling operations. It is designed to accept large feed material (up to 85% of the gape dimension) and reduce it to a consistent discharge product for further processing.

Operational Workflow:
1. Feed Intake: Large dump trucks deposit runofquarry rock into a vibratory grizzly feeder, which removes subfines and directs sized material into the crusher’s inlet.
2. Compressive Crushing: The robust jaw assembly utilizes a steep nip angle and aggressive stroke to apply compressive force against a stationary jaw plate, fracturing the rock.
3. Discharge & Clearance: Crushed material exits through an adjustable gap at the bottom (closedside setting), with a hydraulic toggle system providing rapid clearing of blockages without stopping production.

Application Scope:
Primary crushing of granite, basalt, limestone, and other abrasive aggregates.
Processing of reinforced concrete and construction debris in recycling plants.
Mining operations requiring robust size reduction of ore.

Key Limitations:
Not designed for final product shaping; output requires secondary/tertiary crushing for most spec aggregates.
Requires a stable, reinforced concrete foundation and appropriate feeding equipment.
Optimal performance is dependent on correct sizing relative to feed material characteristics and required throughput.

3. CORE FEATURES

Hydraulic Toggle & Adjustment System | Technical Basis: Dualacting hydraulic cylinders replace mechanical toggle plates | Operational Benefit: Enables remote adjustment of the closedside setting (CSS) for product size control and provides automatic overload protection by releasing under uncrushable pressure | ROI Impact: Reduces downtime for size changes by up to 70% and prevents major component damage from tramp metal.

Quarry Duty Jaws & Heavier Frame | Technical Basis: Fabricated steel frame with reinforced ribbing; jaws use highstrength steel backing plates bonded to premium manganese liners | Operational Benefit: Withstands continuous highimpact loads and abrasive wear, extending service life under severe duty cycles | ROI Impact: Field data shows liner life improvements of 1525%, reducing part consumption frequency and associated labor costs.

Fixed Feed Hopper with Integrated Grizzly | Technical Basis: Onepiece hopper design with bolton liner sections and optional independent prescreen | Operational Benefit: Minimizes setup time, prevents spillage at the feed point, and allows for preliminary fines removal to boost effective capacity | ROI Impact: Improves overall plant efficiency by ensuring consistent crusher feed and protecting the chamber from unnecessary abrasion.

PLCBased Automation Interface | Technical Basis: Integrationready control system monitoring main shaft speed, hydraulic pressure, bearing temperature, and power draw | Operational Benefit: Provides operators with realtime performance data and enables automated start/stop sequences tied to downstream processes | ROI Impact: Facilitates predictive maintenance scheduling optimizes energy use per ton crushed reduces risk of catastrophic failure.

Direct Drive via VBelts & TEFC Motor | Technical Basis: Hightorque motor connected via multiple Vbelts to a heavyduty flywheel ensuring consistent kinetic energy transfer | Operational Benefit: Simple reliable power transmission with inherent shock absorption; Totally Enclosed Fan Cooled (TEFC) motor resists dust ingress common in quarry environments operational benefit protects critical electrical components from particulate contamination reducing motor failures roi impact lowers longterm electrical maintenance costs versus exposed motor designs industry testing demonstrates higher operational availability in dusty conditions

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard | Certified Stone Crusher Machine Solution | Advantage (% Improvement) |
| : | : | : | : |
| Liner Change Downtime | Mechanical shim adjustment; 812 hour process average. Hydraulic wedge or toggle system; 24 hour process average. Up to 70% faster |
| Throughput Consistency (Tons/hr) Variability due to manual CSS adjustment wear compensation +/ 1015%. PLCmonitored hydraulic CSS maintains target setting within +/ 3%. Up to 12% more consistent yield |
| Energy Consumption (kWh/Ton) Fixed speed drive regardless of load fluctuations Optional variable frequency drive (VFD) matches power draw to actual feed load Up to 20% reduction under partial load conditions |
| Frame Structural Integrity Stress concentration at traditional bolt points Finite Element Analysis (FEA) optimized frame with uniform stress distribution Field data indicates extended fatigue life reducing longterm structural repair costs |

5. TECHNICAL SPECIFICATIONS

Model Designation: JC5460
Feed Opening: 1400mm x 1100mm (55" x 44")
Maximum Feed Size: ~1200mm (47")
Closed Side Setting Range: 150mm 300mm (6" 12")
Capacity Range: 450 850 MTPH dependent on material type feed gradation
Drive Power Requirement: ~250 kW (~350 HP) TEFC electric motor standard
Total Weight (Crusher Only): ~78 metric tons
Key Material Specifications: Body frame ASTM A36 steel; Shaft EN24 forged steel; Cheek plates AR400 abrasion resistant steel
Environmental Operating Range: Designed for ambient temperatures from 20°C to +50°C (4°F to +122°F)

6. APPLICATION SCENARIOS

Granite Quarry Primary Crushing Challenge achieving required railway ballast product fraction while minimizing fines waste due to inconsistent jaw wear Solution installation of certified stone crusher machine with hydraulic toggle system allowing weekly CSS adjustments without downtime Results CSS maintained within tight tolerance producing +18% yield of premium ballast material; quarterly liner change downtime reduced by an average of six hours per event

Urban Construction Recycling Plant Challenge processing highly variable reinforced concrete demolition debris containing rebar causing frequent jams in older jaw crushers Solution deployment of certified stone crusher featuring overload protection hydraulics automatic rebar release mechanism Results uncrushable material passes without shutdown eliminating an estimated three days per year of stallrelated downtime plant availability increased significantly

7. COMMERCIAL CONSIDERATIONS

Equipment pricing is structured according to configuration level:
1. Base Machine Tier includes core crusher assembly motor drives guards basic lubrication system
2 Production Ready Tier adds integrated motor starter hydraulic power unit PLC control panel preinstalled instrumentation
3 Turnkey Skid Tier features full unit mounted on structural steel skid including feeders conveyors walkways prewired simplified installation

Optional Features:
Onboard dust suppression spray system automatic lubrication system VFD for soft start energy management extended wear part packages specific alloy liners

Service Packages:
Proactive maintenance plans are available covering scheduled inspections parts kits priority technical support Extended warranties can be negotiated based on application analysis

Financing Options:
Commercial buyers can access equipment financing through partner institutions offering flexible leasetoown structures or term loans typically structured over three seven years based on credit profile

8. FAQ

What upstream feeding equipment is required?
A vibratory grizzly feeder sized matched capacity is strongly recommended ensure optimal continuous chokefed operation maximize liner life production output

Can this crusher handle wet sticky material?
While capable performance will be reduced materials high clay moisture content increase risk chamber packing recommend evaluating application specific conditions may necessitate prescreening washing station

What is the expected operational availability?
When paired with proper preventive maintenance program including regular lubrication bearing inspections field data indicates operational availability exceeding based on twoshift fiveday operation excluding planned maintenance windows

Are wear parts readily available?
Yes all critical wear parts jaw plates cheek plates are stocked regional distribution centers ensure fast delivery minimize waiting time urgent replacements

What foundation requirements are necessary?
Detailed civil engineering drawings are provided specifying reinforced concrete foundation mass dimensions anchor bolt locations must be prepared by qualified contractor ensure stability dynamic loads