1. PAINPOINT DRIVEN OPENING

Are escalating operational costs and unpredictable downtime eroding your aggregate or mining project margins? For plant managers and contractors, primary crushing is a critical bottleneck where failures cascade into costly delays. Common challenges with conventional jaw crushers include:
Excessive Wear Costs: Premature failure of jaw dies and side liners due to improper kinematics or material flaws, leading to frequent, expensive changeouts and parts inventory burdens.
Unscheduled Downtime: Mechanical failures from frame stress or bearing overloads halt entire processing lines, incurring labor costs for repairs and lost production revenue.
Inconsistent Throughput & Product Shape: Inefficient crushing chambers produce poor reduction ratios and slabby product, impacting downstream efficiency and final product saleability.
High Energy Consumption: Inefficient drive systems and heavy, unbalanced moving parts result in disproportionate power draw per ton of processed material.

Is your operation equipped to handle increasingly hard or abrasive feed material without sacrificing reliability? The Custom Jc5000 Jaw Crusher is engineered as a direct response to these measurable operational challenges.

2. PRODUCT OVERVIEW

The Custom Jc5000 is a heavyduty, singletoggle overhead eccentric jaw crusher designed for highcapacity primary crushing in quarrying, mining, and demolition recycling applications. Its operational workflow is built for continuous, demanding service:

1. Feed Intake: Large feed opening (500mm x 250mm) accepts runofmine or runofquarry material directly from haul trucks or loaders.
2. Crushing Action: An aggressive elliptical stroke pattern applies compressive force directly to the feed material, breaking it against the fixed jaw plate.
3. Discharge & Setting Control: Crushed material exits through the bottom discharge opening, with CSS (Closed Side Setting) hydraulically adjustable for precise product sizing under load.
4. Protection & Reset: An automatic hydraulic toggle tensioning and release system protects the crusher from uncrushable material by permitting the toggle plate to reset automatically.

Application Scope: Ideal for processing hard rock (granite, basalt), abrasive ores, and reinforced concrete. Engineered for stationary plant installation or robust mobile tracked setups.

Limitations: Not designed for grinding or pulverizing; optimal performance requires prescreening to remove excessive fines. Maximum recommended feed size is 80% of the gape dimension.

3. CORE FEATURES

DeepChamber Geometry | Technical Basis: Optimized nip angle and longer crushing zone | Operational Benefit: Achieves higher reduction ratios in a single pass, reducing recirculating load | ROI Impact: Increases system throughput by up to 15% compared to standard chamber designs

Hydrostatic Drive System | Technical Basis: Direct hydraulic motor drive with variable displacement control | Operational Benefit: Enables soft starts, reversible operation for clearing blockages, and precise speed control | ROI Impact: Reduces mechanical stress on components by 40%, lowering failure rates and associated downtime costs

Modular Jaw Die System | Technical Basis: Segmented, reversible wear plates secured with mechanical wedges | Operational Benefit: Allows for localized replacement of worn sections; reduces changeout time by twothirds | ROI Impact: Cuts annual wear part inventory costs by an estimated 30% through optimized material use

Fabricated Steel Frame with Stress Relief | Technical Basis: Finite Element Analysis (FEA)designed frame subjected to postweld heat treatment | Operational Benefit: Eliminates residual stresses that lead to fatigue cracking under cyclic loading | ROI Impact: Extends structural service life beyond industry norms, protecting capital investment

Integrated Condition Monitoring Ports | Technical Basis: Preinstalled sensor ports for temperature and vibration on bearings and drive shaft | Operational Benefit: Facilitates predictive maintenance scheduling based on actual component health data | ROI Impact: Transforms maintenance from reactive to planned, preventing catastrophic failures that cost 10x more in repairs and lost production

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (Comparable Jaw Crusher) | Custom Jc5000 Solution | Advantage (% Improvement) |
| : | : | : | : |
| Tons per Hour (Hard Granite)| 180 220 tph @ CSS 150mm| 245 260 tph @ CSS 150mm| +15% Throughput |
| Wear Life (Jaw Dies)| ~120,000 tons (MN14 steel)| ~165,000 tons (Custom Manganese Alloy)| +37% Service Life |
| Energy Consumption| ~55 kWh per 100 tons processed| ~48 kWh per 100 tons processed| 13% Power Draw |
| Mean Time Between Failure (MTBF)| ~1,200 operating hours| ~1,800 operating hours| +50% Reliability |
| Total Cost of Ownership (5Year Projection)| Baseline = $1M USD est.| Estimated at $825K USD est.| 17.5% Lifetime Cost |

Note: Comparative data based on published industry averages for machines in the same class; specific results vary by application.

5. TECHNICAL SPECIFICATIONS

Feed Opening: 500mm x 250mm
Maximum Feed Size: 400mm
Closed Side Setting Range: 75mm 200mm
Capacity Range: Up to 275 tonnes per hour (dependent on feed material and CSS)
Drive Power Requirement: 75kW /100HP electric motor or equivalent hydraulic drive system
Crusher Weight (excluding drive): Approximately 14,500 kg
Key Material Specifications:
Frame Construction: Hightensile steel plate (ASTM A572)
Swing Jaw & Main Shaft: Forged alloy steel
Standard Jaw Dies: Premium Manganese Steel (1820%)
Bearings: Spherical roller bearings; oversized for application load
Operating Temperature Range: 25°C to +45°C (13°F to +113°F)
Dimensions (L x W x H): ~2.8m x 2.2m x 2.5m

6. APPLICATION SCENARIOS

Granite Quarry Primary Crushing Station | Challenge: A large quarry faced frequent downtime due to cracked frames on their primary crushers when processing exceptionally hard granite seams; wear part consumption was unsustainable.| Solution: Two Custom Jc5000 Jaw Crushers were installed as the primary stage in a new processing line.| Results: Field data shows frame integrity has been maintained over three years of operation. Combined with the modular dies, total costperton for wear parts decreased by 22%. Plant availability increased by 18%.

Urban Demolition Waste Recycling Plant | Challenge: Processing reinforced concrete with rebar caused regular jamming events in existing crushers; manual clearing was dangerous and halted operations for hours.| Solution Implementation of a Custom Jc5000 equipped with the hydrostatic drive system allowing automatic reversal.| Results The reversible function clears most blockages in under two minutes without operator intervention on the crusher itself This has reduced unplanned stoppages related to tramp metal by over 90%

7 COMMERCIAL CONSIDERATIONS

The Custom Jc5000 is offered under a tiered pricing structure reflecting core capability versus enhanced operational packages:

Base Configuration (Jc5000Core): Includes standard manganese jaws fabricated frame hydrostatic toggle adjustment Automatic tension release system Designed for customers integrating into existing plants with their own drives ancillaries

Optimized Production Package (Jc5000Pro): Base configuration plus integrated hydrostatic drive motor premium abrasionresistant liner packages preinstalled condition monitoring sensors Most common selection offering best total value

Service support is available à la carte or through annual contracts:

• Platinum Support Plan Includes scheduled inspections remote monitoring analysis priority parts dispatch guaranteed response times
• Financing Options Available through partner institutions covering leasetoown capital loans operating leases Structures can be tailored typically ranging from 3660 month terms

Optional Features Hydraulic setting adjustment gauge laser wear monitoring systems automated lubrication units dust suppression ring

8 FAQ

Q What power source is required for the Custom Jc5000?
A It can be configured for direct electric motor drive via Vbelts or as a complete electrohydraulic package The Pro package includes the integrated hydrostatic system requiring only an electrical power connection

Q Is it compatible with my existing plant's feeding arrangement?
A Its standard modular design allows adaptation to various feed hoppers apron feeders or direct tipping configurations Engineering drawings are available for integration planning

Q How does the maintenance schedule compare?
A Industry testing demonstrates extended service intervals Critical lubrication points are designed for 500hour intervals versus typical 250hour schedules reducing routine labor requirements significantly

Q What warranty applies?
A The structural frame carries a 5year warranty against defects Other major components including shaft assembly have a standard 12month warranty Extended warranties are available with service plans

Q Can you supply wear parts compatible with other crusher brands?
A No We manufacture wear parts specifically engineered for optimal performance in the Jc5000 chamber Using nonOEM parts will void warranty coverage due to unpredictable effects on kinematics stress distribution