1. PAINPOINT DRIVEN OPENING

Are escalating operational costs and unpredictable downtime eroding your aggregate or mineral processing margins? Primary crushing stages present persistent challenges: excessive wear part consumption driving high costperton, unplanned stoppages for tramp metal damage, and inconsistent feed size reduction causing bottlenecks downstream. Consider the impact of just one extra hour of unscheduled maintenance per week on your annual production targets. How much revenue is lost to vibrationrelated foundation stress and premature bearing failures? What is the true cost of a crusher that cannot adapt to varying feed material hardness without manual intervention? These are not merely equipment issues; they are direct threats to plant throughput and profitability. A primary jaw crusher must be a pillar of reliability, not a source of variability.

2. PRODUCT OVERVIEW

The JC5000 is a highcapacity, singletoggle jaw crusher engineered for the most demanding primary crushing applications in mining, quarrying, and largescale construction recycling. Its design focuses on delivering maximum availability and the lowest possible operating cost in its class.

Operational Workflow:
1. Feed Intake: Large runofmine or quarryrun material (up to 1500mm) is directed into the deep, nonchoking crushing chamber.
2. Size Reduction: A robust eccentric shaft drives a dynamically balanced moving jaw in an elliptical motion, applying compressive force to fracture material against the fixed jaw.
3. Discharge: Crushed product exits at the bottom of the chamber, with a discharge setting adjustable via hydraulic wedge or shim systems to ensure precise output gradation.

Application Scope: Ideal for hard rock (granite, basalt), abrasive ores, and demolition concrete. It is designed as a stationary primary unit for hightonnage fixedplant operations.

Limitations: Not suitable for sticky, plastic clays or as a mobile unit without significant structural support. Requires a prepared foundation and substantial primary feed conveyance infrastructure.

3. CORE FEATURES

Hydraulic Toggle & Adjustment System | Technical Basis: Dualacting hydraulic cylinders replace mechanical toggle plates | Operational Benefit: Enables safe, remote clearing of blockages and adjustment of the closedside setting (CSS) in minutes versus hours | ROI Impact: Reduces downtime for routine adjustments by up to 80% and minimizes personnel exposure to hazardous manual tasks.

HeavyDuty Spherical Roller Bearing Cartridge | Technical Basis: Forged steel cartridge with oversized bearings designed for high radial and axial loads | Operational Benefit: Eliminates stress concentrations on bearing seats, extends lubrication intervals, and ensures precise shaft alignment under shock loading | ROI Impact: Field data shows a 40% increase in average bearing service life compared to traditional pillow block designs.

Boltless Fixed Jaw Die Retention | Technical Basis: Wedgelock system secures jaw dies without traditional head bolts | Operational Benefit: Allows faster, safer die changes; eliminates bolt stretch failures and thread seizure issues common in highvibration environments | ROI Impact: Reduces liner changeout time by approximately 30%, increasing crusher availability.

Finite Element Analysis (FEA) Optimized Frame | Technical Basis: Computermodeled stress distribution used to reinforce highload zones with additional steel while optimizing weight elsewhere | Operational Benefit: Provides exceptional rigidity to withstand peak crushing forces with minimal frame flex, protecting internal components | ROI Impact: Mitigates risk of catastrophic frame fatigue failure, protecting longterm asset value.

Integrated PreScreening Grizzly Feeder Option | Technical Basis: Vibrating grizzly section mounted directly onto crusher feed hopper | Operational Benefit: Bypasses subcrushsize fines directly to discharge belt, reducing unnecessary wear in the crushing chamber and boosting effective capacity | ROI Impact: Can increase processed tonnage by 1525% on material with high fines content by eliminating chamber choke points.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (Comparable Class) | JC5000 Solution Documented Result | Advantage (% Improvement) |
| : | : | : | : |
| Wear Part Life (Mn18/22 Jaw Dies) | 120,000 150,000 MTon (Abrasive Granite) | 180,000 220,000 MTon (Abrasive Granite) | +50% Extended Life |
| Annual Planned Maintenance Hours| ~250 hours (incl. liner changes & adjustments) | ~160 hours (incl. liner changes & adjustments) |36% Maintenance Time |
| Power Consumption per Ton Crushed| Baseline (100%) at CSS of 200mm on Basalt| Measured at CSS of 200mm on Basalt |8% Energy Use |
| Noise Emission at 10 Meters| ~105 dBA during operation| ~98 dBA during operation |7 dBA Reduction |

_Based on internal testing reports vs. previous generation designs; actual results may vary based on feed material and operating conditions._

5. TECHNICAL SPECIFICATIONS

Feed Opening: 1500mm x 2000mm (59" x 79")
Maximum Feed Size: Up to 1300mm (51")
Closed Side Setting Range: 175 300 mm (7" 12")
Capacity Range: Up to 1,750 MTPH depending on material type & CSS
Drive Power Requirement: 200 kW / Up to VSD compatible
Total Weight (Crusher Only): Approximately 86 metric tons
Key Material Specifications: Highstrength fabricated steel frame; Forged quenched & tempered eccentric shaft; Manganese steel jaw dies standard.
Environmental Operating Range: Designed for ambient temperatures from 20°C to +50°C (4°F to +122°F). Dust sealing kits available for extreme conditions.

6. APPLICATION SCENARIOS

Hard Rock Quarrying – Granite Aggregate Production

Challenge: A large granite quarry faced unsustainable costs due to frequent jaw die changes every 90k tons and excessive downtime from tramp steel incidents damaging pitman bearings.
Solution: Implementation of two JC5000 units featuring the hydraulic toggle system for quick clearing and boltless die retention.
Results: Achieved an average die life extension to 165k tons per set. The hydraulic system cleared three major tramp metal events in under 30 minutes each—incidents that previously caused 8+ hours of downtime per event—resulting in an estimated 450 additional production hours annually.

Iron Ore Primary Crushing Station

Challenge: An iron ore processing plant required higher primary throughput but was limited by an older crusher's inability to handle variable feed hardness without constant manual CSS adjustment.
Solution: Installation of a JC5000 equipped with automated wear compensation software linked to its hydraulic adjustment system.
Results: The system automatically maintained consistent product top size despite fluctuating ore hardness bands (±15% UCS). This stabilized feed to the secondary circuit, increasing overall plant throughput by an average of 9%. Power monitoring showed a 7% reduction in specific energy consumption versus the retired unit.

7. COMMERCIAL CONSIDERATIONS

The JC5000 is positioned as a capital investment focused on total cost of ownership reduction over a standard duty cycle exceeding 10 years.

Base Equipment Pricing Tier: Reflects its heavyduty construction class; structured around core configuration options such as motor type (fixed speed vs VSD), drive arrangement (sheave & vbelts vs direct coupling), and standard vs heavyduty skid base.
Optional Features & Packages:
Integrated Grizzly Feeder Module
Automated Wear Compensation System
HighAmbient Temperature Lubrication Package
Dust Sealing Kit Level I or II
Remote Monitoring Telematics Package
Service Packages: Available from multiyear preventive maintenance agreements with guaranteed parts availability SLAs upto fullscope performancebased contracts where service provider guarantees uptime percentage.
Financing Options: Available through partners including equipment leasing structures tailored for municipal entities or capital expenditure loans designed for private mining contractors seeking predictable monthly payments aligned with project cash flow.

8. FAQ

1. Is the JC5000 compatible with our existing primary feed conveyor and discharge infrastructure?
Detailed interface drawings are provided during presales engineering review. The crusher requires specific feed heights and discharge clearances which can often be adapted with existing structures; our engineering team conducts compatibility assessments as standard practice.

2. What is the expected operational impact during installation?
As a major stationary unit requiring a reinforced concrete foundation installation typically involves scheduled plant shutdown period ranging from two four weeks depending on site readiness including foundation cure time component assembly commissioning

3. How does warranty coverage work what does it include?
Standard warranty covers defects materials workmanship critical components like main frame pitman eccentric shaft bearings period months operation whichever comes first Wear parts jaw dies subject separate wear life guarantee based negotiated applicationspecific tonnage targets

4. Are spare parts readily available what are lead times?
Critical spare parts rotating assemblies bearing cartridges hydraulic cylinders held regional distribution centers Noncritical fabricated components typically available within weeks from manufacturing Global logistics network supports expedited shipping where required

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