1. PAINPOINT DRIVEN OPENING

Are unplanned shutdowns and ballooning maintenance costs eroding your primary crushing stage profitability? Operational managers face persistent challenges that directly impact the bottom line. Excessive wear part consumption leads to unpredictable budgeting and frequent liner changes, halting your entire processing line. Inconsistent feed size or hard, abrasive material can cause premature failures and catastrophic damage to critical components. Furthermore, inefficient crushing chambers fail to optimize particle shape and throughput, leaving potential tonnage—and revenue—unprocessed. How can you achieve reliable, highvolume reduction while controlling operational expenditure and maximizing equipment uptime? The solution requires a robust engineering approach focused on durability, serviceability, and proven performance.

2. PRODUCT OVERVIEW

The JC5000 is a highcapacity, singletoggle jaw crusher engineered for the primary crushing of hard rock, ore, and aggregate in demanding stationary plant applications. Its operational workflow is designed for simplicity and reliability: (1) Large feed material is introduced into the deep, nonchoking crushing chamber via a vibrating grizzly feeder. (2) A highinertia flywheel and large eccentric shaft drive a robust moving jaw in an elliptical motion to apply compressive force against the fixed jaw plate. (3) The crushed product discharges at the bottom with a consistent CSS (Closed Side Setting), ready for secondary processing. This equipment is specifically scoped for hightonnage primary stations in mining, quarrying, and largescale construction projects. Its design is optimized for hard, abrasive materials but is not intended for recycling applications with high levels of tramp metal or plastic.

3. CORE FEATURES

HeavyDuty Roller Bearing Design | Technical Basis: Utilization of oversized spherical roller bearings on the eccentric shaft, supported by a forged alloy steel housing. | Operational Benefit: Provides exceptional radial and axial load capacity, extending bearing life under shock loads and reducing heat generation for continuous operation. | ROI Impact: Field data shows up to 40% longer bearing service intervals compared to standard designs, lowering part replacement costs and associated labor downtime.

"WedgeLock" Jaw Plate Retention System | Technical Basis: Mechanical wedge locking system secures jaw plates without the use of backing resin or adhesives. | Operational Benefit: Enables fast, safe jaw plate changeouts by plant personnel without specialized heating tools or lengthy curing times. | ROI Impact: Reduces liner change downtime by approximately 50%, directly increasing plant availability and annual throughput capacity.

Hydraulic Toggle Adjustment & Clearing | Technical Basis: Integrated hydraulic cylinder for tensioning the toggle plate and providing automatic overload relief. | Operational Benefit: Allows rapid adjustment of the CSS for product size control and automatically releases tramp metal or uncrushable material to protect the crusher from damage.| ROI Impact: Prevents costly repairs from overload events; enables quick product size adjustments to meet changing spec requirements without manual shim manipulation.

Deep Symmetrical Crushing Chamber | Technical Basis: Optimized chamber geometry derived from kinematic analysis of the elliptical motion path.| Operational Benefit: Promotes interparticle crushing for improved particle shape, increases capacity per stroke, and reduces premature wear at the discharge point.| ROI Impact: Delivers up to 15% higher throughput per installed horsepower compared to previous generation designs, improving energy efficiency.

Modular Frame Construction | Technical Basis: Fabricated from heavyduty steel plate with nonwelded stressrelieved sections bolted together.| Operational Benefit: Simplifies transportation logistics to remote sites and allows for targeted replacement or repair of frame sections if ever required over decades of service.| ROI Impact: Reduces initial shipping costs by up to 30% for certain locations; extends total structural life of the asset beyond typical weldedframe crushers.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard | JC5000 Solution | Advantage (% Improvement) |
| : | : | : | : |
| Average Jaw Plate Life (Abrasive Granite) | 180,000 220,000 tonnes | 280,000 320,000 tonnes | +35% Extended Wear Life |
| Typical Liner ChangeOut Time (Two Plates) | 1824 Hours (Resin System) | 812 Hours (WedgeLock) | ~55% Faster Service |
| Power Consumption per Tonne Crushed | Baseline (100%) Measured kWh/t | Improved Chamber & Kinematics Achieves ~90% Baseline kWh/t| ~10% Energy Efficiency Gain |
| Maximum Feed Size vs Gape Opening Ratio| ~8085% Standard Ratio| Engineered at ~90% Ratio| Enables Larger TopSize Processing |

\ Based on controlled testing with identical feed material.
\\ Actual results vary based on feed material characteristics.
\\\ Ratio indicates ability to accept large blocks relative to crusher inlet dimensions.
\\\\ Industry average derived from published specifications of comparable class crushers.

5. TECHNICAL SPECIFICATIONS

Capacity & Rating: Up to 1,650 tonnes per hour (dependent on feed material & CSS).
Feed Opening: 1500mm x 1300mm (59" x 51").
Power Requirements: 200 kW / 250 HP electric motor drive (standard).
Material Specifications: Highstrength fabricated steel frame; Manganese steel jaw plates (standard); Optional premium alloys available for specific abrasion/impact conditions.
Physical Dimensions & Weight: Approximate installed weight: ~96,000 kg; Specific footprint dimensions available upon request based on feeder/civils design.
Environmental Operating Range: Designed for ambient temperatures from 20°C to +45°C; Dust sealing systems standard; Optional Arctic or tropical packages available.

6. APPLICATION SCENARIOS

Hard Rock Quarrying – Granite Aggregate Production

Challenge: A major quarry operator faced excessive downtime every 68 weeks for jaw liner changes using resinbased systems on their primary crusher. Laborintensive procedures were cutting into peak season production.
Solution: Implementation of a JC5000 Jaw Crusher with its WedgeLock retention system was specified as part of a plant upgrade.
Results: Liner changeout time was reduced from an average of 22 hours to under 10 hours per event. This translated to an estimated gain of over 120 hours of additional crushing time annually while reducing maintenance crew overtime costs.

Primary Iron Ore Crushing Station

Challenge: An iron ore processing plant needed higher primary throughput but was limited by existing crusher capacity and frequent bearingrelated issues due to shock loads from direct dump feeding.
Solution: A JC5000 was selected based on its heavyduty roller bearing design and deep chamber capable of handling large slabby ore directly from the mine.
Results: Plant throughput increased by an average of 18%. After two years of operation with consistent shock loading from direct truck dump feeding campaigns have shown no bearingrelated interventions required beyond scheduled lubrication servicing.

7. COMMERCIAL CONSIDERATIONS

The JC5000 Jaw Crusher is offered in several configuration tiers:
1. Base Unit Tier: Includes core crusher with standard manganese liners, motor drives,and basic lubrication system.
2. Plant Ready Tier: Integrates motor starter package,custom baseframe,vibration isolation pads,and integrated guarding.
3. Optional features include automated grease lubrication systems,dust suppression spray bars,a varietyof jaw plate tooth profiles,and extended wear package components.Service packages rangefrom basic commissioning supportto comprehensive multiyear scheduled maintenanceand parts agreements.Financing options including capital leaseoperating leaseand rentaltoown structures are availableto alignwith project cash flow requirements

8.FAQ

Q: Is the JC5000 compatible with my existing secondary/tertiary crushing circuit?
A: Yes.The CSS adjustment rangeand resultant product gradation are designedto feed efficiently into common cone crusheror further downstream processes.Specific gradation curves can be providedfor your circuit modeling.

Q:What impact will this haveon my operating labor requirements?
A:The design prioritizes serviceability.The WedgeLock systemand accessible lubrication points reduce specialized skill requirementsand time spenton routine maintenance allowingyour existing teamto manage operations effectively

Q:What arethe commercial termsfor critical spare parts?
A:We offer guaranteed inventoryholding agreementsfor critical wearand spare partslike bearingsshaftsand jaw platesto ensureyour planned stock levelsmeet target uptime Key componentsare often availablefor expedited shipping

Q:How long does implementationtypically takefrom orderto commissioning?
A:Lead timesvarybasedon configurationStandard units typically shipwithin X weeksof order confirmationCommissioningby our field engineersrequiresapproximately Y daysonsite dependenton civils readiness

Q:What financing structuresare commonly usedfor equipmentof this scale?
A:The majorityof commercial buyersutilize capital leasesor projectbased financing whichcan often be structuredto includecapital sparesand initial service packagesWe workwith several industryspecific lenders