1. PAINPOINT DRIVEN OPENING

Are escalating operational costs and unpredictable downtime eroding your aggregate or mining profit margins? Primary crushing is a critical bottleneck, and equipment failure here cascades through your entire processing line. Common challenges include:
Excessive Wear Costs: Frequent replacement of jaw dies and side liners due to improper kinematics or material choice, directly impacting your costperton.
Unscheduled Downtime: Premature bearing failures or structural issues requiring fullday shutdowns for major repairs, halting production.
Inconsistent Output & Bridging: Poorly designed crushing chambers causing uneven wear, product gradation fluctuations, and material bridging that requires hazardous manual intervention.
High Energy Consumption: Inefficient drives and heavy, overbuilt structures that consume excessive power without proportional throughput gains.
Rigid Inflexibility: Fixed configurations that cannot adapt to changing feed materials or final product requirements without significant modification.

Is your primary crusher a reliable asset or a recurring liability? The solution requires engineering focused on total cost of ownership, not just initial purchase price.

2. PRODUCT OVERVIEW

The JC5000 Jaw Crusher is a highcapacity, singletoggle primary crusher engineered for the most demanding quarrying, mining, and demolition recycling applications. Its design prioritizes mechanical reliability and longterm operational economy in continuous heavyduty service.

Operational Workflow:
1. Feed & Compression: Large feed material (up to 1.5m edge length) enters the deep, nonchoking crushing chamber.
2. Progressive Crushing: The aggressive elliptical motion of the singletoggle jaw applies high pressure at the inlet, breaking large particles immediately, and continues through the chamber for consistent reduction.
3. Discharge & Clearance: The optimized discharge setting allows crushed material to exit freely with minimal restriction, preventing powerrobbing recirculation and ensuring high throughput.

Application Scope: Ideal for hard rock (granite, basalt), abrasive ores, and concrete demolition debris. Designed as the first stage in a multistage reduction plant.
Limitations: Not suitable for sticky, clayrich materials without prescreening; maximum capacity is defined by feed material density and crushability (Wi).

3. CORE FEATURES

HEAVYDUTY ROTATING ASSEMBLY | Technical Basis: Forged eccentric shaft with oversized spherical roller bearings | Operational Benefit: Handles peak loads from uncrushable objects and variable feed; extends bearing service life beyond 20,000 hours in documented cases | ROI Impact: Reduces risk of catastrophic bearing failure; lowers longterm maintenance parts budget.

ADAPTABLE CRUSHING CHAMBER | Technical Basis: Modular jaw die profiles (quarry, super tooth, slab breaker) and multiple side liner options | Operational Benefit: Operators can configure chamber geometry to optimize for feed size or product shape without changing the crusher body | ROI Impact: Maximizes yield of inspec product; extends wear part life by matching profile to application.

HYDRAULIC TOGGLE ADJUSTMENT & CLEARANCE | Technical Basis: Integrated hydraulic cylinder for setting adjustment and automatic tramp iron release | Operational Benefit: CSS changes take minutes versus hours; uncrushables are ejected without shearing pins or causing stall conditions | ROI Impact: Minimizes downtime for product changes; protects major components from overload damage.

DEEPLY RIBBED FRAME CONSTRUCTION | Technical Basis: Finite Element Analysis (FEA)optimized frame design with stressdiffusing ribbing | Operational Benefit: Distributes high cyclic loads evenly; eliminates frame fatigue cracking observed in boxsection designs | ROI Impact: Ensures structural integrity over the full machine lifecycle; avoids costly frame repairs or replacements.

DIRECT DRIVE SYSTEM WITH VBELT GUARD | Technical Basis: Hightorque motor coupled directly to flywheel via multiple Vbelts with a quickrelease safety guard | Operational Benefit: Efficient power transmission (>96%); simplified belt tensioning and safe, rapid access for inspection | ROI Impact: Lower electrical consumption per ton crushed; reduces maintenance time by 50% compared to complex gearbox systems.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (55"x80" Class) | JC5000 Jaw Crusher Solution | Advantage (% improvement) |
| : | : | : | : |
| Wear Life of Jaw Dies (Abrasive Granite) | 180,000 220,000 tons per set | 260,000 300,000 tons per set | +25% to +35% |
| Average Energy Consumption per Ton Crushed| 0.85 1.0 kWh/t @ CSS 200mm| 0.72 0.82 kWh/t @ CSS 200mm| 15% to 18% |
| Time for ClosedSide Setting Adjustment| 46 hours (shim adjustment)| <1 hour (hydraulic adjustment)| 80% |
| Bearing Service Life (L10 Rating) | ~12,000 hours| ~20,000 hours| +65% |

5. TECHNICAL SPECIFICATIONS

Feed Opening: 1400mm x 1200mm (55" x 47")
Maximum Feed Size: Up to 1500mm edge length
Capacity Range: 750 1500 mtph (dependent on feed material and CSS)
Drive Power Requirement: 375 kW /500 HP electric motor
Crusher Weight (excluding motor): Approximately 95 tonnes
Main Frame Construction: Highintegrity welded steel plate with reinforced ribbing
Jaw Die Material Options: Manganese steel (14%,18%,22%), Composite alloys
Operating Temperature Range: 30°C to +45°C with standard lubrication
Discharge Setting Range (CSS): 150mm – 300mm

6. APPLICATION SCENARIOS

Granite Quarry Expansion Project

Challenge A major quarry needed to increase primary throughput by 40% but was constrained by space for a second crusher and high wear costs on existing equipment.
Solution Installation of one JC5000 Jaw Crusher with "Quarry" profile jaw dies replaced two older smaller units.
Results Throughput increased by 45%. Wear part life improved by 30%, reducing annual consumables cost by an estimated $65，000。 Plant footprint was reduced， allowing for better stockpiling logistics。

Iron Ore Processing Plant Upgrade

Challenge An aging primary crusher suffered from chronic frame fatigue cracks， causing unplanned outages every 810 weeks， jeopardizing pellet plant feed。
Solution The JC5000 was selected specifically for its FEAoptimized frame design。 Installation was planned during a scheduled refinery shutdown。
Results After 24 months of continuous operation， no structural issues have been observed。 Plant availability at the primary stage increased from 88% to >99%， securing downstream production。

7. COMMERCIAL CONSIDERATIONS

The JC5000 Jaw Crusher is offered in three core configuration tiers:
1. Base Machine Tier Includes crusher， motor mounts， drive guards，and basic tooling。
2。 Production Ready Tier Adds hydraulic setting adjustment， automated lubrication system，and motor/Vbelts。
3。 Plant Integrated Tier Includes full walkways， handrails， dust sealing kits，and PLC integration packages。

Optional features include different jaw die metallurgies， wear monitoring systems，and skidmounted configurations。

Service packages range from annual inspection plans to comprehensive lifecycle management contracts covering parts supply（with guaranteed pricing）and prioritized technical support。

Financing options include capital lease agreements operating leases（payperton models available），and traditional equipment loans through our partnered financial institutions。

8.FAQ

Q What is the lead time for a standard JC5000 unit？
A Lead times vary based on configuration。 A Production Ready Tier unit typically has a lead time of 1620 weeks from order confirmation。

Q Can the JC5000 be integrated with our existing plant control system？
A Yes。 The crusher can be supplied with standard I/O interfaces compatible with most industrial PLCs allowing remote monitoring of key parameters like power draw和hydraulic pressure。

Q How does the hydraulic toggle system affect maintenance compared to traditional shim systems？
A It significantly reduces labor time和exposure risk。 There are no heavy shims to handle。 All adjustments are made via a portable power unit improving both safety和speed。

Q What kind of foundation is required？
A Due to its robust design和effective vibration damping pads included），the JC500U requires a substantial but standard reinforced concrete foundation。 Detailed civil drawings are provided upon order。

Q Are wear parts readily available？
A Yes。 We maintain regional inventory hubs for critical wear parts like jaw dies和side liners ensuring availability within 4872 hours in most major markets under our service plans。

Q Does this crusher handle recycled concrete with rebar？
A Effectively 。 The hydraulic toggle release will automatically eject tramp metal like rebar protecting the crusher from damage。 We recommend pairing it with an overband magnet postcrushing。

Q What is the expected operational lifespan of the main structure？
A Industry data on similar FEAdesigned frames indicates a structural lifespan exceeding 25 years in continuous operation when maintained according to protocol