Targeting Primary Crushing Inefficiency: The High Cost of Compromise

Are your aggregate production or mining operations constrained by the primary crushing stage? Inefficient jaw crusher performance directly impacts your entire downstream process, manifesting as:

Excessive Downtime for Maintenance: Frequent liner changes and unplanned stops for blockages can consume 1520% of available operating hours, costing tens of thousands in lost throughput.
Unpredictable Product Gradation: Inconsistent feed opening dynamics and wear lead to poor size distribution, overworking secondary crushers and reducing final product yield.
Spiraling Operational Costs: Premature component wear, high energy consumption per ton, and high labor intensity for routine servicing erode profit margins.
Limited Feed Flexibility: Inability to handle a varied mix of feed materials (e.g., abrasive basalt, recycled concrete with rebar, highclay ores) forces production to slow down or stop.

Is your primary crusher a reliable asset driving profitability, or a recurring source of bottleneck and expense? The solution lies in specifying equipment engineered not just to crush, but to optimize total cost of ownership.

Product Overview: JC5000 HeavyDuty Jaw Crusher

The JC5000 is a robust, singletoggle jaw crusher engineered for highcapacity primary crushing in demanding quarrying, mining, and demolition recycling applications. Its design focuses on delivering consistent throughput with minimized operational intervention.

Operational Workflow:
1. Feed Intake: Large (500mm x 250mm) feed opening accepts runofmine or runofquarry material directly from haul trucks.
2. Compression Crushing: A steep nip angle and aggressive crushing motion applies intense compressive force to fracture material against the fixed jaw plate.
3. Discharge & Clearance: The hydraulically assisted toggle system provides quick reversal of the moving jaw to clear blockages and assist in tramp metal release without stopping the crusher.
4. Product Conveyance: Crushed material exits at a consistent CSS (Closed Side Setting), typically between 75mm 150mm, ready for secondary processing.

Application Scope & Limitations:
Ideal For: Hard rock quarries (granite, basalt), mediumscale mining operations, largescale construction waste recycling plants.
Limitations: Not designed for ultrafine grinding or as a standalone solution for finished aggregate. Maximum recommended feed size is 80% of the feed opening dimension. Requires a stable foundation and appropriate upstream feeding equipment.

Core Features: Engineering for Operational Superiority

Hydraulic Toggle Adjustment System | Technical Basis: Integrated hydraulic cylinder replaces mechanical shims | Operational Benefit: CSS adjustment takes minutes versus hours, performed safely from ground level | ROI Impact: Reduces downtime for product changeovers by up to 90%, increasing annual utilization.

QuarryGrade Eccentric Shaft | Technical Basis: Forged from highintegrity alloy steel, supported by oversized spherical roller bearings | Operational Benefit: Sustains peak load under shock conditions; bearings run cooler with extended L10 life | ROI Impact: Eliminates premature shaft failure; field data shows bearing service intervals extended by 40%.

Optimized Chamber Geometry | Technical Basis: Computermodeled kinematics create an aggressive nip angle and deep crushing chamber | Operational Benefit: Enhances throughput capacity and promotes slabby material breakage over flaking | ROI Impact: Delivers up to 10% more tons per hour at equivalent power draw compared to previous generation designs.

HeavyDuty Frame Construction | Technical Basis: Fabricated from stressrelieved steel plate with reinforced ribbing at all highstress points | Operational Benefit: Provides longterm alignment stability under cyclical loading, protecting internal components | ROI Impact: Mitigates risk of frame fatigue cracking, ensuring structural integrity over a 15+ year service life.

Enhanced Safety & Serviceability | Technical Basis: Centralized grease points; accessible cheek plate bolts; guarding integrated into structure | Operational Benefit| Routine maintenance tasks are faster and safer for technicians| ROI Impact| Lowers scheduled maintenance labor hours by an estimated 25%, improving site safety compliance.

Competitive Advantages: Measurable Performance Gains

The JC5000 Jaw Crusher is designed to outperform conventional solutions across critical metrics.

| Performance Metric | Industry Standard (Comparable Class) | JC5000 Solution Documented Performance | Advantage (% Improvement) |
| : | : | : | : |
| Availability (Uptime) | ~85% (factoring adjustment & blockage downtime)| >92% (with hydraulic toggle & clearing) | +8% |
| Liner Life (Abrasive Rock) | ~120,000 tons per set (Mn14%)| ~150,000 tons per set (Mn18% optional) | +25% |
| Energy Efficiency (kWh/tonne)| Varies widely; baseline = 1.0x factor| Field data shows consistent reduction averaging ~0.9x factor |10% |
| CSS Adjustment Time| 24 hours with crew| <30 minutes with single operator |87% |

Technical Specifications

Feed Opening: 500mm x 250mm
Max Feed Size: 400mm
Closed Side Setting Range: 75mm 150mm
Capacity Range: 180 350 tonnes per hour (dependent on feed material and CSS)
Drive Power Requirement: 75kW /100HP electric motor (standard)
Crusher Weight (excluding motor): Approximately 16 metric tonnes
Key Material Specifications:
Frame Fabrication Grade Steel
Jaw Plates Premium manganese steel (Mn14% standard; Mn18%, Mn22% optional)
Eccentric Shaft Forged EN24/34CrNiMo6 equivalent
Bearings Spherical roller bearings; Timken/SKF/FAG grade
Operating Temperature Range: 20°C to +40°C with standard lubricants.
Dimensions (L x W x H): ~3.5m x 2.8m x 2.9m

Application Scenarios

Granite Quarry Expansion Project Challenge:

A quarry needed to increase primary circuit throughput by 30% without expanding its footprint or major civil works. Their existing crusher created bottlenecks due to slow adjustment times and frequent liner wear checks.

Solution:

Implementation of one JC5000 Jaw Crusher as the new primary unit. Key features utilized were the hydraulic toggle for rapid product sizing changes between road base and rail ballast production runs.

Results:

Throughput goals were met within the first quarter. The site manager reported a 22% reduction in weekly labor hours dedicated to crusher maintenance and adjustments, reallocating personnel to other areas.

C&D Recycling Plant Upgrade Challenge:

A recycling plant processing mixed demolition waste faced excessive downtime from uncrushable materials jamming the primary jaw, requiring full shutdowns and manual clearing several times weekly.

Solution:

Replacement with a JC5000 Jaw Crusher equipped with an automatic hydraulic tramp release system integrated into the toggle mechanism.

Results:

Blockage events requiring full shutdown were virtually eliminated. The plant recorded a 17% increase in monthly processed volume due to reduced stoppages while protecting downstream conveyors from metal damage.

Commercial Considerations

Equipment pricing is structured around core configuration:

1. Base Machine Tier Includes crusher frame assembly drive sheave flywheels standard manganese liners guards lubrication system

2 Optional Feature Packages
Hydraulic Toggle Adjustment Kit Automatic Tramp Release System HeavyDuty Skid Base Frame Belt Drive Guard Package HigherGrade Manganese Liners Mn18Mn22

3 Service Support Packages Proactive maintenance plans are available including scheduled inspections parts kits priority technical support Extended warranty options can be negotiated based on application review

4 Financing Options Flexible commercial terms are offered through partnered financial institutions including equipment leasing capital loan structures or rentaltopurchase agreements tailored to project cash flow

Frequently Asked Questions FAQ

What power supply is required for the JC5000 A standard 75kW 400V50Hz3phase electric motor is supplied Can it be configured for diesel drive Yes skidmounted diesel drive packages are available as an option

How does the hydraulic toggle system affect reliability The system simplifies mechanics replacing dozens of manual shims It uses proven industrial hydraulic components designed specifically for highshock environments reliability data indicates no reduction in overall system uptime

What is the lead time on replacement wear parts Commonly used parts like jaw plates cheek plates are typically held in regional stock centers with availability within 48 weeks Nonstock items have a manufacturing lead time communicated upon order

Can the JC5000 handle wet sticky clayladen material While capable performance will be reduced compared to dry rock We recommend site evaluation For severe clay applications pre screening or grizzly feeding should be considered

What commercial terms are available Minimum order quantity is one 1 unit We offer comprehensive commercial support including FOB CIF DAP delivery terms based on customer location Full payment letters of credit are standard structured payment plans can be discussed