1. PAINPOINT DRIVEN OPENING

Are escalating operational costs and unpredictable downtime eroding your aggregate or mining profit margins? For plant managers and engineering contractors, primary crushing is a critical bottleneck where failures cascade into costly production halts. Common challenges include:
Excessive Wear Part Costs: Frequent replacement of jaw dies due to improper kinematics or material quality, directly impacting your costperton.
Unscheduled Downtime: Premature bearing failures or structural issues from uncrushable materials, stopping your entire processing line.
Inconsistent Output & Product Shape: Poorly controlled discharge settings leading to irregular product gradation, downstream clogging, and reduced final product value.
High Energy Consumption: Inefficient crushing chambers and drive systems that consume excessive power without proportional throughput gains.
Maintenance Complexity: Lengthy, unsafe procedures for routine tasks like setting adjustment or wear part replacement, increasing labor hours and risk.

What if your primary crusher could deliver predictable performance, lower operating costs, and adapt to varying feed materials? The solution requires robust engineering focused on total cost of ownership.

2. PRODUCT OVERVIEW

The JC5000 is a highcapacity, singletoggle jaw crusher engineered for heavyduty primary crushing in quarrying, mining, and demolition recycling applications. Its design prioritizes mechanical reliability and operational efficiency for processing hard rock, ores, and concrete.

Operational Workflow:
1. Feed Intake: Large (up to 1300mm) feed material is directed into the deep, nonchoking crushing chamber.
2. Crushing Action: An aggressive elliptical stroke motion applies high inertia force at the nip angle, breaking material efficiently on both the forward and return strokes.
3. Discharge Control: The closedside setting (CSS) is hydraulically adjustable from a single control point while the machine is under load or stopped.
4. Product Conveyance: Crushed material exits via a large discharge area onto your primary conveyor system.

Application Scope & Limitations:
Scope: Ideal for hightonnage stationary primary crushing plants targeting consistent aggregate production (typically 350mm output) or preparing runofmine ore for secondary processing.
Limitations: Not designed for ultrafine grinding or as a standalone tertiary crusher. Maximum feed size and capacity are contingent on material abrasiveness and density.

3. CORE FEATURES

Hydraulic Toggle Adjustment System | Technical Basis: Dualacting hydraulic cylinders replace mechanical toggle plates | Operational Benefit: Allows operators to adjust the crusher setting in under two minutes for product size changes or to clear a stalled chamber | ROI Impact: Reduces downtime for adjustments by up to 80% compared to manual shim systems.

HeavyDuty Spherical Roller Bearing Cartridge | Technical Basis: Forged steel cartridge with oversized bearings rated for high radial and axial loads | Operational Benefit: Eliminates common stress points; enables reliable operation under peak loads with extended service intervals | ROI Impact: Field data shows bearing life improvements of 3050% in abrasive environments.

Optimized Crushing Chamber Geometry | Technical Basis: Computermodeled kinematics create an aggressive nip angle and deep vertical chamber | Operational Benefit: Enhances throughput capacity while promoting slabby product reduction for better shape characteristics | ROI Impact: Increases throughput by 1015% over previous generation designs with similar power input.

Bolted Main Frame Construction | Technical Basis: Fabricated from hightensile steel plates joined with machined interfaces and hardened bolts | Operational Benefit: Provides superior fatigue resistance versus welded frames; simplifies potential site assembly or future transport | ROI Impact: Mitigates risk of catastrophic frame weld failure, ensuring longterm structural integrity.

Integrated Motor Mount & Drive Guard | Technical Basis: Unified base frame accommodates motor and Vbelt drive with fulllength safety guards | Operational Benefit: Simplifies installation alignment, reduces footprint, and enhances operator safety during operation | ROI Impact: Lowers installation time/cost by approximately 15% through preengineered fitment.

QuickChange Jaw Die Retention System | Technical Basis: Wedgelock system secures jaw dies without complex backing materials or lengthy bolting procedures | Operational Benefit Your maintenance crew can perform liner changes more quickly and safely| ROI Impact Cuts wear part replacement downtime by an average of 25%.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (Comparable Class) | JC5000 Jaw Crusher Solution | Advantage (% Improvement) |
|||||
| Wear Life (Abrasive Rock) | ~450,000 tons per set | Up to 600,000 tons per set | +33% |
| Setting Adjustment Time | 6090 minutes (manual shim) | 92% utilization | +35% |
| Annual Planned Maintenance Hours Estimated at 120150 hours Documented average of 90 hours |25% |
| Noise Emission at 10m ~85 dBA ~78 dBA Reduction of ~7 dBA |

_Based on OEM recommended service schedules._

5. TECHNICAL SPECIFICATIONS

Feed Opening: 1300mm x 1000mm (51" x 40")
Maximum Feed Size: Up to 1100mm edge length (subject to material type)
Capacity Range: 500 1200 mtph (dependent on feed material & CSS)
Drive Power Requirement: 200 kW / 250 hp electric motor (standard)
Total Weight (Crusher Only): Approximately 62,000 kg
Main Frame Material: Highstrength steel plate (ASTM A36 equivalent)
Jaw Die Material Options: Manganese steel (14%,18%,22%), optional premium alloys
Operating Temperature Range: 20°C to +40°C (4°F to +104°F)
Hydraulic System Pressure: Standard working pressure of 180 bar

6. APPLICATION SCENARIOS

Granite Quarry Primary Crushing Plant Challenge A quarry in Eastern Europe faced frequent downtime from tramp metal incidents and needed faster product changeovers between aggregate grades Solution Installation of a JC5000 Jaw Crusher equipped with the hydraulic toggle system Results Unplanned downtime from clearing events reduced by an estimated 70 hours annually Product changeover time decreased from 75 minutes to under 10 minutes contributing to an overall 8 increase in annual production volume

Iron Ore Primary Crushing Station Challenge An aging jaw crusher at a mine site required excessive maintenance offered poor energy efficiency per ton crushed and produced excessive fines Solution The JC5000 replaced the legacy unit with its optimized chamber geometry and efficient drive system Results Throughput increased by 12 while specific energy consumption kWh per ton dropped by 9 The improved product profile reduced recirculating load in the secondary circuit

7. COMMERCIAL CONSIDERATIONS

The JC5000 Jaw Crusher is offered in several commercial configurations:

Pricing Tiers:

1. Base Machine Includes crusher main frame flywheels standard jaw dies motor mount basic guards
2 Production Package Adds hydraulic toggle adjustment system automatic lubrication system premium AR400 jaw dies
3 Turnkey Skid Package Crusher pre mounted on a heavy duty skid complete with motor drives guards walkways

Optional Features Durable composite belt guards onboard dust suppression spray system remote monitoring telematics gateway various wear part alloy options

Service Packages Proactive maintenance plans are available including scheduled inspections genuine parts supply agreements emergency breakdown support Extended warranties are offered when bundled with certified installation

Financing Options Flexible commercial structures can be arranged including capital purchase finance leases or operating leases tailored to balance sheet requirements Project financing support may be available for large scale turnkey installations

8 FAQ

Q What conveyor capacity is required downstream of the JC5000
A To match peak capacity we recommend a main product conveyor rated for at least 1400 mtph with appropriate width speed and impact resistance

Q Can the JC5000 handle recycled concrete with rebar
A Yes its robust construction can process reinforced concrete However consistent feeding of large uncrushable metal pieces like excavator teeth should be avoided using proper prescreening A tramp release system is recommended for such applications

Q How does the hydraulic toggle affect maintenance compared to a traditional system
A It eliminates mechanical shear pins toggle plates seats springs It introduces routine checks of hydraulic fluid level hose integrity Minor leaks are more easily detected than impending mechanical failure reducing risk of secondary damage

Q What is the expected operational lifespan of the main crusher structure
A With proper maintenance industry testing demonstrates that the bolted main frame design can exceed years even in continuous service assuming no abnormal overload events Structural components are not considered consumable items

Q Are installation drawings certified for international projects
A Yes comprehensive general arrangement foundation loading electrical interface drawings are stamped by licensed professional engineers PE suitable for submission to regional permitting authorities

Q What training is provided for our operations team
A Standard delivery includes detailed operation manuals digital access portal videos Onsite commissioning includes handson training Optional multiday operator maintenance courses are available at our training center