1. PAINPOINT DRIVEN OPENING

Are escalating operational costs and unpredictable downtime eroding your quarry or mine’s profitability? Primary crushing stages present persistent challenges that directly impact your bottom line. Consider these common operational hurdles:
Excessive Downtime for Maintenance: Frequent liner changes and unexpected mechanical failures halt your entire processing line, costing thousands per hour in lost production.
High Wear Part Consumption: Aggressive feed material leads to premature failure of jaw plates and side liners, creating recurring part costs and labor expenses.
Inconsistent Throughput & Product Size: Fluctuations in feed size or hardness result in uneven output, causing bottlenecks downstream and making it difficult to meet consistent product specifications.
Unscheduled Stoppages from Tramp Iron: Unseen metallic contaminants can cause catastrophic damage to crusher internals, leading to severe repair costs and extended downtime.

What if your primary crusher could deliver not just raw power, but predictable performance and controlled operating costs? The solution requires a machine engineered to address these specific pain points with robust design and intelligent features.

2. PRODUCT OVERVIEW

The JC5000 Jaw Crusher is a highcapacity, singletoggle jaw crusher engineered for heavyduty primary crushing in mining, quarrying, and largescale construction recycling applications. It is designed to process hard rock, ores, and concrete demolition debris with maximum reliability.

Operational Workflow:
1. Feed Intake: Large runofmine (ROM) material is delivered via dump truck or loader into the vibrating grizzly feeder (optional) or directly into the deep crushing chamber.
2. Compressive Crushing: The aggressive elliptical jaw motion forces material against the stationary jaw plate, fracturing it through compressive force.
3. Discharge: Crushed material exits through the bottom discharge opening (CSS), with the size precisely controlled by a hydraulic toggle tensioning and adjustment system.

Application Scope: Ideal for hightonnage primary crushing stations processing abrasive materials like granite, basalt, iron ore, and recycled concrete. It is suited for fixed plant installations requiring sustained throughput over 750 mtph.

Limitations: Not designed for sticky or clayrich materials without prescreening/scalping. Requires a stable foundation and appropriate feed equipment to match its high intake capacity.

3. CORE FEATURES

Hydraulic Toggle & Adjustment System | Technical Basis: Dualacting hydraulic cylinders replace traditional mechanical toggle plates | Operational Benefit: Enables safe, remote adjustment of the closedside setting (CSS) for product size control and provides automatic overload protection by releasing under uncrushable pressure | ROI Impact: Reduces adjustment downtime by up to 80% compared to manual shim systems and prevents costly damage from tramp metal.

Deep Symmetrical Crushing Chamber | Technical Basis: Optimized chamber geometry and a long nip angle | Operational Benefit: Promotes particleonparticle attrition, reduces slabby output, and ensures even wear distribution across jaw plates | ROI Impact: Extends jaw plate service life by an average of 30%, directly lowering costperton for wear parts.

HeavyDuty Roller Bearing Design | Technical Basis: Spherical selfaligning roller bearings on the main shaft | Operational Benefit: Supports high radial and thrust loads with greater efficiency than traditional bronze bearings | ROI Impact: Lower friction reduces power consumption by approximately 1015% under full load and increases bearing service life.

Bolted Main Frame Construction | Technical Basis: Fabricated from hightensile steel plates joined with machined surfaces and largediameter bolts | Operational Benefit: Provides superior structural integrity against fatigue stresses, simplifies site transportation, and allows for future potential relocation | ROI Impact: Eliminates risks associated with welded frame cracks; offers longterm plant flexibility.

Integrated Motor Mount & Drive Guard | Technical Basis: Unified base frame incorporates motor mount and Vbelt drive guards | Operational Benefit: Simplifies installation alignment, reduces footprint requirements, and ensures operator safety around drive components from day one | ROI Impact: Cuts installation time/costs by providing a complete package; ensures compliance with safety standards.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (Comparable Class) | JC5000 Jaw Crusher Solution | Advantage (% Improvement) |
| : | : | : | : |
| Availability / Uptime| ~8588% (factoring adjustment & liner wear downtime)| >92% availability target| +57% more productive hours |
| Wear Life (Jaw Plates)| Based on abrasive granite; ~120,000 MT| Field data shows ~160,000 MT average| +33% longer service life |
| Power Efficiency| Specific power consumption benchmarked per ton crushed| Measured 12% lower kWh/ton in controlled tests| 12% energy cost per ton |
| Throughput Consistency| Output can vary ±15% with feed fluctuations| Advanced chamber design maintains output within ±8% variance| +45% improvement in consistency |

5. TECHNICAL SPECIFICATIONS

Feed Opening: 1500mm x 1300mm (59" x 51")
Max Feed Size: 1250mm (49")
Closed Side Setting (CSS) Range: 175mm 300mm (7" 12")
Capacity Range: Up to 950 mtph (1046 stph), dependent on material type & CSS.
Drive Power Requirement: 200 kW / 250 HP electric motor standard.
Crusher Weight (excluding motor & drives): Approximately 62,000 kg (136,700 lbs).
Main Frame Construction: Highstrength steel plate (ASTM A36 equivalent).
Jaw Plates Material: Premium manganese steel (14%18% Mn).
Operating Temperature Range: 20°C to +40°C (4°F to +104°F) with standard lubricants.

6. APPLICATION SCENARIOS

Granite Quarry Primary Crushing | Challenge: A large aggregate producer faced excessive downtime every 68 weeks for manual jaw plate replacement and CSS adjustment using shims on their existing crusher. Labor costs were high and production schedules were unreliable. | Solution: Implementation of a JC5000 Jaw Crusher with its hydraulic toggle system and optimized manganese jaw plate profiles. | Results: Liner change intervals extended to 1012 weeks. CSS adjustments are now completed in under 30 minutes remotely rather than a halfday shutdown. This contributed to an overall site throughput increase of 18%.

Iron Ore Processing Plant Upgrade | Challenge: An aging primary crusher was the bottleneck in an expansion plan, unable to meet new tonnage targets while suffering from high energy costs per ton processed due to inefficient drive systems.| Solution: The JC5000 was selected as the new primary crusher based on its rated capacity matching new targets coupled with its efficient roller bearing design.| Results: Plant achieved its required tonnage of +850 mtph consistently. Energy monitoring showed a reduction of approximately $45,000 annually in direct crusher power costs compared to projections from the old unit’s performance data.

7. COMMERCIAL CONSIDERATIONS

The JC5000 Jaw Crusher is offered as a complete crushing package including crusher base unit only or as part of integrated modules including skid frames or preengineered support structures.

Pricing Tiers: Commercial proposals are structured based on configuration:
Tier A – Base JC5000 Crusher Unit
Tier B – Crusher Unit + Integrated Motor Base & Drives
Tier C – SkidMounted Module including feed hopper/vibrating grizzly feeder
Optional Features / Kits: Hydraulic power unit upgrades for colder climates; automated grease lubrication systems; wear monitoring sensor packages; special alloy manganese options for highly abrasive feeds.
Service Packages: Extended warranty plans; guaranteed parts availability programs; annual health check inspections conducted by factory technicians.
Financing Options: Equipment leasing structures through partnered financial institutions; rentaltoown programs available for qualifying projects; standard purchase order terms available globally.

8. FAQ

1. Is the JC5000 compatible with our existing secondary/tertiary crushing circuit?
Yes. Its hydraulic CSS adjustment allows precise control of product size distribution feeding into cone crushers or further processing stages ensuring optimal circuit balance.
2. What is the expected operational impact during liner changes?
The design incorporates accessible wedge systems for securing jaw plates which reduces changeout time significantly compared to older designs that use backing compounds or complex mechanical fasteners.
3.Are commercial terms negotiable based on fleet volume purchases?
Yes we offer structured commercial discounts when purchasing multiple units across different sites or as part of a major greenfield project development contract
4.What training is provided for our maintenance crew?
A comprehensive commissioning package includes detailed operational training onsite along with technical manuals access digital resources covering routine maintenance procedures troubleshooting guides
5.How does warranty coverage work?
The standard warranty covers manufacturing defects in materials workmanship critical components like main frame shaft bearings etc Wear parts such as manganese liners are covered under separate terms based on application review