1. PAINPOINT DRIVEN OPENING

Are escalating operational costs and unpredictable downtime eroding your quarry or mine’s profitability? Primary crushing is a critical bottleneck, and equipment failure here cascades through your entire processing line. Key challenges you likely face include:

Excessive Downtime for Maintenance: Frequent liner changes and unexpected mechanical repairs halt production. Every hour of lost crushing capacity represents significant lost revenue.
High Wear Part Consumption: The cost and labor associated with regularly replacing jaws, cheek plates, and other wear components directly impact your bottom line.
Inconsistent Throughput & Product Shape: An unreliable or underperforming crusher fails to deliver the steady, inspec feed needed for downstream screening and secondary crushing, creating inefficiencies.
Spiraling Energy Costs: Older or inefficient crushers consume disproportionate power for their output, making energy one of your largest variable costs.
Structural Integrity Concerns: Fatigue and stress in the crusher frame or pitman assembly can lead to catastrophic failures, posing safety risks and requiring monumental repair expenses.

Is your primary crusher a source of constant concern rather than a pillar of reliability? It’s time to evaluate a solution engineered for durability and total cost of ownership.

2. PRODUCT OVERVIEW

The JC5000 Jaw Crusher is a highcapacity, singletoggle jaw crusher engineered for heavyduty primary crushing in mining, quarrying, and largescale demolition recycling applications. Its robust design focuses on maximizing uptime and minimizing operational expense in the most demanding environments.

Operational Workflow:
1. Feed Intake: Large runofmine (ROM) material is delivered via dump truck or loader into the vibrating grizzly feeder (optional), which bypasses fines to optimize crushing chamber efficiency.
2. Crushing Action: Material enters the deep, nonchoking crushing chamber. The aggressive elliptical jaw motion applies high pressure at the inlet, breaking large boulders efficiently.
3. Discharge: Crushed product exits at the bottom with a consistent discharge setting, ready for conveyor transport to secondary processing or stockpiling.

Application Scope: Ideal for hard rock (granite, basalt), iron ore, and abrasive aggregates. Suitable for both stationary plants and large mobile tracked setups.

Limitations: Not designed for wet, sticky materials without proper feed system modifications. Requires a solid foundation due to its mass and dynamic forces.

3. CORE FEATURES

Deep Crushing Chamber & Aggressive Kinematics | Technical Basis: Optimized nip angle and long stroke at inlet | Operational Benefit: High reduction ratio in a single pass, reduces need for prebreaking | ROI Impact: Lower primary blast energy costs, increased throughput per cycle.

HeavyDuty Fabricated Frame | Technical Basis: Stressrelieved steel plate construction with finite element analysis (FEA) optimization | Operational Benefit: Eliminates frame fatigue cracking under cyclical loading | ROI Impact: Avoids catastrophic structural repair costs and extends crusher service life by decades.

Hydraulic Toggle Adjustment System | Technical Basis: Replaceable hydraulic cylinder for tensioning & clearing tramp metal | Operational Benefit: Enables quick, safe CSS adjustment and automatic release/reset from uncrushables | ROI Impact: Reduces downtime for setting changes by over 70% and protects major components from damage.

Bolted Bearing Cartridges | Technical Basis: Preassembled, machined cartridge housings with oversized spherical roller bearings | Operational Benefit: Simplifies bearing maintenance; allows for replacement without disturbing shaft or flywheels | ROI Impact: Cuts scheduled bearing service time by 50%, reducing labor costs.

Wedge Lock Jaw Die Retention System | Technical Basis: Mechanically locked wedges secure front and rear jaw dies | Operational Benefit: Faster, safer jaw die changes without backing material adhesives | ROI Impact: Reduces liner changeout time, increasing crusher availability.

Centralized Greasing Point | Technical Basis: Singlepoint lube distribution to all major bearings | Operational Benefit: Ensures consistent lubrication during routine maintenance checks | ROI Impact: Prevents bearing failures due to missed grease points, enhancing reliability.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (Competitive Class) | JC5000 Jaw Crusher Solution | Advantage (% improvement) |
| : | : | : | : |
| Liner Life (Abrasive Granite) | ~ 120,000 MTON | ~ 150,000 MTON| +25% |
| Time for Jaw Die Change (2 personnel) | 68 hours average| 34 hours average| 50% |
| Energy Efficiency (kWh/tonne) at CSS| Varies; baseline = 100%| Field data shows consistent reduction| 10 to 15% |
| Annual Planned Maintenance Hours excluding liners| ~ 80 hours/year estimated| ~ 50 hours/year documented| 37% |
| Bearing Service Interval (Primary) under normal duty| ~ 1218 months typical recommendation| >24 months documented service life common| +33% extension |

_(Based on internal field performance audits under comparable operating conditions.)_

5. TECHNICAL SPECIFICATIONS

Feed Opening: 1300mm x 1600mm (51" x 63")
Maximum Feed Size: ~1100mm (43") lump
Closed Side Setting (CSS) Range: 150mm 300mm (6" 12")
Capacity Range (dependent on material & CSS): Up to 1,500 tonnes per hour
Drive Power Requirement: 200 kW / Up to kW options available
Crusher Weight (excluding motor & drive): Approximately ~95 Tonnes
Key Material Specifications:
Frame Fabrication: Highyield strength steel plate
Jaw Dies Premium manganese steel; multiple profiles available
Shaft Forged alloy steel
Flywheels Ductile cast iron
Bearings Oversized spherical roller type

6. APPLICATION SCENARIOS

Granite Quarry Expansion Project Challenge:

A large aggregate producer needed to increase primary circuit throughput by over % but was constrained by existing foundation space and high wear costs on their older jaw crusher.

Solution:

Two JC5000 Jaw Crushers were installed in parallel configuration due to their high individual capacity fitting within spatial limits.

Results:

Plant capacity increased by %. Combined liner life improved %, reducing annual consumable costs by an estimated $,. The hydraulic toggle system allowed rapid adjustments between rail ballast and concrete aggregate products.

Iron Ore Processing Plant Upgrade Challenge:

An iron ore operation faced chronic downtime from tramp steel damaging their primary crusher's toggle mechanism,causing weekly stoppages averaging hours each.

Solution:

Replacement with a JC5000 Jaw Crusher equipped with the automatic hydraulic toggle release system.

Results:

Unplanned stoppages due to tramp metal were virtually eliminated.The system automatically releasesand resets,saving an estimated + hours of lost production annually.Maintenance team safety was significantly improved during clearing procedures.

7. COMMERCIAL CONSIDERATIONS

The JC5000 Jaw Crusher is offered as a capital investment focused on longterm operational savings.Pricing is structured around core configuration:

• Base Equipment Tier Includes fabricated crusher with standard jaw dies,bearings,lubrication system,and drive sheaves.Foundation drawingsand basic manuals provided.
• Plant Integration Tier Adds motor starter package,vbelt drive guard,fixed plant mounting rails,and commissioning support services.This tier optimizes installation time.
• Optional Features Custom grizzly feeder modules,wearsensor packagesfor liner monitoring,dust suppressionskirt kits,and automated grease systemsare availableto match specific site requirements.
• Service Packages Extended warranty plans,predictive maintenance programswith vibration analysis,and guaranteed wear part performance contracts can be negotiatedto provide fixedcost operational certainty.
• Financing Options Flexible capital equipment leasing structuresand project financing are available through partners,moving the investment from CAPEXto OPEXfor improved cash flow management.A detailed costofownership analysisis recommendedto justifythe business case.

8. FAQ

What are the foundation requirementsfor installinga JC5000?
Detailed civil engineering drawingsare suppliedwith purchase.The design accountsfor dynamic loads,but sitespecific soil testingis always recommended.A substantial reinforced concrete foundationis required;our engineering team can reviewyour proposed installation plans.

Can we use our existing electric motorand drive components?
Potentially yes.The JC5000 can be configuredto match various drive arrangements.Critical specificationslike motor speed,KW rating,and sheave sizemust be reviewedby our application engineersduringthe quotation processto ensure compatibilityand optimal performance.

How does the hydraulic togglecompare mechanicallyto traditional systems?
It replacesmechanical toggle platesand tension rods.The hydraulic cylinderperforms the same tensioningfunction but adds the critical capabilityof adjustingthe CSSvia remote controland providingan immediate releasechamberin secondsif an uncrushableobject enters.This protects themain shaft,bearings,and frame from overloadforces that would otherwisecause severe damageand extendeddowntime.What isthe expectedlead timefrom orderto delivery?
Lead timesvary basedon current production schedulesand optional features.Typical lead timefor a standardconfiguration rangesbetween weeksupon receiptof order.A firm scheduleis providedwith your formal quotation.Can spare partsbe sourcedlocally?
While major fabricated componentsare supplieddirectly,critical consumableitemslike seals,bearings,and standardfastenershave globallyavailablepart numbers.We providea comprehensivecrossreference listto facilitate local sourcingwhere possiblefor faster turnaroundon general maintenanceitems.What trainingis providedfor our maintenancecrew?
Comprehensiveoperationaland maintenance manualsare included.Virtualor onsite training sessionscoveringdaily inspections,safe liner change procedures,CSS adjustment,and basic troubleshootingare offeredas part ofthe commissioningpackageor asa separate service.How doesyour companyhandle technical supportafter installation?
Support is providedthrough dedicatedregional service managers.They coordinatewith authorizedservice partnersworldwidefor onsite needs.Remote supportvia phoneand video callis availablefor immediate troubleshooting.We maintaina complete digital recordof your machine'sasbuilt configurationfor precise partsidentification