1. PAINPOINT DRIVEN OPENING

Are you managing primary crushing operations where inconsistent feed, abrasive materials, and unplanned downtime are eroding your profitability? Consider the tangible costs: a single hour of crusher downtime can halt an entire processing line, costing thousands in lost throughput. Premature wear on jaw dies from silica abrasion leads to frequent, costly changeouts and excessive maintenance labor. Inefficient crushing with poor nip angles results in higher energy consumption per ton and unwanted fines generation. Are you facing the challenge of achieving required capacity without a footprint that disrupts your plant layout? These operational hurdles directly impact your bottom line through increased cost per ton, missed production targets, and strained maintenance budgets. The central question for plant managers is this: how do you secure a primary crusher that delivers consistent performance, withstands severe service, and provides predictable operating costs?

2. PRODUCT OVERVIEW

The JC5000 Jaw Crusher is a highcapacity, singletoggle jaw crusher engineered for stationary primary crushing applications in mining, heavyduty construction, and largescale aggregate production. Its design focuses on reducing runofmine material or large quarry stone to a consistent product for secondary processing.

Operational Workflow:
1. Feed Intake: Large feed material (up to 1,400mm) is directed into the deep, nonchoking crushing chamber via a vibrating grizzly feeder (optional).
2. Crushing Action: A robust eccentric shaft drives a dynamically balanced moving jaw plate in an elliptical motion, applying compressive force against a fixed jaw plate.
3. Discharge: Crushed material exits through the bottom discharge opening, with size determined by the closedside setting (CSS), adjustable via hydraulic toggle adjustment.

Application Scope: Ideal for hard rock mining (iron ore, gold ore), granite/basalt quarries, and slag processing. It is designed as the first stage in a multistage reduction circuit.

Limitations: Not suitable for recycling applications with high levels of rebar or tramp metal without additional protection systems. Requires a stable concrete foundation and appropriate feed system engineering for optimal performance.

3. CORE FEATURES

Hydraulic Toggle Adjustment System | Technical Basis: Integrated hydraulic cylinder replaces manual shims | Operational Benefit: Enables remote CSS adjustment in under 2 minutes versus hours of manual labor; enhances safety by eliminating personnel entry into hazardous areas | ROI Impact: Reduces downtime for product size changes by over 90%, increasing plant flexibility and annual throughput.

Deep Symmetrical Crushing Chamber | Technical Basis: Optimized kinematics and chamber geometry derived from finite element analysis | Operational Benefit: Promotes uniform wear across jaw dies, extends liner life by up to 30%, and ensures consistent product gradation | ROI Impact: Lowers costperton for wear parts and reduces inventory requirements for spare liners.

HeavyDuty Spherical Roller Bearings & Forged Eccentric Shaft | Technical Basis: Oversized bearings with high load ratings and a onepiece machined shaft | Operational Benefit: Handles peak loads from uncrushable material; provides reliable operation under full load with minimal heat generation; extended bearing life | ROI Impact: Predictable maintenance intervals; eliminates premature bearing failure as a source of catastrophic downtime.

PLCBased Automation Interface | Technical Basis: Integrationready control system monitoring main drive amps, bearing temperature, hydraulic pressure | Operational Benefit: Allows operators to monitor crusher health in realtime and integrate into wider plant SCADA systems; enables automated overload protection | ROI Impact: Facilitates predictive maintenance scheduling and prevents costly damage from undetected anomalies.

Bolted & Doweled Main Frame Construction | Technical Basis: Stressrelieved steel sections joined with hightensile bolts on machined surfaces | Operational Benefit: Ensures longterm structural integrity under cyclic loading; simplifies field assembly and future relocation compared to welded frames | ROI Impact: Reduces installation time by approximately 25% and maintains precise bearing alignment for decades.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (Comparable Class) | JC5000 Jaw Crusher Solution | Advantage (% improvement) |
| : | : | : | : |
| Liner Life (Abrasive Rock)| ~450,000 tons per set (estimated)| ~600,000 tons per set (fieldverified) | +33% longer service life |
| Energy Consumption| Specific power draw of ~0.85 kWh/ton| Specific power draw of ~0.78 kWh/ton| Up to 8% more efficient |
| Adjustment Downtime| 46 hours for manual shim change| <10 minutes via hydraulic system| ~95% reduction in downtime |
| Bearing L10 Life| 25,000 hours under ideal conditions| 35,000 hours under rated load| +40% increase in rated life |

5. TECHNICAL SPECIFICATIONS

Capacity Range: 750 – 1,500 mtph (dependent on feed material & closedside setting)
Feed Opening: 1,500mm x 2,000mm (59" x 79")
Max Feed Size: Up to 1,400mm (55")
Drive Power: 200 kW / 250 HP electric motor (standard)
Total Weight: Approximately 125,000 kg (275,000 lbs)
Main Frame Construction: Highintegrity steel plate with bolted reinforcement
Jaw Die Material: Premium manganese steel (18% Mn)
Operating Temperature Range: 30°C to +45°C (22°F to +113°F) with standard lubrication
Discharge Setting Adjustment: Hydraulic system range from 200mm to 300mm

6. APPLICATION SCENARIOS

Hard Rock Iron Ore Mine – Australia

Challenge: A major iron ore operation faced excessive wear on their primary crusher jaws due to highly abrasive ore containing >60% silica. Liner changes every six weeks were causing significant production bottlenecks.
Solution: Implementation of the JC5000 Jaw Crusher equipped with specially profiled quarrygrade jaw plates.
Results: Field data shows jaw liner life increased from approximately 350k tons to over $550k tons before replacement required—a $57$ improvement—reducing annual planned downtime events by three.

Granite Aggregate Quarry – North America

Challenge: The quarry needed to switch final product sizes frequently between road base (50mm) and rail ballast (65mm), but manual CSS adjustments took half a shift each time.
Solution: Installation of the JC5000 with its integrated hydraulic toggle adjustment system.
Results: The plant now performs CSS changes remotely in under $10$ minutes versus $4$ hours previously. This flexibility has allowed them to capitalize on spot market demands for different products without sacrificing primary line availability.

7. COMMERCIAL CONSIDERATIONS

The JC5000 Jaw Crusher is offered as part of a modular solution package:

Base Equipment Tier: Includes crusher assembly with standard manganese jaws,motor drives,and lubrication system.
Optional Features & Modules: Motor starter VFD package,vibration monitoring sensors,dust suppression ring,fixed or vibrating grizzly feeder module,walkin maintenance platforms.
Service Packages: Tiered offerings include:
Basic commissioning & operator training.
Extended warranty coverage up to $36$ months on major components.
Annual inspection & condition reporting program.
Guaranteed parts availability program with $48$hour emergency dispatch.
Financing Options: Available through partner institutions including equipment leasing ($36$60 month terms),rentaltoown structures,and project financing tailored for large capital expenditures.

Pricing reflects its position as premium capital equipment designed for lowest longterm cost of ownership rather than lowest initial purchase price.Investment justification is based on total costperton over an expected minimum service life exceeding $15$ years.

8.FAQ

Q1:What existing plant infrastructure is required?
A1:The JC5000 requires a reinforced concrete foundation designed to specific dynamic load drawings provided by our engineering team.A compatible feed system capable of handling its maximum capacity is essential.Adequate overhead crane capacity ($150+ ton$) is recommended for servicing major components like the eccentric shaft assembly during planned rebuilds every $810$ years depending upon utilization rates observed within similar operations worldwide today

Q2:What impact will this have on my overall plant throughput?
A2:The high capacity ($7501500 mtph$) combined with exceptional reliability directly increases upstream mining or feeding efficiency while reducing bottlenecks downstream due primarily because it produces more consistent product sizes which allows secondary cone crushers operate optimally at their own designed settings leading ultimately towards higher overall circuit stability measured via increased availability percentages typically ranging between two percent ($2\%$) up five percent ($5\%$) according data collected across multiple sites globally since introduction last decade ago

Q3:What are typical lead times?
A3:Crushers are builttoorder following receipt firm purchase order.Current lead time stands at approximately nine months subject raw material supply chain conditions prevailing at time order placement however expedited delivery options may sometimes be available depending upon project schedule requirements discussed during initial quotation phase prior commitment being made either party involved transaction process itself

Q4:What training do you provide?
A4:A comprehensive training program accompanies every installation covering safe operation routine maintenance procedures troubleshooting common issues using actual machine supplied customer site sessions conducted both classroom handson formats lasting total three days duration additionally detailed manuals videos remain accessible online throughout ownership period thereafter ensuring knowledge transfer complete effective manner possible given constraints present modern industrial environments today

Q5:What happens if we encounter tramp metal or an uncrushable object?
A5:The hydraulic toggle system serves dual purpose acting also as automatic release mechanism should uncrushable object enter chamber When pressure exceeds preset limit toggle cylinder relieves allowing moving jaw retreat protecting main frame bearings shaft other critical components from catastrophic damage Once object cleared normal operation resumes quickly minimizing potential disruption caused such events significantly compared designs lacking this protective feature entirely