1. PAINPOINT DRIVEN OPENING

Are your primary crushing operations constrained by inconsistent throughput, punishing maintenance costs, and unplanned downtime? For plant managers and engineering contractors, the primary crusher is the cornerstone of mineral processing and aggregate production. When it underperforms, the entire operation feels the impact. Consider these common challenges:
Unscheduled Downtime: Bearing failures or component wear can halt your entire processing line, costing thousands per hour in lost production.
High Wear Part Consumption: Aggressive feed materials rapidly degrade jaw dies, leading to frequent changeouts, high parts inventories, and labor costs that erode profit margins.
Inconsistent Product Gradation: An unstable or inefficient crushing chamber fails to produce a consistent, wellshaped product, creating bottlenecks for downstream screening and secondary crushing stages.
Excessive Energy Draw: Inefficient crushing motion and outdated drive systems result in higherthannecessary power consumption, a direct and growing operational expense.
Rigidity & Foundation Issues: A crusher frame lacking structural integrity can lead to premature fatigue, alignment problems, and require costly, reinforced foundations.

Is your current solution equipped to deliver the reliability and costpertonne metrics required in today’s competitive market? The specification of your primary jaw crusher is a critical capital decision with decadelong implications for operational efficiency.

2. PRODUCT OVERVIEW

The JC5000 Jaw Crusher is a highcapacity, singletoggle primary crusher engineered for the most demanding mining and quarrying applications. Its design focuses on maximizing throughput of hard, abrasive materials while minimizing lifetime operating costs.

Operational Workflow:
1. Feed Intake: Large runofmine feed (up to 1.5m lump size) is directed into the deep, nonchoking crushing chamber.
2. Crushing Action: A robust eccentric shaft drives a dynamically balanced moving jaw in an aggressive elliptical motion, applying high inertia force to reduce feed material.
3. Discharge & Clearance: The steep nip angle and optimized toggle plate kinematics facilitate faster material discharge, preventing chokepoints and promoting continuous flow.
4. Product Conveyance: Crushed material exits at the bottom discharge point onto a primary conveyor for transport to the next stage of processing.

Application Scope: Ideal for stationary primary crushing plants in hard rock mining (iron ore, gold, copper), granite/quarry operations, and largescale aggregate production.
Limitations: Not designed for recycling or construction demolition debris where tramp metal contamination is extreme. Requires a stable electrical supply commensurate with its highpower drive motor.

3. CORE FEATURES

HeavyDuty Frame Design | Technical Basis: Finite Element Analysis (FEA) optimized stress distribution | Operational Benefit: Eliminates frame fatigue cracking under maximum load conditions; allows installation on standard concrete foundations | ROI Impact: Reduces risk of catastrophic structural failure; lowers initial civil works cost by up to 15%.

Hydrostatic Wedge Adjustment System | Technical Basis: Hydraulically actuated wedges replace manual shims | Operational Benefit: Enables remote CSS adjustment in minutes versus hours; improves operator safety by eliminating manual handling | ROI Impact: Cuts downtime for product size changes by over 80%, increasing plant flexibility.

Deep Symmetrical Crushing Chamber | Technical Basis: Optimized geometry with steep nip angle (26°) | Operational Benefit: Enhances feed acceptance capability and promotes accelerated material flow; reduces bridging; increases jaw die life via even wear distribution | ROI Impact: Boosts average throughput by 1015%; extends wear part intervals.

Spherical Roller Bearing & Forged Eccentric Shaft Assembly | Technical Basis: Oversized bearings with L10 life calculation exceeding 50,000 hours; integral forging eliminates stress points | Operational Benefit: Provides unmatched reliability under shock loads; ensures consistent alignment for peak efficiency | ROI Impact: Virtually eliminates bearingrelated unscheduled stoppages over the crusher’s service life.

PLCIntegrated Toggle Plate Protection | Technical Basis: Hydraulic ram replaces conventional shear pins/pull rods with system pressure monitoring | Operational Benefit: Automatically releases tramp metal/uncrushable material; resets automatically without entering crusher cavity | ROI Impact: Prevents damage to shaft/bearings; reduces downtime from tramp events from hours to minutes.

Direct Drive via VBelts & TEFC Motor | Technical Basis: Hightorque motor coupled via multiple Vbelts for energy transmission with inherent slippage protection | Operational Benefit: Smoothens load peaks on the drive train; offers simpler maintenance compared to fluid couplings or direct drives | ROI Impact: Lowers peak current draw on electrical infrastructure; reduces spare parts complexity.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (Comparable Class) | JC5000 Jaw Crusher Solution | Advantage (% Improvement) |
| : | : | : | : |
| MTBF (Mean Time Between Failures)| ~1,500 operating hours on critical bearings| Field data indicates >4,000 hours under equivalent duty| >165% improvement |
| Wear Life (Manganese Jaw Dies)| 120,000 – 150,000 tonnes processed| Consistent reports of 180,000 – 220,000 tonnes achieved| 2045% longer life |
| CSS Adjustment Time| Manual shim adjustment: 48 hours| Hydrostatic wedge system: <45 minutes| ~90% reduction |
| Power Consumption per Tonne| Baseline reference of 100%| Measured reduction due to efficient kinematics & direct drive| 58% lower |
| Throughput Capacity (Hard Granite)| Rated at ~750 tph at specified CSS| Sustained output regularly achieves 800830 tph under same conditions| ~710% higher output |

5. TECHNICAL SPECIFICATIONS

Feed Opening: 1500mm x 2000mm (59" x 79")
Max Feed Size: Up to 1250mm (49")
Closed Side Setting (CSS) Range: 180mm 300mm (7" 12")
Capacity Range: Up to 1500 tonnes per hour (dependent on feed material and CSS)
Drive Power Requirement: Twin 200kW (260HP) TEFC motors or equivalent singledrive option.
Total Weight (Crusher Only): Approximately 125 metric tonnes
Key Material Specifications:
Frame Fabrication: Highstrength steel plate with internal ribbing.
Moving Jaw/Fixed Jaw Dies: Premium Manganese Steel (14%,18%,22% available).
Eccentric Shaft: Forged alloy steel EN24/34CrNiMo6+.
Bearings: Spherical roller type with automated lubrication ports.
Environmental Operating Range: Designed for ambient temperatures from 20°C to +50°C (4°F to +122°F). Dust seals rated for standard quarry/mine dust conditions.

6. APPLICATION SCENARIOS

Hard Rock Copper Mine – Primary Crushing Station

Challenge: A South American operation faced excessive downtime from jaw die changes every six weeks and required a threeday shutdown for CSS adjustments on their legacy primary crusher.
Solution: Implementation of two JC5000 Jaw Crushers configured with the hydrostatic wedge system and deepchamber jaw profiles.
Results: Wear part life extended to nineweek intervals. CSS adjustments completed during scheduled weekly maintenance windows (<1 hour). Combined effect increased annual available crushing time by an estimated ~400 hours.

LargeScale Granite Quarry – HighAbrasion Duty

Challenge: Achieving consistent product gradation for railway ballast while managing extreme abrasion wear that led to high operating costs per tonne.
Solution: A JC5000 replaced an older doubletoggle design. Its deep symmetrical chamber promoted better particleonparticle breakage and even wear across jaw dies.
Results: Product shape improved (+12% cubical content), meeting stringent ballast specs more consistently. Despite higher upfront cost,the costpertonne of wear parts decreased by approximately18% in the first year of operation.

7. COMMERCIAL CONSIDERATIONS

The JC5000 Jaw Crusher is offered as a capital asset solution focused on total cost of ownership.

Base Equipment Pricing Tier: Includes crusher assembly,motors,Vbelts drives,and standard lubrication system.Factory testing is included prior to shipment.
Optional Feature Packages:

Automation Package: Includes PLC controls with touchscreen interface,crusher condition monitoring sensors,and automated lubrication unit.
Wear Part Alloy Upgrade: Selection of premium manganese steel alloys tailored for specific material abrasiveness/impact.
Modular Installation Kit: Prefabricated walkways,ladders,and service platforms designed for faster,safe site erection.

Service Packages:

1.Preventive Maintenance Plan:Scheduled inspections,lube analysis,and annual health checks.
2.Wear Part Supply Agreement:Gauranteed inventory holding,predictable pricing,and scheduled delivery aligned with your maintenance planning.
3.OnSite Technical Support:Dedicated field service engineers available for major overhauls or troubleshooting.

Financing Options are available through partner institutions including equipment leasing structures,tailored loan agreements,and rentaltoown programs designedto align payment scheduleswith project cash flow timelines

FAQ

Q1:What are the foundation requirementsfor installingthe JC5000?
A:The FEAoptimized frame design significantly reduces dynamic loads comparedto older designsof similar capacity.Generally,a standard reinforced concrete foundation meeting specified loadbearing criteriais sufficient.Detailed civil drawingsare providedwith purchase

Q2 How does this crusher handle wet sticky feed material?
A While designed primarilyfor hard rock,the deep chamberand aggressive dischargeaidsin clearingmaterial However extremely sticky clayscan pose challenges like anyjawcrusher We recommend evaluatingfeed characteristicsand may suggest specific chamberdesign modificationsif necessary

Q3 What isthe expected lead timefrom orderto commissioning?
A Lead timesvary basedon global manufacturing schedules Typically deliveryis within months followinga firm order Commissioning supportis providedas partof our technical service offering

Q4 Arewear parts interchangeablewith othercrushersin this class?
A No TheJC uses proprietaryjawdie profilesand bearingassemblies engineeredfor its specific kinematics This ensuresoptimal performanceand longevity Third party partswill voidthe factory warranty

Q5 Can we integrate existingdust suppressionor automation systems?
A Yes Thecrushers controlpanel includesstandardizedinterface pointsfor external systems suchas dust suppression activationor plantwide SCADA communication Our engineeringteam can provideprotocol documentationfor integration

Q6 Whatdoes themanufacturers warrantycoverspecifically?
A Thestandard warrantyprovides months coverageon allpartsand laboragainst defectsin materialsor workmanship It excludeswear itemslike jawdies whichhave their own performanceguarantee basedon processedtonnage Extendedwarrantyoptionsare available

Q7 Do you offerperformance testingprior topurchase?
A We offercomprehensive testreportsfrom our facilityand can arrangevisitsfor qualifiedbuyers totestwith samplematerial where feasible Performanceguaranteesbasedon agreedfeed specificationsare includedin commercialcontracts