1. PAINPOINT DRIVEN OPENING

Are escalating operational costs and unpredictable downtime eroding your primary crushing circuit's profitability? For plant managers and engineering contractors, the primary jaw crusher is a critical—and often problematic—bottleneck. Common challenges include:
Excessive Wear Part Costs: Premature failure of jaw dies due to improper kinematics or lowquality materials, leading to frequent, costly replacements and laborintensive changeouts.
Unscheduled Downtime: Structural fatigue or bearing failures from uncrushable materials or shock loads, halting your entire processing line for days.
Inconsistent Throughput & Product Shape: Inefficient crushing chamber designs that produce excessive fines or slabby product, reducing downstream efficiency and final product value.
High Energy Consumption: Inefficient drive systems and heavy, powerintensive components that significantly increase your costpertonne.

How do you select a primary crusher that delivers not just promised capacity, but predictable operating costs and sustained availability? The solution requires a focus on engineered durability and intelligent design.

2. PRODUCT OVERVIEW

The JC5000 Jaw Crusher is a highcapacity, singletoggle primary crusher engineered for the most demanding mining, quarrying, and heavyduty construction applications. Its robust design is built to process hard rock, ore, and demolition concrete with maximum reliability.

Operational Workflow:
1. Feed & Initial Compression: Large feed material (up to 1.5m cube) enters the deep, nonchoking crushing chamber.
2. Aggressive Crushing Stroke: The highforce singletoggle mechanism drives the moving jaw in an elliptical motion, applying compressive force efficiently.
3. Discharge & Clearance: The steep nip angle and optimized discharge setting facilitate rapid material evacuation, preventing chokepoints and promoting high throughput.
4. System Integration: The crusher interfaces with vibrating grizzly feeders and downstream conveyors for a continuous feed system.

Application Scope: Ideal for stationary primary crushing plants processing granite, basalt, iron ore, copper ore, and recycled aggregates. It is suited for hightonnage operations (>800 mtph) requiring a top feed size up to 1500mm.

Limitations: Not designed for abrasive recycling applications without specific liner options. Requires a solid foundation and appropriate feeding equipment to achieve stated performance.

3. CORE FEATURES

HeavyDuty Roller Bearing Assembly | Technical Basis: Spherical selfaligning roller bearings with large diameter shafts | Operational Benefit: Handles high radial and thrust loads from tough crushing conditions; extends bearing life by up to 3x compared to standard bearings | ROI Impact: Reduces risk of catastrophic bearing failure; lowers maintenance frequency and associated labor costs.

Hydraulic Wedge Adjustment System | Technical Basis: Dualacting hydraulic cylinders replace manual shim adjustment | Operational Benefit: Allows closedside setting (CSS) adjustments to be made quickly, safely, and accurately in minutes versus hours | ROI Impact: Maximizes plant uptime during product changeovers; improves operator safety by eliminating manual handling.

Optimized Crushing Chamber Geometry | Technical Basis: Computermodeled kinematics with a steep nip angle and deep symmetrical chamber | Operational Benefit: Delivers higher reduction ratios per pass; produces a more consistent product shape with less slabby material | ROI Impact: Increases effective capacity of downstream circuits; improves final product cubicity for higher market value.

BoltOn Wear Liners | Technical Basis: Modular liner design with replaceable cheek plates manufactured from abrasionresistant steel | Operational Benefit: Simplifies liner replacement; protects the main frame structure from wear indefinitely | ROI Impact: Drastically reduces longterm capital asset depreciation; cuts liner changeout time by over 40%.

PLCIntegrated Overload Protection | Technical Basis: Hydraulic toggle plate with pressure sensors linked to the plant control system | Operational Benefit: Automatically releases tramp metal or uncrushable material; resets without manual intervention | ROI Impact: Prevents costly damage to the pitman and bearings; avoids hours of unscheduled downtime per event.

Direct Drive via VBelts & TEFC Motor | Technical Basis: Hightorque motor connected via multiple Vbelts to a heavyduty flywheel | Operational Benefit: Smooth power transmission that absorbs load fluctuations; standard motor compatibility simplifies sourcing and replacement | ROI Impact: Lower installed cost compared to fluid couplings; improved energy efficiency under variable load conditions.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (Comparable Class) | JC5000 Jaw Crusher Solution | Advantage (% Improvement) |
| : | : | : | : |
| Jaw Die Life (Abrasive Granite) | ~450,000 tonnes per set (based on competitor data sheets)| ~550,000 tonnes per set (fieldverified average)| +22% in wear material cost/tonne |
| Bearing Service Interval (MTBF)| 8,000 10,000 operating hours| 14,000+ operating hours (projected)| +40% in service life |
| CSS Adjustment Time (Mechanical to Mechanical)| 46 hours with crew of two| <1 hour with single operator| 80% in downtime for adjustment |
| Power Consumption per Tonne Crushed| Benchmark of 100%| Average of 9295% (sitedependent)| 5% to 8% in energy costs |
| Total Weight / Structural Mass Index| Benchmark of 100% for rated capacity| Index of ~115% (higher masstocapacity ratio)| +15% in structural rigidity & fatigue resistance |

Mean Time Between Failures based on industry lubrication schedules.
Mass index compares total machine weight relative to throughput capacity as an indicator of robustness.

5. TECHNICAL SPECIFICATIONS

Feed Opening: 1500mm x 2000mm (59" x 79")
Maximum Feed Size: Up to 1500mm cube (59")
Closed Side Setting Range: 200mm 300mm (8" 12")
Capacity Range: Up to 1650 mtph (dependent on feed material & CSS)
Drive Power Requirement: 375 kW /500 HP TEFC electric motor
Total Weight (Crusher Only): Approximately ~145,000 kg (~320,000 lbs)
Main Frame Construction: Fabricated steel plate with stressrelieved welds; AR steel liners at wear points.
Operating Ambient Temperature Range: 20°C to +45°C (4°F to +113°F) with standard lubrication.
Discharge Conveyor Recommendation: Minimum width of 1800mm (72") at recommended speed.

6. APPLICATION SCENARIOS

Hard Rock Quarrying – Granite & Basalt Primary Crushing

Challenge A major aggregate producer faced excessive downtime from jaw die changes every ~400k tonnes and frequent adjustments for product gradation changes.
Solution Installation of one JC5000 Jaw Crusher as the new primary unit featuring bolton liners and hydraulic wedge adjustment.
Results Field data shows jaw die life extended by approximately +22%, achieving over $50k annual savings in wear parts alone. CSS adjustments now take under one hour versus half a shift each time they occur.

Mineral Processing – Primary Iron Ore Crushing

Challenge An iron ore operation required higher throughput after mine expansion but had space constraints limiting plant footprint increases.
Solution Replacing two older jaw crushers with one highercapacity JC5000 unit due its deeper chamber allowing greater volume reduction per pass.
Results Plant throughput increased by approximately +30%. The consolidated footprint reduced civil works costs by an estimated $200k USD while lowering overall energy consumption per tonne processed by nearly 7%.

Major Infrastructure – Tunnel Boring Muck Processing

Challenge A largescale tunneling project needed an ultrareliable primary crusher located underground to process mixed geology muck continuously under strict schedule constraints.
Solution Deployment of the JC5000 configured with PLCintegrated overload protection specifically sized for conveyor transport out of the tunnel shaft.
Results The hydraulic toggle system successfully cleared multiple uncrushable objects automatically preventing an estimated >120 hours of potential downtime over the project lifecycle maintaining critical path schedule integrity

7 COMMERCIAL CONSIDERATIONS

The JC5000 Jaw Crusher is offered as part of a complete modular crushing station or as a standalone unit for integration into existing plants

Equipment Pricing Tiers:
1 Base Unit Includes crusher mainframe drive motor flywheel guards basic tool kit
2 Plant Ready Package Adds hydraulic power pack for adjustment integrated walkways ladders preinstalled lubrication system
3 Customized Application Package Includes applicationspecific jaw die metallurgy special guarding environmental packages dust suppression interfaces

Optional Features:
• Automated Greasing System
• Rock Level Sensor Integration
• Special AR Steel Grades for Cheek Plates
• SkidMounted Modular Frame

Service Packages:
• Commissioning Supervision Standard package includes field technician support during startup Extended package includes operator training performance verification testing
• Preventive Maintenance Contracts Tiered plans offering scheduled inspections parts kits priority support based on annual operating hours

Financing Options Available through our partners including equipment leasing capital loans rentaltoown structures tailored project financing

8 FAQ

Q What are the foundation requirements for installing this crusher?
A Detailed civil drawings are provided requiring reinforced concrete foundations designed dynamic loads exceeding static weight Consult engineering specifications early site planning phase

Q Can this crusher handle recycled concrete brick asphalt?
A While capable processing these materials we recommend consultation our engineering team specify appropriate jaw die metallurgy potentially install additional scalping preclean scrap metal Prolonged processing highly abrasive recycled materials may impact wear life expectations

Q How does hydraulic wedge adjustment compare traditional shim systems?
A Hydraulic wedges allow remote controlled adjustment from outside crusher improving safety speed Process takes minutes versus hours required manually add remove steel shims providing precise repeatable control over product size

Q What is typical delivery lead time after order placement?
A Lead times vary based configuration current production schedule Standard Plant Ready Package typically ships within months order confirmation Customized packages may require additional engineering manufacturing time We provide firm delivery schedule upon order confirmation

Q Are spare parts readily available globally?
A We maintain regional inventory hubs key wear components structural parts Critical items like bearings shafts stocked strategic locations ensure availability Most standard wear parts shipped within business days emergency orders