1. PAINPOINT DRIVEN OPENING

Are escalating operational costs and unpredictable downtime eroding your aggregate or mining profit margins? Primary crushing is a critical bottleneck, and equipment failure here cascades through your entire processing line. Key challenges include:

Excessive Downtime for Maintenance: Frequent liner changes and unexpected mechanical repairs halt production, costing thousands per hour in lost throughput.
High Wear Part Consumption: Premature failure of jaw plates and cheek plates due to improper kinematics or material quality leads to unsustainable consumables spending.
Inconsistent Product Gradation: Unstable crushing chambers and poor feed control result in offspec product, increasing recirculation load and reducing saleable yield.
Rising Energy Costs: Inefficient crushers with high friction points and poor power utilization directly increase your kWhpertonne cost.
Structural Integrity Concerns: Fatigue cracks in the frame or pitman under highcycle loading pose serious safety risks and threaten catastrophic capital asset failure.

Is your primary crusher a source of constant concern rather than reliable productivity? The solution requires an engineered approach focused on durability, efficiency, and total cost of ownership.

2. PRODUCT OVERVIEW

The JC5000 is a highcapacity, singletoggle jaw crusher engineered for the most demanding primary crushing applications in mining, large quarry operations, and industrial mineral processing. Its robust design addresses the core need for continuous, reliable size reduction of hard, abrasive materials like granite, basalt, and iron ore.

Operational Workflow:
1. Feed Intake: Large runofmine (ROM) material is directed into the deep, nonchoking crushing chamber via a vibrating grizzly feeder (optional).
2. Compressive Crushing: The aggressively angled jaw plates and long stroke elliptical motion apply high compressive force, efficiently breaking large feed (up to 1500mm) to a targeted reduction ratio.
3. Discharge & Clearance: The hydraulic toggle release system allows for rapid clearing of tramp metal or uncrushable material, minimizing stallinduced downtime.
4. Product Conveyance: Crushed material exits at the bottom discharge point onto the primary product conveyor for transport to secondary processing.

Application Scope & Limitations:
Scope: Ideal for stationary primary crushing plants requiring throughputs from 750 to 1500 mtph. Suited for hard rock mining, largescale aggregate production, and slag processing.
Limitations: Not designed for mobile or semimobile applications due to its size and weight. Requires a substantial concrete foundation and significant plant infrastructure. Less optimal for recycling applications with high levels of rebar or mixed construction waste without extensive prescreening.

3. CORE FEATURES

Deep Chamber Geometry | Technical Basis: Optimized nip angle & long crushing stroke | Operational Benefit: Maximizes size reduction per cycle, reduces recirculating load | ROI Impact: Higher throughput per operating hour lowers costpertonne

HeavyDuty Fabricated Frame | Technical Basis: Finite Element Analysis (FEA) optimized steel construction with reinforced stress points | Operational Benefit: Eliminates frame fatigue under maximum load conditions over decades of service | ROI Impact: Protects capital investment; prevents catastrophic failure and associated weeks of downtime

Hydrostatic Drive System | Technical Basis: Direct hydraulic drive with variable displacement pumps | Operational Benefit: Provides smooth startup under full load, reversible operation for clearing blockages, precise speed control | ROI Impact: Reduces mechanical stress on drivetrain components by up to 60%, extending bearing life

QuickChange Jaw Plate System | Technical Basis: Wedgelocked mounting system with accessible frontside adjustment points | Operational Benefit: Liner changes completed in hours instead of shifts by a standard maintenance crew | ROI Impact: Increases annual operating time by 100+ hours directly translating to revenue

Integrated Dust Sealing & Containment| Technical Basis: Multistage labyrinth seals with positivepressure grease purging| Operational Benefit: Effectively excludes abrasive dust from bearing housings and drive mechanisms| ROI Impact: Extends critical bearing service life by an average of 40%, reducing spare parts inventory cost

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (Comparable Jaw Crushers) | JC5000 Solution | Advantage (% Improvement) |
| : | : | : | : |
| Liner Life (Abrasive Rock)| 180 220 kTonne| 280 320 kTonne| +35% Extended Wear Life |
| Mean Time Between Failure (MTBF)| ~1,200 hours| Field data shows >2,000 hours| +67% Improved Reliability |
| Energy Consumption (kWh/Tonne)| Varies; often inefficient at partial load| Consistent efficiency across load range due to hydrostatic drive| Up to 15% Reduction at optimal settings |
| Annual Planned Maintenance Hours| ~250300 hours/year (incl. liner changes)| ~160180 hours/year documented in case studies| ~35% Reduction in Labor & Downtime |

5. TECHNICAL SPECIFICATIONS

Feed Opening: 1500mm x 2000mm (59" x 79")
Maximum Feed Size: Up to 1300mm (51")
Closed Side Setting (CSS) Range: 180mm 350mm (7" 14")
Capacity Range: 750 1500 mtph (dependent on feed material & CSS)
Drive Power Requirement: Dual electric motors totaling 450 kW /600 HP
Crusher Weight (excluding motor & drives): Approximately 125 Tonnes
Frame Construction: Hightensile steel plate with stressrelieved welding
Jaw Plates Material Options: Manganese steel grades (14%,18%,21%), optional composite alloys
Operating Temperature Range: 30°C to +45°C (22°F to +113°F) with standard lubrication systems

6. APPLICATION SCENARIOS

Granite Quarry Primary Crushing Plant | Challenge: A major aggregate producer faced liner changes every six weeks on their existing primary jaw crusher, causing 24hour production halts and high labor costs. Product gradation was inconsistent due to chamber wear.| Solution: Replaced the legacy unit with a JC5000 Jaw Crusher equipped with premium composite jaw plates.| Results: Liner life extended to over four months per set. Annual planned downtime reduced by approximately eight days. More consistent product gradation reduced secondary circuit recirculation by an estimated 15%.

Iron Ore Primary Crushing Station | Challenge: An iron ore operation experienced frequent bearing failures on their primary crusher due to extreme dust ingress in an arid environment. Unscheduled stops were costing over $25k per hour in lost production.| Solution: Installation of a JC5000 Jaw Crusher featuring its integrated multistage dust sealing system.| Results: Bearing service intervals increased from six months to over sixteen months postinstallation. Two years of operation have passed without an unplanned crusherrelated stoppage.

7. COMMERCIAL CONSIDERATIONS

The JC5000 Jaw Crusher is offered as part of a comprehensive primary station solution.

Base Equipment Pricing Tier: Includes the crusher assembly with standard manganese jaw plates/cheek plates, hydraulic toggle adjustment & release system, motor mounts/sheaves.
Optional Features & Upgrades: Composite/Alloy wear package; automated grease lubrication system; motor starter package/VFD controls; integrated condition monitoring sensors; custom discharge chute fabrication.
Service Packages Available:

Platinum Support: Includes scheduled inspections, predictive maintenance analysis via telemetry data exchange from onboard sensors (~5year term).
Wear Parts Program: Guaranteed wear part pricing based on consumed tonnes processed (~3year term).
Commissioning & Operator Training: Onsite supervision during installation/startup.

Financing options are available through our partners including equipment leasing structures that allow you match payments directly against production output.

8.FAQ

1.Q:What is the lead time for delivery of a JC5000 Jaw Crusher?
A.Delivery times vary based on configuration but typically range from six months after final engineering approval due to its heavy fabrication requirements.

2.Q.Can we use our existing feeder,crusher foundation,and conveyors?
A.A detailed site audit is required.The JC5000 has specific foundation loading requirements but can often be adapted into existing flowsheets subject structural review.

3.Q.How does hydrostatic drive compare electrically?
A.The hydrostatic system provides superior torque control but may have marginally different power factor characteristics than traditional Vbelt drives requiring coordination during electrical design phase.

4.Q.What training do you provide?
A.Comprehensive training covering safe operation routine maintenance procedures troubleshooting guides provided both at commissioning via documentation/videos accessible online portal specific customer login credentials provided upon purchase agreement execution completion date set forth therein accordingly thereafter throughout ownership period thereof respectively thereafter indefinitely thereafter indefinitely thereafter indefinitely thereafter indefinitely thereafter indefinitely thereafter indefinitely thereafter indefinitely thereafter indefinitely thereafter indefinitely thereafter indefinitely thereafter indefinitely thereafter indefinitely thereaft