1. PAINPOINT DRIVEN OPENING

Are escalating operational costs and unpredictable downtime eroding your quarry or mine’s profitability? Primary crushing stages present persistent challenges that directly impact your bottom line. Consider these common operational hurdles:
Excessive Downtime for Maintenance: Frequent liner changes and component wear lead to 1020 hours of nonproductive time monthly, stalling your entire processing line.
Unplanned Stoppages from Tramp Metal: Unseen contaminants cause immediate, damaging blockages, resulting in costly emergency repairs and lost production shifts.
Inconsistent Throughput & Product Shape: Variable feed materials lead to fluctuating output and poor product gradation, complicating downstream processing and reducing saleable product yield.
High Operational Costs: Rising energy consumption per ton crushed, combined with the high frequency of wear part replacement, squeezes profit margins.

Is your primary crusher a reliable asset or a recurring source of delay and expense? The solution requires equipment engineered not just for power, but for predictable performance and controlled operational expenditure.

2. PRODUCT OVERVIEW

The JC5000 is a highcapacity, robust singletoggle jaw crusher engineered for the most demanding primary crushing applications in mining, largescale quarrying, and heavyduty aggregate production. Its design focuses on delivering maximum availability and the lowest cost per ton in its class.

Operational Workflow:
1. Feed Intake: Large runofmine material (up to 1500mm) is directed into the deep, nonchoking crushing chamber.
2. Compressive Crushing: A powerful elliptical motion applies intense compressive force against a fixed jaw plate, effectively breaking even the hardest granite or abrasive basalt.
3. Discharge & Clearance: The aggressive stroke and large discharge opening ensure rapid material evacuation, preventing recirculation and promoting high throughput.

Application Scope: Ideal for hard rock mining, large granite/quarries, and slag processing plants requiring consistent feed to secondary circuits. It is suited for stationary installations with adequate foundation support.

Limitations: Not designed for recycled concrete with excessive rebar without prior magnetic separation. Requires a stable electrical supply commensurate with its highpower drive.

3. CORE FEATURES

HeavyDuty Frame Design | Technical Basis: Modular, nonwelded stressrelieved steel construction | Operational Benefit: Eliminates frame fatigue failures under cyclical loading; withstands peak shock loads from uncrushables | ROI Impact: Extended structural life beyond 15+ years under severe duty, eliminating risk of catastrophic frame replacement.

Hydrostatic Toggle System | Technical Basis: Hydraulic cylinder support for the toggle plate with pressure relief | Operational Benefit: Automatic clearing of chamber blockages and protection from tramp metal without stopping the crusher | ROI Impact: Prevents damage to pitman/bearings; reduces unplanned downtime by up to 80% related to tramp events.

Optimized Chamber Geometry | Technical Basis: Deep symmetrical chamber with aggressive nip angle | Operational Benefit: Promotes firstpass fragmentation, increases throughput capacity by volume, and improves product shape consistency | ROI Impact: Higher yield of inspec product reduces recirculating load; field data shows a 1218% improvement in tons per hour versus comparable models.

Centralized Greasing Point | Technical Basis: Singlepoint automated lubrication system routing to all major bearings | Operational Benefit: Ensures consistent bearing protection with a 5minute daily service task; eliminates missed grease points | ROI Impact: Extends bearing service life by up to 40%, reducing spare parts inventory costs and major service intervals.

Reversible Manganese Jaw Plates | Technical Basis: Symmetrical design allows endtoend rotation when wear occurs at the bottom | Operational Benefit: Doubles effective wear life of jaw plates before replacement is required | ROI Impact: Direct reduction of consumable costs by approximately 50% over the liner's total service life.

Low Maintenance Drive System | Technical Basis: Vbelt drive with guardprotected sheaves mounted on spherical roller bearings | Operational Benefit: Simplified tensioning reduces maintenance complexity; protects motor from crusher shocks | ROI Impact: Lower maintenance labor hours and extended motor life; belt changes can be performed in under 4 hours.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (750mm Feed Jaw Crusher) | JC5000 Jaw Crusher Solution | Advantage (% Improvement) |
| : | : | : | : |
| Availability (Uptime) | ~8588% (including planned maintenance)| >92% (documented field average)| +57% |
| Wear Life Fixed Jaw Plate (Abrasive Granite) | ~120,000 150,000 tons per set| ~220,000 250,000 tons per reversible set| +6070% effective life |
| Energy Consumption (kWh/tonne) | Varies significantly with hardness; baseline = 1.0x| Industry testing demonstrates consistent reduction due to efficient kinematics| 812% per tonne crushed |
| Tramp Metal Recovery Time (Uncrushable Event)| 48 hours (cool down, manual clearing)| <30 minutes (hydrostatic system reversal)| 90% downtime impact |

5. TECHNICAL SPECIFICATIONS

Feed Opening: 1500mm x 1300mm (59" x 51")
Maximum Feed Size: Up to 1250mm edge length (49")
Capacity Range: 650 1,450 tonnes per hour (dependent on closed side setting & material characteristics)
Drive Power Requirement: 200 kW / Up to kW options available
Total Weight (Crusher Only): Approximately ~105 tonnes
Main Frame Construction: Fabricated steel plate, stressrelieved
Shaft & Bearing Specification: Forged alloy steel eccentric shaft running in heavyduty spherical roller bearings
Operating Temperature Range: 20°C to +40°C (4°F to +104°F) with appropriate lubricants

6. APPLICATION SCENARIOS

Hard Rock Copper Mine – Primary Crushing Station

Challenge: A South American operation faced frequent downtime due to uncrushable steel debris from old drilling equipment contaminating ROM feed. Their previous jaw crusher required full chamber cleanout after each event (~6 hours).
Solution: Implementation of a JC5000 Jaw Crusher equipped with the hydrostatic toggle system.
Results: Uncrushable events are now cleared in under minutes via remote hydraulic reversal without stopping the feed conveyor. Annual crusherspecific availability increased by over , contributing directly to meeting quarterly tonnage targets.

LargeScale Granite Quarry – Aggregate Production

Challenge: Inconsistent product shape from the primary stage created bottlenecks at the secondary cone crushers and limited premium product yield.
Solution: Installation of a JC5000 Jaw Crusher optimized for an aggressive nip angle and deep chamber draw.
Results: More consistent firststage fragmentation reduced the recirculating load on secondary circuits by . The plant recorded a increase in saleable chip production due to improved initial particle shape.

7. COMMERCIAL CONSIDERATIONS

The JC5000 Jaw Crusher is offered in configured packages aligned with operational priorities:

Base Configuration Tier: Includes core crusher with standard drive motors and starter equipment.
HighAvailability Tier: Base configuration plus integrated hydraulic toggle system automated grease system motorized discharge setting adjustment.
Turnkey SkidMount Tier: Full crusher assembly premounted on a heavyduty structural skid including walkways ladders guards prewired control panel facilitating rapid site installation

Optional features include various jaw plate tooth profiles feed chute designs dust suppression seals

Service packages range from basic commissioning support through comprehensive multiyear planned maintenance agreements including scheduled inspections wear part monitoring priority parts supply

Financing options are available including capital lease operating lease or projectbased financing structures typically aligned with expected production output over an agreed term

FAQ

What is the typical installation timeframe for a JC5000?

With prepared foundations all necessary utilities available delivery typically requires weeks from order confirmation Installation commissioning by our technicians generally takes working days depending on ancillary plant integration complexity

How does it integrate into an existing SAG mill feed preparation circuit?

The JC5000 is designed as a primary crusher ahead of SAG mills Field data shows its consistent product gradation improves SAG mill throughput stability We provide detailed interface specifications for feed conveyor discharge conveyor dimensions capacities ensuring smooth integration into your existing flow sheet

What are realistic expectations for total cost of ownership?

While initial capital investment is significant industry analysis indicates that over years lower energy consumption extended wear part life reduced unplanned downtime typically result in lower total cost per ton crushed compared many alternatives Our team provides detailed TCO modeling based specific application parameters

Are performance guarantees provided?

Yes we offer guaranteed minimum throughput capacity based agreed material characteristics test results We also provide guaranteed maximum power consumption figures These are formalized within commercial agreement following thorough review application data

What technical support is available postpurchase?

Support includes comprehensive operator maintenance training during commissioning access digital parts manuals schematics Remote diagnostic support via data logs phone/video consultation Global network service engineers available onsite critical interventions if required