1. PAINPOINT DRIVEN OPENING

Are escalating operational costs and unpredictable downtime eroding your project margins? For plant managers and engineering contractors, primary crushing is a critical bottleneck where failures cascade into costly delays. Common challenges include:
Excessive Wear & Spare Parts Costs: Premature failure of jaw dies and components due to poor material selection or design, leading to frequent, expensive changeouts and parts inventory burdens.
Unscheduled Downtime: Unplanned stoppages from mechanical failures or blockages disrupt the entire downstream process, costing thousands per hour in lost production.
Inconsistent Throughput & Product Shape: Fluctuations in feed material cause capacity drops and poor product gradation, impacting secondary crusher efficiency and final product specification.
High Energy Consumption: Inefficient crushing chambers and drive systems result in disproportionate power draw per ton of material processed.
Rigidity & Foundation Issues: Equipment vibration and dynamic forces necessitate overengineered, costly foundations and can lead to longterm structural fatigue.

How do you select a primary crusher that delivers predictable performance, minimizes total cost of ownership, and provides the structural integrity for decades of service? The solution requires engineering focused on durability, efficiency, and operational simplicity.

2. PRODUCT OVERVIEW

The Premium JC5000 is a heavyduty, singletoggle jaw crusher engineered for highcapacity primary crushing in demanding mining, quarrying, and largescale construction applications. Its design prioritizes mechanical robustness and sustained throughput in continuous operation.

Operational Workflow:
1. Feed Intake: Large runofmine or quarryrun material (up to 1300mm) is directed into the deep, nonchoking crushing chamber.
2. Crushing Action: A highinertia flywheel drives an aggressive elliptical motion at the movable jaw, applying intense compressive force to reduce material.
3. Discharge & Clearance: The optimized discharge setting allows crushed material to exit freely without restriction, while the hydraulic toggle system provides instant unblocking capability.
4. Product Conveyance: Sized product is discharged onto the primary conveyor for transport to the next stage of processing.

Application Scope: Ideal for hard rock (granite, basalt), iron ore, and abrasive aggregates. Suitable for stationary plants and large mobile tracked setups.
Limitations: Not designed for recycling applications with high levels of rebar or tramp metal without appropriate prescreening protection. Requires a planned maintenance regimen consistent with all capital equipment.

3. CORE FEATURES

HeavyDuty Roller Bearing Assembly | Technical Basis: Spherical selfaligning roller bearings on both eccentric shaft and swing jaw | Operational Benefit: Handles high radial and thrust loads with minimal friction; supports sustained high horsepower input | ROI Impact: Proven bearing life exceeding 24,000 hours reduces replacement frequency by an estimated 40% versus standard bearings.

Hydraulic Toggle & Adjustment System | Technical Basis: Integrated hydraulic cylinder replaces conventional mechanical toggle plates | Operational Benefit: Enables remote adjustment of crusher setting for product size changes and provides safe, rapid clearing of stalled chambers | ROI Impact: Reduces downtime for clearing blockages from hours to minutes; eliminates manual shim adjustments.

Forged Eccentric Shaft & Robust Frame | Technical Basis: Highstrength alloy steel shaft; stressrelieved fabricated steel frame with reinforced ribs | Operational Benefit: Withstands peak shock loads from uncrushable material; maintains alignment under maximum load conditions | ROI Impact: Eliminates risk of catastrophic shaft failure; foundation costs can be reduced by up to 15% due to superior dynamic stability.

Optimized Crushing Chamber Geometry | Technical Basis: Computermodeled kinematics ensure steep nip angle and deep vertical chamber profile | Operational Benefit: Promotes aggressive bite and efficient reduction throughout the cycle; minimizes bridging and enhances throughput per stroke | ROI Impact: Field data shows a consistent 812% increase in tons per hour compared to previousgeneration designs with equivalent power.

EasyMaintenance Design Philosophy | Technical Basis: Symmetrical frame design allows reversible mounting of jaw dies; accessible grease lines and centralized lube points | Operational Benefit: Extends wear part life by utilizing both ends of jaw dies; simplifies routine servicing tasks for technicians | ROI Impact: Reduces liner inventory requirements; cuts planned maintenance time by an estimated 30%.

HighInertia Flywheels | Technical Basis: Precisely balanced heavyduty flywheels store kinetic energy during each cycle | Operational Benefit: Smoothes out power demand peaks, ensuring consistent crushing force even under variable feed conditions | ROI Impact: Protects drive components from shock loads; contributes to lower overall specific energy consumption (kWh/ton).

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (Comparable Class) | Premium JC5000 Solution | Advantage (% improvement) |
|||||
| Jaw Die Life (Abrasive Rock)| ~450,000 MT | Up to 600,000 MT | +33% |
| Availability (Uptime %) | 9092% | Consistently above 95% | +35% |
| Specific Energy Consumption | ~0.85 kWh/ton | As low as 0.78 kWh/ton | 8% |
| Throughput @ CSS 200mm | ~750 MT/h | ~850 MT/h | +13% |
| Major Bearing Service Life | ~18,000 hours | >24,000 hours | +33% |

5. TECHNICAL SPECIFICATIONS

Feed Opening: 1300mm x 1000mm (51" x 40")
Maximum Feed Size: Up to 1100mm (43")
Closed Side Setting Range: 150 300mm (6" 12")
Capacity Range (Varies by Material & CSS): Up to 1100 MTPH
Drive Power Requirement: 200 kW / Up to kW options available
Total Weight (Crusher Only): Approximately kg
Key Material Specifications: Forged EN24/S155Cr3 Eccentric Shaft; HighStrength Fabricated Steel Main Frame; Manganese Steel Jaw Dies (14%,18%,22% available).
Operating Temperature Range: 20°C to +45°C (4°F to +113°F) with appropriate lubricants.

6. APPLICATION SCENARIOS

Hard Rock Quarry Expansion – Australia

Challenge: A granite quarry needed to increase primary circuit throughput by over % but was constrained by existing foundation limits and high wear costs on their legacy crusher.
Solution Installation of a Premium JC5000 jaw crusher with its optimized dynamic footprint replaced two older units.
Results Achieved a % increase in base layer production while reducing specific liner cost per ton by %. The stable operation allowed use of the existing feed structure with minimal reinforcement.

Iron Ore Primary Crushing – West Africa

Challenge Severe abrasion causing swing jaw bearing failures every months at a remote site logistics nightmare), coupled with excessive energy costs.
Solution Deployment of the JC5000 with its heavyduty roller bearing assembly optimized chamber geometry
Results Bearing service life extended beyond months eliminating two major changeouts per year Plant energy monitoring showed a % reduction in specific power consumption translating directly lower diesel generator fuel costs

7 COMMERCIAL CONSIDERATIONS

The Premium JC5000 is offered as capital equipment within established global pricing tiers based on final configuration

Base Configuration Includes crusher motor motor mounts flywheel guards basic tool kit Optional Features Hydraulic setting adjustment package automated grease lubrication system wear monitoring sensors various manganese steel grades special protective coatings

Service Packages Tiered offerings from basic commissioning supervision comprehensive multiyear planned maintenance agreements including parts kits financing Options Available through partnered financial institutions covering leasetoown operating leases traditional purchase structures tailored project finance

8 FAQ

What are the foundation requirements for the JC5000?
Detailed dynamic load drawings are provided Our design distributes forces effectively but a sitespecific civil engineering review is mandatory We supply all necessary interface data

Can this crusher handle very wet sticky material?
While capable modifications like steeper nip angles specific liner profiles can be specified However highly claybound material may require prescreening scalping for optimal performance

What is the expected delivery lead time?
Standard configurations typically have lead time between weeks subject current order book confirmation Customized builds require additional engineering time

Do you provide wear parts after purchase?
Yes we maintain full OEM spare parts support including genuine manganese dies bearings other critical components ensuring original performance specifications are maintained

Is operator training included?
Comprehensive onsite training covering operation daily checks routine maintenance troubleshooting is included standard commissioning package

What warranty applies?
The Premium JC5000 carries standard months warranty on materials workmanship extended warranties available purchase specific components