1. PAINPOINT DRIVEN OPENING

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

Excessive Wear Part Costs: Frequent replacement of jaw dies due to uneven wear or premature failure, directly impacting your costperton.
Unscheduled Downtime: Mechanical failures, particularly in the pitman assembly or bearings, leading to hours of lost production.
Inconsistent Output Gradation: Fluctuations in feed size causing variable product shape and increasing load on downstream screens and crushers.
High Energy Consumption: Inefficient crushing chambers and drive systems that consume excessive power without maximizing throughput.
Rigid Configuration Limitations: A standard crusher that cannot be optimally tuned for your specific material (e.g., highly abrasive granite vs. recycled concrete), forcing operational compromise.

What if your primary crusher could deliver higher availability, predictable maintenance costs, and be precisely engineered for your site’s material? The solution requires a machine built not just for power, but for precision durability and operational adaptability.

2. PRODUCT OVERVIEW

The Premium JC5000 is a heavyduty, singletoggle jaw crusher engineered for highcapacity primary crushing in quarrying, mining, and demolition recycling applications. Its design focuses on delivering maximum availability and the lowest cost of ownership in its class.

Operational Workflow:
1. Feed Intake: Oversized material (<1200mm) is directed into the deep, nonchoking crushing chamber via a vibrating grizzly feeder (optional).
2. Crushing Action: The aggressive elliptical stroke of the singletoggle design applies compressive force efficiently, breaking material against the fixed jaw plate.
3. Discharge & Clearance: Crushed product exits through a hydraulically adjustable closedside setting (CSS), ensuring consistent output size while the large discharge clearance prevents packing.

Application Scope: Ideal for hard rock (granite, basalt), abrasive ores, and reinforced concrete recycling. Best suited for stationary plants or large mobile tracked setups where feed size is consistently high.

Limitations: Not designed for ultrafine grinding or as a secondary/tertiary unit. Maximum performance requires appropriate upstream feeding equipment and trained operational oversight.

3. CORE FEATURES

DeepChamber Geometry | Technical Basis: Optimized nip angle and longer crushing zone | Operational Benefit: Increased capacity per stroke and improved reduction ratio from a single pass | ROI Impact: Reduces need for secondary crushing stages in some circuits, lowering overall plant capital cost.

HeavyDuty Pitman Assembly | Technical Basis: Forged steel construction with oversized bearings | Operational Benefit: Sustains peak loads from uncrushable objects with minimal stress; extends bearing life by over 40% based on field data | ROI Impact: Drastically reduces risk of catastrophic failure and associated downtime costs.

Hydraulic Toggle & Adjustment System | Technical Basis: Replaceable hydraulic cylinder for tramp iron relief and CSS adjustment | Operational Benefit: Enables quick clearing of blockages without manual intervention; allows remote adjustment of product size | ROI Impact: Cuts unplanned stoppage time by up to 80% for chamber clearing events.

BoltOn Wear Liners | Technical Basis: Modular liner system protecting crusher frame sides | Operational Benefit: Shields main structure from abrasion; replaces faster than welding or rebuilding frame sections | ROI Impact: Preserves asset integrity longterm and simplifies maintenance planning.

PLCIntegrated Drive System | Technical Basis: Variable frequency drive (VFD) compatibility with system health monitoring points | Operational Benefit: Allows softstart capability reducing electrical stress; provides operators with realtime data on power draw and bearing temperature | ROI Impact: Lowers peak energy demand charges and enables predictive maintenance scheduling.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (750mm Feed Class) | Premium JC5000 Solution | Advantage (% Improvement) |
| : | : | : | : |
| Jaw Die Life (Abrasive Granite) | ~180,000 MTONs per set | ~250,000 MTONs per set | +39% Extended Life |
| Annual Availability (Scheduled + Unscheduled) | 8892% Target Uptime| 95%+ Demonstrated Uptime| +47% More Production Time |
| Tramp Iron Recovery Time| Manual disassembly (~48 hours)| Hydraulic clearing (~1530 minutes)| 90% Faster Clearance |
| Energy Efficiency (kWh/TON)| Varies by material; baseline = 1.0x| Industry testing demonstrates 0.85x baseline average| 15% Specific Energy Consumption |
| Maintenance Downtime (Annual Hours)| ~120150 hours/year| ~7090 hours/year| 40% Maintenance Hours |

5. TECHNICAL SPECIFICATIONS

Feed Opening: 1300mm x 1000mm (51" x 40")
Maximum Feed Size: 1200mm (47")
Closed Side Setting Range: 150mm 300mm (6" 12")
Capacity Range: Up to 750 MTPH, dependent on material type and CSS.
Drive Power Requirement: 200 kW / 275 HP Electric Motor.
Crusher Weight (Base Machine): Approximately 62,000 kg (136,700 lbs).
Frame Construction: Highintegrity welded steel with bolton wear liners.
Shaft & Bearings: Forged alloy steel eccentric shaft; spherical roller bearings.
Operating Temperature Range: 30°C to +45°C (22°F to +113°F) with standard lubrication system.

6. APPLICATION SCENARIOS

Granite Quarry Expansion

Challenge: A major quarry needed to increase primary circuit throughput by 25% but was constrained by jaw crusher liner wear costs causing weekly downtime checks.
Solution: Implementation of the Premium JC5000 Jaw Crusher with its deepchamber geometry and bolton liner system.
Results: Achieved a 32% throughput increase while extending jaw die change intervals from every 7 to every 10 days. Annual liner cost per ton reduced by an estimated 22%.

Urban Demolition Recycling

Challenge: Processing heavily reinforced concrete with frequent tramp metal inclusions led to routine shutdowns and risk of bent toggle plates on existing plant.
Solution: Deployment of the Premium JC5000 featuring the hydraulic toggle protection system.
Results: Unplanned stoppages due to tramp metal were virtually eliminated. The plant reported a direct increase in monthly processed volume by 18%, as hydraulic clearing allowed immediate resumption of operation.

7. COMMERCIAL CONSIDERATIONS

The Premium JC5000 is offered in three focused configuration tiers:

1. Base Performance Tier: Includes core crusher with standard motor drive, basic lubrication system, and manual setting adjustment. Focused on CAPEX efficiency for standard applications.
2. HighAvailability Tier: Adds full hydraulic toggle & adjustment system, automated grease lubrication, VFD compatibility, and upgraded monitoring sensors. Designed for operations prioritizing maximum uptime.
3. Turnkey Modular Tier: Crusher premounted on a heavyduty skid base complete with walkways, stairs, guards, and integrated motor control center (MCC). Minimizes installation time and cost.

Optional features include different jaw die profiles (quarry vs. recycling), dust suppression kits, special alloy components for extreme abrasion environments,
and extended warranty packages covering major components up to three years.

Financing options include capital lease agreements tailored to match expected production increases,
as well as scheduled service contracts that provide fixedcost preventive maintenance planning.

8.FAQ

Q1 Is the Premium JC5000 compatible with my existing plant feed system?
A1 The JC5000 requires consistent feeding within its design parameters but can be integrated with most apron or vibrating grizzly feeders rated for its capacity intake width
and feed rate specifications provided during consultation

Q2 How does this model improve operator safety?
A2 Key safety features include remote hydraulic adjustment eliminating manual CSS changes under tension guardprotected moving parts
and optional integrated lifting tools for safer jaw die replacement procedures

Q3 What is the typical lead time from order commissioning?
A1 Lead times vary based on configuration tier but typically range from 20 weeks
for base models allowing detailed project planning

Q4 Are performance guarantees offered?
A4 Yes subject to agreedupon feed material specifications we provide guaranteed minimum throughput
and wear part life metrics backed by engineering analysis

Q5 Can it process wet or sticky materials effectively?
A5 While capable modifications like specific chamber designs
and more aggressive discharge clearances are available as options
to mitigate packing common in such conditions

Q6 What training is provided postpurchase?
A6 Comprehensive onsite operator maintenance training is included
with delivery along with detailed technical manuals
and access to our online parts service portal

Q7 How does financing typically structure payments against project ROI?
A7 Our financial specialists can structure lease payments aligned against projected production tonnage increases helping manage cash flow while new capacity comes online