Jc5000 Jaw Crusher Factories Samples
Onderwerp: Optimizing Primary Crushing: DirectfromFactory Jc5000 Jaw Crusher Samples for HighVolume Operations
1. The Cost of Inefficient Primary Crushing
Every hour your primary jaw crusher is down for unscheduled maintenance or operating below nameplate capacity, you lose an estimated $2,500 aan $8,000 in produksie-inkomste, depending on feed tonnage. Algemene operasionele uitdagings sluit in:
- Premature wear on jaw dies lei tot gereelde veranderinge (elke 46 weeks in abrasive materials).
- Inkonsekwente produkgrootte causing recirculation loads that choke downstream cone crushers.
- High power consumption per ton when the crusher is not matched to the feed material’s compressive strength.
- Difficult access for liner replacement extending downtime from 8 ure aan 24+ ure.
- Feed bridging in the chamber, wat handmatige ingryping vereis en veiligheidsgevare skep.
- Standaard Pakket (Jc5000 Base): $145,000 $165,000 (breker insluit, motor, V-bande, standard Mn13Cr2 dies).
- HighWear Package: $175,000 $195,000 (includes Mn18Cr2 dies, spare eccentric shaft, swaardiens laers).
- Outomatisering pakket: $210,000 $235,000 (includes PLC control, afstandmonitering, outomatiese CSS-aanpassing).
- Hydraulic tramp release system: +$12,000
- Stofonderdrukking spuitstawe: +$4,500
- Custom feed chute adapter: +$3,000
- Basiese waarborg: 12 maande op meganiese komponente.
- Uitgebreide waarborg: 24 maande (includes annual inspection) – 8% of unit price.
- Volle onderhoudskontrak: Sluit kwartaallikse inspeksies in, voeringvervangingsarbeid, and emergency service – $18,000/year.
- 30% afbetaling, balance upon delivery.
- Leasetoown options available (3660 maand terme) met 5.9% APR vir gekwalifiseerde kopers.
- Volume afslag: 5% af vir bestellings van 3+ eenhede.
Are your current crusher specifications limiting your plant’s throughput? Can you verify the metallurgy of the jaw plates before committing to a full fleet order?
2. Produk Oorsig: Jc5000 Kaakbreker
Die Jc5000 Kaakbreker is 'n swaardiens, singletoggle primary crusher designed for continuous hard rock reduction (druksterkte tot 400 MPa). It operates on a proven eccentric shaft mechanism with a deep, symmetrical crushing chamber.
Operasionele werkvloei:
1. Voerinname: Afloopmyn materiaal (up to 500mm feed size) enters the top opening.
2. Compression Cycle: The movable jaw oscillates against the fixed jaw, applying high compressive force.
3. Grootte verkleining: Material is crushed through a combination of compression and shearing action.
4. Ontslag: Processed material (50150mm CSS) exits via the bottom opening.
5. Hidrouliese verstelling: Geslote kant-instelling (CSS) is adjusted via hydraulic rams for quick product size changes.
Toepassingsomvang: Primary crushing in hard rock quarries, gold/copper mines, and large construction aggregate plants.
Beperkings: Nie geskik vir taai kleimateriaal nie (hierbo 15% vog) without a grizzly feeder; vereis 'n minimum 250 kW motor for full capacity.
3. Kernkenmerke
HeavyDuty Eksentriese As-samestelling | Tegniese basis: Forged 40CrNiMo alloy steel, hittebehandel tot 280320 HB | Bedryfsvoordeel: Handles high peak loads without shaft fatigue, reducing unplanned shutdowns | ROI impak: Extends shaft service life to 810 jare, spaar $12,000 in replacement costs per incident
Reversible Jaw Die Design | Tegniese basis: Highmanganese steel (Mn13Cr2) with a 4piece modular design | Bedryfsvoordeel: Operators can flip dies after one side wears, doubling usable life before replacement | ROI impak: Reduces annual liner cost by 35% in vergelyking met nie-omkeerbare ontwerpe
Hidrouliese CSS-aanpassingstelsel | Tegniese basis: Dual hydraulic cylinders with pressure relief valves | Bedryfsvoordeel: Adjust CSS in under 5 minutes without shims or manual tools | ROI impak: Verminder stilstand vir produkverandering deur 90%, byvoeging 23 hours of production per week
Diep, NonChoking Chamber Geometry | Tegniese basis: Curved jaw profile with a 1:6.5 crushing ratio | Bedryfsvoordeel: Prevents material bridging and promotes consistent cubical product | ROI impak: Verminder hersirkulasielading deur 15%, lowering conveyor and screen wear
Geïntegreerde smeerstelsel | Tegniese basis: Automatic grease lubrication with 8point distribution | Bedryfsvoordeel: Ensures all bearings receive correct grease volume at set intervals | ROI impak: Verleng dra lewe deur 40%, jaarlikse instandhoudingskoste te verminder deur $4,500
Modulêre raamkonstruksie | Tegniese basis: Welded steel frame with stressrelieved annealing | Bedryfsvoordeel: Allows for onsite assembly without specialized welding | ROI impak: Verminder installasie tyd deur 30% compared to cast frame crushers
4. Mededingende voordele
| Prestasie-metriek | Bedryfstandaard (500x750mm Class) | Jc5000 Solution | Voordeel (% Verbetering) |
| : | : | : | : |
| Deurset (tph) | 80120 tph | 110160 tph | +25% |
| Jaw Die Life (ure) | 1,200 ure | 1,800 ure | +50% |
| CSS-aanpassingstyd | 2030 minute (handleiding) | 5 minute (hidroulies) | 75% |
| Kragverbruik (kWh/t) | 0.8 1.2 kWh/t | 0.6 0.9 kWh/t | 20% |
| Gemiddelde tyd tussen mislukkings | 800 ure | 1,500 ure | +87% |
| Voertuigwisselingstyd | 8 ure (2persoon bemanning) | 4 ure (2persoon bemanning) | 50% |
5. Tegniese spesifikasies
| Parameter | Spesifikasie |
| : | : |
| Model | Jc5000 |
| Voer opening | 500mm x 800 mm |
| Maksimum voergrootte | 425mm |
| CSS-reeks | 50mm 150 mm |
| Kapasiteit (tph) | 110 160 (afhangende van CSS en materiaaldigtheid) |
| Motor Krag | 250 kW (380V/50Hz of 460V/60Hz) |
| Eksentrieke asspoed | 280 RPM |
| Kaakplaatmateriaal | Mn13Cr2 (standaard), Mn18Cr2 (optional for high abrasion) |
| Masjien gewig | 18,500 kg |
| Afmetings (LxBxH) | 2,800mm x 2,100mm x 2,400mm |
| Bedryfstemperatuur | 20°C tot +45°C |
| Smering | Outomatiese vetstelsel (8 punte) |
6. Toepassingsscenario's
Hard Rock Quarry (Graniet) | Uitdaging: Plant manager needed to increase primary throughput from 90 tph aan 130 tph to feed a new cone crusher circuit. Existing crusher had frequent jaw die breakage. | Oplossing: Installed Jc5000 with Mn18Cr2 jaw dies and hydraulic CSS set to 100mm. | Resultate: Deurset het toegeneem tot 145 tph. Jaw die life extended from 1,100 ure aan 1,900 ure. Annual liner cost reduced by $8,200.
Goudmyn (Ertsverwerking) | Uitdaging: High recirculation load (35%) due to elongated product from existing jaw crusher, causing mill feed instability. | Oplossing: Replaced with Jc5000 featuring deep chamber geometry. CSS set to 75mm. | Resultate: Hersirkulasielading het gedaal tot 18%. Meuldeurset het met 12%. Power consumption per ton reduced by 0.15 kWh/t.
Konstruksie Aggregaat (Kalksteen) | Uitdaging: Frequent downtime for CSS adjustments between road base and concrete aggregate specs. | Oplossing: Jc5000 with hydraulic CSS adjustment. | Resultate: Produk oorskakeling tyd verminder vanaf 25 minute na 4 minute. Jaarlikse produksiewins van 40 ure.
7. Kommersiële oorwegings
Toerustingprysvlakke (FOB fabriek):
Opsionele kenmerke:
Dienspakkette:
Finansieringsopsies:
8. Gereelde vrae
V1: Can the Jc5000 handle feed material with high silica content (kwarts)?
A: Ja. The standard Mn13Cr2 jaw dies are suitable for up to 15% silika. For material above 15% silika, we recommend the optional Mn18Cr2 dies, which field data shows provide 40% longer wear life in quartzrich feed.
V2: What is the typical lead time for factory samples?
A: Standard sample units are available within 46 weke vanaf bestellingbevestiging. Customized metallurgy samples (Mn18Cr2) vereis 810 weke.
V3: How does the hydraulic CSS system perform in cold climates (20°C)?
A: The system uses ISO VG 68 hydraulic fluid with a coldweather additive package. We have verified operation down to 25°C. For sustained operation below 20°C, a hydraulic oil heater is recommended as an optional addon.
V4: What is the warranty on the jaw dies?
A: Jaw dies are considered wear items and are not covered under the standard mechanical warranty. Egter, we guarantee a minimum of 1,500 hours of service life under normal operating conditions (skuur indeks <0.3). If dies fail before 1,200 ure, we will provide a 50% credit on replacement dies.
V5: Can the Jc5000 be retrofitted into an existing plant with a different base frame?
A: Ja. The modular frame design allows for custom base plate drilling patterns. We provide a dimensional drawing with all bolthole locations. A site survey by our engineering team is recommended to verify foundation load capacity.
V6: What is the noise level at 1 meter distance during operation?
A: Gemeet op 8590 dB(A) onder volle vrag. This is within typical OSHA limits for an 8hour shift. We recommend hearing protection for operators within 5 meter.
V7: What financing documentation is required for the leasetoown option?
A: You will need to provide two years of audited financial statements, a current plant production report, and a letter of intent from your primary material supplier. Approval typically takes 57 werksdae.