Chinese Jc5000 Jaw Crusher Inspection
1. APERTURA IMPULSADA POR EL PUNTO DE DOLOR
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 scenarios:
Tiempo de inactividad excesivo para mantenimiento: Frequent liner changes and unexpected mechanical failures halt your entire processing line, costando miles por hora en producción perdida.
Unscheduled Stoppages from Tramp Metal: Unseen metallic contaminants cause catastrophic damage to crusher internals, leading to lengthy, reparaciones costosas.
Rendimiento inconsistente & Tamaño del producto: Fluctuations in feed material hardness or size lead to poor yield control, bottlenecking downstream processes and reducing final product quality.
SkyHigh Energy Consumption: Inefficient crushing chambers and drives result in disproportionate power costs for the tonnage produced.
Degradación rápida de piezas de desgaste: Premature failure of jaw plates and other wear components drives up your costpertonne and increases inventory complexity.
Is your primary crusher a reliable asset or a recurring liability? The solution lies not just in a machine, but in engineered durability and predictable performance.
2. DESCRIPCIÓN GENERAL DEL PRODUCTO
The Chinese JC5000 Jaw Crusher is a heavyduty, singletoggle primary crusher engineered for the most demanding mining, cantera, and demolition recycling applications. It is designed as the first stage in mineral reduction, processing blasted rock, grava de río, and reinforced concrete into a consistent, coarse aggregate.
Flujo de trabajo operativo:
1. Consumo de alimento: Material de alimentación grande (up to 1300mm) is loaded into the deep, nonchoking crushing chamber via dump truck or excavator.
2. Trituración compresiva: A robust eccentric shaft drives a moving jaw plate in an elliptical motion against a fixed jaw plate, applying immense compressive force to fracture the rock.
3. Ajuste de configuración de descarga: The product size is precisely controlled by a hydraulic toggle adjustment system, allowing changes to be made quickly and safely under load.
4. Descargar & Transporte: Crushed material exits through the bottom discharge opening onto a primary conveyor belt for transport to secondary processing or stockpiling.
Ámbito de aplicación & Limitaciones:
Alcance: Ideal for hightonnage primary crushing of abrasive materials like granite, basalto, mineral de hierro, y hormigón reciclado. Suited for stationary plants or largescale mobile setups.
Limitaciones: No diseñado para mojado., sticky materials that may cause packing. Requires a stable, reinforced concrete foundation. Maximum feed size and capacity are finite; detailed feed analysis is required for optimal model selection.
3. CARACTERÍSTICAS PRINCIPALES
HeavyWelded Steel Frame | Base técnica: Análisis de elementos finitos (FEA) distribución de tensión optimizada | Beneficio operativo: Eliminates frame fatigue cracking under cyclical loads; garantiza la integridad estructural a largo plazo | Impacto del retorno de la inversión: Decadeslong service life reduces capital replacement cycles
Hydraulic Toggle Adjustment System | Base técnica: Dualacting hydraulic cylinders replace traditional mechanical shims | Beneficio operativo: Enables remote CSS adjustment in minutes versus hours; allows clearing of stalled chamber under load | Impacto del retorno de la inversión: Reduces downtime for product changeovers by up to 80%, increasing plant flexibility
Deep Symmetrical Crushing Chamber | Base técnica: Optimized nip angle and longer crushing surface | Beneficio operativo: Promotes rockonrock particle degradation, reduces wear on jaw plates themselves; enhances throughput capacity | Impacto del retorno de la inversión: Lowers costpertonne through extended wear part life and higher yield
HeavyDuty Spherical Roller Bearings | Base técnica: Labyrinth seals with grease purging system | Beneficio operativo: Protects bearing integrity from dust ingress; handles high radial and axial loads from uneven feed | Impacto del retorno de la inversión: Prevents the 1 cause of catastrophic bearing failure, avoiding weeks of unscheduled downtime
PLCBased Automated Control & Escucha | Base técnica: Integrated sensors for power draw, bearing temperature, and hydraulic pressure | Beneficio operativo: Provides realtime operational data and predictive maintenance alerts to your control room | Impacto del retorno de la inversión: Enables conditionbased maintenance planning, preventing unexpected failures and optimizing component life
4. VENTAJAS COMPETITIVAS
| Métrica de rendimiento | Punto de referencia estándar de la industria | JC5000 Solution Documented Performance | Ventaja (% Mejora) |
| : | : | : | : |
| Disponibilidad (tiempo de actividad) | ~8590% (programado & paradas no programadas) | Field data shows consistent >94% availability over 24month periods| +5% a +10% |
| Desgaste parte de la vida (Jaw Plates Abrasive Rock) | ~120150k tonnes per set (MN13 steel) Industry testing demonstrates >180k toneladas por juego (MN18 installed) with optimized chamber design| +20% a +30% |
| Eficiencia Energética (kWh/tonelada) Varies by material ~0.8 1.2 kWh/tonne Verified site audits report 0.72 0.95 kWh/tonne on granite applications| Arriba a 15% |
| Tiempo de ajuste de CSS (Mechanical vs Hydraulic)| 24 hours with manual shim handling Average time of <15 minutes via hydraulic system control panel| 90% |
5. ESPECIFICACIONES TÉCNICAS
Apertura de alimentación: 1500mm x 1300mm (59" incógnita 51")
Tamaño máximo de alimentación: 1300milímetros (51")
Configuración del lado cerrado (CSS) Rango: 180mm 300 mm (7" 12")
Rango de capacidad (Varies by CSS & Material): 750 1400 toneladas por hora
Requisito de potencia de accionamiento: 250 kilovatios /335 HP Electric Motor
Peso Total (Solo trituradora): Aproximadamente 86，000 kilos
Especificaciones clave de materiales:
Marco: Highstrength welded steel plate
Mandíbula oscilante & Fixed Jaw Bodies：Highquality cast steel
Standard Jaw Plates：Manganese Steel MN13 / Optional MN18，MN22
Eje excéntrico：Alloy forged steel，ultrasonic tested
Rango de operación ambiental: Diseñado para temperaturas ambiente de 20°C a +45°C (4°F a +113°F). Dust sealing systems are standard.
6. ESCENARIOS DE APLICACIÓN
Granite Quarry， Southeast Asia Challenge：Extremely abrasive feed was causing jaw plate replacement every six weeks， creating unsustainable costpertonne and frequent production halts。 Solución：Installation of one JC5000 Jaw Crusher with optional MN18 premium jaw plates。 Resultados：Wear part life extended to an average of five months。 Combined with faster hydraulic CSS adjustments， this reduced crusherrelated downtime by 35% anualmente， achieving target costpertonne within eight months。
Iron Ore Processing Plant， Australia Challenge：Unpredictable tramp metal events from drill bits和bucket teeth were causing severe damage to the existing primary crusher’s toggle seat和pitman assembly。 Solución：Deployment of the JC5000 with its overloadprotected hydraulic toggle system。 Resultados：In two separate incidents， uncrushable metal was detected和cleared using the hydraulic release function without damage。 This avoided an estimated 14 days of combined downtime和over $250k in saved repair costs。
7. CONSIDERACIONES COMERCIALES
The Chinese JC5000 Jaw Crusher is offered as a capital investment with clear longterm operational savings。
Niveles de precios
- Base Equipment Package：Incluye trituradora， motor mounts， vbelt drive guards， basic tool kit。
- Plant Integration Package：Adds prefabricated discharge chute， walkways及access platforms， motor及starter。
- Premium Wear Parts Package：Includes initial set of MN18 jaw plates及side liners。
- Sistema de lubricación automatizado
- Rock Breaker Mounting Bracket
- Spare Parts Kit（bearings， sellos， fasteners）
- Extended Factory Warranty（available up to 36 months on major components）
Características opcionales：
Paquetes de servicios：
1）Commissioning Supervision（onsite technical support）
2）Annual Health Check Inspection（includes detailed wear measurement报告）
3）FullService Maintenance Contract（covers all labor及planned parts）
Opciones de financiación：
Flexible commercial finance structures are available including equipment leasing和term loans tailored for capital expenditure projects。
8.Preguntas frecuentes
Q1： Is the JC5000 compatible with my existing plant’s control system？
A1： Sí。 The crusher’s PLC can be configured to communicate via standard industrial protocols（e.g。 ， Modbus） providing operational data和alarms directly into your central SCADA system。
Q2 ： What is the expected impact on my overall plant throughput？
A2 ： By providing consistent primary crushed product size at high capacity ，the JC5000 typically eliminates bottlenecks at this stage 。 Actual gains depend on downstream equipment capabilities ， but plants often see an overall throughput increase of 1020%。
Q3 ： How does the pricing compare against European brands？
A3 ： The JC5000 offers a significant initial capital cost advantage while delivering comparable core performance 。 The total cost of ownership ， driven by its durability和energy efficiency ， provides compelling value over its operational lifetime 。
Q4 ： What training is provided for our maintenance crew？
A4 ： Comprehensive training is included with commissioning 。 This covers routine maintenance procedures ， wear part changeout protocols ，and troubleshooting using the onboard diagnostic system 。
Q5 ： Are wear parts readily available globally？
A5 ： Sí 。 A network of regional warehouses stocks critical wear parts like jaw plates 。 Lead times for standard components are typically under 14 días 。
Q6 ： Can it handle recycled concrete with rebar？
A6 ： Sí ， its robust construction makes it suitable for demolition recycling 。 The hydraulic toggle provides protection against uncrushables 。 For highvolume rebar content ，a magnetic separator postcrushing is recommended 。
P7 ： What foundation design is required？
A7 ： Detailed foundation drawings are supplied 。 It requires a substantial reinforced concrete foundation designed by your civil engineer based on local soil conditions 。 Our technical team provides all necessary load data和anchoring specifications