1. APERTURA IMPULSADA POR EL PUNTO DE DOLOR

¿Los crecientes costos operativos y el tiempo de inactividad impredecible están erosionando sus márgenes de ganancias agregadas o mineras?? Para gerentes de planta y contratistas de ingeniería, primary crushing is a critical bottleneck where failures cascade into costly production halts. Los desafíos comunes incluyen:
Costos excesivos de piezas de desgaste: Reemplazo frecuente de matrices de mandíbula debido a cinemática inadecuada o calidad del material, impactando directamente su costoperton.
Tiempo de inactividad no programado: Premature bearing failures or structural issues from uncrushable materials, stopping your entire processing line.
Salida inconsistente & Forma del producto: Poorly controlled discharge settings leading to irregular product gradation, downstream clogging, and reduced final product value.
Alto consumo de energía: Inefficient crushing chambers and drive systems that consume excessive power without proportional throughput gains.
Complejidad del mantenimiento: Largo, unsafe procedures for routine tasks like setting adjustment or wear part replacement, increasing labor hours and risk.

¿Qué pasaría si su trituradora primaria pudiera ofrecer un rendimiento predecible?, menores costos operativos, and adapt to varying feed materials? The solution requires robust engineering focused on total cost of ownership.

2. DESCRIPCIÓN GENERAL DEL PRODUCTO

El JC5000 es un dispositivo de alta capacidad., singletoggle jaw crusher engineered for heavyduty primary crushing in quarrying, minería, y aplicaciones de reciclaje de demolición. Its design prioritizes mechanical reliability and operational efficiency for processing hard rock, minerales, y concreto.

Flujo de trabajo operativo:
1. Consumo de alimento: Grande (hasta 1300 mm) feed material is directed into the deep, cámara de trituración sin asfixia.
2. Acción aplastante: An aggressive elliptical stroke motion applies high inertia force at the nip angle, breaking material efficiently on both the forward and return strokes.
3. Discharge Control: El entorno cerrado (CSS) is hydraulically adjustable from a single control point while the machine is under load or stopped.
4. Transporte del producto: Crushed material exits via a large discharge area onto your primary conveyor system.

Ámbito de aplicación & Limitaciones:
Alcance: Ideal for hightonnage stationary primary crushing plants targeting consistent aggregate production (typically 350mm output) or preparing runofmine ore for secondary processing.
Limitaciones: Not designed for ultrafine grinding or as a standalone tertiary crusher. Maximum feed size and capacity are contingent on material abrasiveness and density.

3. CARACTERÍSTICAS PRINCIPALES

Sistema de ajuste de palanca hidráulica | Base técnica: Los cilindros hidráulicos de doble acción reemplazan las placas de palanca mecánicas | Beneficio operativo: Allows operators to adjust the crusher setting in under two minutes for product size changes or to clear a stalled chamber | Impacto del retorno de la inversión: Reduce el tiempo de inactividad para ajustes hasta en 80% en comparación con los sistemas de cuñas manuales.

HeavyDuty Spherical Roller Bearing Cartridge | Base técnica: Forged steel cartridge with oversized bearings rated for high radial and axial loads | Beneficio operativo: Eliminates common stress points; enables reliable operation under peak loads with extended service intervals | Impacto del retorno de la inversión: Field data shows bearing life improvements of 3050% en ambientes abrasivos.

Geometría optimizada de la cámara de trituración | Base técnica: Computermodeled kinematics create an aggressive nip angle and deep vertical chamber | Beneficio operativo: Enhances throughput capacity while promoting slabby product reduction for better shape characteristics | Impacto del retorno de la inversión: Aumenta el rendimiento mediante 1015% over previous generation designs with similar power input.

Bolted Main Frame Construction | Base técnica: Fabricated from hightensile steel plates joined with machined interfaces and hardened bolts | Beneficio operativo: Provides superior fatigue resistance versus welded frames; simplifies potential site assembly or future transport | Impacto del retorno de la inversión: Mitigates risk of catastrophic frame weld failure, garantizar la integridad estructural a largo plazo.

Montaje de motor integrado & Guardia de conducción | Base técnica: Unified base frame accommodates motor and Vbelt drive with fulllength safety guards | Beneficio operativo: Simplifica la alineación de la instalación, reduce la huella, and enhances operator safety during operation | Impacto del retorno de la inversión: Lowers installation time/cost by approximately 15% through preengineered fitment.

QuickChange Jaw Die Retention System | Base técnica: Wedgelock system secures jaw dies without complex backing materials or lengthy bolting procedures | Operational Benefit Your maintenance crew can perform liner changes more quickly and safely| ROI Impact Cuts wear part replacement downtime by an average of 25%.

4. VENTAJAS COMPETITIVAS

| Métrica de rendimiento | Estándar de la industria (Clase comparable) | Solución de trituradora de mandíbulas JC5000 | Ventaja (% Mejora) |
|||||
| Use la vida (Roca abrasiva) | ~450.000 toneladas por juego | Arriba a 600,000 toneladas por juego | +33% |
| Configuración del tiempo de ajuste | 6090 minutos (cuña manual) | 92% utilization | +35% |
| Annual Planned Maintenance Hours Estimated at 120150 hours Documented average of 90 horas |25% |
| Noise Emission at 10m ~85 dBA ~78 dBA Reduction of ~7 dBA |

_Based on OEM recommended service schedules._

5. ESPECIFICACIONES TÉCNICAS

Apertura de alimentación: 1300mm x 1000 mm (51" incógnita 40")
Tamaño máximo de alimentación: Hasta 1100 mm de longitud de borde (subject to material type)
Rango de capacidad: 500 1200 mtph (dependiente del material de alimentación & CSS)
Requisito de potencia de accionamiento: 200 kilovatios / 250 hp electric motor (estándar)
Peso Total (Solo trituradora): Aproximadamente 62,000 kilos
Material del marco principal: Highstrength steel plate (Equivalente a ASTM A36)
Opciones de materiales de matriz de mandíbula: acero al manganeso (14%,18%,22%), optional premium alloys
Rango de temperatura de funcionamiento: 20°C a +40°C (4°F a +104°F)
Hydraulic System Pressure: Standard working pressure of 180 bar

6. ESCENARIOS DE APLICACIÓN

Granite Quarry Primary Crushing Plant Challenge A quarry in Eastern Europe faced frequent downtime from tramp metal incidents and needed faster product changeovers between aggregate grades Solution Installation of a JC5000 Jaw Crusher equipped with the hydraulic toggle system Results Unplanned downtime from clearing events reduced by an estimated 70 hours annually Product changeover time decreased from 75 minutos a menos 10 minutes contributing to an overall 8 aumento del volumen de producción anual

Iron Ore Primary Crushing Station Challenge An aging jaw crusher at a mine site required excessive maintenance offered poor energy efficiency per ton crushed and produced excessive fines Solution The JC5000 replaced the legacy unit with its optimized chamber geometry and efficient drive system Results Throughput increased by 12 while specific energy consumption kWh per ton dropped by 9 The improved product profile reduced recirculating load in the secondary circuit

7. CONSIDERACIONES COMERCIALES

The JC5000 Jaw Crusher is offered in several commercial configurations:

Niveles de precios:

1. Base Machine Includes crusher main frame flywheels standard jaw dies motor mount basic guards
2 Production Package Adds hydraulic toggle adjustment system automatic lubrication system premium AR400 jaw dies
3 Turnkey Skid Package Crusher pre mounted on a heavy duty skid complete with motor drives guards walkways

Optional Features Durable composite belt guards onboard dust suppression spray system remote monitoring telematics gateway various wear part alloy options

Service Packages Proactive maintenance plans are available including scheduled inspections genuine parts supply agreements emergency breakdown support Extended warranties are offered when bundled with certified installation

Financing Options Flexible commercial structures can be arranged including capital purchase finance leases or operating leases tailored to balance sheet requirements Project financing support may be available for large scale turnkey installations

8 Preguntas frecuentes

Q What conveyor capacity is required downstream of the JC5000
A To match peak capacity we recommend a main product conveyor rated for at least 1400 mtph with appropriate width speed and impact resistance

Q Can the JC5000 handle recycled concrete with rebar
A Yes its robust construction can process reinforced concrete However consistent feeding of large uncrushable metal pieces like excavator teeth should be avoided using proper prescreening A tramp release system is recommended for such applications

Q How does the hydraulic toggle affect maintenance compared to a traditional system
A It eliminates mechanical shear pins toggle plates seats springs It introduces routine checks of hydraulic fluid level hose integrity Minor leaks are more easily detected than impending mechanical failure reducing risk of secondary damage

Q What is the expected operational lifespan of the main crusher structure
A With proper maintenance industry testing demonstrates that the bolted main frame design can exceed years even in continuous service assuming no abnormal overload events Structural components are not considered consumable items

Q Are installation drawings certified for international projects
A Yes comprehensive general arrangement foundation loading electrical interface drawings are stamped by licensed professional engineers PE suitable for submission to regional permitting authorities

Q What training is provided for our operations team
A Standard delivery includes detailed operation manuals digital access portal videos Onsite commissioning includes handson training Optional multiday operator maintenance courses are available at our training center