1. APERTURA IMPULSADA POR EL PUNTO DE DOLOR

¿Los crecientes costos operativos y el tiempo de inactividad impredecible están erosionando la rentabilidad de su circuito de trituración primario?? Para gerentes de planta y contratistas de ingeniería, the primary jaw crusher is a critical—and often problematic—bottleneck. Los desafíos comunes incluyen:
Costos excesivos de piezas de desgaste: Premature failure of jaw dies due to improper kinematics or lowquality materials, llevando a frecuentes, reemplazos costosos y cambios que requieren mucha mano de obra.
Tiempo de inactividad no programado: Structural fatigue or bearing failures from uncrushable materials or shock loads, halting your entire processing line for days.
Rendimiento inconsistente & Forma del producto: Inefficient crushing chamber designs that produce excessive fines or slabby product, reducing downstream efficiency and final product value.
Alto consumo de energía: Inefficient drive systems and heavy, powerintensive components that significantly increase your costpertonne.

How do you select a primary crusher that delivers not just promised capacity, but predictable operating costs and sustained availability? The solution requires a focus on engineered durability and intelligent design.

2. DESCRIPCIÓN GENERAL DEL PRODUCTO

La trituradora de mandíbulas JC5000 es una trituradora de alta capacidad., Trituradora primaria de palanca única diseñada para la minería más exigente, cantera, and heavyduty construction applications. Its robust design is built to process hard rock, mineral, and demolition concrete with maximum reliability.

Flujo de trabajo operativo:
1. Alimentar & Compresión inicial: Material de alimentación grande (up to 1.5m cube) entra en lo profundo, cámara de trituración sin asfixia.
2. Golpe aplastante agresivo: The highforce singletoggle mechanism drives the moving jaw in an elliptical motion, applying compressive force efficiently.
3. Descargar & Autorización: The steep nip angle and optimized discharge setting facilitate rapid material evacuation, preventing chokepoints and promoting high throughput.
4. Integración del sistema: The crusher interfaces with vibrating grizzly feeders and downstream conveyors for a continuous feed system.

Ámbito de aplicación: Ideal for stationary primary crushing plants processing granite, basalto, mineral de hierro, mineral de cobre, and recycled aggregates. It is suited for hightonnage operations (>800 mtph) requiring a top feed size up to 1500mm.

Limitaciones: No diseñado para aplicaciones de reciclaje de abrasivos sin opciones de revestimiento específicas. Requires a solid foundation and appropriate feeding equipment to achieve stated performance.

3. CARACTERÍSTICAS PRINCIPALES

HeavyDuty Roller Bearing Assembly | Base técnica: Rodamientos de rodillos a rótula con ejes de gran diámetro | Beneficio operativo: Handles high radial and thrust loads from tough crushing conditions; extends bearing life by up to 3x compared to standard bearings | Impacto del retorno de la inversión: Reduce el riesgo de falla catastrófica de los rodamientos; lowers maintenance frequency and associated labor costs.

Hydraulic Wedge Adjustment System | Base técnica: Dualacting hydraulic cylinders replace manual shim adjustment | Beneficio operativo: Allows closedside setting (CSS) adjustments to be made quickly, safely, and accurately in minutes versus hours | Impacto del retorno de la inversión: Maximizes plant uptime during product changeovers; improves operator safety by eliminating manual handling.

Geometría optimizada de la cámara de trituración | Base técnica: Computermodeled kinematics with a steep nip angle and deep symmetrical chamber | Beneficio operativo: Delivers higher reduction ratios per pass; produces a more consistent product shape with less slabby material | Impacto del retorno de la inversión: Increases effective capacity of downstream circuits; improves final product cubicity for higher market value.

Revestimientos antidesgaste atornillados | Base técnica: Modular liner design with replaceable cheek plates manufactured from abrasionresistant steel | Beneficio operativo: Simplifica el reemplazo del revestimiento; protects the main frame structure from wear indefinitely | Impacto del retorno de la inversión: Drastically reduces longterm capital asset depreciation; cuts liner changeout time by over 40%.

PLCIntegrated Overload Protection | Base técnica: Hydraulic toggle plate with pressure sensors linked to the plant control system | Beneficio operativo: Automatically releases tramp metal or uncrushable material; resets without manual intervention | Impacto del retorno de la inversión: Prevents costly damage to the pitman and bearings; avoids hours of unscheduled downtime per event.

Transmisión directa a través de VBelts & TEFC Motor | Base técnica: Hightorque motor connected via multiple Vbelts to a heavyduty flywheel | Beneficio operativo: Smooth power transmission that absorbs load fluctuations; standard motor compatibility simplifies sourcing and replacement | Impacto del retorno de la inversión: Lower installed cost compared to fluid couplings; improved energy efficiency under variable load conditions.

4. VENTAJAS COMPETITIVAS

| Métrica de rendimiento | Estándar de la industria (Clase comparable) | Solución de trituradora de mandíbulas JC5000 | Ventaja (% Mejora) |
| : | : | : | : |
| La vida de la mandíbula muere (Granito abrasivo) | ~450.000 toneladas por juego (based on competitor data sheets)| ~550,000 tonnes per set (fieldverified average)| +22% in wear material cost/tonne |
| Intervalo de servicio del rodamiento (MTBF)| 8,000 10,000 horas de funcionamiento| 14,000+ horas de funcionamiento (proyectado)| +40% in service life |
| Tiempo de ajuste de CSS (Mechanical to Mechanical)| 46 hours with crew of two| <1 hour with single operator| 80% in downtime for adjustment |
| Power Consumption per Tonne Crushed| Benchmark of 100%| Promedio de 9295% (dependiente del sitio)| 5% a 8% en costos de energía |
| Peso Total / Structural Mass Index| Benchmark of 100% for rated capacity| Index of ~115% (higher masstocapacity ratio)| +15% in structural rigidity & fatigue resistance |

Mean Time Between Failures based on industry lubrication schedules.
Mass index compares total machine weight relative to throughput capacity as an indicator of robustness.

5. ESPECIFICACIONES TÉCNICAS

Apertura de alimentación: 1500mm x 2000 mm (59" incógnita 79")
Tamaño máximo de alimentación: Up to 1500mm cube (59")
Rango de configuración del lado cerrado: 200mm 300 mm (8" 12")
Rango de capacidad: Arriba a 1650 mtph (dependiente del material de alimentación & CSS)
Requisito de potencia de accionamiento: 375 kilovatios /500 HP TEFC electric motor
Peso Total (Solo trituradora): Approximately ~145,000 kg (~320,000 lbs)
Construcción del marco principal: Fabricated steel plate with stressrelieved welds; Revestimientos de acero AR en los puntos de desgaste.
Rango de temperatura ambiente de funcionamiento: 20°C a +45°C (4°F a +113°F) con lubricación estándar.
Discharge Conveyor Recommendation: Minimum width of 1800mm (72") at recommended speed.

6. ESCENARIOS DE APLICACIÓN

Hard Rock Quarrying – Granite & Basalt Primary Crushing

Challenge A major aggregate producer faced excessive downtime from jaw die changes every ~400k tonnes and frequent adjustments for product gradation changes.
Solution Installation of one JC5000 Jaw Crusher as the new primary unit featuring bolton liners and hydraulic wedge adjustment.
Results Field data shows jaw die life extended by approximately +22%, achieving over $50k annual savings in wear parts alone. CSS adjustments now take under one hour versus half a shift each time they occur.

Mineral Processing – Primary Iron Ore Crushing

Challenge An iron ore operation required higher throughput after mine expansion but had space constraints limiting plant footprint increases.
Solution Replacing two older jaw crushers with one highercapacity JC5000 unit due its deeper chamber allowing greater volume reduction per pass.
Results Plant throughput increased by approximately +30%. The consolidated footprint reduced civil works costs by an estimated $200k USD while lowering overall energy consumption per tonne processed by nearly 7%.

Major Infrastructure – Tunnel Boring Muck Processing

Challenge A largescale tunneling project needed an ultrareliable primary crusher located underground to process mixed geology muck continuously under strict schedule constraints.
Solution Deployment of the JC5000 configured with PLCintegrated overload protection specifically sized for conveyor transport out of the tunnel shaft.
Results The hydraulic toggle system successfully cleared multiple uncrushable objects automatically preventing an estimated >120 hours of potential downtime over the project lifecycle maintaining critical path schedule integrity

7 CONSIDERACIONES COMERCIALES

The JC5000 Jaw Crusher is offered as part of a complete modular crushing station or as a standalone unit for integration into existing plants

Niveles de precios de equipos:
1 Base Unit Includes crusher mainframe drive motor flywheel guards basic tool kit
2 Plant Ready Package Adds hydraulic power pack for adjustment integrated walkways ladders preinstalled lubrication system
3 Customized Application Package Includes applicationspecific jaw die metallurgy special guarding environmental packages dust suppression interfaces

Características opcionales:
• Automated Greasing System
• Rock Level Sensor Integration
• Special AR Steel Grades for Cheek Plates
• SkidMounted Modular Frame

Paquetes de servicios:
• Commissioning Supervision Standard package includes field technician support during startup Extended package includes operator training performance verification testing
• Preventive Maintenance Contracts Tiered plans offering scheduled inspections parts kits priority support based on annual operating hours

Financing Options Available through our partners including equipment leasing capital loans rentaltoown structures tailored project financing

8 Preguntas frecuentes

Q What are the foundation requirements for installing this crusher?
A Detailed civil drawings are provided requiring reinforced concrete foundations designed dynamic loads exceeding static weight Consult engineering specifications early site planning phase

Q Can this crusher handle recycled concrete brick asphalt?
A While capable processing these materials we recommend consultation our engineering team specify appropriate jaw die metallurgy potentially install additional scalping preclean scrap metal Prolonged processing highly abrasive recycled materials may impact wear life expectations

Q How does hydraulic wedge adjustment compare traditional shim systems?
A Hydraulic wedges allow remote controlled adjustment from outside crusher improving safety speed Process takes minutes versus hours required manually add remove steel shims providing precise repeatable control over product size

Q What is typical delivery lead time after order placement?
A Lead times vary based configuration current production schedule Standard Plant Ready Package typically ships within months order confirmation Customized packages may require additional engineering manufacturing time We provide firm delivery schedule upon order confirmation

P ¿Hay piezas de repuesto disponibles en todo el mundo??
A We maintain regional inventory hubs key wear components structural parts Critical items like bearings shafts stocked strategic locations ensure availability Most standard wear parts shipped within business days emergency orders