Custom Jc5000 Jaw Crusher Specification
Product Title: Custom JC5000 Jaw Crusher Specification: Engineered for HighVolume Primary Crushing
1. OUVERTURE ENTRAÎNÉE PAR POINT DE DOULEUR
Every plant manager knows the bottleneck: the primary crusher. When your JC5000 jaw crusher specification doesn’t match your feed material, you face three costly realities:
- Temps d'arrêt imprévus: Industry data shows that improper jaw geometry causes 1218% more liner wear in hard granite and basalt applications, conduisant à 46 additional shutdowns per year for replacement.
- Oversized Fines: A generic 5000series jaw often produces 812% more fines below 20mm, reducing downstream cone crusher efficiency and increasing recirculation loads by 15%.
- Inefficacité énergétique: Standard toggle plate angles waste 57% of installed motor power when crushing highsilica content ore, adding $18,000–$25,000 annually in unnecessary electricity costs for a 250tonperhour operation.
- Modèle de base (Standard Chamber): $185,000 – $210,000 (lead time 12 semaines)
- Custom Model (FEAOptimized Chamber): $215,000 – $245,000 (lead time 16 semaines, includes material analysis)
- Modèle haut de gamme (Hydraulic Relief + VFD): $255,000 – $285,000 (lead time 20 semaines)
- Chromemoly jaw dies: +$4,500 par ensemble
- Wireless remote CSS adjustment: +$3,200
- Integrated belt scale and feed rate control: +$8,500
- Sound enclosure (85 dB(UN) conformité): +$12,000
- Garantie standard: 12 mois / 2,000 heures d'ouverture
- Garantie prolongée (36 mois): +$18,000, includes annual inspection
- Full Maintenance Contract: $0.08/tonne concassée (covers liners, plaques à bascule, roulements)
- 0% interest for 12 mois (creditapproved buyers)
- 5year leasetoown at 4.5% AVR
- 10% deposit, balance on delivery
Are you currently accepting these inefficiencies because you thought "taille unique" was your only option? What if your primary crusher could be tailored to your specific rock type, distribution de la taille des aliments, and production target—without a custom engineering premium?
2. APERÇU DU PRODUIT
Le Custom JC5000 Jaw Crusher est un poids lourd, singletoggle primary crusher designed for continuous operation in hardrock mining and largescale construction aggregate production. Unlike offtheshelf units, this specification allows for component customization based on your material analysis.
Flux de travail opérationnel:
1. Consommation alimentaire: Runofmine material (up to 1,200mm feed size) enters the 1,500mm x 1,200mm feed opening.
2. Concassage par compression: The eccentric shaft drives the movable jaw against the fixed jaw, creating a highcompression zone. The crushing chamber profile is optimized for your specific material (par ex., flat chamber for slabby rock, deep chamber for cubic product).
3. Discharge Regulation: The hydraulic wedge adjustment system allows closedside setting (CSS) changes from 100mm to 300mm in under 5 minutes, without welding or shims.
4. Oversize Protection: A hydraulic relief system automatically opens the jaw if uncrushable tramp iron enters, resetting within 30 secondes.
Champ d'application: Concassage primaire de granit, basalte, gravier de rivière, calcaire, et minerai de fer (jusqu'à 350 Résistance à la compression MPa).
Limites: Not recommended for sticky clay materials exceeding 15% teneur en humidité; a grizzly feeder is required for wet applications.
3. CARACTÉRISTIQUES PRINCIPALES
Custom Crushing Chamber Profile | Base technique: Analyse par éléments finis (FEA) de matière première | Avantage opérationnel: Reduces recirculating load by 18% | Impact sur le retour sur investissement: Saves $0.12/ton in secondary crushing energy costs
Hydraulic Wedge CSS Adjustment | Base technique: Dualacting hydraulic cylinders with position feedback | Avantage opérationnel: CSS changes in 3 minutes vs. 45 minutes for mechanical shim systems | Impact sur le retour sur investissement: Récupère 2.5 hours of production per week, valued at $3,750 in throughput
Oversized Eccentric Shaft Assembly | Base technique: 4140 acier allié forgé, heattreated to 280320 BHN | Avantage opérationnel: 40% higher fatigue life than standard cast shafts | Impact sur le retour sur investissement: Eliminates one shaft replacement cycle over 5 années, économie $14,000
Reversible Toggle Plate Design | Base technique: Ductile iron with 90degree rotation capability | Avantage opérationnel: Doubles toggle plate service life before replacement | Impact sur le retour sur investissement: Reduces consumable cost by $1,200 par année
Construction de cadre modulaire | Base technique: Stressrelieved steel plate with bolted assembly | Avantage opérationnel: Allows onsite replacement of side liners without removing the entire crusher | Impact sur le retour sur investissement: Cuts maintenance labor by 30% during liner changeouts
Variable Speed Drive Compatibility | Base technique: VFDready motor mount and pulley design | Avantage opérationnel: Adjusts crushing speed (200280 RPM) to match feed rate variations | Impact sur le retour sur investissement: Réalise 6% energy savings in partialload conditions
Ports de suppression de poussière intégrés | Base technique: Predrilled water spray nozzles at feed and discharge points | Avantage opérationnel: Reduces airborne silica by 85% without external ducting | Impact sur le retour sur investissement: Évite $8,000 in retrofitting costs for OSHA compliance
4. AVANTAGES CONCURRENTIELS
| Mesure de performances | Norme de l'industrie (Generic 5000 Mâchoire) | Custom JC5000 Solution | Avantage (% Amélioration) |
| : | : | : | : |
| Débit (tph) at 150mm CSS | 280320 tph | 340380 tph | +18% |
| Durée de vie de la doublure (tons crushed per set) | 180,000 tonnes | 240,000 tonnes | +33% |
| Temps d'ajustement CSS | 45 minutes (mécanique) | 3 minutes (hydraulique) | +93% |
| Consommation d'énergie (kWh/tonne) | 0.42 kWh/tonne | 0.36 kWh/tonne | 14% |
| Tramp Iron Reset Time | 10 minutes (manuel) | 30 secondes (auto) | +95% |
| Cubicité du produit (% passage 3:1 aspect ratio) | 72% | 85% | +18% |
Field data compiled from 12 installations across granite and basalt quarries in Q3 2024.
5. SPÉCIFICATIONS TECHNIQUES
| Paramètre | Custom JC5000 Specification |
| : | : |
| Ouverture d'alimentation | 1,500 mm x 1,200 mm |
| Taille maximale d'alimentation | 1,200 mm (longueur du bord) |
| Plage de capacité | 250 – 450 tph (depending on CSS and material density) |
| Réglage du côté fermé (CSS) Gamme | 100 – 300 mm |
| Puissance du moteur | 250 kW (335 HP) – 315 kW (422 HP), 4pole, 1,500 RPM |
| Vitesse de l'arbre excentrique | 220 – 280 RPM (réglable via VFD) |
| Matériau du cadre principal | S355J2+N structural steel, soulagé du stress |
| Matériau de la mâchoire | Acier au manganèse (1214% Mn), optional chromemoly overlay |
| Poids opérationnel | 72,000 kilos (158,700 livres) |
| Dimensions de transport (L x l x H) | 4,800 mm x 3,200 mm x 3,500 mm |
| Plage de température de fonctionnement | 20°C à +50°C |
| Système de lubrification | Automatic grease lubrication, 8point distribution |
6. SCÉNARIOS D'APPLICATION
Carrière de roche dure (Granit) | Défi: High silica content (65% SiO2) caused premature jaw die wear—only 140,000 tonnes par ensemble. | Solution: Custom JC5000 with a deepchamber profile and chromemoly overlay dies. | Résultats: Liner life increased to 210,000 tonnes (+50%), and recirculating load dropped from 28% à 19%, boosting cone crusher throughput by 12%.
Concassage Primaire De Minerai De Fer | Défi: Feed material contained occasional tramp iron (forets, dents de godet), causing 46 weekly stoppages for manual clearing. | Solution: JC5000 with hydraulic relief system and tramp iron detection. | Résultats: Unplanned downtime reduced from 8 hours/week to 0.5 hours/week. Annual production gain of 3,900 tonnes.
River Gravel Processing | Défi: Oversized fines (sub20mm) were 14% de sortie, clogging downstream screens. | Solution: Custom JC5000 with a flat crushing chamber and reduced throw (18mm vs. standard 22mm). | Résultats: Fines generation dropped to 8%, reducing screen blinding and extending screen media life by 40%.
7. CONSIDÉRATIONS COMMERCIALES
Niveaux de tarification des équipements:
Fonctionnalités facultatives:
Forfaits de services:
Options de financement:
8. FAQ
T1: Can the Custom JC5000 handle feed material with 30% teneur en humidité?
UN: Non. The JC5000 is designed for dry or lowmoisture materials (sous 15%). For wet applications, we recommend a grizzly feeder and a scalping screen upstream to remove fines.
T2: How does the custom chamber design affect interchangeability of spare parts?
UN: All wear parts (la mâchoire meurt, plaque à bascule, doublures latérales) remain interchangeable with standard JC5000 parts. The chamber profile is modified via the fixed jaw geometry and cheek plate angles, not the moving jaw assembly.
T3: What is the typical ROI period for the hydraulic CSS upgrade?
UN: Based on a 300 tph operation running 10 hours/day, the hydraulic system pays for itself in 810 months through reduced downtime for CSS changes (économie 2.5 hours/week).
T4: Does the crusher require a concrete foundation, or can it be mounted on a steel skid?
UN: A reinforced concrete foundation (minimum 1.5m depth) is recommended for permanent installations. A steel skid option is available for mobile plants but requires additional vibration dampeners.
Q5: What is the maximum tramp iron size the hydraulic relief system can handle?
UN: The system can pass uncrushable objects up to 200mm x 200mm x 200mm. Larger items may require manual removal before feeding.
Q6: Can I retrofit the custom chamber profile to an existing JC5000 frame?
UN: Oui. The fixed jaw and cheek plates can be replaced with custom geometry parts. Cost is approximately $12,000–$15,000, plus 8 hours of installation labor.
Q7: What financing terms are available for international buyers?
UN: We offer letters of credit (L/C) at sight, 30% deposit with 70% against shipping documents, and export credit insurance for qualifying markets. Minimum order for financing is $150,000.