Subjek: High Quality Jc5000 Jaw Crusher Quotation – Optimizing Primary Crushing for HighVolume Operations

1. PEMBUKAAN PAINPOINT DRIVEN

Is your current primary crushing stage becoming a bottleneck in your aggregate or mining circuit? Many operations face the compounding costs of premature jaw plate wear, frequent toggle plate failures, and inconsistent product sizing. Industry data indicates that unscheduled downtime for jaw crusher maintenance can cost a midsized quarry between $8,000 dan $15,000 sejam dalam pengeluaran yang hilang. Di samping itu, a crusher that cannot handle a consistent feed of 500600mm material often requires costly secondary blasting or hydraulic hammering, menambah $2.50 ke $4.00 per ton to operating costs.

Are you struggling to maintain a tight closedside setting (CSS) under high tonnage loads? Does your current machine require excessive lubrication and bearing maintenance, meningkatkan jumlah kos pemilikan anda? The High Quality Jc5000 Jaw Crusher is engineered to address these specific operational challenges, providing a robust solution for highvolume primary reduction.

2. GAMBARAN KESELURUHAN PRODUK

The High Quality Jc5000 Jaw Crusher is a heavyduty, singletoggle primary crusher designed for continuous operation in hard rock mining and largescale aggregate processing. It operates on the principle of compressive crushing between a fixed jaw and a moving jaw (Swing Rahang), driven by a large eccentric shaft.

Aliran Kerja Operasi:
1. Pengambilan Suapan: Runofmine (ROM) bahan (sehingga 800mm) is fed into the Vshaped crushing chamber via a feeder or directly from a dump truck.
2. Kitaran Mampatan: Aci sipi berputar, driving the swing jaw in an elliptical motion against the fixed jaw. Material is crushed as it moves downward through the chamber.
3. Pelepasan produk: Bahan hancur keluar melalui tetapan sisi tertutup boleh laras (CSS) di bahagian bawah bilik.
4. Pelarasan Hidraulik: The CSS is adjusted via a hydraulic wedge system, allowing for quick setting changes without manual shimming.

Skop Permohonan:

• Penghancuran utama: Basalt, granit, Sungai kerikil, bijih besi, dan batu kapur.
• Saiz suapan: Sehingga 800mm (31.5 inci).
• Saiz produk: Typically 100mm to 250mm depending on CSS setting.
• Batasan: Not suitable for sticky clay materials (kelembapan >8%) without a grizzly feeder; requires a heavyduty foundation to absorb dynamic loads.

3. CIRI TERAS

Aci Sipi Tugas Berat | Asas Teknikal: Forged 40CrNiMo alloy steel with oversized bearings | Faedah Operasi: Reduces shaft deflection under peak loads, maintaining consistent crushing force | Kesan ROI: Memanjangkan hayat galas dengan 40%, mengurangkan kos penggantian dengan $3,000 setiap tahun

Sistem Pelarasan CSS Hidraulik | Asas Teknikal: Dual hydraulic cylinders with locking wedges | Faedah Operasi: Allows operators to change product size in under 5 minit tanpa shimming manual | Kesan ROI: Mengurangkan masa henti untuk menetapkan perubahan dengan 80%, semakin pulih 23 jam pengeluaran setiap minggu

Dalam, Symmetrical Crushing Chamber | Asas Teknikal: Curved jaw profile with 18degree nip angle | Faedah Operasi: Ensures material is gripped and crushed efficiently, reducing slabby product | Kesan ROI: Meningkatkan daya pengeluaran oleh 1215% berbanding dengan bilik standard, menurunkan costperton

Rangka Keluli Tuang Kekuatan Tinggi | Asas Teknikal: FEAoptimized, stressrelieved cast steel (ZG35SiMn) | Faedah Operasi: Withstands high impact loads from large feed material without cracking | Kesan ROI: Frame lifespan exceeds 15 tahun dalam operasi berterusan, eliminating major structural repair costs

Reversible Jaw Plates | Asas Teknikal: Keluli mangan (Mn13Cr2) with symmetrical design | Faedah Operasi: Operators can reverse plates to extend wear life by 50% sebelum penggantian | Kesan ROI: Mengurangkan kos bahagian haus tahunan dengan $4,500 for a typical 300 Operasi TPH

Automatic Grease Lubrication System | Asas Teknikal: Centralized pump with programmable intervals | Faedah Operasi: Ensures consistent lubrication to bearings and toggle seat, menghalang kegagalan dryrun | Kesan ROI: Reduces bearing failure incidents by 90%, penjimatan $8,000 setiap acara penggantian galas

Flywheel with Sheave | Asas Teknikal: Cast iron flywheels with Vbelt drive integration | Faedah Operasi: Stores kinetic energy to smooth out power demand during crushing cycles | Kesan ROI: Mengurangkan beban motor puncak dengan 15%, lowering energy costs and preventing motor overload trips

4. KELEBIHAN KOMPETITIF

| Metrik Prestasi | Piawaian Industri (150Kelas kW) | Jc5000 Jaw Crusher Solution | Kelebihan (% penambahbaikan) |
| : | : | : | : |
| Throughput (Tph) | 250300 Tph | 350450 Tph | +40% |
| Masa Pelarasan CSS | 3045 minit (shims manual) | 5 minit (hidraulik) | 85% |
| Jaw Plate Wear Life | 4,0005,000 jam | 6,0007,500 jam | +50% |
| Selang Penggantian Galas | 8,00010,000 jam | 14,00018,000 jam | +60% |
| Motor Power Consumption (kWj/tan) | 0.65 0.80 kWj/tan | 0.50 0.60 kWj/tan | 20% |
| Saiz suapan maksimum | 600mm | 800mm | +33% |

5. SPESIFIKASI TEKNIKAL

| Parameter | Spesifikasi |
| : | : |
| Model | Jc5000 |
| Pembukaan suapan (W x L) | 500mm x 1000mm (20" x 40") |
| Saiz suapan maksimum | 800mm (31.5") |
| Julat CSS | 60mm 175mm (2.4" 6.9") |
| Kapasiti (Tph) | 180 450 Tph (bergantung pada CSS dan kepadatan bahan) |
| Kuasa motor | 110 kw 160 kw (150 Hp 215 Hp) |
| Kelajuan aci eksentrik | 280 Rpm |
| Bahan Plat Rahang | Mn13Cr2 (Mangan 13%, Chromium 2%) |
| Bahan Bingkai | ZG35SiMn Cast Steel |
| Sistem pelinciran | Automatic Grease (Berpusat) |
| Berat Operasi | 18,500 kg (40,800 lbs) |
| Julat Suhu Operasi | 20°C hingga +45°C (4°F hingga 113°F) |
| Dimensi (L x W x H) | 3,200mm x 2,100mm x 2,800mm |

6. SENARIO APLIKASI

Kuari Batu Keras (Granit) | Cabaran: A quarry in Norway processing 400 TPH of granite (UCS 250 MPa) berpengalaman 8 unscheduled shutdowns per year due to cracked frame welds on their previous crusher. | Penyelesaian: Installed the Jc5000 with a cast steel frame and hydraulic CSS adjustment. | Keputusan: Zero frame failures in 24 bulan beroperasi. Kapasiti meningkat daripada 320 TPH kepada 410 Tph. Pakai separuh hayat dilanjutkan oleh 45%, reducing annual consumable costs by $12,000.

Iron Ore Mine (Penghancuran utama) | Cabaran: A mine in Western Australia needed to reduce ROM ore from 700mm to 150mm at a rate of 350 Tph, but their existing crusher could not handle the high silica content, causing rapid jaw plate wear. | Penyelesaian: Deployed the Jc5000 with reversible Mn13Cr2 jaw plates and a deep chamber profile. | Keputusan: Jaw plate life increased from 3,200 jam ke 5,800 jam. The reversible feature allowed one extra wear cycle before replacement. Total costperton for crushing dropped from $0.18 ke $0.12.



Loji Pemprosesan Kerikil Sungai | Cabaran: A plant in Germany processing 250 TPH of river gravel needed to reduce feed size from 500mm to 80mm for a cone crusher feed. The existing jaw crusher produced excessive fines. | Penyelesaian: Utilized the Jc5000 with a tight CSS of 80mm and optimized nip angle. | Keputusan: Product gradation improved, with fines (5mm) dikurangkan oleh 18%. The cone crusher downstream operated at 95% kapasiti, naik dari 80%. Penggunaan tenaga berkurangan 0.12 kWj/tan.

7. PERTIMBANGAN KOMERSIL

Peringkat Harga Peralatan (Anggaran Pelabuhan FOB):

• Konfigurasi Standard: $78,000 $95,000 (Termasuk penghancur, motor, Pemacu Vbelt, and standard manganese jaw plates).
• Konfigurasi Dipertingkat: $105,000 $125,000 (Includes hydraulic CSS system, pelinciran automatik, and premium Mn13Cr2 jaw plates).
• Full Package: $140,000 $165,000 (Includes enhanced configuration, spare jaw plate set, tool kit, dan waranti 2 tahun).

Ciri Pilihan:

• Motor Options: 110kw, 132kw, or 160kW (price difference: $2,500 $5,000).
• Jaw Plate Material Upgrade: Mn18Cr2 for extreme abrasion (+$3,500 setiap set).
• Modul Pemantauan Jauh: PLC interface for realtime CSS and load monitoring (+$4,200).

Pakej Perkhidmatan:

• asas (tahunan): $4,500/year – Includes 2 pemeriksaan tapak, lubrication system audit, and priority phone support.
• Premium (tahunan): $9,800/year – Includes 4 pemeriksaan tapak, Pakai pengukuran bahagian, bearing condition monitoring, and 48hour spare parts dispatch.

Pilihan Pembiayaan:

• LeasetoOwn: 36penggal bulan dengan 10% residual value at end.
• Pinjaman Peralatan: 5year fixed rate at 6.5% APR (tertakluk kepada kelulusan kredit).
• Program TradeIn: Accepting qualified used jaw crushers (200+ kapasiti TPH) untuk sehingga $25,000 kredit.

8. Soalan Lazim

S1: Can the Jc5000 handle wet or sticky material?
A: The Jc5000 is designed for dry to moderately moist material (moisture up to 6%). For sticky clay or highmoisture feed (>8%), we recommend installing a vibrating grizzly feeder with 50mm spacing ahead of the crusher to scalp fines.

S2: What is the typical lead time for a Jc5000 order?
A: Standard configuration orders typically ship within 810 minggu dari pengesahan pesanan. Enhanced and full package orders require 1214 weeks due to hydraulic component sourcing.

S3: How does the hydraulic CSS system perform in cold climates?
A: Sistem ini menggunakan ISO VG 46 hydraulic oil with a coldweather additive. It is rated for operation down to 20°C. For sustained operation below 15°C, an optional oil heater is recommended.

S4: What is the expected lifespan of the main bearings?
A: Di bawah keadaan operasi biasa (CSS 100150mm, 300 Tph), the spherical roller bearings typically last 14,00018,000 jam. Regular greasing and proper belt tension are critical to achieving this lifespan.

S5: Can the Jc5000 be integrated into an existing plant with a different motor voltage?
A: ya. The crusher is supplied without a motor by default. We can provide a motor pulley to match your existing motor (380V, 415V, 660V, or 3300V). Please specify your motor shaft diameter and RPM when ordering.

S6: Apakah perlindungan jaminan?
A: Perlindungan jaminan standard 12 bulan dari pentauliahan atau 18 bulan dari penghantaran, yang mana dahulu. The enhanced package includes a 24month warranty on the frame and eccentric shaft against manufacturing defects.

S7: How often should the toggle plate be inspected?
A: We recommend visual inspection every 40 waktu operasi. The toggle plate is designed as a sacrificial component to protect the frame from uncrushable material. Replace immediately if any cracks are visible.