Step-by-Step Guide to Replacing Jaw Crusher Liners: 8 Key Phases

Pre-Replacement Preparation

1. Safety Lockout Procedure

• Disconnect power supply and engage mechanical lockout
• Release hydraulic pressure (＞5 minutes bleed time)
• Install fall protection for crusher pit access

2. Tool & Material Checklist

Liner Replacement Process

3. Remove Worn Liners

1. Loosen wedge bolts in diagonal pattern (30% torque reduction)
2. Use liner removal tools to break corrosion bond
3. Extract upper wedges first, then side plates

4. Clean & Inspect Mounting Surface

• Remove debris with pneumatic chisel
• Check for cracks using dye penetrant
• Verify flatness (＜0.5mm/m tolerance)

5. Install New Liners

6. Alignment Verification

Use laser alignment tools to ensure:

• Parallelism ＜0.2mm/m
• Vertical runout ＜0.3mm
• Proper crushing chamber geometry

Post-Installation Procedures

7. Run-in Process

1. Start with 50% feed rate for 2 hours
2. Monitor vibration (＜4.5 mm/s RMS)
3. Retorque after 8 hours operation

8. Documentation & Analysis

• Record liner serial numbers
• Measure initial wear pattern
• Update predictive maintenance schedule

Common Mistakes & Solutions

Quarry Productivity Improvement

A limestone operation reduced liner replacement time from 6.5 to 3.8 hours by:

1. Implementing our 8-step process
2. Using optimized liner profiles
3. Training crew on crusher kinematics

Essential Tools for Efficient Replacement

• Liner handler with vacuum lift
• Infrared thermal camera (check bearing temps)
• Digital thickness gauge (wear measurement)

Precision Saves Costs

Replacing jaw crusher liner requires understanding torque specifications, alignment tolerances, and proper run-in procedures. Therefore, by integrating this guide with your preventive maintenance program and equipment documentation, operations typically achieve 18-24 month liner lifecycles even in abrasive conditions.