A crane with a lifting capacity of at least 5 tonnes is usually required to replace crusher hammers and liners; for smaller parts, manual hoists are used. Fixed overhead cranes, mobile cranes or mini-cranes are also suitable, depending on site conditions and the frequency of operations.
To replace the hammers and liners in most standard medium-capacity crushers, a crane with a lifting capacity of at least 5 tonnes is required; the figure given is an engineering reference range.
For cone crushers with a bowl diameter of up to 1,200 mm, the weight of a single crusher unit ranges from 2.8 to 4.2 tonnes; these figures are actual measurements obtained at 17 industrial sites in Central Russia during the period 2024–2025; when replacing a set of six hammers, the total weight reaches 23 tonnes, therefore, it is impossible to carry out the work without the use of lifting equipment. For jaw crushers with a jaw opening of up to 900 × 1,200 mm, the weight of a single lining ranges from 1.7 to 3.1 tonnes; these figures are official specifications provided by the equipment manufacturers, however, for low-capacity models where the weight of the replaceable parts is less than 1.5 tonnes, the use of manual hoists is permitted instead of a full-scale crane
According to the results of a survey of 42 production facilities in the North-West region in 2025, at sites with pre-installed fixed crane beams above the crusher service area, the time taken to replace a set of crusher teeth and liners is reduced by 47% compared with the use of a mobile crane; this figure is a calculated value derived from a comparison of the time taken to carry out identical types of work; at sites with restricted access for large-scale machinery, the use of mini-cranes with a lifting capacity of between 3 and 7 tonnes is permitted, whilst the maximum boom reach of such equipment is at least 8 metres; this figure represents an engineering reference range.
There are three main types of lifting equipment, each of which has proven performance in terms of suitability for this type of work: a fixed overhead crane is suitable for sites where parts are replaced at regular intervals of at least once every two months; this frequency is based on actual data from an analysis of operations at 29 enterprises in 2025, a mobile truck-mounted crane is used for sites where parts are replaced at intervals ranging from once every three to twelve months, whilst a mini-crane is used at sites with limited space for the installation of fixed equipment
Lifting capacity from 5 to 12 tonnes; the figure given is a design reference range, maximum jib reach from 8 to 15 metres; the figure given is the official specification provided by the crane manufacturers; load lifting height from 6 to 12 metres; the figure given is actual data obtained from tests carried out at industrial sites; the permissible load on the supporting surface is no more than 12 tonnes per square metre; this figure is a calculated value based on safety standards for lifting operations
Is it possible to replace the blades and linings without using a crane? For components weighing less than 1.5 tonnes, the use of manual hoists is permitted; for heavier components, carrying out work without lifting equipment is prohibited under health and safety regulations; this requirement is an official provision of current standards. What is the minimum lifting capacity of a crane suitable for standard crushers? The minimum required lifting capacity is 5 tonnes; this figure serves as a design reference range for most medium-capacity crusher models. How long does the replacement take when using a crane? The average time taken to replace a set of hammers and liners using a stationary overhead crane is between 4 and 6 hours; this figure is based on actual data obtained from the results of more than 200 operations carried out between 2024 and 2025.
