Liners that exceed their intended operating life will cause mechanical problems with the crusher. A liner that is pushed too long will flex and crack, and the flexing of a thin or cracked mantle will cause severe seat surface damage.
There is no 100% definitive way to determine when liners are worn out, but there are two indications it is time to change the liners:
A good indication the Cone Crusher liners need to be changed is when there is a 10% or more drop in production level or throughput.
Depending on the application, If the Cone Crusher liner is wearing evenly throughout the chamber, when it has worn down to about 1” (2.5 cm) thick at the bottom it is generally time to consider changing it. At about 3/4” to 5/8” (1.9 cm to 1.6 cm) thick, the liner will crack, causing the backing material to begin to disintegrate. This will cause the liners to break loose. If the liners break loose, continued operation could destroy the seat on the support bowl or the head of the Cone Crusher.
It is strongly advisable to never place a new concave liner in a crusher with a worn mantle or a new mantle in a crusher with a worn concave liner. Mating new and worn components will change the profile of the crushing chamber and restrict the feed from entering the crushing chamber, which will reduce the output per hour produced.
Preventative maintenance and documentation
CSP recommends that to achieve the most wear life out of your CSP Cone Crusher liners is to conduct regularly scheduled routine maintenance and document the information along the way. This will document how the liners wear, identify wear patterns and understand how the wear affects the production and assist in making required necessary changes to improve your production.