There are four methods to tell when a liner has met utilization goals and should be replaced. Each of these methods is accurate enough to rely on for replacement timing, if appropriate factors are known.
Monitor Production
This means monitoring the amount of stone going through the crusher. In the case of cone crushers, as the liners wear down, the feed opening at the top of the crusher will constrict, and you’ll lose throughput as the opening decreases and crushing cavity volume is reduced. When you have 10% production loss, compared to peak production, it’s time to change your liners. Failing to do so at that point will cost money in lost production and, if the liner wears too thin, could cause severe damage to internal crusher components.
Physical Measurement on the Exterior of the Crusher
A second way to monitor usage one a cone crusher is to measure from the dust cover down to the top of the adjustment ring. The distance will start at a certain height (maybe six inches), and will decrease as adjusted down for wear—it may be two-and-a-half inches at full utility. Make a physical mark on the exterior that signifies full utility and, when the mark is reached, you’ll know that it’s time to change the liners.
Measure Crusher Hours
This requires an understanding of the crusher and the stone being crushed. For example, a certain crusher may operate for 200 hours before it needs to be changed. Some crushers have an hour meter to monitor time.
Measure Total Tons Through the Crusher
This, again, requires an understanding of the crusher and material it’s fed. Depending on those factors, there is an expected cumulative throughput that the crusher will process before liners will need to be replaced. Measuring total tons through the crusher against that number will provide an accurate notification for timing liner replacement.