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How to Replace a Cone Crusher Concave (Bowl Liner)

How to Replace a Cone Crusher Concave (Bowl Liner)

Jul 22, 2025

The Ultimate Guide to Replacing Cone Crusher Liners

 

Step-by-Step Mantle & Concave Change-Out

Replacing your cone crusher’s mantle and concave (bowl liner) is heavy, demanding work. But doing it correctly and safely is the only way to protect your crusher's main shaft, maintain your desired Closed-Side Setting (CSS), and keep your cost-per-ton in check. Whether you're installing OEM parts or upgrading to premium Future Green Machinery (FGM) wear parts, follow this field-tested guide to execute a safe, efficient change-out without the headaches.

How to Replace a Cone Crusher Concave

Standard Operating Procedure (SOP)

Step 1: Secure the Zone (Prep & Safety)

Never cut corners before the heavy lifting begins.

  • Lockout/Tagout (LOTO): This is non-negotiable. Completely de-energize the crusher and lock out controls to prevent accidental start-ups.
  • Gear Up: Hard hats, safety glasses, steel-toed boots, and heavy-duty gloves are mandatory.
  • Clear the Deck: Clear all debris, old rock, and tripping hazards to ensure your crane operator and maintenance crew have unobstructed access.

Step 2: The Tear-Down (Removing Old Liners)

Getting worn parts out is often the hardest part of the job, especially if they have seized.

  • Clear the Top: Remove the feed plate and hopper assembly to gain full access to the chamber.
  • Defeat the Locking Nut: If it has seized from heavy crushing loads, don't waste hours fighting it—use a cutting torch to carefully cut the sacrificial torch ring and unscrew it.
  • Hoist the Mantle: Using a certified crane, carefully lift the worn mantle off the crusher head.
  • Extract the Concave: Use specialized lifting lugs to safely extract the old concave from the upper shell/bowl.

Step 3: Clean, Inspect, and Prep

A new liner is only as good as the surface it sits on.

  • Chip the Epoxy: Thoroughly chip away and grind off all remnants of the old backing compound from both the crusher head and the upper bowl.
  • Inspect Seating Surfaces: Check bare metal for gouges or cracking. Any debris left behind will prevent new liners from seating properly.
  • Wipe it Down: Ensure all surfaces are completely clean, dry, and free of oil or grease.

Step 4: The Rebuild (Installing New Parts)

Precision here prevents catastrophic failures later.

  • Seat the Components: Carefully lower the new FGM concave into the upper bowl, and guide the new FGM mantle perfectly onto the crusher head.
  • Pour Backing Compound: Mix heavy-duty epoxy exactly to specs. Pour it evenly behind the liners to eliminate air pockets. Let it cure fully!
  • Lock it Down: Reinstall the locking nut and torque it precisely to spec. (A loose nut will cause the mantle to spin and ruin the head).
  • Reassemble: Reattach the feed plate and reset automated liner-wear tracking systems.

Step 5: Startup & Calibration

Don't just hit the start button and walk away.

  • Calibrate the CSS: Recalibrate your Closed-Side Setting to match your target product size, as new thicker liners drastically change the gap.
  • Sight & Sound Test: Monitor closely during the first hour of feeding. Listen for metallic clanking, watch for abnormal vibrations, and verify even material draw-down.

💡 Pro Tips from the FGM Pit Crew

🔄 Change as a Pair

Always swap both the mantle and concave at the same time. Mixing a worn liner with a new one alters the crushing profile, reducing capacity and ruining shape.

⏱️ Don't Rush the Cure

Never start crushing before the epoxy backing compound has 100% cured. You will crack the epoxy and completely void the liner's structural support.

📉 Know When to Fold

If your throughput drops by 10%, or your remaining liner thickness dips below 1 inch (~2.5 cm), you are wasting energy and risking frame damage. Replace them immediately.

Need Replacement Liners That Actually Last?

Explore our premium manganese mantles and concaves, precision-engineered to perfectly fit your machine and keep your downtime to an absolute minimum.

VISIT FGMACHINERY.COM
Our Service
Our replacement parts provide durability and reliability equivalent to original equipment manufacturer (OEM) components but at significantly lower prices, tackling the high cost of genuine parts. Benefit from faster delivery and expert remote technical support from our Finland-based team. Choose FG Machinery to minimize downtime, maximize operational efficiency, and keep your mining equipment running at peak performance.

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