rock road refurbishing with the ironwolf crusher · rock road refurbishing with the ironwolf...

2010 ACE CONFERENCE

Rock Road Refurbishing with the IronWolf Crusher

IronWolf Rep: Bo VandergriffDate: October 25, 2010Date: October 25, 2010

1MAKE YOUR OWN ROAD

2010 ACE CONFERENCE

PRESENTATION OVERVIEWObjectives:Objectives:- To provide a brief history of IronWolf and its

various products.p- Describe how the IronWolf Crusher processes

existing material on your roads.g y- Summary of IronWolf Crusher Maintenance

Needs, Operational Costs, Production Levels, and “Road Maintainability”.

- Question and Answer Session.

2MAKE YOUR OWN ROAD

2010 ACE CONFERENCE

HISTORY• The Crusher wasThe Crusher was

originally developed to cut the permafrost i P dh Bin Prudhoe Bay, Alaska.

• The Crusher• The Crusher eliminated the need to rip, haul, and crush the frozen tundra.

3MAKE YOUR OWN ROAD

2010 ACE CONFERENCE

CORPORATE HEADQUARTERS• IronWolf designsIronWolf designs

and manufactures all of its productsall of its products from a 55,000 square foot facilitysquare foot facility located in Noble, OklahomaOklahoma.

4MAKE YOUR OWN ROAD

2010 ACE CONFERENCE

PRODUCT EVOLUTION

5MAKE YOUR OWN ROAD

2010 ACE CONFERENCE

IRONWOLF PRODUCT LINE

– CRUSHER SERIESSLASHER SERIES– SLASHER SERIES

– PROFILER SERIESMULCHER SERIES– MULCHER SERIES

– SNOW REMOVAL MACHINE SERIES700B SERIES– 700B SERIES

6MAKE YOUR OWN ROAD

2010 ACE CONFERENCE

CRUSHER SERIES• The Crusher attachment

consists of a cutter assembly and an auxiliary engine unitengine unit.

• Applications: Road Reclamation and Excavation

• The Crusher Series are crushing attachmentscrushing attachments designed to mount on wheel loaders.

7MAKE YOUR OWN ROAD

2010 ACE CONFERENCE

CRUSHER SPECIFICATIONS• Caterpillar® enginep g• Rexroth® hydraulic pumps• Rexroth® hydraulic motors

O&K Pl t d d i• O&K Planetary drum drives• IronWolf Cutter Drum • Proprietary IronWolf planetary alignment• Proprietary IronWolf planetary alignment

assemblies• Mesabi® radiator, charge-air cooler, bottom

k ili l d h d li il ltank auxiliary cooler and hydraulic oil cooler• Hydraulic accumulator

8MAKE YOUR OWN ROAD

2010 ACE CONFERENCE

CUTTER DRUM• Chevron Pattern:

– Has up to 138 teeth for a 10-foot drum

– Used for Slasher and Crusher models

Chevron Pattern

Crusher models– Enables larger finished

material (~5 inch minus*)• Quad Pattern:

– Has up to 214 teeth for a 10-foot drum

– Used for Crusher models only

Quad Pattern

only– Produces smaller finished

material (~3 inch minus*)* Also depends on stand height relative

t th f t b d

9MAKE YOUR OWN ROAD

to the fracture boards.

2010 ACE CONFERENCE

CUTTER ASSEMBLY WEIGHTSCUTTER ASSEMBLY WEIGHTSModel Approximate Weight (pounds) W x H x D Dimensions (inches)

540 13,100 78 x 50 x 88

548 16 400 78 56 96548 16,400 78 x 56 x 96

540 Tilt 17,100 78 x 80 x 88

548 Tilt 21,500 78 x 90 x 96

540 Heavy 18,200 78 x 50 x 88

548 Heavy 20,500 78 x 56 x 96

840 17,000 114 x 50 x 88

848 25,600 114 x 56 x 96

840 Tilt 21 100 114 x 80 x 88840 Tilt 21,100 114 x 80 x 88

848 Tilt 30,700 114 x 90 x 88

840 Heavy 21,800 114 x 50 x 88

848 Heavy 28,800 114 x 56 x 96

1040 19,500 138 x 50 x 88

1048 28,400 138 x 56 x 96

1040 Tilt 23,600 138 x 80 x 88

1048 Tilt 33,500 138 x 90 x 88

10MAKE YOUR OWN ROAD

1048 Tilt 33,500 138 x 90 x 88

1040 Heavy 25,000 138 x 50 x 88

1048 Heavy 32,000 138 x 56 x 96

2010 ACE CONFERENCE

540/6.540 SERIES CRUSHER CARRIERS

Caterpillar® John Deere® Komatsu® Kawasaki® Volvo® Standard 540/6.540 Model

950G 644-J WA380-5 80ZIV-2 L110E

950G-II 644-J WA380-5 80IZV-2 L110E

962G 644-J WA380-5 80ZV L120E

962G-II 724-J WA400-5 80ZV L120E

C t ill ® J h D ® K t ® K ki® V l ®

Heavy 540/6.540 Model

Caterpillar® John Deere® Komatsu® Kawasaki® Volvo® 966G 744-J WA450-5 85ZV L150E

966G-II 744-J WA450-5 90ZV L150E972G 824-J WA480-5 95ZV L180E

972G-II 824-J WA480-5 95ZV L180E980G-II 844-J WA500 95ZV L220E988G n/a WA600 115ZV L330E


2010 ACE CONFERENCE

800 SERIES CRUSHER CARRIERS800 SERIES CRUSHER CARRIERSStandard 840 Model

Caterpillar® John Deere® Komatsu® Kawasaki® Volvo®

966G 744 J WA450 5 85ZV L150E

Standard 840 Model

966G 744-J WA450-5 85ZV L150E

966G-II 744-J WA450-5 90ZV L150E

Standard 840 Heavy Model

Caterpillar® John Deere® Komatsu® Kawasaki® Volvo®

972G 824 J WA480 5 95ZV L180E

Standard 840 Heavy Model

972G 824-J WA480-5 95ZV L180E

972G-II 824-J WA480-5 95ZV L180E

980G-II 844-J WA500 95ZV L220E

988G WA600 115ZV L330E


2010 ACE CONFERENCE

IronWolf Crusher/Carrier Weights• The IronWolf Crusher with Carrier willThe IronWolf Crusher with Carrier will

range in weight from 65,000 to 95,000 poundspounds.

• The 540 and the 6.540 Series with Carrier will range from 65 000 to 75 000 poundswill range from 65,000 to 75,000 pounds.

• The 840 Series with Carrier will range from 85 000 t 95 000 d85,000 to 95,000 pounds.


2010 ACE CONFERENCE

Various Road Maintenance Projects by theVarious Road Maintenance Projects by the IronWolf Crusher


2010 ACE CONFERENCE

Switch-Back Road Maintenance in Utah


2010 ACE CONFERENCE

Weyerhaeuser (Mt. Rainier, WA) Road Maintenance


2010 ACE CONFERENCE

Kimble County (Junction, TX) Road Maintenance


2010 ACE CONFERENCE

ROCK ROAD REFURBISHING

Arizona Forestry Road


2010 ACE CONFERENCE

CONCRETE REMOVAL


2010 ACE CONFERENCE

City of Seattle Watershed Road Maintenance


2010 ACE CONFERENCE


2010 ACE CONFERENCE

SLASHER SERIES• The Slasher Series is

designed to mount on dozers.Th Sl h tt h t• The Slasher attachment consists of a cutter assembly, C-frame and an auxiliary engine unit.

• Applications: Standing Tree Removal SiteTree Removal, Site preparation, and site excavation.


2010 ACE CONFERENCE

SITE CLEARING & FIREBREAKS


One Pass Up. One Pass Back.

2010 ACE CONFERENCE

PROFILER•Product:Milli tt h t–Milling attachment

designed for graders.

•Applications:–Asphalt Milling–County Road Remediation

•Major Benefit:Major Benefit:–Mobile Milling


2010 ACE CONFERENCE

Profiler – City of Winnipeg


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Mulcher•Product:T d B h–Tree and Brush

cutting attachment.

•Applications:–Land Clearing–Site Preparation

•Major Benefit:–Robust Design–HighRobust Design High Torque


2010 ACE CONFERENCE

IronWolf Snow RemovalIronWolf Snow Removal Machine

1.) Approximately 4,000t h ftons per hour of Snow Removal Capability.

2.) Has a capacity of 10cubic feet per revolution.revolution.

3.) Has a Cutting Width of (9) Nine Feet.

4 ) Powered by a 5354.) Powered by a 535 Horsepower DieselEngine.


2010 ACE CONFERENCE

700BProduct:–Purpose built crawler with Crusher /Slasher h dheads.•Applications:–Land Clearing–Site–Land Clearing–Site Preparation•Major Benefit:–Power and Versatility.


2010 ACE CONFERENCE

700B Has Positive Impact on Local Economy and Environment

• “The innovativeThe innovative techniques of the 700B saved the City of Davis half a million dollars,

li i t d bl tieliminated blasting, rock hauling, tree burning and did notburning, and did not negatively impact the local environment.”


2010 ACE CONFERENCE


2010 ACE CONFERENCE

THE IRONWOLF CRUSHERTHE IRONWOLF CRUSHER

“HOW IT WORKS”


2010 ACE CONFERENCE

BASIC CRUSHER OPERATION• Drive machine forward to desired start location.• Place carrier machine in reverse and apply

brake.• Tilt crusher forward until skids come in contact

with the ground.• Slowly tilt crusher back while putting down

pressure with the carrier.

Pressure Gauge

p• Once cutting depth is achieved, then apply

load with fuel pedal of carrier and release the brake.

• Keep operating pressures in the green by feathering the fuel pedal of the carrier.


2010 ACE CONFERENCE

Material Processing (Up-cut)Fracture Board

Cutter Housing

Cutting Tool

Carrier Machine Mounting Side

Cutting Tool

Cutter DrumDrum

Rotation

Cutting Depth

Travel Direction


Travel Direction

2010 ACE CONFERENCE

Cutting Technique Comparison

DrumRotation

DrumRotation

Travel Direction

UP-CUT: An up-cut pulls material from the bottom of the cut and into the crusher housing to be processed on the fracture

DOWN-CUT: A down-cut breaks the material into the ground and does not

l th t i l th h th h

Travel Direction


housing to be processed on the fracture boards. This method requires less weight to operate.

cycle the material through the crusher housing

2010 ACE CONFERENCE

TRAVEL DIRECTION - CRUSHER

Up-cut

Travel Direction

Drum Rotation

• IronWolf recommends a reverse travel direction creating an up-cut. • If the customer wants to travel forward, the cutter assembly must be removed and

attached to the opposite side of the cutter assembly to maintain an up-cut.


attached to the opposite side of the cutter assembly to maintain an up cut.

2010 ACE CONFERENCE

MATERIAL PROCESSING

• Types of Rock Processed by IronWolf:• Limestone• Granite• Basalt• Productions Levels:• IronWolf averages processing a

mile of road per 8-hour day.mile of road per 8 hour day.


2010 ACE CONFERENCE

IRONWOLF CRUSHER MAINTENANCE

Objectives:Objectives:• To outline the recommended maintenance

schedules for IronWolf’s productsschedules for IronWolf s products.


2010 ACE CONFERENCE

MAINTENANCE SCHEDULES• Planetary Gearboxes: Change oil after first 100 hours y g

then every 250 hours or annually, whichever comes first. Use Mobile Glygoyle 30 (ISO VG 220= SAE 90) Synthetic gear oil.y g

• Twin Pad Pump Drive: Change oil after first 250 hours and then every 2000 hours or annually, whichever comes first Use 75/90 EP Synthetic gear oilcomes first. Use 75/90 EP Synthetic gear oil.

• Hydraulic Charge Filter: Replace element every 250 hours of operation. Element p/n is 104877, one required.H d li R t Filt R l l t ft• Hydraulic Return Filter: Replace elements after every 250 hours of operation. Element p/n is 104861, two required.


2010 ACE CONFERENCE

MAINTENANCE SCHEDULES• Hydraulic Suction Strainers (located inside y (

hydraulic tank): Replace when replacing hydraulic oil. Strainer p/n is 114066, two required.q

• Hydraulic Oil: Test twice per year and replace if ISO/DIS test is not better than 18/15. Use ISO 46 grade hydraulic oil46 grade hydraulic oil.

• CAT® Engine: According to CAT® owners’ manuals.

• Carrier Machine: Maintain carrier machine according to owners’ manual.


2010 ACE CONFERENCE

OPERATIONAL COSTS• OPERATIONAL COSTS-as with every machine, the

Crusher and Slasher has consumable items andCrusher and Slasher has consumable items and maintenance costs

• Consumable items Tools the replaceable inserts used to crush rock and slash timber– Tools-the replaceable inserts used to crush rock and slash timber

– Tool Holders-weld on pockets to hold the tools– Fuel-This machine is running at full rpm and full load 60% of the time.

In other words, it uses the maximum amount of fuelM i t t• Maintenance costs

– Planetary gear boxes-1st service 100hrs and every 250hrs after that– Funk twin drive gear box-1st service 250hrs and every 2000hrs or

annually– Hydraulic charge and return filter-replace elements every 250hrs– Hydraulic oil- test twice per year and replace if ISO/DIS test is not

better than 18/15– Cat engine-according to Caterpillar owners manual


g g p– Carrier machine-according to manufacture’s recommended schedule

2010 ACE CONFERENCE

CONSUMABLE COSTS• Tools:Tools:

– Pricing is different for each application. You can get tools ranging in price from $12.00 to $18.00 per tool.

• Diesel Consumption:– CAT® C-9 engine: 12.5 to 16.7 gallons/hour– CAT® C-15 engine : 23.5 to 25.7 gallons/hour– CAT® C-16 engine : 25.5 to 29.7 gallons/hour


2010 ACE CONFERENCE

CRUSHER OPERATIONAL COSTSOwner of Crusher Hourly Expense and Factors Involvedy p- Fuel Consumption- Operator Wage- Insurance- Consumables (teeth, blocks, etc.)

C (O )- Average Maintenance Costs (Oil, Filters, Hoses, etc.)- Average Hourly Expense will be $175.00 to $225.00.Renter of Crusher Hourly ExpenseRenter of Crusher Hourly Expense- $250.00 plus fuel and consumables.


2010 ACE CONFERENCE

“Road Maintainability”• Roads Prior to Material

Processing by IronWolf:• Problem with large, In-Place

exposed rock.N t i l t k ith f• No material to work with for Grader operator.

• Subsequent Years after Initial Treatment:Treatment:

• IronWolf creates material from 3 inch to fines. Material has structural variation. Allows material to bond together for better road longevity.

• Large rock eliminated.G d bl i l f G d• Good, usable material for Grader operator.


2010 ACE CONFERENCE

New IronWolf 840 Heavy Rental Unit• Crushers areCrushers are

available for Rental by the Month.

• IronWolf Reps will come to your job-site and train your personnel on proper operation andoperation and maintenance.


2010 ACE CONFERENCE

CONTACT INFORMATION• Sales and Rental EquipmentSales and Rental Equipment

– Bo Vandergriff [email protected] 405-245-7429– Todd Howe [email protected] 405-496-2200

• Service Department– Ed Hubkey [email protected] 405-206-4949

P t D t t• Parts Department– Mike Debusk [email protected] 405-872-1890

IronWolf reserves the right to make changes in engineering, design and specifications; add improvements; or discontinue manufacturing at any time without notice or obligation. Caterpillar® is a registered trademark of Caterpillar, Inc. Rexroth® is a registered trademark of Bosch Rexroth AG. Mesabi® is a registered trademark of L & M Radiator, Inc. Copyright© 2005 IronWolf. All rights Reserved.


rock road refurbishing with the ironwolf crusher · rock road refurbishing with the ironwolf...

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