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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.
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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.
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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.
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2010 ACE CONFERENCE
PRODUCT EVOLUTION
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2010 ACE CONFERENCE
IRONWOLF PRODUCT LINE
– CRUSHER SERIESSLASHER SERIES– SLASHER SERIES
– PROFILER SERIESMULCHER SERIES– MULCHER SERIES
– SNOW REMOVAL MACHINE SERIES700B SERIES– 700B SERIES
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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.
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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
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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
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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
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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
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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
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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.
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2010 ACE CONFERENCE
Various Road Maintenance Projects by theVarious Road Maintenance Projects by the IronWolf Crusher
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2010 ACE CONFERENCE
Switch-Back Road Maintenance in Utah
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2010 ACE CONFERENCE
Weyerhaeuser (Mt. Rainier, WA) Road Maintenance
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2010 ACE CONFERENCE
Kimble County (Junction, TX) Road Maintenance
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2010 ACE CONFERENCE
ROCK ROAD REFURBISHING
Arizona Forestry Road
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2010 ACE CONFERENCE
CONCRETE REMOVAL
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2010 ACE CONFERENCE
City of Seattle Watershed Road Maintenance
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2010 ACE CONFERENCE
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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.
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2010 ACE CONFERENCE
SITE CLEARING & FIREBREAKS
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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
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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
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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.
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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.
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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.”
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2010 ACE CONFERENCE
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2010 ACE CONFERENCE
THE IRONWOLF CRUSHERTHE IRONWOLF CRUSHER
“HOW IT WORKS”
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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.
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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
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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
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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.
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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.
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2010 ACE CONFERENCE
IRONWOLF CRUSHER MAINTENANCE
Objectives:Objectives:• To outline the recommended maintenance
schedules for IronWolf’s productsschedules for IronWolf s products.
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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.
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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.
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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
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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
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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.
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“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.
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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.
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2010 ACE CONFERENCE
CONTACT INFORMATION• Sales and Rental EquipmentSales and Rental Equipment
– Bo Vandergriff bo@ironwolf.com 405-245-7429– Todd Howe thowe@ironwolf.com 405-496-2200
• Service Department– Ed Hubkey edh@ironwolf.com 405-206-4949
P t D t t• Parts Department– Mike Debusk mdebusk@ironwolf.com 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.
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