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Table of Contents
Related Manuals for Rockwheel D20
Summary of Contents for Rockwheel D20
- Page 1 Original Operating Manual ROCKWHEEL 2021...
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Page 2: Table Of Contents
3.2.3 Sling points ........................22 3.2.4 Center of gravity ......................23 3.2.5 Transport of the packed machine (loading using a crane, a forklift truck, on rolls) ..24 3.2.6 Transport of unpacked machinery and system parts ............. 26 3/60 D20 Operating Manual 2020... - Page 3 3.13 Disposal ............................ 33 Description ......................34 4.1 Machine overview ........................34 4.2 Function ............................ 35 4.2.1 Examples for application of the Rockwheel ..............36 Drum types ......................38 Technical data ....................39 6.1 Emissions ..........................42 6.1.1 Air-borne sound ......................42 6.2 Type plate ..........................
- Page 4 8.2 Returning into service after a fault .................... 57 Annex ........................ 58 9.1 List of figures ..........................58 9.2 List of tables ..........................59 9.3 Warranty conditions ........................60 9.3.1 Warranty ......................... 60 9.3.2 Disclaimer of warranty ....................60 9.3.3 Liability ........................... 60 5/60 D20 Operating Manual 2020...
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Page 5: Introduction
Introduction 1 Introduction In case of questions with regard to the machine, please contact the customer service, stating the serial number, at: 6/60 D20 Operating Manual 2020... -
Page 6: About The Operating Manual
All rights in drawings and other documents, as well as any power of disposition are held by ROCK.ZONE GmbH. This shall also apply for cases of intellectual property application. 7/60 D20 Operating Manual 2020... -
Page 7: Advice For Use Of The Operating Manual
Automatic mode b) Manual mode F For service and maintenance work Table 1 Marking of text types Notice! This symbol is used for providing important information and advice with regard to handling of the machine. 8/60 D20 Operating Manual 2020... -
Page 8: Declaration Of Conformity
Fluid technology –General rules and safety relevant requirements for hydraulic equipment and the components Name and address oft the responsible for technical documentation: ROCK.ZONE GmbH, Sandweg 10, D-74595 Langenburg Langenburg, Klaus Volkert, Operating Manager Place, Date Name, Function Signature 9/60 D20 Operating Manual 2020... -
Page 9: Safety
This warning note identifies a moderate-risk hazard. Non-compliance with the safety regulations might result in death or severe injury. Warning Type and source of the hazard Consequence of the hazard Ø Remedy of the hazard 10/60 D20 Operating Manual 2020... - Page 10 Ø Remedy of the hazard Attention This warning note identifies a low-risk hazard. Non-compliance with the safety regulations may result in property damage. Attention Type and source of the hazard Consequence of the hazard Ø Remedy of the hazard 11/60 D20 Operating Manual 2020...
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Page 11: Intended Use
Rockwheel is performed through the earthmoving machine. • The hydraulic Rockwheel can be equipped with various drum types and a number of different bit types. Depending on the type of material to be cut, e.g. soil, sandstone, hard rock, asphalt, timber, concrete. -
Page 12: Residual Risks
2.4.1 Hazards due to specific types of use or application of specific accessories • During operation of the Rockwheel there is a risk of flying or projecting stones, dust and debris. • The Rockwheel may cause severe injuries. Protective measures Ø... -
Page 13: Description Of Target Groups
• be trained by ROCK.ZONE GmbH or authorized service staff with regard to service work at the machine. • be trained with regard to conduct in case of fault/failure. 14/60 D20 Operating Manual 2020... -
Page 14: Personal Protective Equipment
The operating manual and the signs and symbols described therein must be read and understood by all persons working at and with the machine. Warning sign Warning sign Hazard point warning Table 3 Warning sign 15/60 D20 Operating Manual 2020... -
Page 15: Warning Signs And Positions At The Machine
Servicing and replacement of safety and warning signs Every safety and warning sign that is damaged or no longer visible must be immediately replaced. • Clean safety and warning signs with a mild detergent and water. Do not use solvent-containing detergents. 16/60 D20 Operating Manual 2020... -
Page 16: Work Area Safety
• Never perform any settings or adjustments at the hydraulic system during operation. • Immediately replace cracked or damaged hoses and tubes. • Only use original spare parts and immediately replace parts when damaged. 17/60 D20 Operating Manual 2020... -
Page 17: Vibration
Vibrations occur during cutting work. These are transferred to the operating equipment and the operator. Depending on the material to be cut, the intensity of vibrations may vary. Material Vibration intensity Working hours per day soil sandstone medium intensity hard rock high intensity 18/60 D20 Operating Manual 2020... -
Page 18: Advice For Operation
The 4 safety rules When working at pneumatic / fluidics equipment, always heed the 4 safety rules: Shut down the hydraulic system. Secure the hydraulic supply against re-start. Depressurize the lines. Check for absence of pressure. 19/60 D20 Operating Manual 2020... -
Page 19: Prior To Work
• At a pressure of >50 bar, the pressure relief valve is triggered. • Do not perform any changes or modifications at the Rockwheel. This also applies for attachment and welding of load-bearing parts. • Wear protective clothing during operation. Remove any rings, scarves, open jackets, etc. For specific work, use goggles, safety shoes, hard hat, protective gloves, high visibility vests, hearing protection, etc. -
Page 20: Transport/Installation/Disassembly
Ø Wear safety shoes. Notice! In order to determine suitable hoisting gear and lifting tackle, the weight and dimensions of the machine must be taken into account. See chapter ‘Technical data’. 21/60 D20 Operating Manual 2020... -
Page 21: Maximum Load Of Hooks, Eyes
Maximum load of hooks, eyes, ... Load Hooks min 1.5 t Eyes min 1.5 t Table 4 Maximum load 3.2.2 Hoisting gear For lifting the Rockwheel use the following hoisting machinery: • Crane • Forklift truck 3.2.3 Sling points Figure 2Sling points Excavator attachment Notice! The weight may change due to special attachments. -
Page 22: Center Of Gravity
Loads toppling over The center of gravity may shift due to attachment of other drums, adapter plates, quick couplers, rotators, etc. The hydraulic Rockwheel may topple over, injure persons or cause property damage. Ø Re-determine the center of gravity after installing attachments. -
Page 23: Transport Of The Packed Machine (Loading Using A Crane, A Forklift Truck, On Rolls)
Ø Carefully lift the crate and slowly and carefully move it to the installation site. Ø At the installation site, slowly and evenly lower the transport unit to the ground. Avoid jerky lowering or slamming. 24/60 D20 Operating Manual 2020... - Page 24 F The pallet may slide off the transport rolls. Constantly check the position of the transport rolls. Ø Remove the transport rolls; to this end slightly lift the pallet. Ø Then, slowly and evenly lower the pallet to the ground. Unpacking Ø Remove the load securing straps. 25/60 D20 Operating Manual 2020...
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Page 25: Transport Of Unpacked Machinery And System Parts
Ø Carefully lift the transport unit and slowly and carefully move it to the installation site. Ø At the installation site, slowly and evenly lower the transport unit to the ground. Avoid jerky lowering or slamming. 3.2.7 Quality check Ø Check for visible damage. 26/60 D20 Operating Manual 2020... -
Page 26: Connection
Hydraulic equipment • Assemble the Rockwheel to the excavator. Connect the Rockwheel to the control circuit (hydraulics) of the excavator as is described below: • Connect the pressure line to the excavator and firmly tighten the screw fitting using an open-end wrench. -
Page 27: Connection, Installation Diagram
A low degree of contamination of the hydraulic oil ensures a long service life of the moving parts in the hydraulic motor (piston, manifold). The required degree of contamination must be below class 9 of NAS 1638. 28/60 D20 Operating Manual 2020... -
Page 28: Quick Coupler
• In case that the Rockwheel rotary hoe is still attached to the excavator, the rotary hoe must be dismounted. •... -
Page 29: Installation For Underwater Applications
3.3.9 Installation for underwater applications The Rockwheel rotary hoes can be used in depths of up to 30 meters. However, in case of long-term applications at depths of more than 10 meters, please contact the ROCK.ZONE service department. In case that the Rockwheel rotary hoe is not connected via a leak oil line, we recommend connecting a line from the overpressure relief to the surface. -
Page 30: Process Sequence
Power of the Rockwheel (kW) x 600 (constant) ------------------------------------------------------------------- Flow (liters) With the Rockwheel having a maximum effective output of 70 kW and with an optimum oil volume of 220 liters, the following pressure setting is obtained: Pressure setting at max. oil volume =... -
Page 31: With The Rockwheel Running Freely
Transport/installation/disassembly With the Rockwheel running freely: Check the Rockwheel drums for correct direction of rotation. If the direction of rotation is not correct, switch over the hydraulic pressure and the return line in the control circuit of the excavator (breaker). -
Page 32: Intermediate Storage
Table 5 Requirements for the storage area 3.11 Preservation measures • Apply corrosion protection agent prior to storing the Rockwheel. 3.12 Returning into service Prior to returning the machine into service after long-term storage, please perform the following work: •... -
Page 33: Description
The figure below provides and overview of the layout of the complete system. The individual sections are described in more detail below. Machine overview Figure 8 Machine overview Return line Supply line Attachment plate Rotary hoe Drum 34/60 D20 Operating Manual 2020... -
Page 34: Function
ROCK.ZONE. Notice! Optimal cutting operation is only possible if the drum of the Rockwheel is guided in the direction of the carrier vehicle. When swiveling the Rockwheel to the sides, it must be ensured that the forces for reaching large distances, acting on the boom or the arm of the... -
Page 35: Examples For Application Of The Rockwheel
Description 4.2.1 Examples for application of the Rockwheel If the Rockwheel is operated at vertical surfaces (walls), the direction of the Rockwheel drum should be changed, i.e. the Rockwheel must be turned. This reduces vibrations and counter-forces during cutting. Examples for application of the Rockwheel in trenches Examples for application of the Rockwheel on asphalt Prevents uncontrolled break-off of large pieces. - Page 36 Examples for application of the Rockwheel at walls Application in water Notice! Application of the Rockwheel in swampy areas or under water in depths of up to 20 m is possible upon conversion of the Rockwheel and upon agreement with our technical service.
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Page 37: Drum Types
Drum types 5 Drum types Selection of the various Rockwheel drums and cutting bits depends on the operating conditions. • Breaker drums/cutting drums These drums are used for cutting of rock with low to medium hardness. The bits must be arranged such that they provide best-possible cutting output. -
Page 38: Technical Data
Notice! Do not operate the rotary hoe with maximum pressure and maximum delivery rate at the same time since this exceeds the admissible nominal output. The Rockwheel must be operated within the nominal output range.Please take into account the output diagram. - Page 39 Connection A mm diameter B height C mm middle web plate E plate F D mm 1058 1155 Table 7 Technical data - dimensions Bit (cutting tools) Standard bit heavy-duty bit Wear-protected Bit excavation bit 40/60 D20 Operating Manual 2020...
- Page 40 Technical data D20 / D30 Standard / AX20 / AX30 Gesamtbreite / Width (mm) Gesamthöhe / Height (mm) Anzahl Bohrungen / No. of holes Stärke Adapterplatte/ thickness adapter bracket 30mm Durchmesser / Diameter (mm) Required bolts and nuts (holes in bracket) Schrauben / Bolt Type Stück/pcs...
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Page 41: Emissions
In free ranging operation the A-rated sound power level is below 75 dBA. Depending on the type of material the machine is used for, the sound power level may be above this value. Type plate Figure 9 Type plate 42/60 D20 Operating Manual 2020... -
Page 42: Servicing
Inform the operating staff, appoint a supervisor. Activities subsequent to servicing work 7.3.1 Cleaning the Rockwheel Ø Free the Rockwheel from dirt and soil using a water jet at regular intervals. 7.3.2 Checking the functions Ø Check that the bits are not stuck Tools / special equipment for maintenance •... -
Page 43: Cleaning
For tenacious soiling: use non-flammable solvents. 7.5.2 Maintenance and replacement of warning signs • Immediately replace any damaged or lost warning signs. • Clean and warning signs using a mild detergent and water. Do not use solvent-containing detergents. 44/60 D20 Operating Manual 2020... -
Page 44: Maintenance Overview
Every 1000 hours / 1x • Check condition of hydraulic motor. per year • Disassemble cutting drums. Check seals and gaskets for leakage. Check screw connections. • Check condition of the slide ring packing. Table 8 Maintenance schedule D20 Operating Manual 2020 45/60... -
Page 45: Description Of Maintenance And Servicing Work For Persons Without Specific Training (Operating Staff)
Crushing hazard due to the Rockwheel Ø Secure the Rockwheel against sliding and falling. • Position the Rockwheel so that the cutting drums can be easily rotated. Warning Hazard due to projecting parts Projecting parts occurring during repair work may cause severe injuries of the eyes up to loss of eyesight. - Page 46 Knock the bit out of the bit holder using a hammer and a reaming tool. • Loosen any stuck bits by driving the wedge into the gap between the bit and the bit holder. • Disassemble all other bits. D20 Operating Manual 2020 47/60...
- Page 47 Servicing Installation of bits Slide the bit into the bit holder of the Rockwheel drum (Fig. 30). Before installing a new bit, clean the tool insertion hole in the bit holder. Notice! Before installing used bits, clean the shank. Notice! Install the bits without using any lubricant (grease or oil).
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Page 48: Checking The Slide Ring Packing
In case of leakage or if the tightening torque is not reached, please contact the service department. Removing the end plate and the packing carrier, checking the slide ring packing. Tightening torque of the M16 hexagon socket head screws Checking for leakage at the venting port Checking for leakage D20 Operating Manual 2020 49/60... -
Page 49: Removal / Installation Of The Cutting Drum
Tighten these screws with a tightening torque of 650 Nm. • This must be ensured, since otherwise damage at the square socket head screw may result. Center of gravity M16 hexagon socket M20 hexagon socket head head D20 Operating Manual 2020 50/60... -
Page 50: Flushing / Filling The Hydraulic Motor
To avoid compromising the warranty, please contact the service department before flushing / filling the hydraulic motor or performing the steps listed below. The D20 Rockwheel has been filled with oil prior to delivery and thus must not be re-filled. In case of leakage, the D20 Rockwheel must be re-filled. -
Page 51: Check Condition Of Hydraulic Motor
Pay attention to the flow rate of the oil from through the discharge line; it should not be higher than 5 lpm. • If a leak oil line is used, the condition can be checked using a measuring device. ½ inch BSP connector D20 Operating Manual 2020 52/60... -
Page 52: In Case Of Leakage Or If The Tightening Torque Is Not Reached, Please Contact The Spare Parts Supply Department
In case of leakage or if the tightening torque is not reached, please contact the spare parts supply department Contact information for spare parts procurement and technical help and advice: 7.8.1 Spare parts list See separate spare parts list. D20 Operating Manual 2020 53/60... -
Page 53: Troubleshooting
Troubleshooting 8 Troubleshooting In case of questions with regard to troubleshooting, please contact the customer service, stating the serial number, at: D20 Operating Manual 2020 54/60... -
Page 54: Description Of Faults, Including Consequences, Causes And Remedial Measures
Check the hydraulic The Rockwheel output depends on Remove the Rockwheel rotary hoe from the circuit at the correct functioning of the hydraulic hydraulic circuit. Check the flow, overpressure excavator circuit of the excavator. - Page 55 In case of 3.) A defect at the shaft gasket is likely. Only one cutting head is rotating Only one cutting head Fault at the internal shaft. The Rockwheel rotary hoe must not be used. is rotating or one Complete disassembly is required. head is rotating faster than the other...
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Page 56: Returning Into Service After A Fault
Troubleshooting Returning into service after a fault Ø Fault has been remedied. Ø Visual inspection of the Rockwheel for other faults and damage. Ø Start-up the Rockwheel. D20 Operating Manual 2020 57/60... -
Page 57: Annex
Figure 5 Transporting the machine using a crane ................. 24 Figure 6 Transporting the packed machine using transport rolls ............25 Figure 7 Connection, installation diagram ..................... 28 Figure 8 Machine overview ........................34 Figure 9 Type plate ..........................42 D20 Operating Manual 2020 58/60... -
Page 58: List Of Tables
Table 4 Maximum load .......................... 22 Table 5 Requirements for the storage area ..................33 Table 6 Technical data .......................... 39 Table 7 Technical data - dimensions ....................40 Table 8 Maintenance schedule ......................45 D20 Operating Manual 2020 59/60... -
Page 59: Warranty Conditions
(provided they are not specified in a separate document) 9.3.1 Warranty ROCK.ZONE GmbH assume a warranty for their products of type D20 as well as all accessories to be free of defects in material and workmanship for the period of 12 months starting with the date of receipt.
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