D10 RockWheel

OPERATING MANUAL
PARTS BOOK
Unit Serial #

ALPINECUTTERS.COM
Contact

ALPINE SALES & RENTAL CORP.

801 Pleasant View Blvd.
Bellefonte, Pennsylvania 16823
U.S.A.

Phone +814 466 7134

Fax +814 355 0046

Website: www.alpinecutters.com

Email: info@alpinecutters.com

Copyright

© 2015
This operating manual is protected by copyright. Without prior written approval by Rokla GmbH it must not be
reproduced in full or in extracts, distributed, or used without authorization for competitive purposes.

All rights in drawings and other documents, as well as any power of disposition are held by Rokla GmbH. This
shall also apply for cases of intellectual property application.
TABLE OF CONTENTS

1. ABOUT THESE OPERATING INSTRUCTIONS......................................................1

2. INSTRUCTIONS FOR USING THE SAFETY NOTES............................................1

2.1 Intended use..............................................................................................................2

2.2 Misuse........................................................................................................................2
2.3 Residual risks.............................................................................................................2
2.4 Operator’s obligations............................................................................................2
2.5 Personal protective equipment............................................................................3
2.6 Work area safety.......................................................................................................5

3. INSTALLATION.........................................................................................................5

3.1 Adapter bracket.......................................................................................................6

3.2 Hydraulic Connection.............................................................................................6
3.3 Hydraulic oil..............................................................................................................7
3.4 Priming (filling) the hydraulic motor casing........................................................7
3.5 Installation of a leak oil line (Optional)................................................................8
3.6 Contamination and filtration.................................................................................9
3.7 Quick Hydraulic Coupler.......................................................................................10
3.8 Flow limiting device..............................................................................................10
3.9 Installation for underwater applications...........................................................10
3.10 Initial commissioning..........................................................................................10
3.11 Dismantling/disassembly..................................................................................11
3.12 Storage..................................................................................................................11
3.13 Preservation measures.......................................................................................12
3.14 Returning into service........................................................................................12
3.15 Disposal.................................................................................................................12

4. DESCRIPTION........................................................................................................12

4.1 Function..................................................................................................................13

5. TECHNICAL DATA................................................................................................15

5.1 Torque Specifications.............................................................................................15

5.2 Cutting drum dimensions........................................................................................................................ 16
5.3 Emissions..................................................................................................................16

6. SERVICING.............................................................................................................17

6.1 Qualification of personnel....................................................................................17

6.2 Activities prior to servicing work........................................................................17
6.3 Activities subsequent to servicing work...........................................................17
6.4 Cleaning...................................................................................................................17
6.5 Maintenance overview.........................................................................................18
6.6 Checking the slide ring packing (Cat eal)...........................................................21
6.7 Removal / installation of the cutting drum.......................................................22
6.8 Flushing / filling the hydraulic motor.................................................................23
6.9 Check condition of hydraulic motor...................................................................24
6.10 Torque specifications..........................................................................................25
6.11 Spare parts list......................................................................................................25
 Table of Contents con’t

7. TROUBLESHOOTING............................................................................................26

8. WARRANTY CONDITIONS..................................................................................28
1. ABOUT THESE OPERATING INSTRUCTIONS NOTES
Read, understand and follow the instructions in this and
other manual supplied with this product. Comply with OSHA, Danger
Federal, State, and Local Regulations..
Use good and safe work practices in a common sense way.. Type and source of the hazard
Only have trained operators – directed by informed and
knowledgeable supervision – operating this product.. Consequence of the hazard
.  Remedy of the hazard
This manual does not take into account any modifications
made to the equipment.If there is anything in this manual Danger
that is not clear or which you believe should be added, please
This warning note identifies a high-risk hazard. .
send your comments to customer service:.
Non-compliance with the safety regulations will result in .
Alpine Sales & Rental Corp. death or severe injury.
801 Pleasant View Blvd..
Bellefonte, PA 16823 USA.
Tel. +814.466.7134
Warning
info@alpinecutters.com.
Type and source of the hazard
Consequence of the hazard
 Remedy of the hazard

Warning
This warning note identifies a moderate risk hazard. Non-
compliance with the safetly regulations may result in death
or severe injury.

Description of target groups Caution

Type and source of the hazard
This operating manual is intended for a wide-range audience.
The knowledge required for any of the target groups is Consequence of the hazard
explained below.
 Remedy of the hazard
Every target group must have read this operating manual and
fully understood its contents.
Caution
Operating staff must This warning note identifies a low-risk hazard. Non-
• be of legal minimum age. compliance with the safety regulations may result in injuries.
• have received instructions in terms of handling the
machine.
• be familiar with the country-specific accident
prevention regulations. Attention
Maintenance staff must Type and source of the hazard
• be of legal minimum age.
• be familiar with the maintenance points at the machine. Consequence of the hazard
• be familiar with the country specific environmental  Remedy of the hazard
protection regulations for disposal of lubricants and
cleaning agents. Attention
This warning note identifies a low-risk hazard. Non-
Service staff must compliance with the safety regulations may result in
• be of minimum age.
property damage.
• have profound school education and vocational
training.
• be trained by Alpine Sales & Rental Corp. or authorized
service staff with regard to service work at the machine. Notice!
• be trained with regard to conduct in case of fault/failure.. This symbol is used for providing
. important information and advice with
. regard to handling of the machine.

2. INSTRUCTIONS FOR USING THE SAFETY

1
2.1 INTENDED USE Limitation of use
Any use other or beyond that stated above, e.g. with higher
power values, for higher speeds, also for lower speeds, in
The Rockwheel is referred to as exchangeable equipment for non-agreed operating conditions or upon any structural
excavators and serves for loosening and removal of hard and modifications is regarded as improper.
solid materials (rock, bitumen, timber, frozen soil, concrete,
demolition work). The Rockwheel is used in road and
tunnel construction, landscaping, in mines / stone quarries,
for demolition work and in the construction machinery 2.3 RESIDUAL RISKS
industry. The appropriate bits must be used depending on At the time of placing on the market, the machine is state of
the structure of the soil/rock.. the art. However, there will still be residual risks for persons
and the machine.
• The Rockwheel is designed for assembly in
earthmoving machinery for cutting work. Media supply Hazards due to specific types of use or application of
for the hydraulic system, setting and monitoring of specific accessories
operating parameters and all equipment/prerequisites • During operation of the Rockwheel there is a risk of
for safe operation of the Rockwheel is performed flying or projecting stones, dust and debris.
through the earthmoving machine. • The Rockwheel may cause severe injuries.
• The Rockwheel can be equipped with various drum
types and a number of different bit types. Depending Protective measures
on the type of material to be cut, e.g. soil, sandstone,  Never stand within the operating range
hard rock, asphalt, timber, concrete.  Wear personal protective equipment
• It is possible for the Rockwheel to be operated in
swampy areas or under water. .
• Initial assembly, commissioning and setting of
parameters of the Rockwheel is performed by Alpine
Sales & Rental Corp. service staff or by authorized 2.4 OPERATOR’S OBLIGATIONS
qualified staff..

The Rockwheel may only be operated as intended. • The operator is obliged to only operate the machine
Intended use also includes compliance with the operating, in sound and impeccable condition. Machines that are
maintenance and servicing conditions established by the not in sound condition may cause personal injury and
manufacturer. property damage.
• Hazard points that occur between the machine
Any use other or beyond that specified above is regarded as and customer’s equipment, must be secured by the
improper. The manufacturer shall not assume any liability for operator.
damage resulting from improper use. The risk for any such • The machine generates heat, which increases the
damage shall be borne by the user.. temperatures in the working environment and may
. affect persons present. The operator is obliged to
ensure consistent appropriate ventilation.
• For working at the machine, the operator must ensure
2.2 MISUSE appropriate lighting.

Appointment and instruction of responsible persons

Foreseeable misuse • Only employ personnel who have receive technical,
• Operating the Rockwheel with parameters (e.g. oil safety-relevant instructions.
pressure) that are outside the limits of the machine. • Clearly define competences of the personnel for
• Operating the Rockwheel with earthmoving machines operation, set-up, maintenance and servicing.
for which they are not designed. • Monitor the personnel in regular intervals for safety-
• Operating the Rockwheel with damaged or missing conscious and hazard-aware working, as well as
bits. compliance with the operating manual.
• Operating the Rockwheel at incorrect direction of
rotation. Obligation for information
• Slamming the Rockwheel onto the working surface in
standstill; this may result in damage of the cutting bits. The operator of the machine must make this operating
• Operating the Rockwheel while persons, who have manual available to all persons involved in working
not received any safety instructions, are present in the with and handling this machine.
hazard area. All persons must have read and understood the operating
• Operating the Rockwheel in potentially explosive manual prior to use of the machine.
atmospheres.
Have the machine staff confirm their knowledge of the
operating manual.
.

2
2.5 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.
The following items of personal protective equipment must be worn during operation of the machine:

Personal protective equipment

Use eye protection

Use hearing protection

Wear protective gloves

Wear safety shoes

Protective clothing

Table 2 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

Hazard point warning

Table 3 Warning sign

3
Warning signs and positions at the machine
The warning signs are attached at the following positions:

Top Position: Bottom Position:

1. 2. 3.

7. 8. 6.

9.

4. 5.

Figure 1 Positions of warning signs

1. Rotary parts warning 6. Caution, release of hydraulic oil

2. Advice, wear goggles 7. Attention: stand clear
3. Rotary parts warning 8. Projecting parts warning
4. Attention: Feed 9 .Attention: read operating manual
5. Attention: Return

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.

4
2.6 WORK AREA SAFETY

General information

Due to the low cutting speed and depending on the type of layers, only slight dust formation occurs with the ALPINE
Rockwheels.

However, in rare cases with high degrees of dust generation, appropriate counter-measures must be taken (e.g. spray water
systems, mobile/fixed anti-dust systems, wearing of personal protective equipment).

Shut-down and protection against re-start

Make sure that all of the following safety notes are read prior to use or maintenance of the Rockwheel in order to prevent any
personal damage or injuries.
• Prior to beginning with any cutting work, it must be ensured that no persons are present in the proximity during
operation. During cutting operation, there is a risk of small fragments being ejected and causing injuries and property
damage. In the event that persons enter or are present in the operating area unexpectedly, immediately stop the cutting
process and shut down the motor.
• During breaks or when dismounting the excavator, always lower the cutting head onto the floor. Always shut down the
motor and secure against re-start (remove the key).
• Before dismounting the excavator, lower the cutting head onto the floor, shut down the motor and secure it against
unauthorized re-start.
• Never touch the Rockwheel while the rotary drums are turning.
• Always shut down the motor and secure against re-start (remove the key) prior to maintenance / .
servicing and inspection work.
• 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..

Warning
Hazards caused by vibration
Vibration may lead to damage to health.
 Never exceed the specified working hours per day.

Vibration
Limits of exposure and trigger values in accordance with Directive 2002/44/EC

For whole body vibration

• the value of exposure per day, standardized for a reference period of 8 hours, is limited to 1.15 m/s2 , or, if required by a
member state, to a vibration dose value of 21 m/s1.75 .
• the daily trigger value, standardized for a reference period of 8 hours, is limited to 0.5 m/s2 , or, if required by a member
state, to a vibration dose value of 9.1 m/s1.75 .

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 low 8
sandstone medium intensity 6
hard rock high intensity 4
3. INSTALLATION

5
 3
1
4

1. Adapter Bracket 2
2. RockWheel
3. Bucket Link
4. Stick Pin

3.1 ADAPTER BRACKET

The Rockwheel requires an adapter bracket in order to fit onto the excavator. The adapter bracket of the cutting unit matches
up to the dipperstick/bucket linkage on the excavator. It can be mounted with pins just as would a bucket.

The normal rotational direction for cutting on the ground is counter-clockwise when looking at the excavator from the left
side. The normal rotational direction for cutting on a vertical wall is clockwise when looking at the excavator from the left
side.

D10 Mounting Bracket Dimensions

ALPINE
The adapter plate ROCKWHEEL
must have D10 of
a minimum thickness ROTARY
25mm andCUTTER BACK PLATE
must be welded by expert personnel
HEAD ADAPTER PLATE WORKSHEET ROCKWHEEL D10

560.0
25.0 PLATE
12 HOLES
. 21.0 THRU
.
.
100.0
. BRACKET EAR
.
.
.
410.0 160.0
.
. 80.0
.
.
. BRACKET EAR 100.0

.
.
80.0 4xR10.0

160.0

Notice! 240.0
In order to be able to correctly connect the machine, the technical data of the machine must be
480.0
taken into account. See chapter ‘Technical data’. Note: all units in millimeters

3.2 HYDRAULIC CONNECTION

6
 [To be done after flow and pressure testing ]

1. Attach the RockWheel to the excavator and connect the hydraulic lines. Feed and return lines are clearly marked on
the cutting unit. (Fig. 7)..

TIP: The RockWheel revolves in one direction only. Therefore the ideal way to connect to the excavator’s circuit is to take
the return directly back to tank via the excavator’s return line filter (Hydraulic Hammers utilize this type of circuit)..

2. Slowly bring the cutting unit up to full speed. Control speed using engine rpms. Hydraulic motor should be running
quietly. If any noises are coming from the cutting unit, stop immediately and contact Alpine..

3. Check pressure in motor return line using the gage port included with the hose assembly.
The RockWheel can be operated without the need for a separate drain line as long as the pressure in the return line
does not exceed 725-psi (50-bar). In the majority of cases the pressure in the return line will be no greater than 220-psi
(15-bar) for this type of circuit..

Pressure spikes will occur during the operation of the RockWheel, but these should not exceed 725-psi (50-bar). In the
event of the pressure exceeding 725-psi (50-bar) a relief to atmosphere prevents any damage occurring. A separate
drain line will have to be fitted in this event. Consult Alpine’s Technical Department if the unit cannot be connected in
this manner. If return pressure exceeds 725-psi (50-bar) see instructions in Section 3.5 on installation of a leak oil drain
line.

It is recommended that a filter be used for the return flow if not already fitted..

4. Check that the cutting unit and adaptor bracket are properly fastened to the
excavator and all hydraulic hoses and fittings are correctly fastened..

5. COMPLETE AND RETURN THE INSTALLATION & COMMISSIONING REPORT

1 2
Connection of pressure and return lines
At Rockwheel motor Code 62 Split flange 3/4”

Towards excavator JIC -12 Female

Internal hose diameter 3/4”

3.3 HYDRAULIC OIL

 Oil type HLP 46 or 68

 HV mineral oil with improved viscosity / better temperature .
properties (DIN 50524, part 3). Category: 46 Viscosity at 40°C
 Category: 68 Viscosity at 40°C Figure 7 Connection, installation diagram
 Biodegradable oil 1 Return Line
2 Supply Line

Notice!
Please contact ALPINE prior to using any other hydraulic oil. The use of other hydraulic
oil types must be approved in writing.

7
3.4 PRIMING (FILLING) THE HYDRAULIC MOTOR CASING

Attention
It is IMPERATIVE that this operation be performed before start-up and after a repair job.

The hydraulic motor casing must be filled after repairs or in the event of leaks..

• Ensure that the operator is equipped with the appropriate level of personal
protective equipment when exposed to the oils used in the hydraulic
system before performing this task.
• Disconnect the drain-oil line at the reservoir end (before the filter). Fill the
casing via this line.
• Remove the purge screw (Fig. 6) and when oil escapes out of the purge .
screw hole, re-fit purge screw and tighten.
• The motor casing capacity is about 0.2 US gal.
• Reconnect the drain-oil line..

Alternatively it is also possible to fill the motor with the gear box lying on .
Fig. 6 Drain plug and hexagonal screw
its side and using the crankcase (cover removed):. A =Drain plug
B = Hexagonal screw

• Remove the hexagonal screws and the cover (Fig. 6).

• Remove the purge screw (Fig. 6) and fill the motor casing with hydraulic oil
until the oil escapes out of the purge screw hole,re-fit purge screw,tighten
and then top up the motor casing.
• Make sure that you use clean oil and that no dirt can get into the motor.
• Reattach the motor cover. Make certain everything is tightened to the
correct torque.

Checking the oil level

• Make sure that the hydraulic oil cannot run out of the hydraulic motor. The Fig. 7 Filling oil
filler opening must be at the top.
• Loosen the level check plug (Fig. 8).
• When oil comes out of this hole, re-tighten the screw.

3.5 INSTALLATION OF A LEAK OIL LINE (OPTIONAL)

8
This kind of work should only be performed by persons who are experienced in working with hydraulic systems. The carrier
(excavator) must be equipped with a third line that is directly connected with the oil reservoir (a filter is also recommended)..
.
The drain line can be installed at any time but it is only required in cases where oil leaks from the overpressure line and it is
not possible to adjust the pressure at the carrier appropriately so that the pressure in the return line can be regulated. It is also
required for underwater operation.

1. If the Rockwheel is still attached to the excavator, it must be uninstalled.

2. Remove the adapter plate.

3. Disconnect the drain line hose as shown (Item A - Fig. 2).

4. Remove the plug on the left or right side of the housing below the supply or return connection (Item B – Fig. 2).

5. Seal the connection of the leak oil accumulation at the return with this plug.

6. Connect the drain line to the drain line port (Item B – Fig. 2).
7. Now, a drain line can be run to the excavator tank. It must be taken into account that the drain line is designed for.
a pressure of at least 725-psi (50-bar) and has an internal diameter of ½ inch. We recommend using a leak oil line .
with a filter.

Disconnect drain line A

Seal with plug B

Remove plug (B) and connect external

drain line. Use this plug to seal the port
where the drain hose was disconnected.

9
3.6 CONTAMINATION AND FILTRATION

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..
.
.
Notice!
In case of insufficient filtration, the manufacturer’s warranty for the hydraulic motor is
limited.

3.7 QUICK HYDRAULIC COUPLER

If several attachments or appliances are exchanged at the excavator, we recommend using a quick coupler. The following
conditions must be met for quick couplers:

Only use flat-type couplers.

• Make sure that the coupler is clean before it is (re-)connected.

• Use at least one 1/2” coupler on both lines.

• Use male and female connection fittings.

• Check that the counter pressure in the return line is not too high;
otherwise, this will result in leakage. .
.

3.8 FLOW LIMITING DEVICE

The flow limiting device can be optionally ordered. It is auxiliary equipment facilitating setting and adjustment of the
Rockwheel.

3.9 INSTALLATION FOR UNDERWATER APPLICATIONS

The Rockwheel 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 Alpine service department. In case that the Rockwheel is not connected via a leak oil
line, we recommend connecting a line from the overpressure relief to the surface. For this purpose, use a ½ inch hose and
connect it to the ¼ BSP connection.

3.10 INITIAL COMMISSIONING

PLEASE SEE ATTACHED INSTRUCTIONS FOR START-UP PROCEDURE.

3.10.1 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).

10
 • Check the pressure in the motor return line.
• The pressure must be at least 72 to 145 psi higher than the pressure in the leak oil line. Only then it is possible to ensure
trouble-free functioning of the hydraulic motor..

3.10.2 TAKING INTO SERVICE

Prior to taking the Rockwheel into service, the following maintenance work must be performed and the following torque
settings must be verified.

• Make sure that the hydraulic circuit corresponds to the technical description of the device.
• During the run-in time, check the hydraulic oil temperature; the value must be between 120°F and 140°F. This
temperature value must not exceed 175°F under any circumstances. If the temperature rises to more than 175°F, the
cooling output must be increased or the power must be reduced.
• Subsequent to the run-in time, the delivery rate and the pressure values must be checked and re-adjusted, as
necessary.

3.11 DISMANTLING/DISASSEMBLY

• Properly disconnect the Rockwheel from the excavator.

• Pump of any liquids as required and dispose of them as appropriate.
• Seal open line ends with proper caps or plugs
• Properly pack the machine and store it in a dry place..
.

3.11.1 RE-PACKING

• Position the Rockwheel on a pallet and secure it with load securing straps.

Packing and inventory check list

• Tool kit for bit replacement

3.12 STORAGE

In order to keep a machine functional even through a longer storage period, the following points must be heeded:

• Use high-pressure water to thoroughly clean all debris from drums, picks and Rockwheel body.
• Remove drums, thoroughly clean, grease and remount drums.
• Seal all hydraulic hoses and connections with metal plugs or caps
• The storage room must be dry and clean. DO NOT STORE IN OR ON WET GROUND.
• Store the Rockwheel on a pallet or other framed box up off the ground
• Clean the machine, apply an acid-free oil film on blank metal parts to protect them from corrosion.
• Cover the machine completely to keep away any dirt and dust.
• Do not expose the machine to extreme cold or heat..

.
.

11
 3.12.1 INTERMEDIATE STORAGE

Requirements
Ground structure solid ground (concrete, rock)
Packaging pallet with load securing straps
Temperature -30°F to +130°F
Humidity dry and sheltered
Table 5 Requirements for the storage area.

3.13 PRESERVATION MEASURES

• Apply corrosion protection agent prior to storing the Rockwheel.

• Use high-pressure water to thoroughly clean all debris.
.

3.14 RETURNING INTO SERVICE

Prior to returning the machine into service after long-term storage, please perform the following work:

• Clean and inspect the entire machine in accordance with the maintenance plan..

3.15 DISPOSAL

• Protect the environment!

• Problematic substances that are no longer used, such as lubricants, must be correctly disposed of at a waste
collection point.
• Prior to disassembly for recycling or scrapping, remove oil and other substances hazardous to water without
leaving any residues..
.
.
.

12
4. 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

2
1

.
Figure 8 Machine overview

1 Return line
2 Supply line
4
3 Attachment plate
4 Rockwheel housing
5
5 Drum .
.
.
.
.
.

4.1 FUNCTION

The Alpine Rockwheel is suitable for attachment to all conventional hydraulic excavators. However, it must be ensured
that the hydraulic excavator provides the required power and that the stability of the excavator is not impaired by the
attachment of the Rockwheel. The Rockwheel is mounted to the bucket arm of the excavator via the quick coupler
equipment. Since ALPINE Rockwheels are very powerful, they can be flexibly used for a variety of applications. They cut
through almost all types of rock, pavement (asphalt), walls (masonry walls made of bricks, concrete, cement) etc. .
.
The Alpine Rockwheel generates less noise than other excavation processes. Nevertheless, the operator must apply the
provisions of the Noise Directive; if required, a measurement of continuous sound pressure level must be performed and
suitable protective measures must be implemented as necessary.

In order to ensure safe operation of the Alpine Rockwheel, correct handling and proper maintenance and servicing at
regular intervals must be observed. Incorrect handling may cause performance impairment. The Alpine D10 Rockwheel
is exclusively designed for excavators and carrier vehicles with a total operating weight between 7 and 17t. For other
vehicles or vehicle that do not comply with the provisions, please contact Alpine.

13
 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.

14
5. TECHNICAL DATA

Quantity / Quality / Value

Max. input power 29kW / 40 hp

Max. delivery rate 120 L/min / 31 gpm

Recommended delivery rate 95 L/min / 25 gpm

Max pressure 400 bar / 5800 psi

Drive shaft torque 4.8 kNm / 3522 ft lb

Bit force 22. 6 Kn / 5076 lbs
Drive shaft speed 80-156 rpm @ 16 gpm-31gpm

Bit speed 1.8 m/s @ 16 gpm | 3.5m/s @ 31gpm

Weight (w/o bracket) 426 kg / 950 lb

Recommended excavator size 7 - 17 tons

Table 6 Technical data

RATED
5.1 TORQUE CAPACITY GRAPH
SPECIFICATIONS
D10 ROCKWHEEL
MAX HORSEPOWER: 40
The output graph below shows the rated capacity of the D10 hydraulic transverse Rockwheel. Note that
Rockwheel must not be operated at max. pressure and max. flow at the same time as this would
exceed the rated capacity and risk damage to the hydraulic motor.

D10
GPM RPM
5 25
10 50
5000 12 61
14 71
16 81
18 91
4000
20 101
Relief Pressure,

22 111
PSI

24 121
3000 26 131
28 141
30 151
32 161
2000

1000

5 10 12 14 16 18 20 22 24 26 28 30 32
Flow Rate, GPM

Notice!
ALPINECUTTERS.COM

Do not operate the Rockwheel with maximum pressure and maximum Flow 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
specifications (Table 6). In case of doubt, please contact Alpine Sales & Rental Corp. 814-466-7134.

15
5.2 CUTTING DRUM DIMENSIONS (DIMENSIONS ARE IN MILLIMETERS (MM)

Figure 7 Technical data – D10 dimensions

5.3 EMISSIONS

5.3.1 AIR-BORNE SOUND

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.

16
6. SERVICING

6.1 QUALIFICATION OF PERSONNEL

The machine must only be serviced by persons who have received safety-related technical instructions and are authorized by
the operator..

6.2 ACTIVITIES PRIOR TO SERVICING WORK

• Shut down the machine in accordance with this operating manual and secure it against accidental re-start.
• Lock the cabin and remove the key and/or attach a warning sign at the main switch.
• For servicing work cordon off a large area.
• Inform the operating staff, appoint a supervisor..

6.3 ACTIVITIES SUBSEQUENT TO SERVICING WORK

6.3.1 CLEANING THE ROCKWHEEL

 Free the Rockwheel from dirt and soil using a water jet at regular intervals.
6.3.2 CHECKING THE FUNCTIONS

 Check that the bits are not stuck

6.4 CLEANING

Attention

Property damage due to improper cleaning work

Incorrect cleaning agent or unsuitable cleaning methods may cause

damage at the machine.
 Only use the recommended cleaning agents.

6.4.1 ADVICE ON CLEANING AGENTS

• Please heed the marking and notes on the packaging of the cleaning agents.
• After cleaning, inspect all supply lines and connections for leaks, loosened connections or fittings, scour marks and
damage. Any identified defects or deficiencies must be remedied immediately.
• For normal soiling: water (pressure washer).
• For tenacious soiling: use non-flammable solvents..

6.4.2 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. .

17
6.5 MAINTENANCE OVERVIEW

6.5.1 MAINTENANCE SCHEDULE

The specified maintenance intervals are intended as guidelines and must be complied with. Shorter maintenance
intervals may result due to local operating conditions.

Notice!
The maintenance intervals have been calculated for single-shift operation (8h/day, 20 days/month,
12 months/year). If the machine is operated in multiple shifts, the maintenance intervals must be
reduced accordingly.

Maintenance interval for

Activity
single-shift operation

• Check external components for leakage.

• Make sure that the cutting heads are securely fastened.
Daily prior to starting
• Check all screw connections.
work
• Check hoses for tightness and any damage.
• Check all bits and bit holders for wear and replace them as required.

• Check all screw connections.

Every 100 hours / 2 weeks • Check for internal leakage.
• Check torque setting at the cutting drums. (Section 6.10)

• Check condition of hydraulic motor.

• Change of the hydraulic oil
Every 1000 hours / 1x per
• Disassemble cutting drums. Check seals and gaskets for leakage. Check
year screw connections.
• Check condition of the slide ring packing.

Table 8 Maintenance schedule

Caution
Hazard due to substances hazardous to the environment

Leaking oil may pollute the environment.

 Wear protective clothing when handling oils.
 Use oil must be collected and correctly disposed of.

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 6.5.2 REPLACEMENT OF BITS ON THE CUTTING DRUMS
The instructions below must be carefully and thoroughly read. Non-compliance with these instructions may render the
warranty null and void. In cases of doubt, please contact Alpine.

Disassembly of bits

• Thoroughly clean the Rockwheel prior to repair work.

• Position the Rockwheel so that the cutting drums can be easily rotated.

Caution
Property damage at the Rockwheel

Damage due to incorrect repair..

Only have repair work performed by trained service staff.

Warning
Crushing hazard

Crushing hazard due to the Rockwheel

 Secure the Rockwheel against sliding and falling.

Warning
Hazard due to projecting parts

Projecting parts occurring during repair work may cause severe injuries
of the eyes up to loss of eyesight.
 Wear goggles or use any other suitably type of eye protection.

Disassembly of a bit with retaining ring

1. Break up the C-retaining ring using a hammer. For this purpose use the installation tool for the securing ring. If the bit
has no outside retaining ring, the bit has internal retention and simply needs hammered out of the holder (figure 2).
2. Knock the bit out of the bit holder using a hammer and a reaming tool.
3. Loosen any stuck bits by driving the wedge into the gap between the bit and the bit holder.
4. Disassemble all other bits

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Figure 1. Remove the retaining ring Figure 2. Use a hammer and reaming tool
to dislodge the bit from holder

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Installation of bits
Slide the bit into the bit holder of the Rockwheel drum (Fig. 30).

Before installing a new bit, clean the 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).

Inserting a bit with C-retaining ring

1. Insert the C-retaining ring into the bit slot at the end of the bit shank.
2. Insert the securing ring installation tool into the groove and subsequently knock in the C-retaining ring using a
hammer until it is fix (figure 3).
3. For the remaining bits, proceed in the same order.

Figure 3 Bit clip removal & installation tool, with C-ring

Notice!
Before performing any cutting work, correct fit of all bits and C-rings must be verified.
The bits must rotate freely within the bit holders.

In case of leakage or if the tightening torque is not reached, please contact the spare parts supply department.

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6.6 CHECKING THE SLIDE RING PACKING (CAT SEAL)
To avoid compromising the warranty, please contact the service department before checking for leakage or per-
forming the steps listed below.
• Shut down the excavator.
• Remove the cutting drums
• Remove the end plate
• At the removed end plate, check if the slide ring packing is damaged or leaking.
• Check the housing for leakage.
• Check if appropriate venting port is present.
• Check the tightening torque of the M8 socket head screws. The torque value must be 31 ft. lbs.

In case of leakage or if the tightening torque is not reached, please contact the service
department.

Removing the end plate,

checking the slide ring packing.
Tightening torque of the M8 Checking for leakage at
socket head screws the venting port

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6.7 REMOVAL / INSTALLATION OF THE CUTTING DRUM
To avoid compromising the warranty, please contact the service department before removing /
installing the cutting drum or performing the steps listed below.
• Shut down the excavator.
• Remove the four M12 x 40 socket head screws, in order to disassemble the cover of the cutting
• drum.
• Remove the eight M14 x 60 socket head screws.
• If required, mount a suitable spacer unit to the end of the shaft using four M12 bolts and position
• the cutting drum on the ground.
• The center of gravity of the cutting drum is approximately at bit number seven.
• Every sling or chain (for transport) must be placed around this point.
• Carefully lift the cutting drum. Make sure that the drive is not damaged.
• For installation of the cutting drum, new M14 x 60 socket head screws must be used.
• Tighten these screws with a tightening torque of 173 ft.lbs.
• This must be ensured, since otherwise damage at the socket head screw may result..
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Drum
M12. hexagon socket
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6.8 FLUSHING / FILLING THE HYDRAULIC MOTOR
This process must only be performed by qualified personnel, who are familiar with the operating
principles of hydraulic systems. To avoid compromising the warranty, please contact the service department before
flushing / filling the hydraulic motor or performing the steps listed below. The Rockwheel has been filled with oil
prior to delivery and thus must not be re-filled. In case of leakage, the D10 Rockwheel must be re-filled.
• Shut down the excavator.
• Remove the cover on both sides to expose the 3/8 inch BSP connectors.
• Remove the two connectors.
• Disconnect the return line from the excavator and remove the quick coupler if used.
• Connect a hose to the right drum by the 3/8 inch BSP connector.
• Pump oil into the Rockwheel until oil runs out of the BSP connector at the opposite side. Please check if the oil running
out is clean.
• Clean the connection.
• The oil quantity in the rotary hoe is sufficient if oil flows back through the return line or the discharge line..
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The Rockwheel is now filled with oil.
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6.9 CHECK CONDITION OF HYDRAULIC MOTOR
This process must only be performed by qualified personnel, who are familiar with the operating
principles of hydraulic systems. To avoid compromising the warranty, please contact the service department before
checking the motor or performing the steps listed below.

• Shut down the excavator.

• Make sure that the hydraulic oil sufficiently cooled down.
• Remove the cover on both sides to expose the 3/8 inch BSP connectors.
• Remove the connector and connect a suitable hose. Lead the hose into a bucket.
• Set up the cutting head so that it cannot spin by shutting down the return.
• Start up the cutting unit.
• Pay attention to the flow rate of the oil from through the discharge line; it should not be higher than 1.5 gpm.
• If a leak oil line is used, the condition can be checked using a measuring device.
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6.10 TORQUE SPECIFICATIONS

Part No. Description Location Torque (ft/lbs)

N/A M20 x 85 Hexhead Mtg plate 449
RWS-0067 M12 x 40 Caphead Drum Cap 122
RWS-0098 M14 x 60 Caphead Drum 196
RWS-0016 M12 x 150 Caphead Hub Assembly 122
RWS-0027 M8 x 25 Caphead Hub Assembly End Plate 36
RWS-0064 M10 x 25 Caphead External Hose split flange 72
RWS-0095 M10 x 35 Hex head Internal hose split flange 53
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6.11 SPARE PARTS LIST

See the attached ‘Parts Manual: D10”

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7. TROUBLESHOOTING
In case of questions with regard to troubleshooting, please contact the customer service, stating the serial number, at:
Alpine Sales & Rental Corp..
801 Pleasant View Blvd..
Bellefonte, PA 16823 USA.
Phone +814 -466- 7134
Fax +814 -355- 0046
Website: www.alpinecutters.com
Email: info@alpinecutters.com
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DESCRIPTION OF FAULTS, INCLUDING CONSEQUENCES, CAUSES AND REMEDIAL MEASURES

Inspection point Diagnose Remedy

Cutting performance declines

A bit must be replaced if the hard
Check all bits and bit metal insert has been lost or damaged. Bits and/or bit holders must be replaced/repaired if the cutting
holders for damage The bit holders must be replaced if head holder is worn.
they are damaged.

Remove the Rockwheel from the hydraulic circuit. Check the

The Rockwheel output depends on flow, overpressure and hydraulic pressure (see provisions for
Check the hydraulic
correct functioning of the hydraulic hydraulic hoses / tubes, molded parts and quick couplers).
circuit at the excavator
circuit of the excavator. The higher the main pressure connection, the better the
cutting output. The ideal setting is 330 bar/4785psi

Oil leaks into the atmosphere if

the pressure in the return line is
Tightness of the
higher than 725psi. For optimum Make sure that the return line is not clogged.
external supply line
performance, the Rockwheel requires
a direct return into the reservoir
Check that the
Remove the cutting drums, remove the hoses and quick
pressure between Excessive pressure may result in
couplers. Try to rotate the drive shaft using a suitable lever. If
supply and return mechanical problems.
the shaft does not turn, the Rockwheel must be disassembled
is not higher than
for inspection.
750psi.

Check the speed of

The correct flow rate may be lost due Check the condition of the hydraulic motor.
the cutting heads in
to a defective valve or a worn hydraulic If the leakage of the motor is within the limit range, it is likely
connection with the
motor. due to a defective start-up valve.
flow (11 rpm = 2gpm).

With the motor worn, oil may leak at

the pistons, which reduces the cutting
The hydraulic motor must be replaced.
output.
Check the hydraulic
motor Please return the motor to Alpine for analysis.
Contaminated oil and/or low viscosity
of the oil and too high flow rates are
the main reasons for motor failure.

Cutting drums do not rotate

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Inspection point Diagnose Remedy
Remove the Rockwheel from the hydraulic circuit; check the
The Rockwheel output depends on flow, overpressure and hydraulic pressure (see provisions for
Check the hydraulic
correct functioning of the hydraulic hydraulic settings).
circuit of the excavator
circuit of the excavator. Also check all hydraulic hoses / tubes, molded parts and quick
couplers.

Remove the cutting heads and remove all hoses and quick
couplers.
Check the pressure in the Excessive pressure may result in
Try to rotate the drive shaft using a suitable lever. If the shaft
supply line mechanical problems.
blocks, the Rockwheel must be disassembled for inspection.

Oil leakage at external components

Oil leaks into the atmosphere if

Remove the Rockwheel from the hydraulic circuit; check the
the pressure in the return line is
flow, overpressure and hydraulic pressure (see provisions for
Check the hydraulic higher than 725psi. For optimum
hydraulic settings).
circuit of the excavator performance, the Rockwheel
Also check all hydraulic hoses / tubes, molded parts and quick
requires a direct return into the
couplers.
reservoir

With the motor worn, oil may leak

at the pistons, which reduces the
Check condition of cutting output. Contaminated oil The hydraulic motor must be replaced. Please return the motor
hydraulic motor. and / or low viscosity of the oil and to Alpine for analysis.
too high flow rates are the main
reasons for motor failure.

Oil leakage

Oil leaks out of the area

In this area, a number of hoses and
between the adapter Remove the adapter plate to obtain access to the leakage area.
fittings are installed which may be
plate and the Rockwheel
damaged or most often loose.
fastening surface

Remove the cutting head.

Determine the leakage point
Oil may leak in the following points:.
Oil leaks out between In case of (1.) Leakage is probably caused by a damaged FTL
1. Between housing and drums
the cutting head and the seal which needs to be replaced
2. At the coverplate on the housing.
housing In case of (2.) remove the coverplate. Check the seal and
remove if necessary.

Only one cutting head is rotating

Only one cutting head is

rotating or one head is The Rockwheel must not be used.
Fault at the internal shaft.
rotating faster than the Complete disassembly is required.
other

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8. WARRANTY CONDITIONS
(provided they are not specified in a separate document)

8.11.1 WARRANTY

Alpine Sales & Rental Corp. assume a warranty for their products of type D10 (NEW) as well as all NEW accessories to be free of
defects in material and workmanship for the period of 12 months starting with the date of receipt, unless otherwise noted.

8.11.2 DISCLAIMER OF WARRANTY

The warranty does not cover any faults and defects that occur due to:

• incorrect or insufficient maintenance by the customer;

• unauthorized structural modifications or improper use;
• parts that are subject to natural wear, such as bits;
• application of D10 beyond its admissible maximum load.
8.11.3 LIABILITY

Rokla GmbH., in their capacity as the manufacturer of the machine, and Alpine Sales & Rental Corp., in their capacity as distributor
of the machine, are not liable for any damage if:

• D10 is handled incorrectly;

• Repair / maintenance or assembly is not performed by authorized persons;
• D10 is not used in compliance with this operating manual;
• Parts of D10 are disassembled.

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