Efcient Milling and Granulating of Road Pavements

The World of
Wirtgen Cold Milling Machines
Contents
Introduction 4 -5

History 6 -7

Small milling machines in detail 8 -11

Large milling machines in detail 12 -15

Leadership in technology 16 -21

Product portfolio 22 -23

Manufacturing technology 24 -25

Reliable customer service 26 - 27

In operation around the globe 28 - 29

Environmental sustainability 30 - 31

2 // 3
INTRODUCTION

Cutting-edge technology
for better roads
Wirtgen is setting the
pace in road rehabilitation

International trafc volumes are

steadily increasing. As a result,
road systems are required to cope
with ever higher demands. The
state-of-the-art milling technology
meets all requirements in terms
of the economically efcient and
environmentally friendly rehabilita-
tion of roads.

Our inspired concept to rehabil-

itate damaged road pavements
quickly and efciently with the in-
novative milling process heralded
the era of the cold milling tech-
nology. Since that time, Wirtgen
has been considered the world
market leader in this multi-facet-
ed segment. Fascinated by the
innite possibilities it offers, we are
pressing ahead with the continu-
ous development of this method,
ensuring that our innovative solu-
tions will continue to vitalize the
road network in the future.

Cold milling has gained accept-

ance worldwide, and it is unrivalled
when it comes to economic
efciency and environmental
sustainability.

4 // 5
HISTORY

From milling contractor

to world market leader

Innovative milestones
1971 1973
The prototype of a The SF 2500 is
The powerful, technically mature hot milling machine equipped with large
cold milling machines of today is successfully milling gas tanks increasing
off damaged asphalt the machines produc-
need some two minutes to ll a layers. tivity.
30-tonne truck with granulated
asphalt material. They have come a
long way and Wirtgen has played
a vital role in their breathtaking
development.
1980 1984
In 1971, Wirtgen built the rst of a Like all small milling The 2000 VC is the
machines of the first first front-loader,
total of 100 hot milling machines generation, the 500 C making a deep and
for the contracting eet it owned offers a milling depth lasting impact on site
of up to 100 mm. logistics.
at that time. The technological
leap from hot milling to cold milling
was sparked in 1979 by the use of
carbide tools commonly used in
the mining industry.
1992 1999
From the rst cornerstone devel- The first replaceable The W 2000 large
opment of the cold milling technol- toolholder system in- milling machine sets
creases the economic a new standard in
ogy for road construction to date, efficiency of the cold operation and perfor-
we have paved the road to success milling machines. mance.
of this technology with numerous,
innovative milestones. Today, the
name Wirtgen is distinctively and
inextricably tied to tried-and-tested
cold milling technology of superior
quality.
2006 2010
The VCS extraction The proprietary
system reduces dust LEVEL PRO automatic
emissions during levelling system in-
operation. creases both precision
and operator comfort.
 1979
The 3800 C, a cold
milling machine of
the first generation,
is a rear loader with
hydraulic milling drum
drive.

1988
The range of appli-
cations is broadened
considerably by the
DC model range,
which offers work-
ing depths of up to
300 mm.

2001
The flexibility of the
machines is enhanced
by the FCS quick-
change system for
milling drums.

2011
A dual-engine concept
is implemented in the
W 210 for the first time
to reduce operating
costs.

6 // 7
SMALL MILLING MACHINES IN DETAIL

Specialists for the more delicate jobs

Cutting the corner with
small milling machines

Not only large-scale construction

projects but also and in particu-
lar rehabilitation jobs carried
out on a smaller scale play a vital
role in the structural maintenance
of road networks. Small milling
machines are the ideal candidates
for this type of job. Their com-
pact design and extremely small
milling radius enable them to work
with maximum precision even in
extremely conned conditions.
These highly manoeuvrable ma-
chines play their many economical
advantages in particular when
carrying out partial repairs, milling
tie-ins, removing road markings,
milling around road xtures or
constructing trenches for supply
lines. Their repertoire also includes
the efcient milling of larger sur-
faces.

Working in tandem, large milling

machines the specialists for
removing surfaces on a large scale
and small milling machines are a
perfect team.

8 // 9
SMALL MILLING MACHINES IN DETAIL

Operating principle and components

LOADING CONVEYOR
Working efciently with Slewing and height-adjustable
conveyor for continuous loading
small milling machines of the milled material

Small milling machines are usually

equipped with wheels, their milling
drum being arranged at the rear of
the machine. A one-stage con-
veyor accepts the asphalt material
granulated by the rotating milling CONVEYOR BELT SPEED
drum, discharging it directly onto Variable conveying speed for
efcient loading of trucks
waiting trucks. This is why small
milling machines are also called
rear loaders. Depending on job
site conditions, the milled material
can also be deposited in a wind-
row next to the machine via the
HEIGHT ADJUSTMENT
Hydraulic height adjustment of the
slewing conveyor, or can be left in two rear wheel units for precise
the milled cut after the conveyor adjustment of the milling depth

has been removed.

The manoeuvrable small milling

machines mill off road pave-
ments at working widths ranging MILLING DRUM DRIVE
Highly efcient mechanical milling
from 35 cm to 1.3 m. In addition, drum drive
their all-wheel drive, compact
dimensions, front wheels with
large steering angles, and fold-in
right-hand rear wheel enable ef-
cient milling along obstacles or in RIGHT-HAND REAR WHEEL
Fold-in right-hand rear wheel for milling
restricted space conditions. ush to kerb or along obstacles

MILLING DRUM
Milling drums offering different widths and
variable tool spacings for a wide range of
applications
OPERATORS PLATFORM
Ergonomically designed operators
platform for non-tiring, productive
working

SOUNDPROOFING
Effective engine soundproong
for low noise emission levels

ENGINE
Powerful diesel engine for
high milling performance

WHEELS
3 or 4 wheels with large
steering angles at the front
for small turning radii

ALL-WHEEL DRIVE
Permanent all-wheel drive
for reliable traction

10 // 11
LARGE MILLING MACHINES IN DETAIL

Maximum power for large surfaces

High daily production
rates guaranteed

Large milling machines offer deci-

sive advantages when it comes to
large-scale rehabilitation projects:
superior area performance, fast
completion of construction pro-
jects and minimum disruptions to
trafc are all marks in favour of
the use of these high-performance
machines. Their central eld of
application is the removal of road
pavements at full depth on mo-
torways, federal roads or airports.
Under ideal conditions, the largest
cold milling machine model the
W 250i is capable of removing up
to 1,200 tonnes per hour of asphalt
material, equalling the loading
capacity of 60 trucks.

Large milling machines equipped

with ne milling drums are also
eminently suitable for the produc-
tion of specied surface textures.
These applications include levelling
of irregularities on large, continu-
ous trafc surfaces, ne milling of
surfaces prior to applying a new,
thin pavement layer, or restoring the
skid resistance of road pavements.

12 // 13
LARGE MILLING MACHINES IN DETAIL

Operating principle and components

DUAL OPERATORS PLATFORM

High-performance Spacious, ergonomically designed operators platform with
two identical workplaces for non-tiring, productive working
rehabilitation of roads

Large milling machines are mostly

designed with crawler tracks,
SOUNDPROOFING
a milling drum arranged in the Effective engine soundproong for
central part of the machine and a low environmental emission levels

forward-loading conveyor sys-

tem and are called front load-
ENGINE / DUAL ENGINE
ers. Loading the milled material Economical, powerful engine for
towards the front offers many high milling performance
benets: the machine operator
has a direct view of the loading
operation and can ensure opti-
mum loading of trucks. The slew-
ing, height-adjustable discharge
conveyor enables exible and
cost-effective loading. Front load-
ing also permits trucks to change
on the y quickly, ensuring that
the milling operation can continue
non-stop. In addition, front loading
allows trucks to easily pull in and
out of the owing trafc.

The high-performance machines

meet the requirements placed on
them thanks to their high engine
power. A smooth ow of trafc is
ensured in most projects as vehi-
cles can drive past the job site on
TRACK UNITS
adjacent lanes. Hydraulically steerable and height-
adjustable track units for precise
adjustment of the milling depth and
precise machine manoeuvring
CONVEYOR BELT SPEED
Continuously adjustable conveying speed to
alter the discharge pattern and ensure that
trucks are loaded to full capacity

DISCHARGE CONVEYOR
Discharge conveyor for continuous
loading of the granulated material
onto trucks

VACUUM CUTTING SYSTEM

Vacuum cutting system for extracting
ne material particles in the area of the
milling drum housing

PRIMARY CONVEYOR
Primary conveyor of the two-stage
conveyor system to accept the granu-
lated material from the milling chamber

CUTTING TOOLS
Optimized arrangement of tool-
holders, equipped with point-attack
cutting tools, and edge segments
for high milling performance

MILLING DRUM
Milling drums offering widths
of up to 4.4 m and variable
tool spacings for a wide range
of applications

14 // 15
LEADERSHIP IN TECHNOLOGY

Core expertise in cutting technology

Milled surfaces
made to measure

Whether milling drum, toolholder

system or point-attack cutting
tool: Wirtgen is the leader in
cutting technology and is press-
ing ahead with the continuous
further development of this key
area. A cold milling machines
core element is the milling drum,
which rotates against the direc-
tion of travel and is equipped with
point-attack cutting tools. During
milling, the cutting tools remove
the pavement, granulating it into
small-sized, reusable material.
The operation produces an even
surface with excellent bonding
properties and accurate milling
edges. The texture of the milled
surface is determined by the tool
spacing.

The patented Flexible Cutter

System (FCS) is unique worldwide,
enabling the quick and simple
exchange of milling drums of
different working widths or tool
spacings. Our tried-and-tested
quick-change toolholder systems
are yet another successful propri-
etary development. They reduce
idle times and increase the service
life of milling drums.
16 // 17
LEADERSHIP IN TECHNOLOGY

Powerful material loading system

Flexibility comes as a
standard feature

The conveyor systems of cold

milling machines from Wirtgen are
distinctive for their wide conveyor
belts with high ribs, large slewing
angles to both sides and variable
conveyor belt speed.

The conveyor of rear loaders or

small milling machines can be
attached or removed quickly by
means of a quick-release cou-
pling. Choosing from several con-
veyor options of different lengths
enables exible adjustment of the
machine to any given job condition
and space requirement.

The conveyor system of front

loaders or large milling machines
is comprised of a primary and a
high-capacity discharge conveyor.
It is tailored to high performance
and permits exible adjustment
to conditions prevailing on the job
site. The conveyor system makes
an easy job of loading trucks even
in narrow bends or when negotiat-
ing obstacles.
18 // 19
LEADERSHIP IN TECHNOLOGY

Perfect operation and control

High productivity
in focus

Our perfectly engineered operating

and visibility concept paired with
state-of-the-art control technolo-
gy is a decisive factor in ensuring
relaxed, productive working. The
ergonomically designed operators
platform enables intuitive opera-
tion, high operator comfort and
perfect visibility.

Support of the machine operator

in his highly responsible job by
providing increased operator com-
fort without impairing the milling
quality that was our goal when
developing the innovative machine
management system WIDRIVE.
WIDRIVE combines the different
functions of a cold milling machine
into one unit. It carries out functions
that greatly facilitate work for the
operator. It is not surprising, there-
fore, that top production rates are
the order of the day. The state-of-
the-art automatic levelling system
LEVEL PRO PLUS is also part of
the WIDRIVE system. Its clear-cut
and intuitive handling permits supe-
rior, high-quality milling results.

20 // 21
PRODUCT PORTFOLIO

The worlds biggest eet

of cold milling machines

Numerous equipment
features

Wirtgen offers by far the broadest

portfolio of cold milling machines
worldwide. The standard milling
widths range from 30 cm to 2.2 m
and can be extended to an impres-
sive 4.4 m. The choice of machines
ranges from the exceptionally small
W 350 E an electrical cold milling
machine designed for indoor use
all the way to the W 250i which
completes large projects on motor-
ways or airports in record time.

Our delivery range caters to all

needs. It offers made-to-measure,
technically superior solutions for
all customer requirements. Con-
veyor length, milling drum width,
tool spacing, integrated dust ex-
traction, track or wheel units to
name just a few options. Custom-
ers can generally choose from a
multitude of equipment options for
their cold milling machine in order
to achieve maximum performance
rates even when having to deal
with complex site conditions.
W 350 E W 35 DC W 50 W 50 Ri W 60 Ri W 100

W 100i W 100 H W 130 H W 100 F W 100 Fi W 120 F

W 120 Fi W 130 F W 130 Fi W 150 W 150i W 1900

W 2000 W 200 W 200i W 200 H W 200 Hi W 210

W 210i W 220 W 250i

22 // 23
MANUFACTURING TECHNOLOGY

High quality guaranteed

Expertise in
manufacturing

At our main production plant in

Windhagen, the machines are built
for a long life, safe operation and
extreme toughness.

Our high-quality manufacturing

processes are characterized by
state-of-the-art production tech-
nology, outstanding core compe-
tencies and experienced staff. This
unparalleled wealth of expertise is
our recipe of success for ensuring
the production of durable, robust
quality equipment.

Both small milling machines

and large milling machines
are assembled in a cyclic pro-
cess. Optimized assembly lines
guarantee consistently high quality
and short lead times.

24 // 25
RELIABLE CUSTOMER SERVICE

Full customer service around the globe

Efcient after-sales
service

Complying with our entirely

customer-oriented company
philosophy, we have created a
close-meshed, global service in-
frastructure. Around 60 sales and
service companies and an exten-
sive network of dealers are reliable
local partners of our customers in
all parts of the world.

Our subsidiaries support custom-

ers around the globe with spare
parts and dependable customer
services. Our highly qualied and
fully equipped service engineers
are on site quickly to provide
active support, Large inventories
of stocked parts ensure that our
tried-and-tested original spare
parts are available in sufcient
quantities as and when needed.
26 // 27
IN OPERATION AROUND THE GLOBE

On the road of success in over

100 countries around the world

Cold milling is state-of-the-art

technology around the globe
The path to global success of the cold milling technology
began in Germany and quickly spread across Europe to
overseas and the Far East. Today, cold milling is an inter-
nationally accepted construction method. Innovative small
and large milling machines are maintaining the lead in over
100 countries when it comes to the powerful rehabilitation of
motorways, federal roads, airports or industrial sites. Today,
Wirtgen is the world market leader in cold milling.
28 // 29
ENVIRONMENTAL SUSTAINABILITY

Environmentally friendly
machine technology

Signicant reduction of
emissions
y
Wirtgen is very strongly committed
chnolog
te
to actively protecting the environ-
g ine emissions
ment and saving natural resources. n e
rt e d nois
The reclaimed asphalt is valuable a n
e- t a
us

h
recycling material that is fully re-
ha

f-t
ex
-o
used for the production of asphalt

es
te
mixes. Large milling machines fea-

uc
Sta
red
turing the dual-engine concept
enable the second engine to be
switched off in accordance with the
job at hand to save diesel fuel and
ment system

reduce exhaust emissions. And last

emissions

but not least, it goes without saying

that our fuel-efcient diesel engines
comply with current international
exhaust emission standards. The
chi st and noise
anage

WIDRIVE machine management

system, which greatly improves
m

operator comfort, offers numerous

u
ne
a

automated features to ensure a

exh

fuel-efcient and low-emission

IV ces
a

milling process.
m
u
ID red
E
R

Our effective VCS vacuum cutting

system for large milling machines W
reduces dust emissions and im- ons
issi
proves the air quality in the area of and noise
em
the milling drum housing. Effective
ort
upp
engine s
soundproong and anti-vibration
mounting of the engine ensure low
noise and vibration levels.
 30 // 31
Sound
pro on
reduces no g
ise e
missi
m on
s
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S
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is
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Vac
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 Wirtgen GmbH
Reinhard-Wirtgen-Str. 2 53578 Windhagen Germany
Phone: +49 (0) 26 45 / 131-0 Fax: +49 (0) 26 45 / 131-392
Internet: www.wirtgen.com E-Mail: info@wirtgen.com

Illustrations and texts are non-binding and may include customized ttings. Subject to technical changes.
Performance data depend on operational conditions. No. 2176052 EN-09/14 by Wirtgen GmbH 2014. Printed in Germany