The World of Wirtgen Cold Milling Machines

Efficient 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 traffic 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 efficient and
environmentally friendly rehabilitation of roads.
Our inspired concept to rehabilitate damaged road pavements
quickly and efficiently with the innovative milling process heralded
the era of the cold milling technology. Since that time, Wirtgen
has been considered the world
market leader in this multi-faceted segment. Fascinated by the
infinite possibilities it offers, we are
pressing ahead with the continuous development of this method,
ensuring that our innovative solutions will continue to vitalize the
road network in the future.
Cold milling has gained acceptance worldwide, and it is unrivalled
when it comes to economic
efficiency and environmental
sustainability.
4 // 5
HISTORY
From milling contractor
to world market leader
Innovative milestones
The powerful, technically mature
cold milling machines of today
need some two minutes to fill a
30-tonne truck with granulated
asphalt material. They have come a
long way – and Wirtgen has played
a vital role in their breathtaking
development.
In 1971, Wirtgen built the first of a
total of 100 hot milling machines
for the contracting fleet it owned
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.
From the first cornerstone – development of the cold milling technology for road construction – to date,
we have paved the road to success
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.
1971
1973
The prototype of a
hot milling machine
is successfully milling
off damaged asphalt
layers.
The SF 2500 is
equipped with large
gas tanks increasing
the machine’s productivity.
1980
1984
Like all small milling
machines of the first
generation, the 500 C
offers a milling depth
of up to 100 mm.
The 2000 VC is the
first front-loader,
making a deep and
lasting impact on site
logistics.
1992
1999
The first replaceable
toolholder system increases the economic
efficiency of the cold
milling machines.
The W 2000 large
milling machine sets
a new standard in
operation and performance.
2006
2010
The VCS extraction
system reduces dust
emissions during
operation.
The proprietary
LEVEL PRO automatic
levelling system increases 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 applications is broadened
considerably by the
DC model range,
which offers working depths of up to
300 mm.
2001
The flexibility of the
machines is enhanced
by the FCS quickchange 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 particular – 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 compact design and extremely small
milling radius enable them to work
with maximum precision even in
extremely confined conditions.
These highly manoeuvrable machines play their many economical
advantages in particular when
carrying out partial repairs, milling
tie-ins, removing road markings,
milling around road fixtures or
constructing trenches for supply
lines. Their repertoire also includes
the efficient milling of larger surfaces.
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
Working efficiently with
small milling machines
Small milling machines are usually
equipped with wheels, their milling
drum being arranged at the rear of
the machine. A one-stage conveyor accepts the asphalt material
granulated by the rotating milling
drum, discharging it directly onto
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 windrow next to the machine via the
slewing conveyor, or can be left in
the milled cut after the conveyor
has been removed.
The manoeuvrable small milling
machines mill off road pavements at working widths ranging
from 35 cm to 1.3 m. In addition,
their all-wheel drive, compact
dimensions, front wheels with
large steering angles, and fold-in
right-hand rear wheel enable efficient milling along obstacles or in
restricted space conditions.
LOADING CONVEYOR
Slewing and height-adjustable
conveyor for continuous loading
of the milled material
CONVEYOR BELT SPEED
Variable conveying speed for
efficient loading of trucks
HEIGHT ADJUSTMENT
Hydraulic height adjustment of the
two rear wheel units for precise
adjustment of the milling depth
MILLING DRUM DRIVE
Highly efficient mechanical milling
drum drive
RIGHT-HAND REAR WHEEL
Fold-in right-hand rear wheel for milling
flush to kerb or along obstacles
MILLING DRUM
Milling drums offering different widths and
variable tool spacings for a wide range of
applications
OPERATOR’S PLATFORM
Ergonomically designed operator’s
platform for non-tiring, productive
working
SOUNDPROOFING
Effective engine soundproofing
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 decisive advantages when it comes to
large-scale rehabilitation projects:
superior area performance, fast
completion of construction projects and minimum disruptions to
traffic are all marks in favour of
the use of these high-performance
machines. Their central field of
application is the removal of road
pavements at full depth on motorways, 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 fine milling drums are also
eminently suitable for the production of specified surface textures.
These applications include levelling
of irregularities on large, continuous traffic surfaces, fine 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 OPERATOR’S PLATFORM
High-performance
rehabilitation of roads
Large milling machines are mostly
designed with crawler tracks,
a milling drum arranged in the
central part of the machine and a
forward-loading conveyor system – and are called front loaders. Loading the milled material
towards the front offers many
benefits: the machine operator
has a direct view of the loading
operation and can ensure optimum loading of trucks. The slewing, height-adjustable discharge
conveyor enables flexible and
cost-effective loading. Front loading also permits trucks to change
“on the fly” quickly, ensuring that
the milling operation can continue
non-stop. In addition, front loading
allows trucks to easily pull in and
out of the flowing traffic.
The high-performance machines
meet the requirements placed on
them thanks to their high engine
power. A smooth flow of traffic is
ensured in most projects as vehicles can drive past the job site on
adjacent lanes.
Spacious, ergonomically designed operator’s platform with
two identical workplaces for non-tiring, productive working
SOUNDPROOFING
Effective engine soundproofing for
low environmental emission levels
ENGINE / DUAL ENGINE
Economical, powerful engine for
high milling performance
TRACK UNITS
Hydraulically steerable and heightadjustable 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
fine material particles in the area of the
milling drum housing
PRIMARY CONVEYOR
Primary conveyor of the two-stage
conveyor system to accept the granulated material from the milling chamber
CUTTING TOOLS
Optimized arrangement of toolholders, 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 pressing ahead with the continuous
further development of this key
area. A cold milling machine’s
core element is the milling drum,
which rotates against the direction 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 proprietary 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 coupling. Choosing from several conveyor options of different lengths
enables flexible 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 flexible adjustment
to conditions prevailing on the job
site. The conveyor system makes
an easy job of loading trucks even
in narrow bends or when negotiating 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 technology is a decisive factor in ensuring
relaxed, productive working. The
ergonomically designed operator’s
platform enables intuitive operation, high operator comfort and
perfect visibility.
Support of the machine operator
in his highly responsible job by
providing increased operator comfort 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, therefore, that top production rates are
the order of the day. The state-ofthe-art automatic levelling system
LEVEL PRO PLUS is also part of
the WIDRIVE system. Its clear-cut
and intuitive handling permits superior, high-quality milling results.
20 // 21
PRODUCT PORTFOLIO
The world’s biggest fleet
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 impressive 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 motorways or airports in record time.
Our delivery range caters to all
needs. It offers made-to-measure,
technically superior solutions for
all customer requirements. Conveyor length, milling drum width,
tool spacing, integrated dust extraction, track or wheel units – to
name just a few options. Customers 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 technology, outstanding core competencies 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 process. Optimized assembly lines
guarantee consistently high quality
and short lead times.
24 // 25
RELIABLE CUSTOMER SERVICE
Full customer service around the globe
Efficient after-sales
service
Complying with our entirely
customer-oriented company
philosophy, we have created a
close-meshed, global service infrastructure. Around 60 sales and
service companies and an extensive network of dealers are reliable
local partners of our customers in
all parts of the world.
Our subsidiaries support customers around the globe with spare
parts and dependable customer
services. Our highly qualified 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 sufficient
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 internationally 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
ex
E
IV ces
R
u
ID red
exh
ment system
anage
m
ne
emissions
chi st and noise
a
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m
a
es
us
ha
W
engine s
upp
Our effective VCS vacuum cutting
system for large milling machines
reduces dust emissions and improves the air quality in the area of
the milling drum housing. Effective
soundproofing and anti-vibration
mounting of the engine ensure low
noise and vibration levels.
y
nolog
h
c
te
ine emissions
g
n
e
t e d nois
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a
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ort
and noise
e
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issi
ons
Wirtgen is very strongly committed
to actively protecting the environment and saving natural resources.
The reclaimed asphalt is valuable
recycling material that is fully reused for the production of asphalt
mixes. Large milling machines featuring the “dual-engine concept”
enable the second engine to be
switched off in accordance with the
job at hand to save diesel fuel and
reduce exhaust emissions. And last
but not least, it goes without saying
that our fuel-efficient diesel engines
comply with current international
exhaust emission standards. The
WIDRIVE machine management
system, which greatly improves
operator comfort, offers numerous
automated features to ensure a
fuel-efficient and low-emission
milling process.
Sta
te
-o
red
f-t
uc
h
Significant reduction of
emissions
Vac
uum
ns
sio
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ys
Cu
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S
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Sound
pro
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reduces no
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s
30 // 31
A
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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: [email protected]
Illustrations and texts are non-binding and may include customized fittings. Subject to technical changes.
Performance data depend on operational conditions. No. 2176052 EN-09/14 © by Wirtgen GmbH 2014. Printed in Germany