Maximum milling performance in the top-class range Cold Milling Machine … Plane W… · The easy,...
Transcript of Maximum milling performance in the top-class range Cold Milling Machine … Plane W… · The easy,...
Maximum milling performance in the top-class range
Cold Milling Machine W 2200
W 2200 – the unrivalled top performer
There is one golden rule for construction sites where
large pavement areas have to be milled off in the
shortest possible time: There’s never enough performance!
The flagship product in the Wirtgen cold milling division, the
giant W 2200 machine, is designed to meet these extremely
demanding requirements. Incredible engine power and a
sophisticated design make the high-end machine a top
performer with maximum milling output. In addition, the
W 2200 offers a huge amount of excess power – no other
top-class cold milling machine provides this enormous
reserve capacity. This makes even the heaviest-duty job a
routine exercise, such as the use of 4.40 m wide milling
drum assemblies.
No other milling machine achieves a higher output in road construction
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The ultra-strong engine and high conveying capacity of
the front-loading system make the W 2200 the ideal
choice for jobs involving extremely high outputs.
This cold milling machine is particularly efficient in
large-scale surface course removal jobs using up
to 4.40 m wide milling drum assemblies.
High advance rates and milling depths ensure speedy
operation and quick completion of large construction
jobs.
Using the unique FCS, the W 2200 can be operated
with twelve different milling widths.
A machine that lets performance
speak for itself
The W 2200 – quick completion ofmajor milling jobs made easy
“The power of the W 2200 isboundless, which makes themachine an unbeatable choice for larger areas, such as motor-ways and airports”
On big construction sites, only the strong survive
This large milling machine is unrivalled in the 2-metre range
Everything standing in the way of the W 2200 is
instantly crushed to small-sized material by this
top-performing machine. For example, the 350-mm deep
removal of hard asphalt surfacing on an airport runway is
not a big deal at all. This is demonstrated in the W 2200
performance diagram shown on the next page. This data
can be used to estimate the actual milling performance to
be expected in each specific case. In this exercise, an
allowance factor is used to account for parameters or
circumstances having an adverse effect on performance,
such as interruptions by traffic, waiting periods until trucks
arrive, discontinuous milling areas or road fixtures. This
factor equals 0.6 for an open stretch of motorway and 0.4
for a country road.
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The powerful engine and the intelligent engine manage-
ment ensure unrivalled productivity for milling depths of
up to 350 mm.
Beyond the single-pass removal of entire road
pavements, individual courses can also be milled off
extremely efficiently.
Under ideal conditions, the W 2200 removes over
1,200 tons of asphalt per hour, which corresponds to
the payload of 60 trucks.
The generously designed front-loading conveyors ensure
that no capacity bottlenecks occur in the process of
loading the milled material.
Reserve capacity tocater to all needs
At high advance rates, the W 2200 is working its
way through the road surface
Calculation of area performance,taking into account varying siteconditions
Milling depth (cm)36
32
28
24
20
16
12
8
4
00 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36
0 500 1,000 1,500 2,000 2,500
0 500 1,000 1,500 2,000 2,500 3,000 3,500 4,000 4,500
Hard asphalt
Soft asphalt
Most frequent operating area
Practical areaperformance(m2/h)
Practical areaperformance(m2/h)
Practical areaperformance(m2/h)
0 250 500 750 1,000 1,250 1,500 1,750 2,000 2,250
Country road, long haulagedistance of trucks(allowance factor: 0.5)
0 200 400 600 800 1,000 1,200 1,400 1,600 1,800
Country road, through trafficinterrupts work(allowance factor: 0.4)
Open stretch of motorway(allowance factor: 0.6)
Theoretical areaperformance(m2/h)
Advance rate(m/min)
The intelligent Wirtgen technology playing its part in
the operation of the machine supports the driver and
provides all required information in a timely fashion. This
particularly applies to the optional WIDIS 32 Wirtgen on-
board information and diagnostic system. On the screen,
the system continuously displays current operating parame-
ters of both engine and hydraulic system. Visual and audible
alarms are triggered as and when necessary. All other
controls are also located within easy reach in the operator’s
field of view, labelled in a language-neutral manner and easy
and intuitive to operate. Hence, the operator can always
dedicate his full attention to what really counts – the perfect
execution of the milling job.
Effortless handling of the large milling machine
High-tech – easy to operate
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The easy, intuitive operation of the large milling machine
enables the operator to always remain fully focused on
his work.
In addition, the compact design of the W 2200 provides
all-round visibility across the site.
Crew members on the ground can use control panels
mounted to the sides of the machine to set or modify
key parameters, such as the milling depth.
Unmatched ease of operation
WIDIS 32 also includes a diagnosticsystem to simplify troubleshooting
The self-explanatory controlpanel design of the W 2200makes work much easier
A fully equipped, ergonomic workplace
Perfectly ergonomic to keep up performance
How to fully utilize the maximum capacity of a machine
with the least possible effort? What really counts for
the W 2200 operator in this respect is the ergonomic design
of the operator’s platform. The walk-through platform is
accessible via ladders from both sides and offers ample
legroom and elastically supported treads. Highly comfort-
able: the two identical control panels adjustable in height
and inclination according to operator preference. Together
with the two comfortable driver’s seats, the panels can be
moved to project over the left or right edge of the machine.
The fully equipped W 2200operator’s platform providesample space
Both control panels can be moved to project
over the edge of the machine
Lockable control covers
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The ergonomic design of the fully equipped workplace
ensures stress-free, no-fatigue operation over long
periods.
The hydraulically retractable canopy (available as an
optional feature) protects the operator from both rain
and sun exposure.
Many features can be controlled from the ground via
separate panels, such as the raising and lowering of the
scraper blade.
Effectively eliminating factors
contributing to fatigue
Holders for refreshments mounted within easy reach
Ingeniously folded-in accessladder enabling the machine to
be driven close up to walls
Convenient access to the operator’s platform
The position of both protectivecanopy and control panel can beadjusted to specific needs
Even more accurate milling results with LEVEL PRO
The optional LEVEL PRO system – a sound investment in your future
Accurate and safe levelling systems are part of our
core expertise. Wirtgen has developed a ground-
breaking proprietary system including a software that
has been designed specifically for cold milling machines:
LEVEL PRO. The overall system includes sensors, a con-
troller unit and an operating panel. The graphics-enabled
LEVEL PRO screen shows key parameters in a clearly
legible fashion. For example, target and actual values for the
left and right milling depth and slope parameters are clearly
and unambiguously shown on the displays. In addition, the
memory feature is very useful to program, store and invoke
target values.
Wire-rope sensors measure the exact milling depth on both sides of the machine
The LEVEL PRO panel is located in the direct field of view of theoperator, within easy reach
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A great variety of sensors can be integrated into the
automatic levelling system as and when required, such
as wire-rope, slope and ultrasonic sensors.
Optional features include the control of milling depths via
a reference wire and the compensation of irregularities in
longitudinal direction using a multiplex system.
Large tactile switches enable the operator to enter or
correct parameters quickly and safely.
State-of-the-art digital signal processing ensures
unmatched milling job accuracy.
State-of-the-artlevelling technology
The optional electronic slope sensorfor the milling of pre-set cross slopes
Scanning the surface in front of the milling drum using a wire-rope sensor (optional)
Switchoverbutton
AutomaticON/OFF
Target value
Actual value
Controller output
Memory 1
Horn
Settings
Target value RAISE/
LOWER
Calibration
CylinderRAISE/LOWER
Memory 2
Impressive manoeuvrability despite giant size
Swift progress under any conditions
Sometimes even a true giant becomes incredibly small
– in this case, when turning the machine. The compact
W 2200 owes its outstanding manoeuvrability to an intelli-
gent all-track steering system, which provides clearly
superior performance compared to any other system. The
smooth hydraulic steering system enables large angles of all
four track units, and thus an extremely small turning circle of
the entire machine. But the highly manoeuvrable giant has
even more to offer in crab steering mode: the W 2200 un-
erringly approaches the track to be milled even in extremely
space-restricted conditions. In addition, the machine
provides high ground clearance due to its track units being
individually adjustable in height, which makes previously
difficult manoeuvres extremely easy.
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Due to the high ground clearance of the track units,
activities such as reversing or loading the machine onto
a low-loader can be handled effortlessly.
The manually selectable differential lock provides the
required tractive force at a consistently high level under
any ground conditions.
A specially designed sliding block guide uncouples the
steering function from height adjustment.
Speed can be continuously adjusted from zero to the
high maximum speed the machine can attain.
All-track drive withhigh tractive force
Precise steering with the parallelsliding block guide working inde-pendently of the height selected
Crab steering ensures an easyapproach to the track to be milled
Top-class engine performance
In order to also mill off complete pavements quickly,
the W 2200 is equipped with a high-performance
diesel engine: The twelve cylinders of this state-of-the-art
engine unleash tremendous power when it counts. In addi-
tion, an intelligent engine management system controls the
advance rate of the cold milling machine depending on the
engine load, which does not only result in fuel savings but
also reduces noise. The engine compartment is also fitted
with a highly effective, all-round sound insulation.
More than enough performance reserves
Technology designed for topperformance – the powerful diesel engine
Characteristic curves in the critical operating range
Engine always runswithin the optimalrange M [Nm]
[1/min]210019001700150013001100
100
150
200
250
300
350
400
450
500
550
600
P [kW]
1400
1600
1800
2000
2200
2400
2600
2800
3000
3200
3400
1000 1200 1400 1600 1800 2000 2200900
650
700
3600
3800
The engine output remains constant even at extremely high engine loads
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Maximum efficiency with mechanical milling drum drive
The mechanical drive acts directly on the milling drum
via three multiple V-belts with five ribs each, which
ensures highly efficient operation.
The almost complete power transmission guarantees
highest efficiency and top-of-the-range daily production
rates.
In day-to-day operation, the gentle V-belt drive results
in distinct advantages: low fuel consumption, a long
service life and easy maintenance.
The V-belts are readily accessible and can be replaced
very quickly.
Taking the direct route –always the best way
A hydraulic cylinder adjusts thetension of the multiple V-belts in
accordance with the load
Focused power for high millingadvance rates
High degree of utilization ensures profitable operation
When awarding contracts, there is a clear trend
towards procuring all required services from a single
supplier. This is why building contractors are in the best
position whenever they are able to offer a range of services
that is as complete as possible. The W 2200 puts up an
outstanding performance also in this regard: depending on
specific project needs, the W 2200 can be fitted with
standard milling drums, ECO cutters or fine milling drums.
The varying spacing of the cutting tools results in different
degrees of roughness of the milled surface, and in significant
differences in milling output. This makes the big machine a
flexible choice for many applications on the milling site. The
increased degree of utilization results in a considerable cost
advantage – an opportunity not to be missed.
Versatility reduces operating cost
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Standard milling drums are ideally suited to the removal
of one or more pavement layers, ensuring a good
interlock between the milled surface and the new
pavement layers.
The optional ECO cutters equipped with a reduced
number of point-attack tools ensure the highest
possible area performance.
The optional fine milling drums create finely textured
surfaces ideally suited as a base for the application of
thin pavement layers.
Other special milling drums for various applications are
available upon request.
ECO cutterMilling width: 2,200 mmMilling depth: 0 – 350 mmTool spacing: 25 mm
Standard milling drumMilling width: 2,200 mmMilling depth: 0 – 350 mmTool spacing: 15 mm
Fine milling drumMilling width: 2,200 mmMilling depth: 0 – 100 mmTool spacing: 8 mm
Wide range ofapplications
Fine milling drums are fitted with a dense pattern of cutting
tools, which results in a very finely textured surface
Range of milling drums for the W 2200
Effective operation with oversized milling drum assemblies
Milling widths of up to 4.40 metres
Contractors are often concerned about the time
pressure and tight schedules on major construction
sites where extremely high milling outputs are an absolute
requirement. Such demanding jobs cannot reasonably be
completed on time with the standard milling width of 2.20 m.
But there is hope – here comes the Flexible Cutter System
in XXL design! As an optional feature, the W 2200 high-
performance milling machine can be fitted with this modular
system including milling widths from 2.20 to 4.40 m. This
Wirtgen system makes it possible to change the milling
drum assembly within only a few hours.
Using the housing extension,wide roads can be milled off
efficiently in a single pass
The mounting carriage is used toattach the milling drum assemblyto the chassis
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Following the removal of the standard milling drum
assembly, the new, larger assembly is moved under the
W 2200 on a mounting carriage.
Once the new assembly has been bolted and connected
to the machine, the W 2200 is ready for the next job.
Trained staff can change the complete drum assembly
within a short period of time.
Changing the milling drum assembly permits a whole
range of entirely different applications.
Flexibility the XXL way
Wide range of applications between 2.20 and 4.40 m
XXL-size milling drum assemblies provide cost and quality benefits
The large W 2200 milling machine has got a truly
unique selling proposition: when using the optional
housing extension, it can be fitted with up to 4.40 m wide
milling drums. This increases both the range of possible
applications and the efficiency of the machine. The milling
drum assemblies wider than 2.20 m show their extremely
high area performance in particular when milling off surface
courses at depths of up to 10 cm. In addition, the milled
surfaces impress with perfect evenness. This results in
enormous savings potentials since a process using greater
milling widths reduces the number of adjacent cuts and of
the turning manoeuvres required while also driving down
labour cost.
A housing extension can be used to mount up to 4.40 m wide milling drums
Milling width: 2.20 m
Milling width: 2.50 m
Milling width: 3.10 m
Milling width: 3.50 m
800 mm
Milling width: 3.80 m
Milling width: 4.40 m
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The oversized milling drum assemblies demonstrate
their advantages especially on wide urban roads,
motorways, highways and airports.
Complete, up to 4.40 m wide road pavements can be
removed quickly in a single pass.
As part of the standard equipment package, the front-
loading system and engine of the W 2200 are designed
for milling operations using a 4.40 m wide assembly.
Milling off wide roads in a single pass
Belgium: high-performancesurface course removal at amilling width of 3.80 m
Italy: a milling job using the 2.20 m wide standard assembly
USA: the W 2200 in full swing, using a 3.80 m wide
milling drum assembly
Ingenious to the very last detail
The optional HT11 quick-change toolholder system
offers many advantages that pay off quickly during
heavy-duty operation on the job site, including the optimal
rotating characteristics of the cutting tools, the additional
tool cooling provided by the holder design and the extremely
low degree of wear. In addition, cutting tools can be
replaced quickly and effortlessly while wear markers ensure
easy monitoring of the degree of upper part wear. These are
just some of the numerous advantages this system pro-
vides. Overall, the HT11 system contributes to ensuring
efficient operation of the machine whilst reducing operating
cost in the long term.
HT11 quick-change toolholder systemensures maximum milling output
Together with the milling drum andcutting tools, the quick-changetoolholders create a perfect system
HT11 offers a number ofsignificant application benefits
Efficiency driven to the max
Strong retaining bolt prevents un-wanted loosening of upper part
Conical pressure stud for reliabletransmission ofclamping force
Seal to allow simple and quickinsertion/removal
of upper part
Chip breaking rib for additional crushing
of milled material
Optimized shaft angle geometry forimproved componentstrength
Wear markers at 5 mmintervals for improvedmonitoring
Upper part covers bottom part completely to minimize deformation of contact surface
Contact surfaceincreased by 75%
for improved durabilityof bottom part
Protective plugprevents soiling of bolt head
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The optional automatic drum turning device is the
ideal solution to ensure quick and convenient cutting
tool replacement.
The wire remote control unit can be mounted in any
position, and is used to turn the milling drum to the left
or to the right to arrive at exactly the required position.
The pneumatic cutting tool extractor makes tool
replacement even quicker.
As a further option complementing the cutting tool
storage containers attached to the rear track units, a
seat can be attached to make tool replacement even
more convenient.
Cutting tool replacement at record speed
Drum turning devicekeeps downtime low
Other useful options include acomfortable seat and a pneumaticcutting tool extractor
Drive of the drum turning device
The remote control unit can be attached within easy
reach of the operator
Heavy-duty milling drum assemblywith sophisticated features
For reliable material loading
To put up top performance, a heavy-duty milling drum
assembly forms part of the on-board equipment. The
W 2200 assembly has been cleverly designed: For full load-
ing of the milled material, the operator lowers the scraper
blade hydraulically. When raised and locked at the required
height, the scraper blade enables the milled material to be
either partially loaded or to remain in the milled track. In
addition, the scraper blade can be swung open by 100
degrees for cutting tool replacement. The side plates left
and right are raised via hydraulic cylinders to achieve optimal
milling results along road fixtures. Raising the side plates
also prevents them from digging into the ground in unpaved
areas.
The hydraulically adjustablegradation control beam preventsthe asphalt from breaking intolarge slabs…
The side plates can be pressedonto the asphalt surface
When driving over obstacles, the side plates can be raised
… and thus protects the primaryconveyor from premature wear
24 // 25
Both the amount and pressure of the water provided by
the hydraulically operated water system can be set from
the ground.
The integrated water spray system provides highly
effective cooling of the cutting tools and extends their
service life.
Scraper blade, gradation control beam and protective
side plates provide effective closure of the milling
chamber.
The low-wear carbide metal plates on the scraper blade
are designed for convenient, separate replacement.
For perfect milling results
When swung open, the scraperblade provides ample space forcutting tool replacement
The hydraulically adjustable scraper blade – a standard feature in
all large Wirtgen milling machines
With the scraper blade in “locked” position, the milled
material can be partially loaded
Makes transport convenient: the folding conveyor
The W 2200 provides a great discharge height
Effectively closed transfer zone from primary to discharge conveyor
Reliable material loading even under full load
Loading trucks faster than ever
The W 2200 has been designed for maximum perfor-
mance. For this reason, the machine also includes a
robust loading system providing an extremely high conveying
capacity. Due to its swivel-mounted and height-adjustable
design, the discharge conveyor can load huge amounts of
milled material onto trucks in a flexible and cost-efficient
manner: as the system ensures that trucks can change
“on the fly”, the milling operation is never interrupted. The
variable speed of the discharge conveyor belt also ensures
that even large articulated trucks are loaded to full capacity.
But what happens when the machine is fitted with a 4.40 m
wide milling drum? There is a clear answer to that question:
Although the W 2200 produces even more material, the
standard loading system easily copes with the additional
challenge.
The folding conveyor is foldeddown within only a few seconds
26 // 27
For reliable discharge of large amounts of milled
material, the conveyor belts have rugged cleat profiles.
The optional folding conveyor reduces the transport
length of the W 2200 by approx. 3 m and makes it
possible to use shorter low-bed trailers.
The optional belt scales determining the weight of the
milled material loaded ensures that trucks are always
loaded to full capacity.
The operator is always fully aware of the loading
process carried out by the front loader and of moving
traffic.
Economical loading of milled material
1,100 mm wide conveyor belt to ensure high-performancematerial transport
Wide slewing angles to the left and right …
… enable flexible truck loading
Maintenance made easy
Higher productivity due to quick maintenance
The W 2200 leads by example when it comes to com-
bining maximum performance with the lowest possible
amount of maintenance. At the flick of a switch, hydraulic
cylinders open the huge engine cowling. All points of main-
tenance are arranged in a clear pattern and can be readily
accessed. In order to simplify maintenance procedures,
lubrication and service points have been grouped together
intelligently. In addition, the large milling machine provides
ample space to store spare cutting tools and machine
equipment, as well as the toolkit also included in the stan-
dard package. When the job has been done, the W 2200
can be properly prepared for the next day on site using the
optionally available high-pressure water jet cleaner.
28 // 29
Maintenance of the W 2200 is made totally easy –
the entire machine is readily accessible.
Easily accessible filling ports ensure quick and con-
venient filling of the large-volume water and fuel tanks.
Long work cycles without refuelling and long servicing
intervals pay off very quickly.
Hydraulic, air, fuel and return line filters are readily
accessible under the engine cowling and can be
replaced quickly.
For peace of mind in operation
The high-pressure cleanercomes complete with a long
hose and reaches even the mostdistant corner of the W 2200
The air filter replacement from the operator’s platform hasalso been designed with userfriendliness in mind
A convenient feature: 200 litres ofextra storage space at the rear
of the machine (optional)
Nothing can stop the W 2200
Work at night to prevent delays
For our top-class W 2200 milling machine, the day only
ends when the job is finished. This machine puts up
an equally compelling performance during night and day.
For the lighting system provides an optimal degree of illumi-
nation both in the important work areas and around. Safe
working under adverse conditions offers an optimal degree
of utilization of the machine, and is a compelling argument in
favour of the W 2200. As a matter of course, the large milling
machine is fitted not only with flexible lights but also with
easily accessible emergency stop switches, exterior mirrors
and a clearly audible reversing horn.
Construction work at night – anall-round success due to thepowerful lighting system
The freely adjustable lights can be attached in no time
Bright spotlights provide optimal lighting
Mirrors mounted in convenientpositions on the machineprovide all-round visibility
30 // 31
Heavy-duty transport made easy
Despite its size, the W 2200 can be easily loaded and
transported.
The transport length is significantly reduced if the
folding conveyor design is chosen. Transport height is
minimized if the protective canopy is ordered.
Many loading and lashing lugs ensure safe fastening for
low-bed trailer haulage.
Our offering also includes conveyor support legs to
support the standard conveyor during transport on a
low-bed trailer.
Transport of the W 2200 – a
smooth affair
Low-bed trailers carry the largemilling machine effortlessly
At the push of a button, the optional protective canopy is folded down
The ideal transport height is reached in no time
Illustrations are non-binding and may include customized fittings. Subject to technical changes. Performance data depend on operational conditions. No. 18-10 EN-05/08 © by Wirtgen GmbH 2008. Printed in Germany
Wirtgen GmbHReinhard-Wirtgen-Strasse 2 · 53578 Windhagen · GermanyPhone: +49 (0) 26 45 / 131-0 · Fax: +49 (0) 26 45 / 131-242
Internet: www.wirtgen.com · E-Mail: [email protected]