The new generation Cold Recycler and Soil Stabilizer WR series. WR 200 WR 200 i WR 240 WR 240 i WR 250

Transcription

1 The new generation Cold Recycler and Soil Stabilizer WR series WR 200 WR 200 i WR 240 WR 240 i WR 250

2 Contents

3 Added value that pays dividends... 4 Three machines world class to the power of three... 6 Broad range of applications... 8 Designed with human-machine interaction in mind Perfect ergonomic design and handling Automated function for the working process Perfect visibility and comprehensive camera system Compelling features designed for an entirely new performance class Outstanding all-terrain mobility Steering system built to field requirements Efficient engine and diagnostic systems High tech for top quality: it s the mix that counts High milling and mixing performance Precise metering system for binding agents // 3

4 Added value that pays dividends

5 i Highlights Use your smartphone to get more information. 1 ERGONOMICS Performance-enhancing, ergonomic design of the spacious operator s cabin 2 VISIBILITY Perfect all-round visibility 3 OPERATION In full control with the multifunctional joystick 9 4 CAMERA SYSTEM Full monitoring of all work processes MAINTENANCE State-of-the-art diagnostic systems and extra long maintenance intervals 6 LIGHTING Intelligent lighting concept 7 STEERING Steering system with small turning radius greatly improves operator comfort 11 8 OFF-ROAD MOBILITY All-wheel drive, independent suspension with high lift, fast 4-fold full-floating axle 7 9 ENGINE STATION High-torque diesel engine with automatic speed adjustment ROTOR HOUSING Various rotor speeds and adjustable crusher bar 11 ROTOR DRIVE Effective direct drive via power belt 12 AUTOMATED FUNCTION Time-saving, automatic lowering and raising of the milling and mixing rotor to start or stop the milling process 4 // 5

6 Three machines world class to the power of three Consistently superior machine design The compact option WR 200 / WR 200 i The WR 200 / WR 200 i machine is easy to transport without special approval or permit due to its compact dimensions and low weight. It is well-suited to both soil stabilization and cold recycling. The all-rounder WR 240 / WR 240 i The WR 240 / WR 240 i is the proverbial all-rounder in the Wirtgen fleet. As a result of its large working width and depth and unrivalled milling and mixing performance, this machine provides maximum flexibility for any type of soil stabilization or cold recycling job. The top performer WR 250 The WR 250 is the high-performance option suitable for exceedingly complex tasks. Its enormous milling and mixing output makes this machine the perfect choice for even the toughest soil stabilization jobs and the pulverization of tough asphalt layers. Taken together, the range of benefits offered by the WR 250 sets the industry standard for the biggest conceivable challenges in soil stabilization and cold recycling.

7 Solutions tailored to each application Working width: 2,000 mm Cutting power: 1.6 kw / cm Working depth: WR 200 maximum engine power: WR 200 i maximum engine power: CE operating weight: mm 315 kw / 428 PS 320 kw / 435 PS 23,900 kg Ideal performance range in soil stabilization: 1,000 5,000 m 2 /day Ideal performance range in cold recycling: m 2 /hour Thickness of recyclable asphalt layer: cm Working width: 2,400 mm Cutting power: 1.9 kw / cm Working depth: WR 240 maximum engine power: WR 240 i maximum engine power: CE operating weight: mm 455 kw / 619 PS 447 kw / 608 PS 29,400 kg Ideal performance range in soil stabilization: 4,000 8,000 m 2 /day Ideal performance range in cold recycling: 500 1,000 m 2 /hour Thickness of recyclable asphalt layer: cm Working width: 2,400 mm Cutting power: 2.4 kw / cm Working depth: mm Ideal performance range Maximum engine power: 571 kw / 777 PS in soil stabilization: 6,000 12,000 m 2 /day CE operating weight: 31,000 kg Ideal performance range in cold recycling: 700 1,200 m 2 /hour Thickness of recyclable asphalt layer: cm 6 // 7

8 Broad range of applications Perfect soil stabilizer Second-to-none performance and mixing quality The finely graded Wirtgen WR series includes a tailored solution for any soil stabilization and cold recycling job. As a result, these machines are ideally suited to the powerful, large-scale stabilization of ground with insufficient bearing capacity. The stabilization process converts poor-quality soil into a premium construction material. In addition, its perfect ergonomic design and maximum visibility, high engine power and mixing quality, superior all-terrain mobility, automated features and many other highlights make the WR a pioneer in terms of output at low operating costs regardless of the type of soil stabilization job.

9 i Soil stabilization Use your smartphone to get more information. Ideal performance ranges in soil stabilization Top performance whatever the job WR 200 / WR 200 i WR 240 / WR 240 i WR 250 The WR ensures perfect mixing quality while producing the hydraulically bound base layer Complete performance range Ideal performance range WR 200 / WR 200 i WR 240 / WR 240 i WR ,000 m 2 / day 1,000 10,000 m 2 / day 2,000 15,000 m 2 / day 1,000 5,000 m 2 / day 4,000 8,000 m 2 / day 6,000 12,000 m 2 / day The WR series includes all performance classes in soil stabilization Ensuring unrivalled mixing quality, the WR meets exceedingly demanding requirements in a wide variety of soil stabilization jobs. The WR series covers the entire range of applications as a result of varying engine powers tailored to the specific job needs. Its striking benefits include the all-wheel drive, fourfold full-floating axle and automatic power control system providing the perfect prerequisites for any job on difficult terrain or wet ground. The water metering system is easy to operate its process parameters can be effortlessly adjusted to any requirements. 8 // 9

10 Broad range of applications The WR operating as a soil stabilizer Pre-spread binding agent 7 Milling and mixing rotor 8 Stabilized, homogeneous mix of soil and binding agent Stabilizing soils of poor bearing capacity on a large scale Soil exchange continues to be specified very often even though it no longer represents the state of the art. Working as a soil stabilizer, the WR uses its powerful milling and mixing rotor to mix pre-spread binders, such as lime or cement, into existing soil of poor bearing capacity to a working depth of up to 560 mm, converting it into a premium construction material right on the spot. The resulting homogeneous soil-binder mix offers high levels of tensile strength, compressive strength and shear strength as well as lasting water resistance, frost resistance and volume stability. Typical applications include the construction of paths, roads, motorways, parking lots, sports grounds, industrial parks or facilities, airports, dams, backfills or landfills.

11 1 Binding agent spreader 2 WR soil stabilizer 3 Single-drum compactor 4 Grader 5 Single-drum compactor 1 The powerful milling and mixing rotor mixes the existing soil with pre-spread cement and water, if required to produce a homogeneous mix. The WR effortlessly pushes a water tanker truck which delivers water via a hose connection. The fast-paced, environmentally friendly in-situ process dispenses with expensive soil exchange. Soil stabilization is clearly superior to soil exchange as it requires fewer truck transports, shortens job completion times, reduces resource consumption and lowers carbon emissions. 10 // 11

12 Broad range of applications Various solutions for high-quality soil stabilization Homogenization WR Single-drum compactor Soil stabilization with lime Binding agent spreader WR Soil stabilization with cement Binding agent spreader Water tanker truck WR

13 To homogenize existing soil, the powerful milling and mixing rotor of the WR granulates and loosens the material without the addition of binding agents. A grader is used to finish grade the previously stabilized, homogeneous soil mix, and compaction is effected by various Hamm rollers. Grader Single-drum compactor To stabilize existing soil, binder is pre-spread in a first step by the all-wheel drive Streumaster SW 19 SC Rhino. Following right behind the binding agent spreader, the powerful milling and mixing rotor of the WR mixes the existing soil with the pre-spread binding agent to produce a homogeneous mix. A grader is used to finish grade the previously stabilized soil mix, and compaction is effected by various Hamm rollers. Single-drum compactor Grader Single-drum compactor To produce a new hydraulically bound base layer, a Streumaster towed spreader pre-spreads cement, followed by a water tanker. The powerful milling and mixing rotor of the WR mixes the existing material with the pre-spread cement to produce a homogeneous mix. At the same time, water is injected into the mixing chamber via an injection bar. A grader is used to finish grade the previously stabilized base layer, and compaction is then effected by various Hamm rollers. Single-drum compactor Grader Tandem roller Pneumatic-tyred roller 12 // 13

14 Broad range of applications Top-performing cold recycler Perfect mixing quality and utmost metering accuracy Machines of the WR series are not only state-ofthe-art soil stabilizers. They are full liners offering equally compelling cold recycling features. When operated in cold recycling mode, the WR machines convert asphalt layers in need of rehabilitation to high-quality base layers regardless of the site area and working depth. Additives and binders used for this purpose include cement, water, bitumen emulsion and foamed bitumen. Perfect job outcomes are ensured by highly accurate metering, a consistently superior mixing quality, the clearly structured, easy operation of the machine and its precise levelling. There s no doubt at all: the WR is the ultimate option for perfect road repair and maintenance.

15 i Cold recycling Use your smartphone to get more information. Performance ranges in cold recycling State-of-the-art road rehabilitation WR 200 / WR 200 i WR 240 / WR 240 i WR 250 The WR meets the challenges of cold recycling quickly and efficiently Ideal performance range Thickness of recyclable asphalt layer WR 200 / WR 200 i WR 240 / WR 240 i WR 250 up to 840 m 2 /hour up to 1,000 m 2 /hour up to 1,200 m 2 /hour cm cm cm The WR series caters to the complete range of cold recycling applications From thin asphalt layers on uncrowded rural roads to up to 250 mm thick asphalt layers on busy motorways exposed to high loads and stresses the various machines of the WR series are perfectly suited to any of these recycling jobs, catering to all performance ranges. The cold recycling process is made exceedingly efficient by the intuitive input of injection system parameters and a second-to-none visualization of binder metering. State-of-the-art microprocessors enable the highly accurate metering of added quantities, ensuring top-quality cold recycling results. 14 // 15

16 Broad range of applications The WR operating as a cold recycler Milling and mixing rotor 8 Injected foamed bitumen 9 Injected cement slurry 10 Recycled, homogeneous construction material High construction output at low cost Steadily increasing volumes of truck traffic cause structural damage to the different layers of asphalt roads over time, while at the same time reducing their bearing capacity. In recycling mode, the WR eliminates these deficiencies quickly, economically and in a resourcesaving manner. It is equipped with a powerful milling and mixing rotor and state-of-the-art injection systems. The cold recycler mills and granulates worn-out asphalt pavements, injects binding agents and water in precisely metered quantities and mixes them with the pavement material to be recycled, all in a single machine pass. The new base layers produced by means of this in-situ process are distinctive for their exceptionally high bearing capacity.

17 1 Bitumen tanker truck 2 WM 1000 slurry mixer (only in combination with WR 240 / WR 240 i, WR 250) 3 Cold recycler WR 240 / WR 240 i, WR Single-drum compactor 5 Grader 6 Tandem roller 1 Tanker trucks driving ahead of the WR and linked to the cold recycler via hose connections supply water and various binding agents. Water, cement slurry, bitumen emulsion or foamed bitumen are injected into the mixing chamber via microprocessor-controlled injection bars. Foamed bitumen for the production of exceptionally stable base layers is produced in the cold recycler. The WR recycles pavements in situ, meaning that no damaged material needs to be disposed of nor virgin material supplied. 16 // 17

18 Broad range of applications High-quality cold recycling with cement Pulverization WR Single-drum compactor Recycling with pre-spread cement Binding agent spreader Water tanker truck WR Recycling with cement slurry WM 1000 slurry mixer WR 240 / WR 240i, WR 250 Single-drum compactor

19 With its powerful milling and mixing rotor, the WR pulverizes damaged asphalt layers and part of the subgrade without the addition of binding agents. A grader is used to finish grade the pulverized, homogeneous granulated material, and compaction is effected by various Hamm rollers. Grader Single-drum compactor To produce a hydraulically bound base layer, a Streumaster binder spreader pre-spreads a layer of cement, followed by a water tanker truck. The powerful milling and mixing rotor of the WR granulates the damaged pavement layers, simultaneously mixing in the pre-spread cement and injected water. A grader is used to finish grade the previously recycled, homogeneous construction material, and compaction is effected by various Hamm rollers. Single-drum compactor Grader Tandem roller Pneumatic-tyred roller To produce a hydraulically bound base layer, a Wirtgen WM 1000 slurry mixer travels ahead of the WR 240 / WR 240 i, WR 250, supplying the recycler with cement slurry. The powerful milling and mixing rotor granulates the damaged pavement layers, simultaneously mixing in the cement slurry injected via an injection bar. A grader is used to finish grade the previously recycled, homogeneous construction material, and compaction is effected by various Hamm rollers. Single-drum compactor Grader Tandem roller Pneumatic-tyred roller 18 // 19

20 Broad range of applications High-quality cold recycling with bitumen emulsion Recycling with pre-spread cement and bitumen emulsion Binding agent spreader Water tanker truck Emulsion tanker truck Recycling with cement slurry and bitumen emulsion Emulsion tanker truck WM 1000 slurry mixer WR 240 / WR 240i, WR 250

21 Small quantities of cement are pre-spread by a Streumaster binding agent spreader, which is followed by a water and an emulsion tanker truck. The powerful milling and mixing rotor of the WR granulates the damaged pavement layers, simultaneously mixing in the pre-spread cement as well as the water and bitumen emulsion injected into the mixing chamber via two separate, microprocessorcontrolled injection bars. A grader is used to finish grade the previously recycled, homogeneous construction material, and compaction is effected by various Hamm rollers. WR Single-drum compactor Grader Tandem roller Pneumatictyred roller An emulsion tanker travels ahead, followed by a Wirtgen WM 1000 slurry mixer. The emulsion tanker and the slurry mixer supply the WR 240 / WR 240 i, WR 250 with the binding agents required for processing the pavement in need of rehabilitation. The powerful milling and mixing rotor of the WR 240 / WR 240 i, WR 250 granulates the damaged pavement layers, simultaneously mixing in the cement slurry and bitumen emulsion injected into the mixing chamber via two separate, microprocessor-controlled injection bars. A grader is used to finish grade the previously recycled, homogeneous construction material, and compaction is effected by various Hamm rollers. Single-drum compactor Grader Tandem roller Pneumatic-tyred roller 20 // 21

22 Broad range of applications High-quality cold recycling with foamed bitumen Recycling with pre-spread cement and foamed bitumen Binding agent spreader Water tanker truck Bitumen tanker truck WR Recycling with cement slurry and foamed bitumen Bitumen tanker truck WM 1000 slurry mixer WR 240 / WR 240i, WR 250

23 Small quantities of cement are pre-spread by a Streumaster binding agent spreader, which is followed by a water and a bitumen tanker truck. The powerful milling and mixing rotor of the WR granulates the pavement layers in need of rehabilitation, simultaneously mixing in the pre-spread cement as well as the water and foamed bitumen injected via two separate, microprocessor-controlled injection bars. Foamed bitumen is produced in so-called expansion chambers by means of injecting small amounts of water and compressed air into hot bitumen. The hot bitumen then foams abruptly, expanding to many times its original volume, and is evenly distributed in the mineral aggregate mix to be recycled. A grader is used to finish grade the previously recycled, homogeneous construction material, and compaction is effected by various Hamm rollers. Single-drum compactor Single-drum compactor Grader Tandem roller Pneumatictyred roller A bitumen tanker travels ahead, followed by a Wirtgen WM 1000 slurry mixer. The bitumen tanker truck and slurry mixer supply the WR 240 / WR 240 i, WR 250 with the binding agents required for processing the pavement in need of rehabilitation. The recycler s powerful milling and mixing rotor granulates the damaged pavement layers, simultaneously mixing in the cement slurry and foamed bitumen injected via two separate, microprocessor-controlled injection bars. A grader is used to finish grade the previously recycled, homogeneous construction material, and compaction is effected by various Hamm rollers. Single-drum Single-drum compactor compactor Grader Tandem roller Pneumatic-tyred roller 22 // 23

24 Designed with human-machine interaction in mind

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26 Perfect ergonomic design and handling A new dimension in ergonomic design The individually adjustable, comfortable seat ensures a perfect posture of the operator The multifunctional joystick in the right-hand arm console fits right into the palm of the operator s hand Driver s seat swivels through 90 degrees no unnecessary movements when checking the zero side The colour screen mounted at the steering column is positioned in the operator s immediate field of view Ergonomic design boosts operator performance The anatomically shaped driver s seat with spring and air cushioning is the ergonomic showpiece of the WR series. It can be fully adjusted to different body sizes, guaranteeing a perfect seating position for many hours. In addition, ergonomically designed controls are integrated in both arm consoles they are arranged within easy reach to enable intuitive operation. All basic machine functions have been grouped together logically in the multifunctional joystick on the right-hand arm console, providing unrivalled ease of use. The entire driver s seat including arm consoles and steering column can be swivelled through 90 degrees to either side, giving the operator a full view towards the rear of the machine while maintaining a relaxed body posture.

27 Space and operator comfort two prerequisites for success Operator comfort is a key efficiency driver, which is why we have paid special attention to the workplace of the machine operator. The soundproof, spacious WR cabin provides ample room to move, a comfortable interior and pleasant indoor temperatures. Its range of equipment includes a comfortable driver s seat, a powerful climate control and heating system, a standard cooler, a radio with CD player, a compressed air connection and air gun for easy cabin cleaning, backlit controls and numerous storage options, to name but a few. They facilitate work for the operator, thus increasing not only operator comfort and performance but also the machine s productivity on a daily basis. 26 // 27

28 Perfect ergonomic design and handling Perfect visibility whatever the time of day or night Maximum performance even during night operations Construction projects are nowadays carried out under tremendous pressure of time with no regard for adverse weather, darkness or night. This is where the intelligent lighting system of the WR comes into play. It comprises six headlights at the front of the cabin, optionally in LED design, two spotlights each on the left and right side, two curve lights at the rear and two spotlights for flexible mounting by means of magnetic bases to fully illuminate all important work areas around the machine. Operation of the machine can thus continue at full power even after the sun has set and the WR is utilized to full capacity.

29 The WR makes work easier every day A high-pressure cleaner is part of the on-board equipment Complete work faster Easy access to the spacious operator s cabin is ensured The WR is approved for transport on all standard flatbed trucks Welcome and Go home lights feature: when arriving at or walking away from the WR, the machine s environment can be illuminated by LED lights. The WR 200 / WR 200 i machine is easy to transport without special approval or permit due to its compact dimensions and low weight. Safety first: side railings are folded up in a few simple steps when working on the engine or cooler. The cabin conforms to the ROPS/FOPS standards, providing maximum operator safety. 28 // 29

30 Automated function for the working process Automated processes boost performance and quality Working without any time loss The operator uses the joystick to initiate the automatic lowering and raising process In a first step, the machine is lowered rapidly The milling and mixing rotor moves into the preselected position Performance boost at the push of a button The WR is equipped with an intelligent automatic system to control lowering and raising of the milling and mixing rotor. It relieves the operator of part of his workload, increases daily performance and improves quality. The operator uses the multifunctional joystick to activate the automatic process; all other steps are completed automatically by the WR. In a first step, the machine is lowered rapidly, and the front and rear rotor plates move into their preselected positions. Once the lifting columns have reached their working position, the milling and mixing rotor is lowered into the soil until the programmed working depth has been reached. Moving the joystick forward then enables forward movement of the machine.

31 i Automated function Use your smartphone to get more information. At the end of the stabilized track, the front rotor plate is pressed down and the recycler reverses During reversing, the rotor is raised out of the soil The cut developing in the area of the rotor at the end of each track is closed by activating the automatic raising mechanism using the joystick. Depending upon whether the rotor is raised in forward or reverse travel, the rotor plates move into their specified positions. While the WR travels a few metres, the corresponding rotor plate closes the cut completely. At the same time, the rotor is slowly raised from the cut, and the lifting columns move the machine into transport position. 30 // 31

32 Perfect visibility and comprehensive camera system Enhanced visibility increases productivity With the cabin moved far to the right, the operator can turn his seat to enjoy an unobstructed view of the working edge on the right-hand side of the machine Working flush to kerb is enabled by the right-hand wheels arranged within the working width of the machine Working flush to kerb poses no problem at all Good visibility is of vital importance to ensure safe operation and allow fast-paced processes. The WR offers a visibility concept that is unique in the industry: large glass panes at the front, left and right side of the cabin, and a set of mirrors in line with field requirements allow a full view of the entire construction site. The spacious cabin, which can be moved beyond the edge of the machine on the right, and the driver s seat swivelling through 90 degrees offer a free view of the entire working edge on the right-hand side so that working flush to kerb without the need for extensive reworking is no problem at all. In short: optimal visibility for the machine operator enhances productivity and maximizes profits on every construction site.

33 i Visibility Use your smartphone to get more information. Large glass panes and numerous mirrors offer excellent visibility The cabin is moved far to the right hydraulically, for example, to look past a recycling train travelling ahead of the machine An excellent view of the working edge on the right side of the machine enables precise recycling along the kerbs of road pavements. The intelligently arranged windscreen wipers and anti-fog feature of the air-conditioning system improve visibility even further, if required. In addition, a good view of the right-hand working edge enables highly precise overlaps in soil stabilizing operations. The side window on the right can optionally be locked in various functional positions. 32 // 33

34 Perfect visibility and comprehensive camera system Many eyes are better than two Second-to-none camera system Camera systems are developing into increasingly important support tools when it comes to monitoring the operational processes and procedures of machines where good visibility is a must. The camera solutions available for the Wirtgen WR give the machine operator the additional eyes he needs to view important but otherwise inaccessible work situations. A reversing camera is part of the WR basic on-board equipment package. It can optionally be upgraded to a full equipment package consisting of four cameras installed at various points of the machine.

35 The camera installed at the rear provides images of what is going on behind the machine Reversing camera is a standard feature The control screen displays the rear camera image as soon as the reverse gear is engaged The image is displayed on the control screen with automatic reverse assist A rear camera with automatic reverse assist is part of the basic equipment package, ensuring a full view of what is happening behind the WR. The multifunctional control screen mounted at the steering column switches to camera mode automatically during reverse travel. The high-resolution colour images are displayed on the control screen in an exceptionally high quality. The intelligent reverse assist system supports the machine operator during reverse travel by fading in driving assistance lines. 34 // 35

36 Perfect visibility and comprehensive camera system Continuous monitoring with comprehensive camera system Overview of cameras: 1 Camera on the left machine side Camera at the rear of machine Permitting an unobstructed view of critical areas Upon the customer s request, a system comprising four high-resolution colour cameras can be installed at various points of the machine at the rear of the machine, on the left side of the machine and underneath the machine at the front and rear rotor plates. If several cameras are used, an additional screen is installed to display the camera image. Selecting the camera image to be displayed is effected conveniently using the joystick. Continuous monitoring of important operating processes and areas, such as driving up to obstacles or assessing work results, offers various benefits: in the final analysis, it results in a significant increase in performance, economic efficiency and quality.

37 Even better visibility and operator comfort 1 3 Camera at the front rotor plate Switching between cameras is effected manually via the joystick 4 Camera at the rear rotor plate Four cameras offer perfect visibility and maximum operator comfort The camera on the left side of the machine is used, for example, to drive up to any lateral obstacles quickly and with maximum precision. The camera installed at the front rotor plate shows obstacles or pre-spread binding agent; it enables precise overlapping with the working edge and a precise start of the stabilizing or recycling operation. The camera installed at the rear rotor plate shows when obstacles in the recycled track have been negotiated; it also helps assess the quality of the recycled material. The wide angular coverage of all four cameras offers maximum fields of view; the screen always displays true-sided camera images. 36 // 37

38 Compelling features designed for an entirely new performance class

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40 Outstanding all-terrain mobility An easy job on heavy ground All-wheel drive guarantees ideal traction properties Traction is the magic word when it comes to stabilizing on deep, muddy ground, and of that the WR has enough and to spare. Extra large, deep-tread tyres very effectively transport the engine s high drive power into the soil. The powerful all-wheel drive ensures constant maximum traction of each of the four separately hydrostatically driven wheels. In addition, uniform traction is ensured by the sophisticated weight distribution across the machine frame. The machine s advance speed is load-dependent and governed by an automatic power control system that dispenses with the need to engage or disengage the differential lock. In short: the WR is the ideal candidate for mixing in binding agents on difficult ground.

41 Even deep, wet ground poses no problem thanks to the all-wheel drive Getting stuck? Nearly impossible. The all-wheel drive system evenly distributes the drive power to all four wheels When deep, muddy ground requires ample ground clearance, the four-fold full-floating axle always ensures the automatic adjustment of the machine height. The advance speed is continuously adjustable from zero to maximum speed both during operation and in transport mode. The switchable hydraulic flow divider guarantees consistently high traction regardless of ground conditions. When parked, the machine is automatically secured by the parking brake. 40 // 41

42 Outstanding all-terrain mobility Stable driving performance and ample ground clearance in off-road operation The machine s lifting column design with a lift of up to 500 mm enables a large levelling stroke and high ground clearance The WR effortlessly compensates for any ground irregularities Maximum machine stability on bumpy ground The WR travels effortlessly even on extremely bumpy ground while always retaining its horizontal alignment. Important aids to ensure high machine stability and balance are the automatic four-fold full-floating axle and electronic slope sensor. The slope sensor enables the WR to work parallel to the surface or at the specified cross slope. The tried-and-tested, four-fold full-floating lifting column design can be relied on to quickly and dynamically compensate for any major ground irregularities. As a result, the milling and mixing rotor always maintains the specified depth both on the left and right side, thus ensuring precise work results. The operator benefits, too high driving convenience promotes relaxed working.

43 i Off-road mobility Use your smartphone to get more information. Longitudinal and cross slope are adjusted conveniently via the left-hand joystick The machine retains its horizontal alignment The slope sensor is used to set and maintain the specified cross slope Roll feature: the machine balances out horizontally at a mere flick of the wrist The sophisticated lifting column design enables high ground clearance and thus optimum driving performance even on very soft, deep ground. When driving crosswise on sloping terrain, the operator can adjust the machine to a more convenient horizontal position by means of the Roll feature. The wheels are height-adjustable in pairs left, right, front or rear for full adjustment to conditions prevailing on the construction site. The excellent gradeability of the WR is a major advantage when creating embankments or operating on sites with steep slopes. 42 // 43

44 Steering system built to fi eld requirements Field-proven manoeuvrability and superior ease of operation Electronic steering system with three different steering modes The WR has everything it takes to ensure easy and smooth steering because it features an electrohydraulic steer-by-wire steering system. The operator can choose from three different steering modes: straightahead, crab or cornering mode. The currently selected steering mode is displayed clearly at all times and can be changed conveniently via the multifunctional joystick. The highly precise steering system and free choice of steering mode increase operator comfort, enabling the operator to work more productively and to fully focus on ensuring that his work meets highest quality standards.

45 Minimum turning radius in cornering mode with oversteering: R min = 3,150 mm R R min Minimum turning radius in cornering mode: R = 4,500 mm Each of the three steering modes straight-ahead, crab and cornering is the fastest way to achieve the goal in the specified field of application. In cornering mode, the WR is capable of performing a minimum turning radius of only 4,500 mm. The innovative oversteering feature of the steering wheel enables the rear wheels to be moved even further, allowing the WR to perform an exceptionally small turning radius of 3,150 mm. This is significantly smaller than the minimum turning radius of standard passenger cars. 44 // 45

46 Steering system built to fi eld requirements Fast manoeuvring in tight spaces saves time and money Working direction Straight-ahead mode Straight-ahead mode: the front wheels are steered via the steering wheel. The rear wheels remain in straight-ahead position automatically but can be steered separately via the joystick. Crab steering mode Working direction Crab steering mode: all four wheels are steered in the same direction and at the same angle via the steering wheel. Cornering mode with oversteering feature In soil stabilization projects, a significant amount of time is spent on countless turning and repositioning manoeuvres each day. The WR performs exceptionally small turning circles, however, which saves time at the end of each cut and increases productivity. How does the WR do that? In cornering mode, the front and rear wheels are steered synchronously via the steering wheel, allowing small turning circles already. In addition, the operator can oversteer the rear axle. The effect: the extra large steering angle of the rear wheels enables even smaller turning circles, which is especially useful for time-saving turning and repositioning manoeuvres in restricted space conditions.

47 i Steering Use your smartphone to get more information. Working direction Cornering mode: the front and rear wheels are steered synchronously via the steering wheel, which allows for small turning radii. Cornering mode Working direction Cornering mode with oversteering Cornering mode with oversteering: once a certain steering angle has been reached, the rear wheels can be steered even further via the steering wheel. Oversteering allows for even smaller turning circles. In straight-ahead mode, the rear wheels remain in straight-ahead position independent of the steered front wheels. In crab steering mode, all four wheels are steered in the same direction and at the same angle via the steering wheel. The straight-ahead mode is usually selected during the working operation. Crab steering allows the WR to be driven up to the working edge quickly, under an angle and with minimum space requirements. 46 // 47

48 Efficient engine and diagnostic systems Superior engine technology For tough jobs and economical operations The state-of-the-art, high-torque diesel engine installed in the WR is the ideal candidate for powersapping stabilizing and recycling operations. But it also uses its brains, for the intelligent, fully electronic engine management optimizes engine performance: The torque remains at a consistently high level even in the case of extreme engine lugging. The engine output can be increased further thanks to ample torque reserve. Automatic adjustment of the engine speed reduces fuel consumption. Needless to say that the engine technology installed in the WR complies with the currently applicable exhaust emission standards.

49 M [Nm] Complying with all current exhaust emission standards Torque [1/min] P (kw) 600 Engine output The sound-insulated engine cowling can be opened effortlessly [1/min] WR 200 WR 200 i WR 240 WR 240 i WR 250 Engine speed in operation = 1,650-2,100 min -1 Ideal characteristics of all WR series engines: with increased loading, the speed decreases and the torque increases while the output remains nearly constant The tried-and-tested engine technology installed in the WR 200 and WR 240 complies with the emission standards of EC Stage 3a / US Tier 3. The WR 240 i features advanced engine technology that complies with the demanding specifications of EC Stage 3b / US Tier 4i. The WR 200 i features state-of-the-art engine technology for lowest environmental emission levels which comply with the stringent specifications of EC Stage 4 / US Tier 4f exhaust emission standards. The tried-and-tested, robust engine technology installed in the WR 250 complies with the emission standards of US Tier // 49

50 Efficient engine and diagnostic systems Fast on-board diagnostics High-tech diagnostic systems increase productivity State-of-the-art measuring technology is by far superior to conventional, manual measuring methods. We have equipped the WR with high-tech diagnostic systems which enable effortless maintenance diagnostics, parameter settings or troubleshooting via the control panel in the operator s cabin. The machine s auto-diagnostic system independently monitors valves, sensors and control elements. Numerous, clearly visualized display pages provide quick and accurate information on the operating state of the machine. In addition, maintenance requirements are minimized by extended servicing intervals and an intelligent maintenance concept. In short: maximum operational readiness of the WR is ensured.

51 Maximum machine availability The oil level can be checked quickly and easily from the ground Diagnostics and parameter settings are performed via the control screen When opened, the engine cowling offers ready access to the engine compartment, hydraulic system, air filter and pumps Optimally adjusted service intervals increase productivity and economic efficiency. The few points of maintenance are arranged in a clear pattern and offer easy access from the ground or via access ladders. Wide opening service panels and engine cowling offer ample space to the operator for carrying out maintenance procedures. Convenient, lockable storage compartments are part of the standard equipment package, offering ample space for the comprehensive toolkit, cutting tool containers, spare parts and wearing parts. 50 // 51

52 High tech for top quality: it s the mix that counts

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54 High milling and mixing performance Heart and soul the mature milling and mixing rotor Comparison of working width and working depth Comparison of engine power and cutting power WR 200 / WR 200 i WR 240 / WR 240 i WR 250 WR 200 / WR 240 / WR 200 i WR 240 i WR 250 WR 200 / WR 200 i WR 240 / WR 240 i WR 250 WR 200 / WR 200 i WR 240 / WR 240 i WR 250 Working width 2,000 mm 2,400 mm 2,400 mm Maximum power 315 kw 320 kw 455 kw 447 kw 571 kw Working depth mm mm mm Cutting power 1.6 kw / cm 1.9 kw / cm 2.4 kw / cm Fully geared for tough operations Milling technology is our core business, which is why the milling and mixing rotor installed in the WR also appears as if it were cast from a single mould. Engine and cutting power of the individual machines are optimally adjusted to each other. The specific working width/depth combination enables an efficient machine performance. The massive rotor design promotes smooth, shock-free operation, which reduces stress and strain on the drive elements. Regardless of the working depth, perfectly arranged toolholders on high bases guarantee homogeneous mixing of the construction materials. In addition, the hardwearing quick-change toolholder system ensures optimum cutting tool rotation, easy tool replacement and continuous operation for extended periods of time.

55 Easy cutting tool replacement using the hydraulic tool extractor Simple tool replacement guaranteed Wirtgen milling and mixing rotors produce high-quality mixes The hydraulic drum turning device moves the rotor into the ideal position with no effort to facilitate tool replacement for the machine operator. The toolholders mounted on the rotor have high bases to provide sufficient space for the construction material mix, thus ensuring good mixing quality. Removable edge ring segments open at the sides reduce tension at the rotor edges, thus ensuring low wear and tear of the rotor and rotor housing. The toolholder bases are also particularly sturdy and robust, making the rotor the perfect choice for tough jobs. 54 // 55

56 High milling and mixing performance Rotors customized to the specifi c machines Milling and mixing rotor for WR 200 / WR 200 i, WR 240 / WR 240i Tool arrangement precisely adjusted to the machine output of WR 200 / WR 200 i, WR 240 / WR 240 i Hard-wearing quickchange toolholder system Tool arrangement with a spacing of TS = 20 mm High, heavy-duty holder bases Low-weight rotor design Interchangeable edge ring segments open at the sides TS 20 rotor for WR 200 / WR 200 i, WR 240 / WR 240i Whether soil stabilization or cold recycling operations are required just a single milling and mixing rotor is needed to complete all jobs to be performed by the specific type of machine. For instance, the rotor used for the WR 200 / WR 200 i and WR 240 / WR 240 i comprises cutting tools arranged at a 20 mm spacing. The tool components are thus fully aligned with the output of these machines, providing the perfect solution for all soil stabilization and cold recycling applications. Depending on the specific job site requirements, toolholders in shank diameters of 22 or 25 mm can be used.

57 Milling and mixing rotor for WR 250 Tool arrangement precisely adjusted to the machine output of the WR 250 Hard-wearing quick-change toolholder system Tool arrangement with a spacing of TS = 30x2 mm High, heavy-duty holder bases Large number of tools to ensure high mixing quality at high advance rates Rotor specially designed for tough cold recycling jobs such as pulverization Interchangeable edge ring segments open at the sides TS 30x2 rotor for WR 250 The WR 250 rotor features a tool spacing of 30x2 mm: for each rotation, two cutting tools are positioned at a distance of 30 mm to each other. Combining the high engine power with a particularly sturdy rotor ensures a perfectly fine mix even at high advance rates of the machine. The rotor is equipped with a large number of tools to fully respond to the machine s high power and advance rate. Depending on the specific job site requirements, toolholders in shank diameters of 22 or 25 mm can be used. 56 // 57

58 High milling and mixing performance Efficient milling rotor drive Taking the shortest path to success Translating engine power into productivity: the direct mechanical rotor drive of the WR translates high engine power into an equally high milling and mixing output. Large wrap-around angles with the belt pulleys enable the heavy-duty power belt to transmit the engine power to the rotor gearbox with only minimal performance losses, thus ensuring high efficiency. Positive side effects of the intelligent drive concept are low fuel consumption and ease of maintenance. In addition, many different rotor speeds can be selected as needed to meet the full range of standard work requirements.

59 The efficient drive is easy to access and maintain The shortest path is the best Direct mechanical drive via power belt with automatic belt tensioner Even during toughest operations, the high-torque, fuel-efficient engine provides a sufficient amount of reserve capacity. Maximum efficiency and high daily performance rates are enabled by an almost complete power transmission. The power belt absorbs peak loads and ensures a long service life. At the correctly set rotor speed, the WR achieves the intended mixing results at the highest possible advance rate whilst keeping fuel consumption to a minimum. 58 // 59

60 High milling and mixing performance Always ensuring the optimum rotor speed Engine speed Ø 400 mm Ø 315 mm Ø 355 mm Ø 315 mm Ø 355 mm Ø 400 mm Ø 355 mm Ø 400 mm Ø 315 mm WR 200 / WR 200 i 108 min min min min min min min min min -1 WR 240 / WR 240 i 108 min min min min min min min min min -1 WR 200 / WR 200 i, WR 240 / WR 240 i settings Each type of soil requires specific values in terms of advance rate and rotor speed to ensure optimum mixing quality. The operator can comfortably select three different engine speeds using a button integrated in the right-hand arm console inside the cabin. Repositioning of the belt pulleys enables three different transmission ratios. As a result, the WR 200 / WR 200 i and WR 240 / WR 240 i machines provide a total of nine different rotor speeds.

61 Gear ratio Engine speed Ø 355 mm Ø 400 mm Ø 400 mm Ø 355 mm WR 250 twelve different speeds 87 min min -1 I II 97 min min -1 WR min min min min -1 I II 145 min min -1 Selecting the engine speed and shifting the rotor gear from the cabin 160 min min -1 can be combined with repositioning of the belt pulleys to set twelve different rotor speeds WR 250 settings Three different engine speeds can be selected via the right-hand arm console in the cabin. The operator can reposition the belt pulleys to set two different transmission ratios. The right-hand arm console also serves to actuate the two-speed rotor gear. As a result, the WR 250 provides a total of twelve different rotor speeds. 60 // 61

62 High milling and mixing performance Premium-class mixing quality whatever the working depth The front rotor plate opens wide and is equipped with a crusher bar which can be adjusted to produce the specified particle size The pivoting scraper at the rear rotor plate always maintains an optimal angle to the surface to ensure perfectly even levelling of the ground Outstanding mixing results The mixing chamber of the WR has been designed in line with field requirements and is of vital importance for the high quality of the recycled subgrade. Very important: the design of the rotor housing and rotor plates has been perfectly matched to the powerful milling and mixing rotor. At the same time, the volume of the mixing chamber is adjusted to the current working depth and material quantity automatically by raising or lowering the rotor. These features guarantee a perfectly homogeneous mixing result of the milled material and binding agents added. In addition, optimal transport of the mix inside the rotor housing results in a tremendous increase in throughput and productivity.

63 Optimum mixing chamber size guaranteed Small mixing chamber at shallow working depths The hydraulically adjustable crusher bar mounted on the front rotor plate pulverizes even large asphalt slabs Large mixing chamber at large working depths Optimum mixing chamber size regardless of the working depth The rotor plates at the front and rear provide effective closure of the mixing chamber, function as material guides and are used to level off and smooth out the stabilized or recycled layer. As soon as the milling and mixing rotor has been fully raised automatically, the rotor plates move into their preselected positions to protect the rotor from damage by flying stones. The variable mixing chamber increases with the working depth, thus ensuring maximum performance and good mixing results even at the maximum working depth. In cold recycling applications, the front rotor plate is used as a crusher bar which can be adjusted to produce the specified particle size. 62 // 63

64 Precise metering system for binding agents Microprocessor-controlled addition of binding agents Giving operators the full picture Simply keying in the specified parameters once is not enough to achieve high-quality mixing results. They need to be maintained at their preselected values for the entire duration of the stabilizing or recycling operation. The WR has all it takes to meet these requirements: parameters are entered quickly and conveniently via a small number of controls in the left-hand arm console and via the control screen. The menus are structured clearly and logically, enabling the individual pages to be called up quickly. Large, readily comprehensible displays keep the operator fully informed of current parameters during the operation and, if need be, he can adjust the relevant parameters quickly and easily.

65 Quick entry of parameters The printer logs job data and input parameters All at a glance: important parameters are continuously displayed in the bottom menu bar of the metering menu Parameters such as spraying width and spraying quantities are set intuitively Microprocessor-controlled flow meters govern the addition of water, emulsion or foamed bitumen. The binding agents are added in accordance with the preselected parameters, such as working width, working depth, material density and machine advance rate. The up to sixteen spray nozzles in an injection bar can be switched on or off separately at any time during the process to adjust the spraying width. A printer installed in the cabin keeps a written log of job data or any parameter changes during the working operation. 64 // 65

66 Precise metering system for binding agents Injecting water Precise metering is paramount 1 Hose connection for water 2 Injection bar for water 3 Injected water Working direction All hose connections have been grouped together at the front cross beam Governed by a microprocessor, the injection bar introduces the specified amount of water into the mixing chamber Microprocessor-controlled metering and injection Strictly maintaining the preselected metered quantities of the binding agents to be added is of paramount importance in high-quality stabilizing and recycling operations. The WR is fully equipped to meet these requirements: robust, microprocessor-controlled injection systems ensure meticulous control of the various additives, which include water, emulsion or foamed bitumen. Several injection bars can be installed, depending upon the application, and several additives can be injected simultaneously. In addition, a special quick-mounting system enables quick installation or removal of the injection bars.

67 Injecting water and bitumen emulsion 1 Hose connection for water 2 Injection bar for water 3 Injected water 4 Hose connection for emulsion 5 Injection bar for emulsion 6 Injected emulsion Bitumen emulsion a tried-and-tested binding agent Working direction Readily accessible connections for water and emulsion When injecting two additives, such as water and emulsion, two injection bars can be operated simultaneously Tanker trucks driving ahead of the recycler deliver water and emulsion to the injection bars via hose connections. The microprocessor-controlled injection bars for water and emulsion are of identical design and can be used for both media depending on job requirements. Bitumen emulsion increases the flexibility of the new base layer and reduces cracking. The optimum moisture content is achieved by adding water to the process. 66 // 67

68 Precise metering system for binding agents Injecting water and foamed bitumen 1 Hose connection for water 2 Injection bar for water 3 Injected water 4 Hose connection for hot bitumen 5 Injection bar for foamed bitumen 6 Expansion chambers for foaming 7 Injected foamed bitumen Working direction Hot bitumen is foamed by injecting metered quantities of compressed air and water A test nozzle offers easy access for continuous assessment of the foam quality during the recycling operation Foamed bitumen innovative and economically effi cient To construct base layers of exceptionally high quality, the WR produces foamed bitumen in up to sixteen separate expansion chambers by injecting small amounts of water and compressed air into bitumen that has been heated to approx. 180 C. The hot bitumen then foams abruptly, expanding to many times its original volume. In this state, the foamed bitumen is distributed very evenly in the mineral aggregate mix to be recycled. All components carrying hot bitumen are heated and kept at operating temperature which dispenses with the need to flush the system. On balance, foamed bitumen is a very cost-efficient binding agent.

69 Self-cleaning comes as a standard feature Individual tappets clean the up to 16 nozzles at pre-determined intervals Ensuring a high level of operational safety Self-cleaning feature: the tappets remove any build-ups of binder at the nozzle exit Movable tappets automatically remove any build-ups of binder in the area of the nozzle exit. Regular self-cleaning of the spray nozzles via the tappets ensures precise metering across the entire working width. Cleaning of the nozzles is not only carried out automatically at fixed time intervals but can also be conveniently activated manually via the screen whenever necessary. Simultaneous manual raising of the revolving rotor to maximum height enables material deposits in the area of the nozzle exit to be removed. 68 // 69