Cold Recycler WR 4200 Large working width and cutting-edge technology for economical cold recycling
Recycling and paving carriageways true to cross-section, line and level, all in a single pass Building experience Wirtgen has accumulated working together with clients around the globe, the cold recycler WR 4200 was developed as the successor model of the WR 4500 in 2002. Extensive knowledge in application technology plus the latest breakthroughs in mechanical and control engineering were channelled into the newly designed unit. The main field of application of the WR 4200 is the rapid and economical rehabilitation of defective roads, as the unit can process carriageway pavements up to a width of 4.20 m into high quality base courses in a single pass. The machine granulates the carriageway pavement and mixes water, hydraulic binder, bitumen emulsion or foamed bitumen thoroughly with the reclaimed granulated material. The integrated tamping screed then lays the prepared paving material true to cross-section, line and level and compacts it. The result: a base course, which can be re-opened to traffic following final compaction with rollers. Many of the features of the new WR 4200 ensure that the material is optimally prepared and forms a durably cohesive road structure: The large working width of up to 4.20 m means that complete carriageways for one can be rehabilitated in a single pass without joints and true to cross-section, line and level. The working width is infinitely adjustable, even while the work is in process. A produces a homogenous mixture from granulated pavement and additional materials. The WR 4200 can attain a maximum mixing performance of 400 t/h while maintaining a mixing quality which meets that of conventional mixing plants. The new course must only be compacted with rollers after the pass and is then immediately ready for the resumption of traffic. This makes for a minimal obstruction to traffic. Injection system for bitumen emulsion Injection system for water Water tank Generator for the hot bitumen system Drive unit with two diesel engines Hydraulic oil tank Diesel tank Injection system for foamed bitumen milling drum Injection system for cement-water slurry Two variable tamping screed Vögele AB 500 TV Schematic diagram of the components of the WR 4200. The output of the travel drives is dimensioned so as to ensure that the recycler can also easily push connected vehicles such as the slurry mixing plant WM 1000 and a bitumen tank trailer. 2
Advanced technology for all cold recycling applications Illustration of the variable working width of the WR 4200: the position of the two front is infinitely variable. The mixes the entire milled material thoroughly with the binders, whatever the working width. The screed then pre-compacts the material. The cold recycler WR 4200 has much to commend it. First, there is its powerful drive: two forceful engines drive the hydraulic pumps of the machine. The largest portion of the engine output is required to drive the. While the front drums operate according to the cut-down milling process, the rear drum operates in an up-milling. This combination results in the optimum grain size of the milled material. The milling depth ranges up to 200 mm. If the carriageway is pre-milled with separate cold milling machines, the mixer and screed can even process and place the pavement up to a depth of 300 mm. Binder and / or water are injected to the milled granulate in the, precisely metered according to the required proportions. And the result: a homogenous, high quality. A cuttingedge electrically heated Vögele screed AB 500 TV with integrated automatic level control then places the mixture true to cross-section, line and level and pre-compacts the new base course. The electrically heated foamed bitumen system is another advantage of the WR 4200. The heating maintains the hot bitumen at the right temperature in the entire system, in order to optimally stabilize the temperature for the production of foamed bitumen. The PLC (programmable logic controller) ensures that all subprocesses in the WR 4200 are linked intelligently. Its microprocessors monitor the process parameters and control the addition of binders according to the proportions, advance speed and working depth set. The tried-and-tested Wirtgen automatic levelling system helps the PLC keep to the desired working depth. The recycler is simple to operate, for all its technical sophistication. Clearly labelled operating elements operator s platform and easily accessible panels and screed make operation a simple task and ensure the economical use of this high-performance recycler. 3
Cold recycling of carriageways with cement Variant: Spreading of cement ahead of the machine; injection of water in metered quantities via the WR 4200 water tanker truck pump for the injection of water Spreading of cement ahead of the machine Spreading of cement ahead of the machine Injection of water mixing in, paving and Variant: Cement and water is pre-mixed by the slurry mixer WM 1000 and injected by means of the WR 4200 to the slurry mixer WM 1000 pump of the WM 1000 for the injection of the cementwater slurry WM 1000: pre-mixing and infeed of slurry admixing, paving and Above: Cement is spread ahead of the machine and water from the tanker truck is sprayed into the twin-shaft via the injection system. Below: The WM 1000 produces a slurry of cement and water and supplies it to the twin-shaft of the WR 4200 in metered quantities. 4
Cold recycling of carriageways with bitumen emulsion Variant: Metered injection of water and bitumen emulsion via the WR 4200 water tanker truck Microprocessorcontrolled pump for the injection of water pump for the injection of emulsion emulsion tanker Infeed of water Infeed of emulsion mixing in, paving and Variant: Injection of bitumen emulsion and cement-water slurry via separate spray nozzles emulsion tanker pump for the injection of emulsion pump of the WM 1000 for the injection of the cementwater slurry slurry mixer WM 1000 Infeed of emulsion WM 1000: mixing and infeed of slurry mixing in, paving and Above: The injection units convey water and emulsion to the twin-shaft. Below: The injection unit conveys the emulsion from the tanker to the twin-shaft ; the WM 1000 delivers metered quantities of pre-mixed cement-water slurry. 5
Cold recycling of carriageways with foamed bitumen Variant: Metered injection of foamed bitumen and water via the WR 4200 bitumen truck Microprocessorcontrolled pump for the addition of hot bitumen pump for the injection of water for compaction water tanker truck pump for the injection of water for foam production Infeed of water Infeed of bitumen admixing, paving and Variant: Metered injection of foamed bitumen; Cement and water is pre-mixed and injected by the slurry mixer WM 1000 pump for the addition of hot bitumen bitumen truck pump for the injection of water for foam production pump of the WM 1000 for the injection of the cementwater slurry slurry mixer WM 1000 Infeed of bitumen WM 1000: mixing and infeed of slurry admixing, paving and Above: The injection units convey water and hot bitumen from the tanker trucks to the twin-shaft. Water is added from the machine tank for the production of foamed bitumen. Below: The WM 1000 meters the slurry in the twin-shaft. 6
Technical Data Cold Recycler WR 4200 Dimensions in mm 3,000 2,050 6,000 1,290 3,075 12,415 width mm 2,800 4,200 depth mm 0 300 Milling depth mm max. 200 Spacing mm 20 Number of cutters 76 each Diameter of cutting circle mm 1,000 Spacing mm 20 Number of cutters 142 Diameter of cutting circle mm 1,000 Engines Manufacturer CAT Type 2 x C 16 ATAAC Cooling Water Number of cylinders 2 x 6 R Output kw/ HP/ PS 2x (470/ 630/ 640) Revolutions min -1 2,100 Displacement cm 3 2 x 15,800 Fuel consumption at full load l/h 2 x 115 Fuel consumption at 2 /3-load l/h 2 x 75 Electrical installation V 24/ 42/ 380 Dimensions (LxWxH) mm 3,200 x 2,000 x 1,150 Mixing performance m 3 /min 4 Travelling properties speed m/min 0 16 Travelling speed km/h 0 3.6 Gradeability in working mode % 45 Gradeability in travel mode % 15 Ground clearance mm 700 Crawler tracks (LxWxH) mm 2,550 x 500 x 800 Weights Operating weight, CE dan (kg) approx. 80,000 Filling quantities Fuel l 2,070 Hydraulic oil l 1,600 Water l 2,900 Type Vögele AB 500 TV Paving width mm 2,500 5,000 Crowning device, max. % 4 Transport dimensions Machine (LxWxH) mm 12,200 x 3,000 x 3,000 7
Wirtgen GmbH Hohner Strasse 2 53578 Windhagen Germany Phone: +49 (0) 26 45 /131-0 Fax: +49 (0) 26 45 /131-242 Internet: www.wirtgen.com Illustrations are without obligation. Subject to technical changes. Performance data depend on operational conditions. No. 52-10 EN-06/02 by Wirtgen GmbH 2002 Printed in Germany