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

2 // 3

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.

4 // 5

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

6 // 7

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

8 // 9

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

10 // 11

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.

12 // 13

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

14 // 15

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

16 // 17

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

18 // 19

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

20 // 21

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

22 // 23

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: info@wirtgen.com