Cold Milling Machine W 2200 - Wirtgen GmbH

Maximum milling performance in the top-class range
Cold Milling Machine W 2200

W 2200 –
the unrivalled top performer
No other milling machine achieves a higher output in road construction
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.

The W 2200 – quick completion of
major milling jobs made easy
A machine that
lets performance
speak for itself
“The power of the W 2200 is
boundless, which makes the
machine an unbeatable choice
for larger areas, such as motorways
and airports”
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.
High advance rates and milling depths ensure speedy
operation and quick completion of large construction
jobs.
This cold milling machine is particularly efficient in
large-scale surface course removal jobs using up
to 4.40 m wide milling drum assemblies.
Using the unique FCS, the W 2200 can be operated
with twelve different milling widths.
2// 3

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.

Milling depth (cm)
36
32
28
24
20
Hard asphalt
Soft asphalt
Most frequent operating area
16
12
8
4
0
0 2 4 6 8 101214161820222426 2830323436
0 500 1,000 1,500 2,000 2,500 3,000 3,500 4,000 4,500
Open stretch of motorway
(allowance factor: 0.6)
0 500 1,000 1,500 2,000 2,500
Country road, long haulage
distance of trucks
(allowance factor: 0.5)
0 250 500 750 1,000 1,250 1,500 1,750 2,000 2,250
Country road, through traffic
interrupts work
(allowance factor: 0.4)
0 200 400 600 800 1,000 1,200 1,400 1,600 1,800
Advance rate
(m/min)
Theoretical area
performance
(m 2 /h)
Practical area
performance
(m 2 /h)
Practical area
performance
(m 2 /h)
Practical area
performance
(m 2 /h)
Reserve capacity to
cater 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 site
conditions
The powerful engine and the intelligent engine management
ensure unrivalled productivity for milling depths of
up to 350 mm.
Under ideal conditions, the W 2200 removes over
1,200 tons of asphalt per hour, which corresponds to
the payload of 60 trucks.
Beyond the single-pass removal of entire road
pavements, individual courses can also be milled off
extremely efficiently.
The generously designed front-loading conveyors ensure
that no capacity bottlenecks occur in the process of
loading the milled material.
4// 5

High-tech –
easy to operate
Effortless handling of the large milling machine
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 onboard
information and diagnostic system. On the screen,
the system continuously displays current operating parameters
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.

WIDIS 32 also includes a diagnostic
system to simplify troubleshooting
Unmatched ease
of operation
The self-explanatory control
panel design of the W 2200
makes work much easier
The easy, intuitive operation of the large milling machine
enables the operator to always remain fully focused on
his work.
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.
In addition, the compact design of the W 2200 provides
all-round visibility across the site.
6// 7

A fully equipped,
ergonomic workplace
Lockable control covers
Both control panels
can be moved to project
over the edge of the machine
The fully equipped W 2200
operator’s platform provides
ample space
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 comfortable:
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.

Holders for refreshments
mounted within easy reach
Effectively
eliminating factors
contributing to fatigue
The position of both protective
canopy and control panel can be
adjusted to specific needs
Ingeniously folded-in access
ladder enabling the machine to
be driven close up to walls
Convenient access to
the operator’s platform
The ergonomic design of the fully equipped workplace
ensures stress-free, no-fatigue operation over long
periods.
Many features can be controlled from the ground via
separate panels, such as the raising and lowering of the
scraper blade.
The hydraulically retractable canopy (available as an
optional feature) protects the operator from both rain
and sun exposure.
8// 9

Even more accurate milling results
with LEVEL PRO
The LEVEL PRO panel is located
in the direct field of view of the
operator, within easy reach
Wire-rope sensors measure
the exact milling depth on
both sides of the machine
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 groundbreaking
proprietary system including a software that
has been designed specifically for cold milling machines:
LEVEL PRO. The overall system includes sensors, a controller
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.

The optional electronic slope sensor
for the milling of pre-set cross slopes
State-of-the-art
levelling technology
Scanning the surface in front
of the milling drum using a
wire-rope sensor (optional)
Automatic
ON/OFF
Settings
Switchover
button
Target value
Horn
Target value
RAISE/
LOWER
Actual value
Controller
output
Calibration
Cylinder
RAISE/LOWER
Memory 1
Memory 2
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.
10 // 11

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 intelligent
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 unerringly
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.

Precise steering with the parallel
sliding block guide working independently
of the height selected
All-track drive with
high tractive force
Crab steering ensures an easy
approach to the track to be milled
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.
12 // 13

Top-class engine performance
Engine always runs
within the optimal
range
P [kW]
700
M [Nm]
3800
650
3600
600
3400
550
3200
500
3000
450
2800
400
2600
350
2400
300
2200
Technology designed for top
performance – the powerful
diesel engine
250
200
150
2000
1800
1600
100
900
1400
1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200 [1/min]
Characteristic curves in
the critical operating range
The engine output remains constant even at extremely high engine loads
More than enough performance reserves
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 addition,
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.

Maximum efficiency with
mechanical milling drum drive
Taking the direct route –
always the best way
A hydraulic cylinder adjusts the
tension of the multiple V-belts in
accordance with the load
Focused power for high milling
advance rates
The mechanical drive acts directly on the milling drum
via three multiple V-belts with five ribs each, which
ensures highly efficient operation.
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 almost complete power transmission guarantees
highest efficiency and top-of-the-range daily production
rates.
The V-belts are readily accessible and can be replaced
very quickly.
14 // 15

Versatility reduces
operating cost
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.

Wide range of
applications
ECO cutter
Milling width:
Milling depth:
Tool spacing:
2,200 mm
0 – 350 mm
25 mm
Standard milling drum
Milling width: 2,200 mm
Milling depth: 0 – 350 mm
Tool spacing:
15 mm
Fine milling drum
Milling width:
Milling depth:
Tool spacing:
2,200 mm
0 – 100 mm
8 mm
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
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.
16 // 17

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 highperformance
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.

Flexibility
the XXL way
Using the housing extension,
wide roads can be milled off
efficiently in a single pass
The mounting carriage is used to
attach the milling drum assembly
to the chassis
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.
18 // 19

Wide range of applications
between 2.20 and 4.40 m
A housing extension can be used to mount up to 4.40 m wide milling drums
800 mm
Milling width:
2.20 m
Milling width:
3.50 m
Milling width:
2.50 m
Milling width:
3.80 m
Milling width:
3.10 m
Milling width:
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.

Milling off wide roads
in a single pass
USA: the W 2200 in full
swing, using a 3.80 m wide
milling drum assembly
Belgium: high-performance
surface course removal at a
milling width of 3.80 m
Italy: a milling job using the
2.20 m wide standard assembly
The oversized milling drum assemblies demonstrate
their advantages especially on wide urban roads,
motorways, highways and airports.
As part of the standard equipment package, the frontloading
system and engine of the W 2200 are designed
for milling operations using a 4.40 m wide assembly.
Complete, up to 4.40 m wide road pavements can be
removed quickly in a single pass.
20 // 21

HT11 quick-change toolholder system
ensures maximum milling output
Efficiency driven
to the max
Upper part covers
bottom part completely
to minimize deformation
of contact surface
Wear markers at 5 mm
intervals for improved
monitoring
Chip breaking rib
for additional crushing
of milled material
Together with the milling drum and
cutting tools, the quick-change
toolholders create a perfect system
Protective plug
prevents soiling
of bolt head
Strong retaining
bolt prevents unwanted
loosening
of upper part
Conical pressure
stud for reliable
transmission of
clamping force
Optimized shaft
angle geometry for
improved component
strength
Contact surface
increased by 75%
for improved durability
of bottom part
Seal to allow
simple and quick
insertion/removal
of upper part
HT11 offers a number of
significant application benefits
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 provides.
Overall, the HT11 system contributes to ensuring
efficient operation of the machine whilst reducing operating
cost in the long term.

Cutting tool replacement
at record speed
Drum turning device
keeps downtime low
The remote control unit
can be attached within easy
reach of the operator
Other useful options include a
comfortable seat and a pneumatic
cutting tool extractor
Drive of the drum
turning device
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.
22 // 23

Heavy-duty milling drum assembly
with sophisticated features
… and thus protects the primary
conveyor from premature wear
When driving over obstacles,
the side plates can be raised
The hydraulically adjustable
gradation control beam prevents
the asphalt from breaking into
large slabs…
The side plates can be pressed
onto the asphalt surface
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 loading
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.

For perfect
milling results
With the scraper blade
in “locked” position, the milled
material can be partially loaded
When swung open, the scraper
blade provides ample space for
cutting tool replacement
The hydraulically adjustable
scraper blade – a standard feature in
all large Wirtgen milling machines
Both the amount and pressure of the water provided by
the hydraulically operated water system can be set from
the ground.
Scraper blade, gradation control beam and protective
side plates provide effective closure of the milling
chamber.
The integrated water spray system provides highly
effective cooling of the cutting tools and extends their
service life.
The low-wear carbide metal plates on the scraper blade
are designed for convenient, separate replacement.
24 // 25

Reliable material loading
even under full load
The folding conveyor is folded
down within only a few seconds
Effectively closed transfer
zone from primary to
discharge conveyor
Makes transport convenient:
the folding conveyor
The W 2200 provides a
great discharge height
Loading trucks faster than ever
The W 2200 has been designed for maximum performance.
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.

Economical loading
of milled material
… enable flexible
truck loading
1,100 mm wide conveyor belt
to ensure high-performance
material transport
Wide slewing angles
to the left and right …
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.
26 // 27

Maintenance made easy
Higher productivity due to quick maintenance
The W 2200 leads by example when it comes to combining
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 maintenance
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 standard
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.

A convenient feature: 200 litres of
extra storage space at the rear
of the machine (optional)
For peace of mind
in operation
The high-pressure cleaner
comes complete with a long
hose and reaches even the most
distant corner of the W 2200
The air filter replacement
from the operator’s platform has
also been designed with user
friendliness in mind
Maintenance of the W 2200 is made totally easy –
the entire machine is readily accessible.
Long work cycles without refuelling and long servicing
intervals pay off very quickly.
Easily accessible filling ports ensure quick and convenient
filling of the large-volume water and fuel tanks.
Hydraulic, air, fuel and return line filters are readily
accessible under the engine cowling and can be
replaced quickly.
28 // 29

Nothing can stop the W 2200
Mirrors mounted in convenient
positions on the machine
provide all-round visibility
Bright spotlights provide
optimal lighting
Construction work at night – an
all-round success due to the
powerful lighting system
The freely adjustable lights
can be attached in no time
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 illumination
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.

Heavy-duty transport made easy
Transport of the
W 2200 – a
smooth affair
The ideal transport height
is reached in no time
Low-bed trailers carry the large
milling machine effortlessly
At the push of a button,
the optional protective
canopy is folded down
Despite its size, the W 2200 can be easily loaded and
transported.
Many loading and lashing lugs ensure safe fastening for
low-bed trailer haulage.
The transport length is significantly reduced if the
folding conveyor design is chosen. Transport height is
minimized if the protective canopy is ordered.
Our offering also includes conveyor support legs to
support the standard conveyor during transport on a
low-bed trailer.
30 // 31

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 GmbH
Reinhard-Wirtgen-Strasse 2 · 53578 Windhagen · Germany
Phone: +49 (0) 26 45 / 131-0 · Fax: +49 (0) 26 45 / 131-242
Internet: www.wirtgen.com · E-Mail: info@wirtgen.com