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The new generation

Cold Recycler and Soil Stabilizer


WR series
WR 200 | WR 200i | WR 240 | WR 240i | WR 250
Contents
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 .......................................................... 24


Perfect ergonomic design and handling........................................................................................ 26
Automated function for the working process .......................................................................... 30
Perfect visibility and comprehensive camera system ...................................................... 32

Compelling features designed for an entirely new performance class ............. 38


Outstanding all-terrain mobility ............................................................................................................ 40
Steering system built to field requirements ............................................................................... 44
Efficient engine and diagnostic systems ..................................................................................... 48

High tech for top quality: its the mix that counts ................................................................ 52
High milling and mixing performance ............................................................................................. 54
Precise metering system for binding agents ............................................................................ 64

2 // 3
Added value that pays dividends

8
i Highlights

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more information.

1 ERGONOMICS
Performance-enhancing, ergonomic
design of the spacious operators
cabin

2 VISIBILITY
Perfect all-round visibility

3 OPERATION
In full control with the multifunctional
joystick

4 CAMERA SYSTEM
9 Full monitoring of all work processes

5 MAINTENANCE
12 State-of-the-art diagnostic systems
and extra long maintenance intervals
5 6 LIGHTING
Intelligent lighting concept

7 STEERING
Steering system with small turning
radius greatly improves operator
comfort

8 OFF-ROAD MOBILITY
11 All-wheel drive, independent
suspension with high lift,
fast 4-fold full-floating axle

9 ENGINE STATION
High-torque diesel engine with
7 automatic speed adjustment

10 ROTOR HOUSING
10 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
Three machines
world class to the power of three
Consistently superior machine design
The compact option

The WR 200 / WR 200 i machine is easy to transport without


WR 200 / WR 200 i

special approval or permit due to its compact dimensions


and low weight. It is well-suited to both soil stabilization
and cold recycling.

The WR 240 / WR 240 i is the proverbial all-rounder in the


WR 240 / WR 240 i

Wirtgen fleet. As a result of its large working width and


The all-rounder

depth and unrivalled milling and mixing performance, this


machine provides maximum flexibility for any type of soil
stabilization or cold recycling job.

The WR 250 is the high-performance option suitable for


The top performer

exceedingly complex tasks. Its enormous milling and mix-


ing output makes this machine the perfect choice for even
the toughest soil stabilization jobs and the pulverization of
WR 250

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.
Solutions tailored to each application

Working width: 2,000 mm Cutting power: 1.6 kW/cm

Working depth: 0500 mm Ideal performance range


in soil stabilization:  1,0005,000 m2/day
WR 200 maximum engine power: 315 kW/428 PS
WR 200i maximum engine power: 320 kW/435 PS Ideal performance range
in cold recycling: 400800 m2/hour
CE operating weight: 23,900 kg
Thickness of recyclable asphalt layer: 1015 cm

Working width: 2,400 mm Cutting power: 1.9 kW/cm

Working depth: 0510 mm Ideal performance range


in soil stabilization:  4,0008,000 m2/day
WR 240 maximum engine power: 455 kW/619 PS
WR 240i maximum engine power: 447 kW/608 PS Ideal performance range
in cold recycling: 5001,000 m2/hour
CE operating weight: 29,400 kg
Thickness of recyclable asphalt layer: 1520 cm

Working width: 2,400 mm Cutting power: 2.4 kW/cm

Working depth: 0560 mm Ideal performance range


in soil stabilization:  6,00012,000 m2/day
Maximum engine power: 571 kW/777 PS
Ideal performance range
CE operating weight: 31,000 kg
in cold recycling: 7001,200 m2/hour

Thickness of recyclable asphalt layer: 2025 cm

6 // 7
Broad range of applications
Perfect soil stabilizer

Second-to-none performance and mixing quality


The finely graded Wirtgen WR series includes a material. In addition, its perfect ergonomic design and
tailored solution for any soil stabilization and cold maximum visibility, high engine power and mixing quality,
recycling job. As a result, these machines are ideally suited superior all-terrain mobility, automated features and many
to the powerful, large-scale stabilization of ground with other highlights make the WR a pioneer in terms of output
insufficient bearing capacity. The stabilization process at low operating costs regardless of the type of soil
converts poor-quality soil into a premium construction stabilization job.
i Soil stabilization

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more information.

Ideal performance ranges in soil stabilization Top performance


whatever the job

The WR ensures perfect mixing


WR 200 / WR 240 / quality while producing the
WR 200 i WR 240 i WR 250 hydraulically bound base layer

WR 200 / WR 200 i WR 240 / WR 240 i WR 250


Complete
500 8,000 m2/ day 1,000 10,000 m2/ day 2,000 15,000 m2/ day
performance range
Ideal The WR series includes
1,000 5,000 m2/ day 4,000 8,000 m2/ day 6,000 12,000 m2/ day all performance classes
performance range
in soil stabilization

Ensuring unrivalled mixing quality, the WR meets ex- Its striking benefits include the all-wheel drive, four-
ceedingly demanding requirements in a wide variety of fold full-floating axle and automatic power control
soil stabilization jobs. system providing the perfect prerequisites for any job
on difficult terrain or wet ground.
The WR series covers the entire range of applications
as a result of varying engine powers tailored to the The water metering system is easy to operate its
specific job needs. process parameters can be effortlessly adjusted to any
requirements.

8 // 9
Broad range of applications
The WR operating as a soil stabilizer

5
4

6
8 7

6 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 The resulting homogeneous soil-binder mix offers high
even though it no longer represents the state of the levels of tensile strength, compressive strength and shear
art. Working as a soil stabilizer, the WR uses its powerful strength as well as lasting water resistance, frost resist-
milling and mixing rotor to mix pre-spread binders, such as ance and volume stability. Typical applications include
lime or cement, into existing soil of poor bearing capacity the construction of paths, roads, motorways, parking
to a working depth of up to 560 mm, converting it into a lots, sports grounds, industrial parks or facilities, airports,
premium construction material right on the spot. dams, backfills or landfills.
1 Binding agent spreader 3 Single-drum compactor
2 WR soil stabilizer 4 Grader
5 Single-drum compactor

The powerful milling and mixing rotor mixes the The fast-paced, environmentally friendly in-situ
existing soil with pre-spread cement and water, if process dispenses with expensive soil exchange.
required to produce a homogeneous mix.
Soil stabilization is clearly superior to soil exchange as
The WR effortlessly pushes a water tanker truck which it requires fewer truck transports, shortens job comple-
delivers water via a hose connection. tion times, reduces resource consumption and lowers
carbon emissions.

10 // 11
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


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
Broad range of applications
Top-performing cold recycler

Perfect mixing quality and utmost metering accuracy


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

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more information.

Performance ranges in cold recycling State-of-the-art road


rehabilitation

The WR meets the


WR 200 / WR 240 / challenges of cold recycling
WR 200 i WR 240 i WR 250 quickly and efficiently

WR 200 / WR 200 i WR 240 / WR 240 i WR 250


Ideal
up to 840 m2/hour up to 1,000 m2/hour up to 1,200 m2/hour
performance range
Thickness of recy- The WR series caters to
10 15 cm 15 20 cm 20 25 cm the complete range of
clable asphalt layer
cold recycling applications

From thin asphalt layers on uncrowded rural roads to The cold recycling process is made exceedingly
up to 250 mm thick asphalt layers on busy motorways efficient by the intuitive input of injection system
exposed to high loads and stresses the various parameters and a second-to-none visualization of
machines of the WR series are perfectly suited to any binder metering.
of these recycling jobs, catering to all performance
ranges. State-of-the-art microprocessors enable the highly
accurate metering of added quantities, ensuring
top-quality cold recycling results.

14 // 15
Broad range of applications
The WR operating as a cold recycler

6
5

4
3

8 9

10
7
7 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 The cold recycler mills and granulates worn-out asphalt
structural damage to the different layers of asphalt pavements, injects binding agents and water in precisely
roads over time, while at the same time reducing their metered quantities and mixes them with the pavement ma-
bearing capacity. In recycling mode, the WR eliminates terial to be recycled, all in a single machine pass. The new
these deficiencies quickly, economically and in a resource- base layers produced by means of this in-situ process are
saving manner. It is equipped with a powerful milling distinctive for their exceptionally high bearing capacity.
and mixing rotor and state-of-the-art injection systems.
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 250
4 Single-drum compactor
5 Grader
6 Tandem roller

Tanker trucks driving ahead of the WR and linked to Foamed bitumen for the production of exception-
the cold recycler via hose connections supply water ally stable base layers is produced in the cold recycler.
and various binding agents.
The WR recycles pavements in situ, meaning that no
Water, cement slurry, bitumen emulsion or foamed damaged material needs to be disposed of nor virgin
bitumen are injected into the mixing chamber via material supplied.
microprocessor-controlled injection bars.

16 // 17
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


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, simultane-
ously 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
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


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, 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.

Pneumatic-
WR Single-drum compactor Grader Tandem roller
tyred 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
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


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 com-
paction is effected by various Hamm rollers.

Single-drum Single-drum Pneumatic-


compactor compactor Grader Tandem roller tyred 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 240i, WR 250 with the binding agents required for processing the pavement in need of rehabilitation. The recyclers power-
ful 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
Designed with human-machine
interaction in mind
25 // 25
24
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
operators hand

Drivers 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 operators
immediate field of view

Ergonomic design boosts operator performance


The anatomically shaped drivers seat with spring have been grouped together logically in the multifunctional
and air cushioning is the ergonomic showpiece of the joystick on the right-hand arm console, providing unri-
WR series. It can be fully adjusted to different body sizes, valled ease of use. The entire drivers seat including arm
guaranteeing a perfect seating position for many hours. In consoles and steering column can be swivelled through 90
addition, ergonomically designed controls are integrated in degrees to either side, giving the operator a full view to-
both arm consoles they are arranged within easy reach wards the rear of the machine while maintaining a relaxed
to enable intuitive operation. All basic machine functions body posture.
Space and operator comfort two prerequisites for success

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

26 // 27
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 two curve lights at the rear and two spotlights for flexible
under tremendous pressure of time with no regard for mounting by means of magnetic bases to fully illuminate
adverse weather, darkness or night. This is where the intel- all important work areas around the machine. Operation of
ligent lighting system of the WR comes into play. It com- the machine can thus continue at full power even after the
prises six headlights at the front of the cabin, optionally in sun has set and the WR is utilized to full capacity.
LED design, two spotlights each on the left and right side,
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


operators cabin is ensured

The WR is approved for transport


on all standard flatbed trucks

Welcome and Go home lights feature: when arriving Safety first: side railings are folded up in a few simple
at or walking away from the WR, the machines environ- steps when working on the engine or cooler.
ment can be illuminated by LED lights.
The cabin conforms to the ROPS/FOPS standards,
The WR 200/WR 200i machine is easy to transport providing maximum operator safety.
without special approval or permit due to its compact
dimensions and low weight.

28 // 29
Automated function
for the working process
Automated processes boost performance and quality

Working without The operator uses the


joystick to initiate the automatic
any time loss 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 is lowered rapidly, and the front and rear rotor plates move
system to control lowering and raising of the mill- into their preselected positions. Once the lifting columns
ing and mixing rotor. It relieves the operator of part of have reached their working position, the milling and mixing
his workload, increases daily performance and improves rotor is lowered into the soil until the programmed working
quality. The operator uses the multifunctional joystick to depth has been reached. Moving the joystick forward then
activate the automatic process; all other steps are com- enables forward movement of the machine.
pleted automatically by the WR. In a first step, the machine
i Automated
function
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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 While the WR travels a few metres, the corresponding
of each track is closed by activating the automatic rotor plate closes the cut completely. At the same time,
raising mechanism using the joystick. the rotor is slowly raised from the cut, and the lifting
columns move the machine into transport position.
Depending upon whether the rotor is raised in forward
or reverse travel, the rotor plates move into their
specified positions.

30 // 31
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
orking width of the machine
w

Working flush to kerb poses no problem at all


Good visibility is of vital importance to ensure safe the machine on the right, and the drivers seat swivelling
operation and allow fast-paced processes. The through 90 degrees offer a free view of the entire working
WR offers a visibility concept that is unique in the indus- edge on the right-hand side so that working flush to kerb
try: large glass panes at the front, left and right side of the without the need for extensive reworking is no problem
cabin, and a set of mirrors in line with field requirements at all. In short: optimal visibility for the machine opera-
allow a full view of the entire construction site. The spa- tor enhances productivity and maximizes profits on every
cious cabin, which can be moved beyond the edge of construction site.
i Visibility

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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 The intelligently arranged windscreen wipers and
of the machine enables precise recycling along the anti-fog feature of the air-conditioning system improve
kerbs of road pavements. visibility even further, if required.

In addition, a good view of the right-hand working The side window on the right can optionally be locked
edge enables highly precise overlaps in soil stabilizing in various functional positions.
operations.

32 // 33
Perfect visibility and
comprehensive camera system
Many eyes are better than two

Second-to-none camera system


Camera systems are developing into increasingly additional eyes he needs to view important but otherwise
important support tools when it comes to monitoring inaccessible work situations. A reversing camera is part of
the operational processes and procedures of machines the WR basic on-board equipment package. It can option-
where good visibility is a must. The camera solutions avail- ally be upgraded to a full equipment package consisting of
able for the Wirtgen WR give the machine operator the four cameras installed at various points of the machine.
The camera installed at the rear
provides images of what is going Reversing camera is a
on behind the machine 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 high-resolution colour images are displayed on the
the basic equipment package, ensuring a full view of control screen in an exceptionally high quality.
what is happening behind the WR.
The intelligent reverse assist system supports the
The multifunctional control screen mounted at the machine operator during reverse travel by fading in
steering column switches to camera mode automati- driving assistance lines.
cally during reverse travel.

34 // 35
Perfect visibility and
comprehensive camera system
Continuous monitoring with comprehensive camera system

Overview of cameras:

1 Camera on the left machine side

2 3

2 Camera at the rear of machine

Permitting an unobstructed view of critical areas


Upon the customers request, a system compris- to be displayed is effected conveniently using the joystick.
ing four high-resolution colour cameras can be Continuous monitoring of important operating processes
installed at various points of the machine at the rear of and areas, such as driving up to obstacles or assessing
the machine, on the left side of the machine and under- work results, offers various benefits: in the final analysis, it
neath the machine at the front and rear rotor plates. If results in a significant increase in performance, economic
several cameras are used, an additional screen is installed efficiency and quality.
to display the camera image. Selecting the camera image
Even better visibility
and operator comfort

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 The camera installed at the rear rotor plate shows
example, to drive up to any lateral obstacles quickly when obstacles in the recycled track have been
and with maximum precision. negotiated; it also helps assess the quality of the
recycled material.
The camera installed at the front rotor plate shows ob-
stacles or pre-spread binding agent; it enables precise The wide angular coverage of all four cameras offers
overlapping with the working edge and a precise start maximum fields of view; the screen always displays
of the stabilizing or recycling operation. true-sided camera images.

36 // 37
Compelling features designed for an
entirely new performance class
38 // 39
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 stabiliz- the sophisticated weight distribution across the machine
ing on deep, muddy ground, and of that the WR has frame. The machines advance speed is load-dependent
enough and to spare. Extra large, deep-tread tyres very and governed by an automatic power control system that
effectively transport the engines high drive power into the dispenses with the need to engage or disengage the dif-
soil. The powerful all-wheel drive ensures constant maxi- ferential lock. In short: the WR is the ideal candidate for
mum traction of each of the four separately hydrostatically mixing in binding agents on difficult ground.
driven wheels. In addition, uniform traction is ensured by
Even deep, wet ground
poses no problem thanks to Getting stuck?
the all-wheel drive Nearly impossible.

The all-wheel drive system


evenly distributes the drive
power to all four wheels

When deep, muddy ground requires ample ground The advance speed is continuously adjustable from
clearance, the four-fold full-floating axle always en- zero to maximum speed both during operation and in
sures the automatic adjustment of the machine height. transport mode.

The switchable hydraulic flow divider guarantees con- When parked, the machine is automatically secured by
sistently high traction regardless of ground conditions. the parking brake.

40 // 41
Outstanding all-terrain mobility
Stable driving performance and
ample ground clearance in off-road operation

The machines 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 column design can be relied on to quickly and dynamically
ground while always retaining its horizontal align- compensate for any major ground irregularities. As a result,
ment. Important aids to ensure high machine stability and the milling and mixing rotor always maintains the specified
balance are the automatic four-fold full-floating axle and depth both on the left and right side, thus ensuring precise
electronic slope sensor. The slope sensor enables the work results. The operator benefits, too high driving con-
WR to work parallel to the surface or at the specified cross venience promotes relaxed working.
slope. The tried-and-tested, four-fold full-floating lifting
i Off-road mobility

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more information.

Longitudinal and cross slope


are adjusted conveniently via The machine
the left-hand joystick 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 When driving crosswise on sloping terrain, the op-
ground clearance and thus optimum driving perfor- erator can adjust the machine to a more convenient
mance even on very soft, deep ground. horizontal position by means of the Roll feature.

The wheels are height-adjustable in pairs left, right, The excellent gradeability of the WR is a major
front or rear for full adjustment to conditions prevail- advantage when creating embankments or operating
ing on the construction site. on sites with steep slopes.

42 // 43
Steering system
built to field 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 changed conveniently via the multifunctional joystick. The
smooth steering because it features an electro- highly precise steering system and free choice of steering
hydraulic steer-by-wire steering system. The operator mode increase operator comfort, enabling the operator to
can choose from three different steering modes: straight- work more productively and to fully focus on ensuring that
ahead, crab or cornering mode. The currently selected his work meets highest quality standards.
steering mode is displayed clearly at all times and can be
Minimum turning radius in cor-
nering mode with oversteering:
Rmin = 3,150 mm

R Rmin

Minimum turning radius in


cornering mode: R = 4,500 mm

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

44 // 45
Steering system
built to field 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 are steered synchronously via the steering wheel, allowing
time is spent on countless turning and reposition- small turning circles already. In addition, the operator can
ing manoeuvres each day. The WR performs exceptionally oversteer the rear axle. The effect: the extra large steering
small turning circles, however, which saves time at the angle of the rear wheels enables even smaller turning cir-
end of each cut and increases productivity. How does the cles, which is especially useful for time-saving turning and
WR do that? In cornering mode, the front and rear wheels repositioning manoeuvres in restricted space conditions.
i Steering

Use your
smartphone to get
more information.

Working
direction

Cornering mode: the front and rear wheels are steered synchronously via the steering Cornering mode
wheel, which allows for small turning radii.

Cornering mode
Working with oversteering
direction

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 In crab steering mode, all four wheels are steered
straight-ahead position independent of the steered in the same direction and at the same angle via the
front wheels. steering wheel.

The straight-ahead mode is usually selected during Crab steering allows the WR to be driven up to the
the working operation. working edge quickly, under an angle and with mini-
mum space requirements.

46 // 47
Efficient engine
and diagnostic systems
Superior engine technology

For tough jobs and economical operations


The state-of-the-art, high-torque diesel engine extreme engine lugging. The engine output can be in-
installed in the WR is the ideal candidate for power- creased further thanks to ample torque reserve. Automatic
sapping stabilizing and recycling operations. But it also adjustment of the engine speed reduces fuel consumption.
uses its brains, for the intelligent, fully electronic engine Needless to say that the engine technology installed in the
management optimizes engine performance: The torque WR complies with the currently applicable exhaust emis-
remains at a consistently high level even in the case of sion standards.
M [Nm]
3.500
Complying with
all current exhaust
3.000 emission standards
2.500
Torque

2.000

1.500

1.000
800 900 1.000 1.100 1.200 1.300 1.400 1.500 1.600 1.700 1.800 1.900 2.000 2.100 2.200 [1/min]

P (kW)
600

500
Engine output

400

300
The sound-insulated
200 engine cowling can be
opened effortlessly
100
800 900 1.000 1.100 1.200 1.300 1.400 1.500 1.600 1.700 1.800 1.900 2.000 2.100 2.200 [1/min]

Ideal characteristics of all WR series


engines: with increased loading, the
WR 200 WR 240 WR 250 Engine speed in operation
= 1,650-2,100 min-1 speed decreases and the torque
WR 200i WR 240i increases while the output remains
nearly constant

The tried-and-tested engine technology installed in The WR 240i features advanced engine technology
the WR 200 and WR 240 complies with the emission that complies with the demanding specifications of EC
standards of EC Stage 3a / US Tier 3. Stage 3b / US Tier 4i.

The WR 200i features state-of-the-art engine technol- The tried-and-tested, robust engine technology
ogy for lowest environmental emission levels which installed in the WR 250 complies with the emission
comply with the stringent specifications of EC Stage 4 / standards of US Tier 2.
US Tier 4f exhaust emission standards.

48 // 49
Efficient engine
and diagnostic systems
Fast on-board diagnostics

High-tech diagnostic systems increase productivity


State-of-the-art measuring technology is by far trol elements. Numerous, clearly visualized display pages
superior to conventional, manual measuring meth- provide quick and accurate information on the operating
ods. We have equipped the WR with high-tech diagnostic state of the machine. In addition, maintenance require-
systems which enable effortless maintenance diagnostics, ments are minimized by extended servicing intervals and
parameter settings or troubleshooting via the control panel an intelligent maintenance concept. In short: maximum
in the operators cabin. The machines auto-diagnostic operational readiness of the WR is ensured.
system independently monitors valves, sensors and con-
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 produc- Wide opening service panels and engine cowling offer
tivity and economic efficiency. ample space to the operator for carrying out mainte-
nance procedures.
The few points of maintenance are arranged in a clear
pattern and offer easy access from the ground or via Convenient, lockable storage compartments are part
access ladders. of the standard equipment package, offering ample
space for the comprehensive toolkit, cutting tool
containers, spare parts and wearing parts.

50 // 51
High tech for top quality:
its the mix that counts
52 // 53
tsbreite/Arbeitstiefe

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 240/ WR 200/ WR 240/


WR 200i WR 240i WR 250 WR 200i WR 240i WR 250

WR 200/ WR 240/ WR 200/ WR 240/


WR 250 WR 250
WR 200i WR 240i WR 200i WR 240i
315 kW 455 kW
Working width 2,000 mm 2,400 mm 2,400 mm Maximum power 571 kW
320 kW 447 kW

Working depth 0500 mm 0510 mm 0560 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 operation, which reduces stress and strain on the drive
why the milling and mixing rotor installed in the WR elements. Regardless of the working depth, perfectly ar-
also appears as if it were cast from a single mould. Engine ranged toolholders on high bases guarantee homogeneous
and cutting power of the individual machines are optimally mixing of the construction materials. In addition, the hard-
adjusted to each other. The specific working width/depth wearing quick-change toolholder system ensures optimum
combination enables an efficient machine performance. cutting tool rotation, easy tool replacement and continuous
The massive rotor design promotes smooth, shock-free operation for extended periods of time.
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 The toolholders mounted on the rotor have high bases
into the ideal position with no effort to facilitate tool to provide sufficient space for the construction mate-
replacement for the machine operator. rial mix, thus ensuring good mixing quality.

Removable edge ring segments open at the sides The toolholder bases are also particularly sturdy and
reduce tension at the rotor edges, thus ensuring low robust, making the rotor the perfect choice for tough
wear and tear of the rotor and rotor housing. jobs.

54 // 55
High milling and
mixing performance
Rotors customized to the specific 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, Hard-wearing quick-
WR 240 / WR 240 i change toolholder system

Tool arrangement
with a spacing of
TS = 20 mm

High, heavy-duty
holder bases

Interchangeable edge
Low-weight rotor design 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 ents are thus fully aligned with the output of these machi-
are required just a single milling and mixing rotor is nes, providing the perfect solution for all soil stabilization
needed to complete all jobs to be performed by the spe- and cold recycling applications. Depending on the specific
cific type of machine. For instance, the rotor used for the job site requirements, toolholders in shank diameters of
WR 200 / WR 200 i and WR 240 / WR 240 i comprises cut- 22 or 25 mm can be used.
ting tools arranged at a 20 mm spacing. The tool compon-
Milling and mixing rotor for WR 250

Hard-wearing
Tool arrangement precisely adjusted quick-change
to the machine output of the WR 250 toolholder system

High, heavy-duty
Tool arrangement holder bases
with a spacing of
TS = 30x2 mm

Large number of tools to


ensure high mixing qual-
ity at high advance rates

Rotor specially designed


for tough cold recycling Interchangeable edge
jobs such as pulverization ring segments open at the sides

TS 30x2 rotor for WR 250


The WR 250 rotor features a tool spacing of 30x2 mm: Combining the high engine power with a particularly
for each rotation, two cutting tools are positioned at a sturdy rotor ensures a perfectly fine mix even at high
distance of 30 mm to each other. advance rates of the machine.

The rotor is equipped with a large number of tools to Depending on the specific job site requirements,
fully respond to the machines high power and ad- toolholders in shank diameters of 22 or 25 mm can be
vance rate. used.

56 // 57
High milling and
mixing performance
Efficient milling rotor drive

Taking the shortest path to success


Translating engine power into productivity: the direct ensuring high efficiency. Positive side effects of the intel-
mechanical rotor drive of the WR translates high en- ligent drive concept are low fuel consumption and ease of
gine power into an equally high milling and mixing output. maintenance. In addition, many different rotor speeds can
Large wrap-around angles with the belt pulleys enable the be selected as needed to meet the full range of standard
heavy-duty power belt to transmit the engine power to the work requirements.
rotor gearbox with only minimal performance losses, thus
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, The power belt absorbs peak loads and ensures a long
fuel-efficient engine provides a sufficient amount of service life.
reserve capacity.
At the correctly set rotor speed, the WR achieves
Maximum efficiency and high daily performance rates the intended mixing results at the highest possible
are enabled by an almost complete power transmis- advance rate whilst keeping fuel consumption to a
sion. minimum.

58 // 59
High milling and
mixing performance
Always ensuring the optimum rotor speed

400 mm 315 mm 355 mm


Engine speed

315 mm 355 mm 400 mm 355 mm 400 mm 315 mm

108 min-1 137 min-1 154 min-1


WR 200/WR 200i

117 min-1 149 min-1 168 min-1

127 min-1 161 min-1 181 min-1

108 min-1 137 min-1 154 min-1


WR 240/WR 240i

120 min-1 153 min-1 172 min-1

133 min-1 169 min-1 190 min-1

WR 200/WR 200i, WR 240/WR 240i settings


Each type of soil requires specific values in terms of Repositioning of the belt pulleys enables three different
advance rate and rotor speed to ensure optimum mix- transmission ratios.
ing quality.
As a result, the WR 200/WR 200i and WR 240/
The operator can comfortably select three different en- WR 240i machines provide a total of nine different
gine speeds using a button integrated in the right-hand rotor speeds.
arm console inside the cabin.
WR 250 twelve
Engine speed
Gear ratio

different speeds
355 mm 400 mm 400 mm 355 mm

87 min-1 111 min-1

I II
97 min-1 124 min-1

108 min-1 137 min-1


WR 250

129 min-1 164 min-1


Selecting the engine speed
and shifting the rotor gear
from the cabin
I II
145 min-1 184 min-1

can be combined with reposi-


160 min-1 203 min-1 tioning of the belt pulleys to set
twelve different rotor speeds

WR 250 settings
Three different engine speeds can be selected via the The operator can reposition the belt pulleys to set two
right-hand arm console in the cabin. different transmission ratios.

The right-hand arm console also serves to actuate the As a result, the WR 250 provides a total of twelve
two-speed rotor gear. different rotor speeds.

60 // 61
High milling and
mixing performance
Premium-class mixing quality whatever the working depth

The front rotor plate opens wide and is equipped with which can be adjusted to produce the specied particle size
a crusher bar

The pivoting scraper at the rear rotor plate always maintains to ensure perfectly even levelling of the ground
an optimal angle to the surface

Outstanding mixing results


The mixing chamber of the WR has been designed in quantity automatically by raising or lowering the rotor.
line with field requirements and is of vital importance These features guarantee a perfectly homogeneous mixing
for the high quality of the recycled subgrade. Very impor- result of the milled material and binding agents added. In
tant: the design of the rotor housing and rotor plates has addition, optimal transport of the mix inside the rotor hous-
been perfectly matched to the powerful milling and mixing ing results in a tremendous increase in throughput and
rotor. At the same time, the volume of the mixing cham- productivity.
ber is adjusted to the current working depth and material
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 As soon as the milling and mixing rotor has been fully
closure of the mixing chamber, function as material raised automatically, the rotor plates move into their
guides and are used to level off and smooth out the preselected positions to protect the rotor from damage
stabilized or recycled layer. by flying stones.

The variable mixing chamber increases with the working In cold recycling applications, the front rotor plate
depth, thus ensuring maximum performance and good is used as a crusher bar which can be adjusted to
mixing results even at the maximum working depth. produce the specified particle size.

62 // 63
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 via the control screen. The menus are structured clearly
enough to achieve high-quality mixing results. They and logically, enabling the individual pages to be called
need to be maintained at their preselected values for the up quickly. Large, readily comprehensible displays keep
entire duration of the stabilizing or recycling operation. the operator fully informed of current parameters during
The WR has all it takes to meet these requirements: the operation and, if need be, he can adjust the relevant
parameters are entered quickly and c onveniently via a parameters quickly and easily.
small number of controls in the left-hand arm console and
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 ad- The up to sixteen spray nozzles in an injection bar can
dition of water, emulsion or foamed bitumen. be switched on or off separately at any time during the
process to adjust the spraying width.
The binding agents are added in accordance
with the preselected parameters, such as working A printer installed in the cabin keeps a written log of
width, working depth, material density and machine job data or any parameter changes during the working
advance rate. operation.

64 // 65
Precise metering system
for binding agents
Injecting water

Precise metering 1 Hose connection for water


is paramount 2 Injection bar for water
3 Injected water

Working
direction

3 1

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 quanti- tives, which include water, emulsion or foamed bitumen.
ties of the binding agents to be added is of para- Several injection bars can be installed, depending upon
mount importance in high-quality stabilizing and recy- the application, and several additives can be injected
cling operations. The WR is fully equipped to meet these simultaneously. In addition, a special quick-mounting
requirements: robust, microprocessor-controlled injection system enables quick installation or removal of the injec-
systems ensure meticulous control of the various addi- tion bars.
Injecting water and bitumen emulsion

1 Hose connection for water


Bitumen emulsion
2 Injection bar for water a tried-and-tested
3 Injected water binding agent
4 Hose connection for emulsion
5 Injection bar for emulsion
6 Injected emulsion

Working
direction

5
2
6
3 1

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 Bitumen emulsion increases the flexibility of the new
water and emulsion to the injection bars via hose base layer and reduces cracking.
connections.
The optimum moisture content is achieved by adding
The microprocessor-controlled injection bars for water water to the process.
and emulsion are of identical design and can be used
for both media depending on job requirements.

66 // 67
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
6

5 4
2
A test nozzle offers easy
7
access for continuous assess- 1
ment of the foam quality during 3
the recycling operation

Foamed bitumen innovative and economically efficient


To construct base layers of exceptionally high quality, this state, the foamed bitumen is distributed very evenly in
the WR produces foamed bitumen in up to sixteen the mineral aggregate mix to be recycled. All components
separate expansion chambers by injecting small amounts carrying hot bitumen are heated and kept at operating
of water and compressed air into bitumen that has been temperature which dispenses with the need to flush the
heated to approx. 180 C. The hot bitumen then foams system. On balance, foamed bitumen is a very cost-effi-
abruptly, expanding to many times its original volume. In cient binding agent.
Self-cleaning comes as a standard feature

Individual tappets clean


the up to 16 nozzles at Ensuring a high level
pre-determined intervals 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 Cleaning of the nozzles is not only carried out auto-
of binder in the area of the nozzle exit. matically at fixed time intervals but can also be con-
veniently activated manually via the screen whenever
Regular self-cleaning of the spray nozzles via the tap- necessary.
pets ensures precise metering across the entire work-
ing width. 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
Wirtgen GmbH
Reinhard-Wirtgen-Str. 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

Illustrations and texts are non-binding and may include customized fittings. Subject to technical changes.
Performance data depend on operational conditions. No. 2231808 83-10 EN-04/13 by Wirtgen GmbH 2013. Printed in Germany