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Training W 200
12.20 M1 – Machine operation
W200 - Machine operation

W 200 W 220
W 200i W 220i

W 210 W250i
W 210i

Presentation is valid for the indicated machines.


For the main differences the particular machine can be selected from the
presentation.

2
Content

1) Machine introduction 3
2) Safety devices 55
3) Setup the workplace 87
4) Work prior to start the engine 107
5) Machine operation 119
6) Diagnostic 273

3
Machine introduction

Removal of wearing Complete pavement


course removal

Concrete pavement Fine milling

4
Machine introduction/
Complete pavement removal

5
Machine introduction/
Complete pavement removal
Job definition:

Milling area: 6.000 m²


Milling depth: 33 cm
Reclaimed quantity:
approx. 2.000 m³

W210
Milling width: 2.000 mm
Working time: approx. 5 hours

6
Machine introduction/
Removal of wearing course

Layer-by-layer removal of the surface course and the binder course

7
Machine introduction/
Removal of wearing course
Job definition:

Milling area: 6.000 m²


Surface course: 4 cm
Binder course: 8 cm
Total milling area:
12.000 m²
Reclaimed quantity:
approx. 720 m³

Working time: approx. 9 hours


Machine selection: W210 with the working width of 2000 mm

8
Machine introduction/
Removing the concrete pavement

9
Machine introduction/
Removing the concrete pavement
Job definition:

Milling area: 25.000 m²


Exposing the steel
dowels: 10 cm
Remaining concrete: 20
cm
Total milling area:
50.000 m²
Removal volume:
approx. 7.500 m³

Working time: approx. 150 hours


Machine selection: W250 with a working width of 2.200 mm

10
Machine introduction/Fine milling

Fine milling

11
Machine introduction/Fine milling

Job definition:

Milling area:
45.000 m²
Average milling
depth: 1.5 cm
Removal volume:
approx. 675 m³

Working time: approx. 20 hours


Machine selection: W250 with a working width of 4.000 mm

12
Machine introduction/Machine views

Front view W200

13
Machine introduction/Machine views

14
Machine introduction/Machine views

Right side view W220

15
Machine introduction/Machine views

Rear view W250

16
Machine introduction/Operating principle

Cold milling is a cutting process that removes construction materials in individual


layers, while granulating them at the same time. This process is extremely
environment-friendly

Cold milling is a cutting process that removes construction materials in individual


layers, while granulating them at the same time. This process is extremely
environment-friendly, because 100% of the removed material can be reused. At the
heart of every cold milling machine there is a milling drum equipped with picks. While
the machine is travelling forwards, the milling drum rotates and its picks granulate
the carriageway surface. The milling drum rotates opposite to the travel direction,
which means the carriageway surface is removed from the bottom upwards. A
levelling system ensures that the milling depth is correctly maintained. In most
applications, the milled granulate is unloaded from the milling space onto a truck by
means of one or two-section belt conveyors. Partial loading is also possible. In that
case, part of the milled material is left in the trench.

17
Machine introduction/Operating principle

Milling drum unit Levelling

Material loading

Picks are arranged on the mechanically driven milling drum in the form of a helix. They
granulate the carriageway surface while the drum is rotating, and thus remove it.
Ejectors on the milling drum assist with the transfer of the milled material onto the
charging system. The milling drum is sprayed with water during the milling process. This
cools the picks. The milling drum operates in a completely closed housing. For individual
applications, however, the side plates and the scraper can be lifted behind the milling

18
Machine introduction/Operating principle

drum using hydraulic cylinders. The only opening in the milling box is the material
transfer to the loading system. In all front loaders, a material depressor directly in front
of the milling drum presses down on the surface that should be milled. This prevents
large clumps from breaking out of the carriageway surface.

When removing carriageway layers in road building, it is of decisive importance for the
machines to remove the surface exactly at the specified height. This is precisely the task
of the levelling system in the cold milling machines: It ensures that the milling depth is
maintained. The levelling system continuously compares the current milling depth with
the preset nominal amount. The actual milling depth is measured by optical or
mechanical sensors which scan a reference surface. If the milled surface should have a
particular slope, it is possible to use a slope sensor in conjunction with a grade controller.
The Wirtgen levelling system can work with a large number of different sensors. If the
system detects deviations from the nominal value, these are corrected proportionately.
The automatic function operates quickly and without overshoots in this case.

A material loading system transports the milled material from the milling drum unit to
the truck. Depending on the machine type, this system consists of one or two load belts.
In small milling machine with a working width up to 1 m, the discharge conveyor is
located at the rear of the machine. The conveyor can be slewed and adjusted in height.
This means the milling machine operator can respond flexibly to the field situation and
load the truck or wheeled loader fully. All larger cold milling machines are front loaders
and have a two-piece transport system. The first conveyor (primary conveyor) transfers
the milled granulate from the milling space. The second conveyor (discharge conveyor)
transports it continuously to the truck. The discharge conveyor can be slewed and
adjusted in height. Using the variable conveyor speed, the milling machine operator can
change the discharge parabola and load the truck fully.

19
Machine introduction/Product information

W 200 W 220
W 200i W 220i

W 210 W250i
W 210i

20
Machine introduction/Product information

The most important data W200

Milling width: 2.0 m


Milling depth: 0-330 mm
Engine: Cummins QSL 15; 550 PS
(W200i: 600 PS)
Weight: approx. 27.5 t

21
Machine introduction/Product information

22
Machine introduction/Product information

23
Machine introduction/Product information

Transport for W200 or W200i

24
Machine introduction/Product information

The most important data W210

Milling width: 2.0 m


Milling depth: 0-330 mm
Engine: Cummins QSL 8.9 + QSL 8.3; 670 PS
(W210i: Cummins QSL 9 + QSL 9; 715 PS)
Weight: approx. 29.5 t

25
Machine introduction/Product information

26
Machine introduction/Product information

27
Machine introduction/Product information

Transport for W210 or W210i

28
Machine introduction/Product information

The most important data W220

Standard milling width: 2.2 m


Milling width max.: 3.8 m
Milling depth: 0-350 mm
Engine: Caterpillar C18; 777 PS
Weight: approx. 36.4 t

29
Machine introduction/Product information

30
Machine introduction/Product information

31
Machine introduction/Product information

Transport for W220

32
Machine introduction/Product information

Maschinendaten W250i

Standard milling width: 2.2 m


Milling depth: 0-350 mm
Engine: Cummins QSL 15 + QSL 8.9
(W250: 1.005 PS)
Weight: approx. 44 t

33
Machine introduction/Product information

34
Machine introduction/Product information

35
Machine introduction/Product information

Transport for W250

36
Machine introduction/Product information

Milling drum unit


Engine
Conveyor
Chassis
Operator's stand
ISC Intelligent Speed Control / Anti-slip control

37
Maschinenvorstellung/Produktinformationen

Milling drum unit

38
Machine introduction/Product information

Optimum access to the milling


drum

Milling drum rotation device

Optimum access to the milling drum


The scraper can be slewed upwards
hydraulically and unlocked automatically,
allowing access to the heart of the
Water spraying beam machine, the milling drum, over a large
area.

Saving time during pick changes


The pick change can be made faster with
a hydraulic milling drum rotation device
when the engine is switched off. The
corresponding remote control with a long
spiral cable can be attached close to the
operator.

Water spraying beam


Two separate water spraying beams with
their water flow rates automatically
optimised according to performance
ensure optimum pick cooling. This
extends the service life of the picks and
reduces dust generation.

39
Machine introduction/Product information

Transport mode
To prevent collisions during manoeuvring, the gradation control beam, scraper blade and
side plates are raised when in transport mode.

40
Machine introduction/Product information

Diesel engine

The fully electronic WIDRIVE machine management system enables both of the engines
to always work in the optimal performance and torque ranges, at extremely low fuel
consumption rates and low operating costs.

41
Machine introduction/Product information

W210 & W250


Engine 1 (= main engine) must always be switched on, because all hydraulic drives are
linked to it.
Engine 2 (= secondary engine) can be switched on if required.
In the «i» variant with diesel particulate filter (1), direct-flow air filter (2) and exhaust
gas recirculation (3).

42
Machine introduction/Product information

Low noise level Easily accessible engine


compartment for simple
maintenance

Low noise level


The noise level is reduced because the engines are very quiet in any event, there is
effective noise insulation, flexible engine mounts as well as the possibility of operating
with only one engine temporarily.

Easily accessible engine compartment for simple maintenance


The engine cover opens hydraulically at the push of a button. The small number of
maintenance points are clearly laid out and can easily be reached from the operator's
stand or the ground.

43
Machine introduction/Product information

Automatic starting parallel to the road surface


After the LEVEL PRO automatic function has been activated, all chassis move down in
parallel. When the milling drum unit reaches the milling surface, the lowering speed is
reduced and the milling drum penetrates as far as the nominal value.

44
Machine introduction/Product information

Operator's stand

Few controls
According to the philosophy of "less is more", the operator only has to familiarise himself
with a small number of buttons and switches. The large milling machine can be
intuitively controlled even after an extremely short familiarisation period.

45
Machine introduction/Product information

Control panels with equivalent Milling work from a seated


functions position

Control panels with equivalent


functions
The workplace is arranged on the left
and right with control panels that have
equivalent functions.

Milling work from a seated position


Individually adjustable comfort seats on
both sides of the large milling machine
increase the working comfort for the
operator.

Signals by signal lights


Signals by signal lights Signal lights are integrated in the
mirrors which can be folded and
adjusted electrically from the operator's
stand. These are used for
communication with the truck driver and
replace the loud horn that is otherwise
widely used especially when working at
night.

46
Machine introduction/Product information

Ergonomic operator’s stand

Mirrors

Mirror / Angle of view

- Two mirrors at the front, two mirrors at the centre, and one mirror at the rear of the
machine for an improved overview of the machine
- Mirrors at the front: providing a view towards the rear (standard rear view mirror)
- Mirrors near the access area: providing a view of the opposite machine side
- Mirror at the rear: providing a view of the area behind the machine (to facilitate
manoeuvring)

47
Machine introduction/Product information

Folding ladder Left ladder

Vandalism protection

48
Machine introduction/Product information

The canopy folded down for machine transport

49
Machine introduction/Product information

W 200 & W 210


1. Fuel tank: 1.220 litres
2. Water tank: 3.350 litres
3. Hydraulic oil tank: 200 litres

W 220 & W 250i


1. Fuel tank: 1.440 litres
2. Water tank: 4.850 litres
3. Hydraulic oil tank: 300 litres

- Fuel tank capacity is always sufficient for one full working day, and for as long as
2-3 working days in field mix!
- Refuelling during work is not required
- Less stoppages – longer milling intervals
- Increased daily production rates

50
Machine introduction

Exercise

Theoretical exercise…
Practical exercise on the machine…

51
Exercise/Machine introduction

Exercise chapter 1

Find on the machine:


Hydraulic tank, hydraulic tank filler port and the sight glass for
the hydraulic oil level!
Diesel tank, diesel tank filler port!
Water tank, water tank filler port and the sight glass for the
water fill level!

52
Exercise/ Machine introduction

Work direction

1) __________________________________________________
2) __________________________________________________
3) __________________________________________________
4) __________________________________________________
5) __________________________________________________
6) __________________________________________________
7) __________________________________________________
8) __________________________________________________
9) __________________________________________________
10) __________________________________________________

53
54
Content

1) Machine introduction 3
2) Safety devices 55
3) Setup the workplace 87
4) Work prior to start the engine 107
5) Machine operation 119
6) Diagnostic 273

55
Safety devices

Follow the remarks in your safety manual during all work!

56
Safety devices/Correct use

The machine is designed:

For milling load bearing road surfaces made of


asphalt, asphalt concrete and cement concrete.
For removing markings on the road surface.

The machine is only intended to be used commercially on enclosed


construction sites.

57
Safety devices/Incorrect use

In particular, the machine is not allowed


to be used:

To carry people who are not personnel for operating


the machine
As lifting equipment
For milling or removing tracks, pipes, manhole covers
and other objects set into the road surface

58
Safety devices/
Machine-specific safety instructions
Machine-specific safety instructions

Automatic movements of machine components


may be triggered by disengaging an
EMERGENCY STOP switch: side plate, material
depressor and scraper will lower if they were
lifted before.
Ensure there are no people or objects in the machine's danger
zone.

59
Safety devices/Danger zones/Safety devices

5° (8,7%)

14° (25%)

DANGER

In case of milling on uphill / downhill slopes with values above those stated above, the
machine is to be secured with an adequately dimensioned winch (winch truck).
On travelling / transferring / transporting the machine, attention is to be paid to
sufficient pendulum stroke.
On travelling / transferring / transporting the machine, it must be horizontal in the
lateral direction and raised to the highest point.
On travelling / transferring / transporting / loading the machine, the discharge conveyor
must point in the "straight ahead" direction.

60
Safety devices/
Danger zones, Safety devices

During work inside or under the machine, the available safety


supports must be fitted, and the chassis supported on them.

61
Safety devices/Danger zones/Safety devices

Observe national and/or local regulations and retrofit a fire


extinguisher, if required.
The provided mounting position was specified by WIRTGEN.

62
Safety devices/Danger zones/Safety devices

For detailed security information in handling with the Wirtgen large milling machines
please read the security manual (ID 2082121) or attend one of the security trainings for
large milling machines.

63
Safety devices/
Electric/Manual engine cover

Opening of the engine cover

64
Safety devices/
Electric/Manual engine cover

Electric opening of the engine cover

- Open the engine hood via the switch on the left picture
- To avoid an unintendend closing please use the safty bar

65
Safety devices/
Electric and manual engine cover

Switching over the hoses from the hydraulic unit to the hand
pump

Turn solenoid valve completely to the right

If the engine has failed, the engine cover can also be opened manually.

- Hydraulic hoses must be switched over (disconnect 1 and 3 in the picture, connect
4 and 5 instead)
- Solenoid valve must be completely opened

66
Safety devices/
Electric/Manual engine cover

Opening the engine cover using the hand pump

By changing over the ball cock, it is possible to determine whether the cover will open
or close.
Use the hand lever to open the cover.

67
Safety devices/External control panels

External control panels with emergency stop


at front right and front left

External control panels with emergency stop at rear


right and rear left

68
Safety devices/Lighting/Warning device

- Quick identification of all switches when working at night


- Improves safety at work
- Convenient working

69
Safety devices/Lighting/Warning device

Floodlight Patrol light

Warning light

- Working light for working during the night


- Moving machines must be equipped with a rotating beacon
- Warning lights are activated as soon as the milling drum flap or the side plates
are moved

70
Safety devices/Workspace illumination

Workspace illumination

Indirect lighting: perfect illumination of the entire machine surroundings

71
Safety devices/Workspace illumination

Xenon lighting package

- Lighting package with 6 xenon and 8 halogen headlights


- Significantly improved illumination compared to halogen headlights
(3.200 vs. 1.750 lumens)
- Sensible if the machine is used frequently when working at night

72
Safety devices/Ladders, cover panel,
storage boxes, maintenance flaps

Ladders, cover panel, storage boxes, maintenance flaps

[1] Storage box


[2] Left footstep
[3] Cover
[4] Access to diesel engine
[5] Access to electrical switching cabinet
[6] Cover panel
[7] Access to water tank filling pump
[8] Acoustic protection grille

73
Safety devices/Ladders, cover panel,
storage boxes, maintenance flaps

Folding ladder Left ladder

Vandalism protection

Folding-in ladder permits milling close to the edge.

Vandalism protection: All control panels can be provided with protection and be
individually locked.

74
Safety devices/Ladders, cover panel,
storage boxes, maintenance flaps

Unlocking and locking of the ladder / footstep

To prevent the ladder from moving out during travelling and transportation, the
footstep should be secured using the bolt.

75
Safety devices/Mirrors

Ergonomic operator’s stand Mirrors

Mirror / Angle of view

- Two mirrors at the front, two mirrors at the centre, and one mirror at the rear of the
machine for an improved overview of the machine
- Mirrors at the front: providing a view towards the rear (standard rear view mirror)
- Mirrors near the access area: providing a view of the opposite machine side
- Mirror at the rear: providing a view of the area behind the machine
(to facilitate manoeuvring)

76
Safety devices/Signal lights

Signals by signal lights


Signal lights are integrated in the mirrors which can be folded and adjusted electrically
from the operator's stand. These are used for communication with the truck driver and
replace the loud horn that is otherwise widely used especially when working at night.

77
Safety devices/Checking safety devices

Engine STOP button


Engine STOP button
Functional check: Daily before Check:
starting on-site operation - With diesel engine running (idling
speed), press button.
- Diesel engine must stop.

EMERGENCY STOP switch


Check:
a) Unlock all EMERGENCY STOP switches
on the machine.
b) Start diesel engine and set to idling
speed.
c) Press an EMERGENCY STOP switch.

Diesel engine must stop immediately.


Check all other EMERGENCY STOP
switches one after the other using steps
EMERGENCY STOP switch a), b) and c).

Warning horn
Check:
- Press the button with the electrical
power supply switched on. Horn must
sound.

You must pay special attention to the


safety devices installed in the machine.
They must always be checked for correct
function.

If the safety devices do not function


or function incorrectly, you are not
Warning horn allowed to operate the machine.

78
Safety devices/Checking safety devices

Reversing horn Patrol light

Reversing horn
Check:
- Switch on drive mode.
- Pull back the advance drive lever with the diesel engine running (machine travels in
reverse).
- The horn must sound intermittently.
- Stop reverse travel.

Patrol light
Check:
- Press the button.
- Patrol light must flash.

79
Safety devices/Checking safety devices

Wire ropes: visual check

- Visual inspection
- Damage ropes must be replaced.

80
Safety devices/Checking safety devices

Discharge conveyor safety grid Warning beacons

Discharge conveyor safety grid


Check:
- Visual inspection
- Safety grids must be correctly fitted and in correct working order.
- Incorrectly fitted safety grids must be repaired or replaced.

Warning beacons
Check:
- Fold out the warning beacon at the rear and clean if necessary.
- Adhesive foil must exist at the left rear and must be cleaned if necessary.
- It must be possible to freely fold out the warning beacon on the right side and it must
be clean.
- Adhesive foils must exist and must be clean.

81
Safety devices/Checking safety devices

- Lift side plate on the right / left side.


- Right / left warning lights must flash with side plate lifted.

82
Safety devices/Checking safety devices

Safety latch (milling drum flap)

Lift the milling drum flap with the diesel engine running.
The safety latch must snap into place.

83
Safety devices/Signs/Stickers

GS mark Information box

VDE approval sticker

INFO
You will find the information about safety labels in safety training (ID 2366912)

84
Safety devices

Exercise

Theoretische Übung…
Practical exercise on the machine…

85
Exercise/Safety devices

Exercise chapter 2

Answer the following questions:


When does the operator have to check the safety devices?

___________________________________________________

What does the operator have to do if a safety device is not


functioning correctly?

___________________________________________________

Practical exercise on the machine:


Check all safety devices on the machine!
It is permitted to refer to the instruction manual for assistance.

86
Content

1) Machine introduction 3
2) Safety devices 55
3) Setup the workplace 87
4) Work prior to start the engine 107
5) Machine operation 119
6) Diagnostic 273

87
Setup the workplace/Operator's seat

Sitting position Standing position

88
Setup the workplace/Operator's seat

Operator's seat
Weight, backrest, armrest , foot rests.

89
Setup the workplace/Operator's seat

Adjust the Level Pro and the display

90
Setup the workplace/Operator's seat

Adjusting the wasp waist

- Comfortable and fatigue-free working position


- Good visibility of the work surface
- Ergonomics for relaxed working for hours

91
Setup the workplace/Operator's seat

Comfort cabin

92
Setup the workplace/Operator's seat

Reset job data

conveniently and clearly structured using the colour display

- High-contrast colour display can be clearly read at all times; the operator is always
fully informed about the machine status
- Highly detailed 3D display of the machine

93
Setup the workplace/Windscreen and roof

Setting up the protective canopy

94
Setup the workplace/Rear window

Attention: If the engine cover should be opened, the rear flap of the weather canopy
must be closed.
The clamping bolt must be opened to fold in the weather canopy.

95
Setup the workplace/
Canopy: electrical actuation

Switching on the electrical power supply

Open the canopy

- Disconnects the batteries from the system. This switch should be turned off if the
machine is shut down for a lengthy period of time.
- The canopy can be folded in directly using a switch on the ladder/footstep on the left
hand side.

96
Setup the workplace/
Canopy: electrical actuation

97
Setup the workplace/
Canopy: electrical actuation

- Push the operator seats back and secure with the eccentric latches.
- Fold armrests and backrests down.
- Slide the rear window to the central position and fold closed.
- Press button and keep pressed until the diesel engine is switched off.

98
Setup the workplace/
Canopy: manual actuation

Manual opening of the canopy

In case of a fault, the canopy can also be moved out without using the engine.

99
Setup the workplace/
Canopy: manual actuation

[1 + 3] Hose couplings - The electro-hydraulic pump is connected


[2] Solenoid valve with regulation knob
[4 + 5] Hose couplings - for the hydraulic hand pump

100
Setup the workplace/Mirrors

Folding mirrors in and out

101
Setup the workplace/Mirrors

With the "electric mirror" option, the mirrors can be folded in and out using a switch. The
mirrors can be adapted for each operator using electrical adjustment. This adjustment
can be made using the display. A heater can also be switched on to prevent the mirrors
from fogging over and freezing.

102
Setup the workplace/
Camera/Monitor system

Camera images at a glance

Camera arrangement on the machine

If the machine is equipped with a camera system, the individual pictures can be
selected using an additional monitor. The position of the cameras is set and specified.

103
Setup the workplace

Exercise

Theoretical exercise…
Practical exercise on the machine…

104
Exercise/Setup the workplace

Exercise chapter 3

Practical exercise on the machine:


Try out the various workplace settings!
Comply with the safety guidelines!

105
106
Content

1) Machine introduction 3
2) Safety devices 55
3) Setup the workplace 87
4) Work prior to start the engine 107
5) Machine operation 119
6) Diagnostic 273

107
Work prior to start the engine

Checking the fuel level


Check the filling level of the fuel tank and fill up if necessary.

If the diesel fill level is too low, this is shown by a message on the display, the warning
horn is activated and the diesel fill level symbol lights up.
Check the filling level of the fuel tank and fill up if necessary.

108
Work prior to start the engine

Checking the engine oil level

Checking the coolant level

Checking the engine oil level


Pull out oil dipstick. The dipstick must indicate a level between MIN and MAX; if
necessary top-up engine oil.

Checking the coolant level


- Remove the radiator cap.
- Perform visual inspection, if necessary top-up coolant.
- Fit the radiator cap.

109
Work prior to start the engine

Checking the hydraulic oil level

Checking the oil level in the pump splitter gearbox

Checking the hydraulic oil level


- Visually inspect the sight glass.
- The indication must indicate a level between MIN and MAX, if necessary top-up
hydraulic oil.

Checking the oil level in the pump splitter gearbox


- Visually inspect the oil dipstick.
- The oil dipstick must indicate a level between MIN and MAX; top up gear oil, if
necessary.

110
Work prior to start the engine

- Open and empty the dust dump valves [1] by pressing them together.
- Loosen dust deposits and remove.

111
Work prior to start the engine

- Check for contamination.


- The mechanical indicators [1] and [2] must not be in the red range.
- The red fault LED on the control panel must not be illuminated.
If necessary, however at least once a year, clean or change filter element.

112
Work prior to start the engine

Water level check

- Remove tank lid [1].


- Insert water hose and fill the tank.
- Re-fit tank lid [1].

113
Work prior to start the engine

Cleaning the spraying nozzles

114
Work prior to start the engine

Cleaning the water filter


This filter should be unscrewed and removed for the winter so that the frost will not
cause the filter to burst.

All EMERGENCY STOP switches


- Turn EMERGENCY STOP switches in the direction of the arrow.
It is to be ensured all EMERGENCY STOP switches are unlocked, otherwise it will not
be possible to start the diesel engine.

115
Work prior to start the engine

Exercise

Theoretical exercise…
Practical exercise on the machine…

116
Exercise/
Work prior to start the engine
Exercise chapter 4

Practical exercise on the machine:


Carry out the work before starting the machine!
It is permitted to refer to the instruction manual for assistance!
Comply with the safety guidelines!

117
118
Content

1) Machine introduction 3
2) Safety devices 55
3) Setup the workplace 87
4) Work prior to start the engine 107
5) Machine operation 119
6) Diagnostic 273

119
Machine operation/Control panels

[1] Control panel material depressor, washer unit and high pressure cleaner
[2] Control panel material depressor, washer unit and high pressure cleaner
[3] LEVEL PRO control panel
[4] Control panel CENTRE
[5] Display for on-board computer
[6] Control panel RIGHT
[7] Control panel LEFT
[8] Milling drum rotation device
[9] External control panel REAR LEFT
[10] External control panel REAR RIGHT

120
Machine operation/Control panels

These operation panel you will find on the front of the machine left hand and right hand.
All function on the panel you will find on the operation main desk on the top of the
machine too.

121
Machine operation/Control panels

On the back of the machine you will find on both side the operation panels for the
functions of the drum housing, steering and height adjustment

122
Machine operation/Hydraulic unit

Move cylinder functions using the hydraulic unit

The machine have a electrical-hydraulical emergency unit which you can use
for the most important machine function without running engine

123
Machine operation/Hydraulic unit

Cylinder functions of the milling drum unit can be moved

124
Machine operation/Hydraulic unit

Additional cylinder functions can be moved by changing the position


of the ball cock

Move the ball cock 90 degrees

125
Machine operation/Hydraulic unit

Front steering, lift, lower, swivel conveyor

The individual cylinder functions can now be moved using the control panel.

126
Machine operation/Battery main switch

The batteries can be accessed under the air filter when an engine cover is open. The
main switch is located on the right behind the flap for the storage compartment.

127
Machine operation/Control panel left

The control panel is located on the operator's stand on the left hand side.
Red frame stands for height adjustment.
Yellow frame stands for milling drum unit.
Blue frame stands for water unit.

In the light grey area there are all the switches that are continuously required by the
operator.

128
Machine operation/Control panel centre

The control panel is located centrally on the operator's stand of the machine. All
functions are not frequently used.

In the light grey area there are all the switches for turning on the options (folding belt,
generator, etc.).

Furthermore, the diagnosis LEDs for the controls are fitted here.
The ignition and the engine functions are fitted in the dark grey area.

129
Machine operation/Control panel right

You will find the operation panel on the right hand of the operator stand.
The red frame indicates the height adjustement, the yellow one for drum unit and the
blue frame for the water system.
In the light grey area on the desk you will find the most used switches on the desk.

130
Machine operation/Exhaust post-treatment

Machines without exhaust post-treatment

Machines with exhaust post-treatment

131
Machine operation/Exhaust treatment

Control unit exhaust treatment

The control unit is located on the operator's stand behind the cover on the engine cover.
The switch for opening the engine cover is also fitted here.

132
Machine operation/Exhaust treatment

Regeneration process active Regeneration deactivated

Pilot light for particulate filter


status lights up

133
Machine operation/Exhaust treatment

The particulate filter is almost full The particulate filter is full


Carry out a stationary
regeneration immediately
The engine rated output and the
engine speed are noticeably
reduced

Start stationary regeneration

134
Machine operation/Exhaust treatment

Prerequisite:

Advance drive lever in central position.


Switch off milling drum drive.
Low idling speed.
The diesel engine must be at operating temperature.

Duration: ca. 60 min

135
Machine operation/On-board computer display

[1] Selector switch (turn and press)


[2] Display
[3] Diagnostics - quick access
[4] Camera display (change from camera 1 to camera 2)
[5] Favourites button
[6] Function keys
[7] Light intensity sensor
[8] Accept condition message
[9] General fault
[10] HOME key (return to start screen)
[11] ESC button (back)

136
Machine operation/On-board computer display

On the display you can see all important/relevant functions. Fault messages,
Operation hours, fuel filling level, speed etc.

With F1 you can change the water flow


With F2 you can control the speed of the conveyor belt
With F3 you change the milling with for the funczion „job data“

137
Machine operation/On-board computer display

Adjustment of the mirrors

With the turning button you can select the different mirrors and with the
Buttons F1-F4 you can adjust them.

138
Machine operation/On-board computer display

Diagnostic about visualize function groups. In the example you see the functions from
the drum unit with the indicaton that there are the sensor signal is missing.

139
Machine operation/Starting with jump leads

Jump starting

1. Preparation
1) Ensure that the batteries have same nominal voltage.
2) Use jump leads with insulated pole clamps and a cross section of at least 25 mm².
3) The pole clamps of one cable must not touch those of the other cable.
4) Do not disconnect a discharged battery from the electrical system of the vehicle.
5) The vehicle providing the jump start and the vehicle receiving the jump start must not
touch each other.

140
Machine operation/Starting with jump leads

Jump start connection points

2. Connecting the cables


- Set the electrical power supply of the vehicle receiving the jump start to OFF.
- First connect the positive cable to the positive terminal [+] on the external power
source.
- Connect the other end of the positive cable to the positive connection [1] provided
(pull off protective cap).
- Then connect the negative cable to the negative terminal [+] on the external power
source.
- Connect the other end of the negative cable to the negative connection [2] provided.

141
Machine operation/Starting with jump leads

3. Starting
- Start the diesel engine of the vehicle providing the jump start and run it at medium
engine speed.
- Start the diesel engine of the vehicle receiving the jump start after about 5 minutes.
- Let both diesel engines run for at least 3 minutes at medium engine speed with
connected jump leads.

4. Removing the jump leads


- In order to prevent overloads in the electrical system before removing the jump leads,
switch on an electrical load on the vehicle receiving the jump start (e.g. headlight).
- Remove the jump leads; first the negative cable [-], then the positive cable [+].

142
Machine operation/Starting with jump leads

Starting with jump leads by 2-engine machines

This chapter can be skipped with the W200 and W220. Use the link instead!

143
Machine operation/Starting with jump leads

Diesel engine II Press the F1 key on the on-board


emergency start computer and follow the
sequence

Diesel engine I starts

144
Machine operation/Starting with jump leads

Press rocker switch (-) until the Switch on milling drum


lower diesel engine speed is
reached

Press the F1 key and start diesel


engine II

145
Machine operation/Starting with jump leads

Diesel engine I Press the F2 key on the on-


emergency start board computer and follow the
sequence

Set lever of ball cock horizontal

146
Machine operation/Starting with jump leads

Diesel engine II starts Press rocker switch (-) until the


lower diesel engine speed is
reached

147
Machine operation/Starting with jump leads

Press and hold the switch and, at the same time, press "F1" and
hold it until diesel engine "I" has started (after that set lever of ball
cock vertical).

148
Machine operation/Level Pro control panel

LEVEL PRO
milling depth regulation

Correct setting of the milling depth presupposes that the "0" level of the machine and the
"0" position on the LEVEL PRO control panel were set correctly beforehand.

149
Machine operation/Level Pro control panel

Automatic PTS system

150
Machine operation/Sensors

Levelling sensors

[1] Hydraulic cylinder for side plate


[2] Sensor connection
[3] Slope sensor

151
Machine operation/Sensors

Sensing in front of the milling drum

Milling depth is sensed in relation to the area directly in front of the drum which has not
yet been milled
Application is recommended wherever there is no suitable reference line other than the
milled track

152
Machine operation/
Milling drum rotation device

Milling drum rotation device

The drum turning device (wire remote control with magnetic base) permits automatic,
slow turning of the milling drum (in clockwise or anti-clockwise direction) to facilitate tool
replacement.
Increased productivity
- Increased productivity in combination with hydraulic pick extractor
- Additional rotary buttons are located on the extractor
In different versions for milling width 2.200-3.100 mm and 3.500-4.400 mm

[1] ROTATE milling drum ANTICLOCKWISE


[2] ROTATE milling drum CLOCKWISE

INFO
Switch off engine
Press both buttons [1] + [2] simultaneously and hold for 3 seconds.

153
Machine operation/Camera

Camera images at a glance

Camera arrangement on the machine

154
Machine operation/Milling drum drive

Milling drum drive with quick change toolholder system

155
Machine operation/Milling drum drive

The mechanical drive belt converts the powerful engine rated output
directly into milling performance

The power of the engine is transmit about the pulleys to the drum.
V-belt and pulleys are wear parts and need to be controlled on aregular base.
Important is the control of the tensioner pressure to make sure that the belt tension is
always in the right range.

156
Machine operation/Milling drum drive

Functional areas of the milling drum

a) Outer ring area


b) Conveyor spiral area
c) Ejection area

Main tasks of the milling drum:


1. Cutting and breaking out of material particles from the compound.
2. Conveying: Transport of the separated material particles to the area of the ejector.
3. Ejection of the removed material particles onto the loading conveyor.

157
Machine operation/Milling drum drive

Higher output, lower costs

Longer life, shorter downtimes

Robust, durable Wirtgen cutting technology components cut


operating costs

HT 22: Generation X point-attack cutting tools

158
Machine operation/Milling drum drive

Road rehabilitation Concrete application

Depending on the job side you need different picks for the different applications.

159
Machine operation/Milling drum drive

1.600 U/min (5,0 m/s) complete pavement removal. Reasonable also in combination with
the EcoCutter drum (LA25) -> less cutting tools and less cutting tool consumption
1.800 U/min (5,6 m/s) for common milling work
2.000 U/min (6,2 m/s) for fine milling and to improve the cutting pattern at high milling
speeds

160
Machine operation/Milling drum drive

161
Machine operation/Milling drum drive

162
Machine operation/Milling drum drive

Via mode switch the engine speed can be selected between 1.600 min -1, 1.800 min-1 and
2.000 min-1
Thus changes the cutting speed of the milling drum:
1.600 U/min engine -> 5,0 m/s milling drum
1.800 U/min engine -> 5,6 m/s milling drum
2.000 U/min engine -> 6,2 m/s milling drum

Advantages:
Low engine speed -> minimizes the fuel consumption
Low cutting speed -> minimizes the cutting tool consumption
Low cutting speed -> allows higher milling speeds -> better cost-benefit ratio

Recomended applications:
1.600 U/min (5,0 m/s) complete pavement removal. Reasonable also in combination with
the EcoCutter drum (LA25) -> less cutting tools and less cutting tool consumption
1.800 U/min (5,6 m/s) for common milling work
2.000 U/min (6,2 m/s) for fine milling and to improve the cutting pattern at high milling
speeds

163
Machine operation/Milling drum drive

What are the differences among the control panel at the left and the control
panel at the right?

Side plate left and right


Favourites button 2 (Sensing in front of the milling drum)

164
Machine operation/Scraper

165
Machine operation/Scraper

Scraper blade

- Hydraulically movable and adjustable scraper blade with automatic locking function.
- The scraper has an additional hydraulic valve for locking the scraper blade. Contact
pressure can be adjusted by means of a control wheel.
- Applications: partial loading, milling down into the subbase layer (no digging into the
layer)

166
Machine operation/Scraper

The scraper plate is controlled using these switches.

Manual UP/DOWN
Scraper plate can be fixed at any height (leave material lying)

Top left: Lifting


Bottom left: Lowering

Top right: Fixing


Bottom right: Floating position
The scraper is in the floating position when the rocker switch is released. The green LED
lights up on all control panels.

167
Machine operation/Scraper

Thorough cleaning of the milled area


1. The top layers of bituminous road pavements are milled off
2. The scraper blade is pressed down with the pre-selected downward
3. The scraper blade edge slides on the surface as if spring-loaded
4. The drum housing is sealed off to the rear

Milling down to the top edge of the subbase layer


1. The asphalt is milled off down to the subbase layer
2. The scraper blade is locked hydraulically
3. The scraper blade does not dig into the subbase layer
4. Material is picked up

Trench milling with partial loading


1. Possibly leave part of the milled material in the trench
2. Milled material is removed at a later date
3. For this purpose, scraper blade is locked at the required height
4. Part of the milled material is loaded
5. The remainder is profiled and left in the trench

168
Machine operation/Scraper

Contact pressure is adjustable

Because of wear, it will be necessary to increase the contact pressure of the plate from
time to time in order to retain a clean milling pattern. These setting valves are located on
the rear left part of the machine in the area of the control unit. Make sure that the
pressure is not too high. Otherwise, this will influence the control of the machine
(automatic level control).

169
Machine operation/
Scraper-cylinder position teach-in

Scraper cylinder must be teach-in

Therefor the hydraulic cylinders have impact on the regulation circuit of the machine you
need to teach the machine the current values from the the sensors in the cylinders.
This teach in you can do about the display. The exact procedure you will find in the
operation instruction of the machine.

170
Machine operation/
Scraper-cylinder position teach-in

[1] Control panel material depressor, washer unit and high pressure cleaner
[2] Control panel material depressor, washer unit and high pressure cleaner
[3] LEVEL PRO control panel
[4] Control panel CENTRE
[5] Display for on-board computer
[6] Control panel RIGHT
[7] Control panel LEFT
[8] Milling drum rotation device
[9] External control panel REAR LEFT
[10] External control panel REAR RIGHT

171
Machine operation/Milling drum flap

Important is that the drum door is locked (hook in) during the pick change/ inspection.
To open the drum door you need to use a special switch combination.

172
Machine operation/Milling drum flap

To open the milling drum flap, first move the scraper up and then unlock the milling
drum flap. To do this, press the switch of the milling drum flap down until the milling
drum flap is unlocked. After that, press the button for the milling drum flap until the
milling drum flap engages in the hook.

173
Machine operation/Milling drum flap

[1] Control panel material depressor, washer unit and high pressure cleaner
[2] Control panel material depressor, washer unit and high pressure cleaner
[3] LEVEL PRO control panel
[4] Control panel CENTRE
[5] Display for on-board computer
[6] Control panel RIGHT
[7] Control panel LEFT
[8] Milling drum rotation device
[9] External control panel REAR LEFT
[10] External control panel REAR RIGHT

174
Machine operation/Material depressor

Hydraulic material depressor with conveyor lift function

Heavy-duty design, left and right sides connected in a torsion-resistant fashion

Effectively prevents the pavement in front of the milling drum assembly from breaking
into slabs
- Particle size of the milled material makes it suitable for being sold to asphalt plant
operators
- Protects the loading conveyor (large slabs would slash the belt)

175
Machine operation/Material depressor

The material depressor can be operated on the control panels at the left and right. As
soon as the lowering button is pressed, the function goes to floating position. The
green LED lights up as well.
Furthermore, the material depressor can be pressed on the control units at the front
left and right (same function as the top control panels). An LED in the switch displays
that the material depressor is in the floating position.

176
Machine operation/Material depressor

1. Typical of urban milling operations: Obstacles, such as rainwater inlets or gully oles
2. When approaching the obstacle, the primary conveyor is lifted hydraulically without
interrupting the milling operation.
3. Thus it is possible to mill close to the gully lid. Manual removal of remaining asphalt
material is reduced to a minimum

177
Machine operation/Material depressor

[1] Control panel material depressor, washer unit and high pressure cleaner
[2] Control panel material depressor, washer unit and high pressure cleaner
[3] LEVEL PRO control panel
[4] Control panel CENTRE
[5] Display for on-board computer
[6] Control panel RIGHT
[7] Control panel LEFT
[8] Milling drum rotation device
[9] External control panel REAR LEFT
[10] External control panel REAR RIGHT

178
Machine operation/Side plate

Sealing of the milling drum


Levelling

179
Machine operation/Side plate

- Right-hand side plate with a lift of 450 mm to the lower cutting tool tip
- Application: pavement removal at full depth on roads that do not have edge stones,
extending right to the kerb.
- Road without edge stones / A=150 mm / B=300 mm / C=450 mm

180
Machine operation/Side plate

Rocker switch for side plate

If the rocker switch for the side plate is pressed, the warning lights on the machine flash
automatically.

181
Machine operation/
Side plate-register cylinder length

Side plate-register cylinder length

The edge protection cylinder is a position measuring cylinder and is used as a sensor for
the levelling. As a result, it is important for it to be programmed by teach-in.

182
Machine operation/
Side plate-register cylinder length

[1] Control panel material depressor, washer unit and high pressure cleaner
[2] Control panel material depressor, washer unit and high pressure cleaner
[3] LEVEL PRO control panel
[4] Control panel CENTRE
[5] Display for on-board computer
[6] Control panel RIGHT
[7] Control panel LEFT
[8] Milling drum rotation device
[9] External control panel REAR LEFT
[10] External control panel REAR RIGHT

183
Machine operation/MDI

Milling depth indicator (MDI)

MDI (Milling Depth Indicator)


- shows the difference between the side plate and the scraper.

MDI = Milling Depth Indicator


The milling depth indicator (MDI) shows the difference between the side plate and the
scraper.
In the example above, the difference is 3.5 cm on the left side and 8.5 cm on the right
side.

NOTE
The indication changes due to normal wear on the picks. Check the milling depth
at regular intervals.

184
Machine operation/Pick extractor

Hydraulic pick extractor

The work of exchanging the picks can be facilitated using a hydraulic pick ejector
drift. The drum can be rotated slowly using the two buttons. The conventional method is
to use a drift and a hammer.

185
Machine operation/Folding seats

Folding seats for checking the picks

Optionally available, additional dual seats between the rear crawler track units enable
the driver to replace the cutting tools conveniently and without tiring.
The additional seats offer storage space for four tool containers each and are folded in
during the milling operation.

186
Machine operation/Height adjustment

Height adjustment

The machine has 4 lifting columns and each lifting column can be controlled individually.

187
Machine operation/Height adjustment

The lever must be deflected beyond the noticeable pressure point for fast lifting
or lowering.
Only a slight deflection of the lever is required for low lifting or lowering.

188
Machine operation/Height adjustment

Lift the front and the rear

Milling drum drive OFF.


Conveyor drives OFF.
Water sprinkling of milling drum and conveyor system OFF.
Lifting and locking the material depressor.
Lift and lock the side plate on the right and left hand side.
Lift and lock the scraper.
LEVEL PRO automatic system OFF.

189
Machine operation/
Quadruple pendulum system

Quadruple pendulum system

If a crawler unit encounters an obstacle whilst milling (e.g. a tall milled edge), the
other crawler units compensate for the difference in height.
This means it is possible to minimise the effects of disruptions to the machine
height (stones, kerbs) and to increase driving stability. The improvement in stability
can be felt throughout the machine. The pendulum system is permanently
active when the diesel engine is running.

190
Machine operation/
Quadruple pendulum system

[6] Control panel RIGHT


[7] Control panel LEFT
[9] External control panel REAR LEFT
[10] External control panel REAR RIGHT

191
Machine operation/Control panel Level Pro

LEVEL PRO
milling depth regulation

Correct setting of the milling depth presupposes that the "0" level of the machine and the
"0" position on the LEVEL PRO control panel were set correctly beforehand.

192
Machine operation/Control panel Level Pro

Raise the machine until the Switch on milling drum drive.


milling drum can rotate freely.

Check operational mode for left


and right side of the machine and
switch to MANUAL if necessary.

193
Machine operation/Control panel Level Pro

Raise the scraper. Lower the milling drum…

…until the milling drum lightly


scratches the surface.

194
Machine operation/Control panel Level Pro

Set both "ACT" displays to Adjust the required milling


"zero". depth.

Switch on AUTOMATIC.

195
Machine operation/PTS

PTS - Parallel to surface

If one of the crawler track units hits an obstacle (such as an elevated milling edge)
during the milling operation, the other three units contribute to compensating the height
offset: this design ensures that height compensation occurs much more rapidly.

196
Machine operation/PTS

[1] Milling machine on starting


[2] Move into the milling track
[3] Milling machine during milling
[4] Leaving the material behind

Principle of the "PTS" system:


PTS is a system integrated in LevelPro which keeps the milling machine parallel to the
road surface in the lengthways direction during the milling process.
The system can be switched on and off at the push of a button [5] on the "main control
panel left" and "main control panel right" as well as on both external control panels. The
current status is displayed on an LED displayed close to the button.

197
Machine operation/PTS teach-in

Press the PTS key and hold for 5 seconds.

The teach-in of the PTS function must be repeated after the "LEVEL PRO micro
controller" has been changed, or the "LEVEL PRO micro controller" has been reset.

NOTE
- The teach-in of the lifting column, side plate and scraper sensors must be performed.
- Position the machine on a flat, level sub-base.
- The scraper is in the floating position.
- Switch on PTS.
- Lower the machine to the sub-base in the longitudinal and transverse directions
until the scraper touches the ground on both sides.
- Lower the machine by about 1 cm further.

NOTE
This pushes the scraper up slightly and moves it to the teach-in position.
- Press the key and hold for 5 seconds.
- The successful teach-in procedure is displayed by the LED flashing three times.

NOTE
If the teach-in confirmation (LED flashing three times) is not given then the teach-in
procedure has failed.
In this case, check the parallel alignment of the machine. See "Height adjustment
and side plate - cylinder position teach-in".

198
Machine operation/PTS teach-in

[6] Control panel RIGHT


[7] Control panel LEFT
[9] External control panel REAR LEFT
[10] External control panel REAR RIGHT

199
Machine operation/Steering

Steering the machine

200
Machine operation/Steering

Rear crawler units


- Push steering lever [2] to the right. The crawler units steer to the right.
- Push steering lever [2] to the left. The crawler units steer to the left.

Automatic steering of rear crawler units


Three different automatic functions are available:
[1] = CENTRAL POSITION
[3] = COORDINATE
[4] = CRAB

201
Machine operation/Steering

Automatic steering CENTRAL Automatic steering


POSITION COORDINATE

Automatic steering
CRAB

Activating the CENTRAL POSITION automatic steering


Press lever forward and release. LED [1] is switched on.
NOTE
If the AUTOMATIC mode is activated, the crawler units will return to the central
position after the actuation of the control lever. If the AUTOMATIC mode is
switched off, the crawler units will remain in the steering position.

202
Machine operation/Steering

Activating the CRAB automatic steering


Pull the lever back and hold (approximately 2 seconds) until LED [3] is switched on.
NOTE
The milling drum must not be in contact with the ground during travel.
If the AUTOMATIC mode is activated, the crawler units will return to the previous
position after the actuation of the control lever.
If the AUTOMATIC mode is switched off, the crawler units will remain in the steering
position.

Activating the COORDINATE automatic steering


Pull back lever and release. LED [4] is switched on.
NOTE
If the AUTOMATIC mode is activated, the crawler units will return to the previous
position after the actuation of the control lever.
If the AUTOMATIC mode is switched off, the crawler units will remain in the steering
position.

203
Machine operation/Steering

Steering in front

Keep the button pressed for 5 seconds

- Machine moves up completely


- Side plates move up
- Milling drum switches off
- Water system goes to standby

204
Machine operation/
Steering (external control panels)

For special applications, the rear crawler units can be steered by ground personnel.
The ground personnel is to be instructed prior to operation on-site. The machine
operator has steering priority and can take over the steering at any time.

Steering enable
Steering can be done by ground personnel as soon as the LED [3] is switched on.

NOTE
The steering enable is removed if the machine operator switches over from the
working speed to the travelling speed.

Automatic indication
When LED [4] is switched on, automatic steering is switched on.
When LED [4] is not switched on or flashes, automatic steering is switched off.

Steering
Press rocker switch [2] left or right and hold until the required steering angle has been
reached.

Steering effects after releasing the switch:


Case 1 (LED [4] is switched on - one automatic steering system is active).
The crawler units slew immediately to a new steering position after the switch is
released.
Case 2 (the white LED [2] is not illuminated or is flashing)
The crawler units remain in the selected steering position after release.

205
Machine operation/
Steering - cylinder position teach-in

Steering - cylinder position teach-in

206
Machine operation/
Steering - cylinder position teach-in

[1] Control panel material depressor, washer unit and high pressure cleaner
[2] Control panel material depressor, washer unit and high pressure cleaner
[3] LEVEL PRO control panel
[4] Control panel CENTRE
[5] Display for on-board computer
[6] Control panel RIGHT
[7] Control panel LEFT
[8] Milling drum rotation device
[9] External control panel REAR LEFT
[10] External control panel REAR RIGHT

207
Machine operation/Travelling

[1] LED drive mode


[2] LED milling mode
[3] Symbol for advance drive lever
[4] LED forwards travel
[5] Button for drive mode ON
[6] Button for milling mode ON
[7] LED reverse

208
Machine operation/Travelling

209
Machine operation/Travelling

Travelling forward
- Push the advance drive lever forward and hold it until the machine has reached the
required speed.
- LED [4] is switched on.
NOTE
When the advance drive lever is released, it returns to the central position and
the machine keeps running at the current speed.
The maximum possible travelling speed is adapted depending on the steering
angle of the rear crawler units.
For small steering angles of the rear crawler units, the machine can be driven at
maximum travelling speed.
For larger steering angles of the rear crawler units, the maximum possible travelling
speed is reduced automatically.
A symbol is shown on the display drawing the driver's attention to this condition.

Stopping from forwards travel


- Pull the advance drive lever backwards against the stop and hold it until the machine is
stationary.
- The machine stops.
- LED [4] switches off.

Travelling reverse
- Pull the advance drive lever backwards and hold it until the machine has
reached the required speed.
- LED [7] is switched on.
NOTE
When the advance drive lever is released, it returns to the central position and
the machine keeps running at the current speed.
The maximum possible travelling speed is adapted depending on the steering
angle of the rear crawler units.
For small steering angles of the rear crawler units, the machine can be driven at
maximum travelling speed.
For larger steering angles of the rear crawler units, the maximum possible travelling
speed is reduced automatically.
A symbol is shown on the display drawing the driver's attention to this condition.

Stopping when driving reverse


- Push the advance drive lever forward.
- The machine stops.
- LED [7] switches off.

210
Machine operation/Travelling

ISC (Intelligent Speed Control)

Intelligent, electronic crawler track control with hydraulic four-track drive

3 basic functions:
1) electronic anti-slip control
2) automatic adjustment of crawler track speed when driving in bends
3) load limit controller

211
Machine operation/Travelling

Intelligent, electronic crawler track control with hydraulic four-track drive

3 basic functions:
1) electronic anti-slip control
2) automatic adjustment of crawler track speed when driving in bends
3) load limit controller

A) Tracking of steering angle


B) Tracking of advance speed
C) Diesel engine speed

212
Machine operation/Travelling

ISC automatically aligns the cornering speeds of the inner and outer crawler tracks,
thus reducing track pad wear.

- The electronic differential lock is also active when cornering


- To minimise track pad wear, the correct cornering speeds for the inside and outside
chassis are calculated depending on the steering angle, and this information is sent
back to the chassis

213
Machine operation/Engine load control

- The power control unit controls the machine’s advance speed in accordance with the
engine load
- Machine works at maximum possible advance speed in any given milling situation
- The performance capacity of the diesel engine is always utilized in the best way
possible

214
Machine operation/Engine load control

Activate the engine load control

215
Machine operation/Engine load control

Changing the engine load limit speed

216
Machine operation/ASR

Electronic differential lock = anti-slip control

- Prevents the individual crawler track units from slipping


- Guarantees optimum traction even in difficult milling situations

Technical principle
The speed of all four crawler track units (n1-n4) is continuously determined via sensors
and is then directly aligned with the lowest speed.

217
Machine operation/ASR

Anti-slip control - Emergency mode

- Select the crawler unit (in this example, the front left crawler unit).
- Enter the value (in this example, a value of 50% has been selected).
- The traction control system for the front left crawler unit has now been set to
the fixed value of 50%.

218
Machine operation/ASR

NOTE
The selected value must be changed if the crawler unit chain continues to slip. A
larger value reduces the traction.

NOTE
This intervention in the TCS control is only allowed to be used for a short period,
for example in order to complete a work section which has already been started.
The presented measure must never be used as an alternative to repairing an
existing malfunction.

219
Machine operation/Towing away

Towing of the machine in case of engine failure

220
Machine operation/Towing away

Loosen the high pressure valves of the advance pump with an open-
end wrench and turn out by three turns.

221
Machine operation/Towing away

- Connect [3]and [4] hose couplings


- Press in [2] brake release device.
- Build up a pressure of 40 bar with the hand pump. The pressure is displayed on the [1]
pressure gauge.
- Height adjustment, steering and additional cylinder functions can be operated with the
electro-hydraulic unit.
- The machine can now be pulled out of the danger zone.

Completing the towing process


- Disconnect [3] and [4] hose coupling.
- Tighten the high-pressure valves of the advance pump with an open-end wrench.
NOTE
Only disconnect the coupling with the towing vehicle if the brake release device [2] has
been removed.
- Pull out brake release device [2].

222
Machine operation/Discharge conveyor

Discharge conveyor

The folding belt is hydraulically articulated and reduces the transportation length of the
machine by 2.6 m on the total length of the machine of 12.4 m. This means shorter
transport vehicles can be used.
The conveyor system can be ordered with various equipment configurations:
Standard conveyor system or conveyor system with folding belt device.
The theoretical delivery capacity of the conveyor system is 375 m³/h.
The maximum conveyor speed is 4.1 m/s.
Electronic monitoring and control means the loading belt capacity does not drop, even
when the diesel engine is under pressure.

223
Machine operation/Discharge conveyor

- Extremely powerful conveyor system

- Belt width of primary conveyor and discharge conveyor:


W200(i) and W210(i): 850 mm;
W220: Belt width of primary conveyor: 1.100 mm and discharge conveyor: 1.000 mm;
W250i: 1.100 mm

- Maximum belt speed: 4 m/s

- Theoretical conveying capacity:


W200(i) and W210(i): 375 m³/h (+ 14% compared with W 1900) through increased
belt width (+ 50 mm)
W220: 552 m³/h
W250i: 668 m³/h

Benefits: no material congestion in drum chamber / fast removal of material from


drum chamber / high milling performance!

224
Machine operation/Discharge conveyor

The conveyor has a slewing range of 60° to either side


- Permits the loading of trucks even in narrow bends, roundabouts and turning bays
- The time needed for manoeuvring, thus increasing productivity

225
Machine operation/Discharge conveyor

Small turning radius

Continuously adjustable travel speed


Small turning radius
The wide steering angles of all crawler units gives the large milling machine surprisingly
small turning circles.

Continuously adjustable travel speed


The speed can be infinitely variably adjusted from standstill to maximum in milling and
travelling gear.

226
Machine operation/Discharge conveyor

- Place ball cock in "operational position".

Switching on the belt conveyor drive


- Press the button.
- The LED is switched on.

227
Machine operation/Discharge conveyor

Switching off the belt conveyor drive


- Press the button.
- The LED switches off.

Starting reverse driving


- Press button and keep pressed.

Adjusting the belt conveyor speed


- Select the screen and set the speed with the rotary knob.

Intermediate positions for the lever


For the possible intermediate positions the functions LIFT / LOWER are combined
with the function SLEWING.

228
Machine operation/Discharge conveyor

[6] Control panel RIGHT


[7] Control panel LEFT

229
Machine operation/Discharge conveyor

Proprietary Wirtgen “vacuum cutting system” (protected by patent in Europe


(EP1507925B1) and the USA (7175364))
- Specially developed radial fan to generate a negative pressure
- Hosing system next to the conveyor to allow discharge onto the discharge conveyor
Optimized sealing at the drum housing and conveyor channel

The negative pressure generated in the drum housing extracts the air/water vapour
mixture and feeds it back at the upper end of the conveyor
- Improved air quality, in particular in the area of the operator’s platform and in the
surroundings of the milling drum housing
- Significantly improved visibility for both the driver and ground staff
- Reduced soiling of machine and air filters
- Reduced water consumption in various working situations
- Improved working comfort

230
Machine operation/VCS

Dust dump valve Sprinkling

Automatic or continuous
operation

Opening the dust dump valve

Open the valve for sprinkling the VCS unit


- Move the handle of the valve in the longitudinal direction.

Switch on automatic operation


- Press the button.
- The green LED is switched.

231
Machine operation/VCS

[4] Control panel CENTRE

232
Machine operation/Signal lights

Signal lights

Move the truck up to the discharge conveyor


- The machine operator observes the procedure and switches over the lights.
- The red and the green LED do not light.

233
Machine operation/Signal lights

Stop the truck


- The machine operator switches over the lights.
- The truck driver stops and waits until the truck is loaded or should be moved
further forwards.
- The red LED lights up and the green LED does not light.

Driving the truck


- The machine operator switches over the lights.
- The green LED lights up, the red LED does not light.
- The truck driver drives the truck forwards a little and stops as soon as the machine
operator switches over the lights again (stop truck).

The truck is fully loaded


- The machine operator switches over the lights. Press the button and hold for
approx. 3 seconds (running light).
- The green LED flashes, the red LED does not light.
- The truck driver drives away with the milled material.

Job data:
- The truck counter is increased by 1.
- The truck loading is set to zero.
- The machine operator switches over the lights.

Move the truck up to the discharge conveyor


- The machine operator observes the procedure and switches over the lights.

234
Machine operation/Signal lights

3 hydraulically fold-in mirror with heavy-duty cover and a stoplight system for the
truck driver are available as an equipment option.
- 2 of 3 hydraulically fold-in mirror are heatable.
- The stoplight system permits visual communication with the truck driver and replaces
the audible horn signal.

Depending on the symbol, the truck driver knows whether he needs to A) stop, B)
move forward, or C) drive away.
When passing along obstacles, the driver can fold the mirrors in hydraulically from the
operator’s platform without stopping and descending from the machine.
- Economy of time
- Convenient

235
Machine operation/Folding conveyor

- The W 210’s folding conveyor is folded hydraulically and shortens the transport length
by 2.600 mm to an overall length of 12.400 mm, thus permitting the use of shorter
transport vehicles.
- A manual locking/unlocking of the folding conveyor is not necessary because of an
integrated locking-position.
- Requires less / no additional investments in transport vehicles.

236
Machine operation/Folding conveyor

Unfolding discharge conveyor

Folding together discharge conveyor

237
Machine operation/Folding conveyor

[4] Control panel CENTRE

238
Machine operation/Sprinkler unit

Sprinkler unit

Generally, the water system is used for cooling and improving the rotation behaviour of
the picks, as well as for reducing dust during the milling process and cleaning the
machine. Water can be sprayed into the milling box through either one or two spraying
beams. The picks are cooled and cleaned. The water binds the dust and it is
transported with the milled material to the conveyor system.
Spraying water at the transition points from the milling drum to the primary conveyor
and from the primary conveyor to the discharge conveyor minimises the amount of
dust generated. On the monitor, the operator can adjust the amount of water that
should be sprayed in according to the requirements of the field.

239
Machine operation/Sprinkler unit

AUTOMATIC mode CONTINUOUS operation

Switch off

AUTOMATIC mode
- Press the rocker switch.
- The LED is switched on.
NOTE
During interruptions to on-site operation, the water pump is AUTOMATICALLY
shut down. The LED switches off.

CONTINUOUS operation
- Press the rocker switch twice.
- The LED is switched on.

240
Machine operation/Sprinkler unit

- Two separately usable water spray bars in the milling drum assembly for optimum
tool cooling and reduction of dust development
- Two spray bars in the conveyor channel / One cleaning hose as part of the standard
equipment

241
Machine operation/Filling the water tank

Filling the water tank

The water tank is equipped with an overflow. The tank is full as soon as water emerges
from the overflow.
- Remove tank lid [1].
- Insert water hose and fill the tank.
- Re-fit tank lid [1].

242
Machine operation/Filling the water tank

Water system/
Water filling pump

The machine is capable of taking in water from any reservoir autonomously and is thus
independent of tankers with separate pump
- Helps to ensure smooth construction progress

Delivery rate:
W200(i) and W210(i): 550 litres/min
W220 and W250i: 520 litres/min

243
Machine operation/Shut-off valves

- The water system, which is a standard feature, supplies up to 67 l/min at max. 18 bar.
- The water can optionally be switched to the spraying nozzles at: the drum (1,2),
primary conveyor (3) or material transfer (4), or several of these simultaneously, or
alternatively to the wash-down system (5).
- Water rate and pressure are continuously adjustable

[1] Spray bar 1


[2] Spray bar 2
[3] Primary conveyor
[4] Conveyor transfer
[5] Wash-down system
[6] Air connector (clearing machine from snow in winter)
[7] Water drainage

244
Machine operation/Shut-off valves

[1] Hand gun


[2] Hose reeler

245
Machine operation/Shut-off valves

High-pressure pump

- Hydraulically operated high-pressure pump with a maximum performance of 150 bar


and 15 l/min
- The scope of delivery additionally includes a high-pressure gun with hose
- Improves daily machine cleaning significantly

246
Machine operation/Hydraulic unit

Use cylinder functions of the milling drum unit

The electro-hydraulic unit enables the following functions to be operated without


starting the diesel engine:
- Opening and closing the hoods of the machine.
- Opening and closing the canopy.
- Raise, lower, turn and shift the cabin.
- Turn milling drum.

247
Machine operation/Hydraulic unit

Set lever of ball cock horizontal to use additional cylinder functions

In addition, various cylinder functions of the machine can be operated.

For example:
- Lifting and adjusting the height adjustment.
- Operating the rear steering.
- Lifting and lowering the scraper and milling drum flap.

248
Machine operation/Hydraulic unit

Height adjustment, conveyor, steering

249
Machine operation/Display

Operator guidance

250
Machine operation/Display

Selection menu

- Exiting the current screen is done by pressing the ESC key.


- The Home key can be used to switch from the current screen to the main screen.

251
Machine operation/Display

Selection menu

252
Machine operation/Display

Setup

The assignment of function keys F1, F2 to F5 changes both depending on the displayed
screen and the status of the machine.
The displayed symbols give the user further instructions.

253
Machine operation/
On-board computer symbols

On-board computer symbols

254
Machine operation/Job data

Job data

- The distance is calculated automatically by the on-board computer.


- The area, the volume and the weight are calculated.
- The accuracy of these calculated values significantly depends on the input values for
the milling depth, milling width and density of the material to be milled.
- The loaded trucks are counted by actuating the traffic light control. Every time the
traffic lights are switched (press the favourites button "I") by the operator, the counter
for the number of trucks is increased.

- Turn the selector switch to select menu item "7", for example.
- Press the selector switch - the colour of the input box changes and the required
value can be set by turning the selector switch.
- Press the selector switch - the set value is transferred from the on-board
computer.
- Repeat these working steps until the milling depth, milling width and density have been
set.

255
Machine operation/Total job data

Total job data

"Total job data" displays values that are summarised during the entire application
time:
- Distance driven in metres (m).
- Milled surface in square metres (m2).
- Milled material in cubic metres (m3) and tonnes (t).
- Number of loaded trucks.

256
Machine operation

Exercise

Theoretical exercise…
Practical exercise on the machine…

257
Exercise/Machine operation

Exercise chapter 5

258
Exercise/Machine operation

259
Exercise/Machine operation

260
Exercise/Machine operation

261
Exercise/Machine operation

262
Exercise/Machine operation

263
Exercise/Machine operation

264
Exercise/Machine operation

265
Exercise/Machine operation

266
Exercise/Machine operation

267
Exercise/Machine operation

268
Exercise/Machine operation

269
Exercise/Machine operation

270
Exercise/Machine operation

271
272
Content

1) Machine introduction 3
2) Safety devices 55
3) Setup the workplace 87
4) Work prior to start the engine 107
5) Machine operation 119
6) Diagnostic 273

273
Diagnostic/Operating state messages
(machine)

The machine is equipped with a monitoring system.


After switching on the electrical power supply, starting the diesel engine, or during on-
site operation, messages on the state of the machine can be displayed.
The cause of the message is to be determined in every case and, if necessary, the fault
or the error rectified.

If there is a fault:
- A warning horn sounds for 5 seconds, the red LED [1] lights up, the red CAUTION
key [2] lights up, a text message appears on the display.
- Establish the cause of the fault. Rectify fault, if necessary contact WIRTGEN customer
service.

The message is confirmed by pressing a key


- The text message on the display disappears, the red CAUTION key [2] goes out, the
red LED [1] remains lit.

274
Diagnostic/Operating state messages
(machine)

View fault message list


Select "Operating state messages" box
Press the pushbutton - a list of all fault messages appears

Once all fault messages have been confirmed, the list with the operating state
messages can also be opened with the CAUTION key.

View fault message text


Select required field
Press pushbutton - the corresponding text message appears in the large message
window

275
Diagnostic/Operating state messages
(machine)

276
Diagnostic/Operating state messages
(machine)

277
Diagnostic/Operating state messages
(machine)

Fault message category 1 - white


Press the red CAUTION key - the corresponding text message appears in the large
message window with a white symbol

Fault message category 2 - blue


Press the red CAUTION key - the corresponding text message appears in the large
message window with a blue symbol

278
Diagnostic/Operating state messages
(machine)

Fault message category 3 - yellow


Press the red CAUTION key - the corresponding text message appears in the large
message window with a yellow symbol

Fault message category 4 - red


Red text message are displayed directly in the large message window with a red
symbol

279
Diagnostic/Machine operating state messages
(flash code)

If there is a fault:
- A warning horn sounds for 5 seconds,
- One of the two red LEDs on the centre control panel is switched on.

NOTE
When LED 1 is switched on, control system 1 has determined a fault.
When LED 2 is switched on, control system 2 has determined a fault.
Output of the flash code is started by pressing the DIAG key.

Example
LED 1 is switched on.

BLOCK [A]
LED 1 blinks 7 times
Then there is a pause of 1.5 seconds.
LED 1 blinks 1 times
Then there is a pause of 1.5 seconds.
LED 1 blinks 3 times
Between the blocks [A] and [B] there is a pause of 5 seconds.

BLOCK [B]
LED 1 blinks 2 times
Then there is a pause of 1.5 seconds.
LED 1 blinks 6 times
Error code 713-26 was determined in the example.

280
Diagnostic/Diagnostic system

Status of diagnostic messages

281
Diagnostic/Diagnostic system

[1] Fuse OK
[2] Fuse has switched off
[3] Device is inactive
[4] Device is active
[5] Load-holding valve of the height adjustment FRONT LEFT has short circuit
[6] Valve FRONT RIGHT down has cable break
[7] Load-holding valve FRONT RIGHT is inactive
[8] Valve switch-over FRONT active but cable break
[9] Load-holding valve REAR LEFT active
[10] PTS status message (active)

NOTE
Turning the selector switch displays further information.
Rectify fault, if necessary contact WIRTGEN customer service.

282
Diagnostic/Diagnostic system

Advance drive

283
Diagnostic/Diesel engine operating state
messages

The diesel engine is equipped with a monitoring system.


After switching on the electrical power supply, starting the diesel engine, or during
on-site operation, messages on the state of the diesel engine can be displayed.

If there is a fault:
- A warning horn sounds for 5 seconds,
- The red LED is switched on [1] on the on-board computer,
- The CAUTION key is [2] red,
- The a SPN____ / FMI____ number appears on the display.
- Establish the cause of the fault, rectify fault, if necessary contact WIRTGEN customer service.

284
Diagnostic/Diesel engine operating state
messages (flash code)

The diesel engine is equipped with a monitoring system.


After switching on the electrical power supply, starting the diesel engine, or during
on-site operation, messages on the state of the diesel engine can be displayed.
The cause is to be determined in every case and, if necessary, the fault or the error
rectified.

285
Diagnostic/Diesel engine operating state
messages (flash code)

ENGINE WARNING (Possible to continue working for a short period)


- Yellow LED is illuminated - red LED is off
- Switch off diesel engine / switch on electrical power supply.
- Press and hold the DIAG button. Keep the DIAG button pressed until the flash codes
have been read out.
- Yellow and red LED illuminate
- Short pause
- Yellow and red LED switch off
- Short pause
- The red LED outputs the flash code for the fault (here e.g. 4-3-5 = engine oil pressure
sensor)
- Determine the cause of the fault - see "Table" SPN/FMI and flash code (diesel engine) -
read off the corresponding message.
- Rectify fault, if necessary contact WIRTGEN customer service.

To read other flash codes, press the button briefly and release.

286
Diagnostic

Exercise

Theoretical exercise…
Practical exercise on the machine…

287
Exercise/Diagnostic

Exercise chapter 6

288
Exercise/Diagnostic

1=

2=

289
Exercise/Diagnostic

290
Exercise/Diagnostic

291
This training document is not a substitute for technical documentation
(instruction manual, safety instruction and spare parts catalogue).
It is not subject of the technical modification service. All technical instructions
for description, operation, maintenance, etc. are taken by the instruction
manual, the safety manual or the spare parts list.

Publisher
Reinhard-Wirtgen-Straße 2
53578 Windhagen, Germany
Phone: +49 (0) 2645 / 131 – 0
http://www.wirtgen.de

Copyright
© Wirtgen GmbH 2016
Distribution and copying of this document, usage and communication of its
content are forbidden, unless specifically permitted. Infringements will result in
the obligations to pay damages. All rights reserved in case of a patent, utility
model or registration of a design.

292

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