Parts 2005 Wirtgen Betek [PDF]

Zitiervorschau

Parts and More Catalogue 2005

Wirtgen Group Original Spare Parts

Wirtgen GmbH Picks 4 • Top-quality picks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 • Picks for road milling machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 • Picks for cold recyclers and soil stabilizers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 • Picks for Surface Miners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Toolholders 36 • Toolholder systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 • Welded toolholders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 • Ejectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Milling drums 52 • Milling drums from the market leader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 • Milling drums for your machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Scraper blades and wear protection segments 68 Conveyors 72 • Conveyor belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 • Drive and return pulleys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 • Idle pulleys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Water system 78 • Service packages for pump- and nozzle units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Levelling 82 • Levelling systems for road milling machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 • Components of the levelling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 Crawler unit parts 90 • Crawler track units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 • Track pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 • Track rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 Tyres and wheels 96 Clutches 98 Power belts and belt pulleys 102 Filters 104 Hydraulic pumps and -motors 110 Hydraulic cylinders 116 Electrical accessories 118 • Electrical Service Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 • Work light, partol light, horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 Tools 122 • Tools for milling drums . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 • Test Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 • Special service tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 Electric and hydraulic vibrators

128

3

Get ahead with quality picks for high-performance milling machines Mio. pcs. 14,0 13,0 12,0 11,0 10,0 9,0 8,0 7,0 6,0 5,0 4,0 3,0 2,0 1,0 90 91 92 93 94 95 96 Sales of tools for road milling machines

If you want low operating costs, use superior quality equipment A fast advance rate, plus few tool changes, equals high daily output. To make this equation for low operating costs work out right, you need powerful machines and high-quality tools. Only picks of the highest quality, which are closely adapted to the machine and application, can guarantee a long service life and flawless rotation. Wirtgen, together with BETEK, recognises the critical nature of this issue and has taken steps to ensure better economic efficiency. The technical expertise of the two leading manufacturers has been pooled to result in unique collaboration in all sectors: development, production, quality assurance, consulting and sales.

97

98

99

00

01

02

03

04 Years High-quality, low-wear operating costs.

minimise

System partnership made for success The result is coordinated system components with a high savings potential for users. The user gets everything he needs from a single source and reliable delivery to any job site around the globe. Comprehensive support is provided to the user, even on a job site if necessary. If problems or questions arise, a solution is elaborated immediately, even if it means providing special tools for difficult milling tasks. Rising sales figures confirm the effectiveness of this formula for success, the main objective of which is to ensure customer satisfaction. Furthermore, extensive practical experience guarantees continuous improvement: new application scenarios frequently occasion the optimisation of picks or the development of new products. Despite the high demands imposed on the engineers of both companies, they achieve short cycles times from development to production - further proof of effective collaboration for the benefit of customers.

4

tools

Tungsten carbide particles encased in soft cobalt.

Quality as a result of production, not follow-up controls Consistent quality management, certified to DIN EN ISO 9001 and 9002, guarantees high quality at BETEK in every production step, all the way to final inspection. Similarly, the environmental friendliness of the production process is certified to DIN ISO 14 001.

BETEK offers a comprehensive range of picks for all Wirtgen machines and every application.

Treatment

Sintering lends resistance.

Machine

the

picks

high

wear

Holder system/drum

Pick

The relationship between all parameters is taken into account in the development of BETEK picks.

The carbide tips are optimized using the finite element method (FEM).

5

Original Wirtgen-Betek picks for road milling machines: Low operating costs in daily use Wirtgen road milling machines are used on job sites around the world. Operating costs incurred during use can be reduced considerably by using high-quality milling tools. The system partnership between Wirtgen and BETEK, a global leader in tungsten carbide manufacturing, has proven to be particularly successful for this purpose. BETEK produces the W6H pick - the most frequently used cutting tool in Wirtgen road milling machines worldwide.

Rough-grain carbide tip with 6% cobalt for long tool life Optimised carbide shapes for maximum advance speeds Special hard soldering process to ensure a high-strength joint between the carbide and the steel base Extremely hardened pick head and soft pick shank to minimise steel wear Pick head geometry adapted for high cutting capacity Collar for good chip-breaking behaviour and optimum toolholder protection 1.2 mm thick R-sleeve made of high-quality spring steel for constant tension force over a long period of time Original Wirtgen logo for unequivocal identification of high-quality picks Hardened spring steel plate with System 44 for low toolholder wear

Pretensioned R-sleeve for simple pick assembly R-sleeve technology to minimise wear of the toolholder bore

6

The complete delivery range of picks 2005 for milling machines Carbide tip

Standard with Standard without Special designs extractor groove Ø 20 extractor groove Ø 22 without extractor groove Ø 13 / Ø 20

W4

W4 E

W5

W5 E

W5 H

W6

W6

W6 H

W6 E

W6 E

W6 E H

W7

WM4-13

W8 / 22

W8 E

W1-17

W6 / 22

W7 S P

W8

W1-13

W6 S

W7 E H

W7 S P

W1-10

Stabilizing, recycling without extractor groove Ø 22

W8 E H

W1-10

W1-13

W1-13 / 22

W1-17 / 22

7

Optimum milling performance with low pick costs Every pick is subject to constant wear due to contact with the highly abrasive material to be milled. The extent to which the machine can penetrate into the pavement material decreases as the pick becomes increasingly worn. The maximum possible rate of advance also declines as the picks become increasingly worn. In other words, milling performance deteriorates when using severely worn picks. However, the machine’s potential can be maximized by replacing the picks in good time. Typical signs of wear: as soon as the base material begins to display distinct notches (right) it will be more economical to change the picks than to continue working with the same.

Penetration

Penetration

Penetration

Penetration

100%

97%

83%

33%

Ø

.54 11

Ø

.2 18

39

.65 10

42

Ø

45

48

Ø

.5 10

= Material wear The effective diameter of the carbide tip becomes larger as the pick wears down. At the same time, its penetration is reduced and the maximum possible machine performance declines.

8

Working economically with the right choice of pick

Features of an optimally worn pick: • Symmetrical form of the remaining carbide tip • Uniform tapered form of the base material • Sufficient base material to support the hard metal core

If the pick is used in excessively soft material, the base material will wear down more rapidly than the carbide tip. Result: the base material can no longer support the carbide tip and it may break. The disadvantageous form of the pick will additionally cause the toolholder to wear down more rapidly. The situation is different in the case of picks which have worn down irregularly and therefore too rapidly. Such picks always indicate that the picks cannot rotate in the toolholders due, among other things, to a worn toolholder or small particles of milled material between the pick shank and the clamping sleeve.

It is always worth examining the wear pattern, for a pick can only produce the best possible results throughout its service life if it wears down optimally.

Example 1: Pick W5 used in excessively soft material

Example 2: Pick W1–13 used in excessively soft material

Example 3: Pick which could not rotate in the toolholder

Recommendation: Use a pick with larger carbide tip, e.g. W6 or W7 H

Recommendation: Use a pick with mushroomshaped carbide tip, e.g. W6 (protects the base material more effectively)

Recommendation: • Check toolholder for signs of wear • Check water spray system in drum chamber or water level in tank

Typical wear patterns of incorrectly used picks. The use of other picks is recommended for examples 1 and 2 as this will permit a longer tool life and higher milling performances. The toolholder should be examined for signs of wear in the case of example 3.

9

Pick WM4 / 13 for road milling machines

NEW!

WM4 / 13 Part No.: 182598

28

16

ø 8.5

ø 16

ø 26 55

The new miniature pick with a shank diameter of 13 mm for super-fine milling drums • Optimized carbide tip for low cutting forces and long service life • Special hard soldering process to ensure a high-strength joint between the carbide and the steel base • Hardened pick head for optimized pick life

ø 13

• Thick-walled, cylindrical R-sleeve for a constant clamping force, even over a long period of service Unit of measurement in mm

Our delivery service

Packaging: Handy toolbox Quantity: 200 picks per toolbox Weight: approx. 16.4 kg per toolbox Dimensions: approx. 26 x 18.5 x 22 cm

10

Pick W4 E for road milling machines W4 E Part No.: 175592

48

16

ø 8.5

ø 16

88

ø 30

The new all-round pick for use on any site in small milling machines • Optimized carbide tip for low cutting forces and long service life

4

ø 44

• Special hard soldering process to ensure a high-strength joint between the carbide and the steel base • Extractor groove in the pick head for drawing out the pick with the pick extractor

ø 20

• Hardened pick head for optimized pick life • Pick head with ridges for improved asphalt breaking properties and optimized pick rotation

Unit of measurement in mm

Our delivery service

• Wear plate with outer diameter of 44 mm for low degree of toolholder wear and optimized pick rotation • Centring function on the wear plate for low wear toolholder bore • Thick-walled, cylindrical R-sleeve for a constant clamping force, even over a long period of service

Packaging: Handy toolbox Quantity: 50 picks per toolbox Weight: approx. 13.6 kg per toolbox Dimensions: approx. 26 x 18.5 x 22 cm

• Prestressed R-sleeve for simple and rapid pick assembly • Long R-sleeve to minimize wear to the toolholder bore

11

Pick W5 E for road milling machines

NEW!

W5 E Part No.: 128301

48

16

ø 9.5

ø 17.5

88

ø 34

The new universal pick in the one-metre class for all job sites • All-round carbide tip for tough operations in small milling machines and machines of the one-metre class

ø 44

• Extractor groove in the pick head for drawing out the pick with the pick extractor

4

• Special hard soldering process to ensure a high-strength joint between the carbide and the steel base ø 20

• Hardened pick head for optimized pick life • Wear plate with outer diameter of 44 mm for low degree of toolholder wear and optimized pick rotation • Centring function on the wear plate for low wear toolholder bore

Unit of measurement in mm

Our delivery service

• Thick-walled, cylindrical R-sleeve for a constant clamping force, even over a long period of service • Prestressed R-sleeve for simple and rapid pick assembly • Long R-sleeve to minimize wear to the toolholder bore

12

Packaging: Handy toolbox Quantity: 50 picks per toolbox Weight: approx. 14.8 kg per toolbox Dimensions: approx. 26 x 18.5 x 22 cm

Pick W5 H for road milling machines W5 H Part No.: 121475

48

16

ø 9.5

ø 17.5

88

ø 34

The pick with the excellent price-performance ratio • All-round carbide tip for tough operations in small milling machines and machines of the one-metre class

4

ø 44

• Special hard soldering process to ensure a high-strength joint between the carbide and the steel base • Hardened pick head for optimized pick life

ø 20

• Wear plate with outer diameter of 44 mm for low degree of toolholder wear and optimized pick rotation • Centring function on the wear plate for low wear toolholder bore

Unit of measurement in mm

• Thick-walled, cylindrical R-sleeve for a constant clamping force, even over a long period of service

Our delivery service

• Prestressed R-sleeve for simple and rapid pick assembly • Long R-sleeve to minimize wear to the toolholder bore

Packaging: Handy toolbox Quantity: 50 picks per toolbox Weight: approx. 15.7 kg per toolbox Dimensions: approx. 26 x 18.5 x 22 cm

13

Pick W6 for road milling machines W6 Part No.: 128302

48

17.5

ø 10.5

ø 19 ø 34

• Long, sturdy carbide tip for all-round use in large milling machines

88

One of the top-selling large milling machine picks worldwide for use on all job sites ø 44

• Extractor groove in the pick head for drawing out the pick with the pick extractor

4

• Special hard soldering process to ensure a high-strength joint between the carbide and the steel base ø 20

• Hardened pick head for optimized pick life • Wear plate with outer diameter of 44 mm for low degree of toolholder wear and optimized pick rotation • Centring function on the wear plate for low wear toolholder bore

Unit of measurement in mm

Our delivery service

• Thick-walled, cylindrical R-sleeve for a constant clamping force, even over a long period of service • Prestressed R-sleeve for simple and rapid pick assembly • Long R-sleeve to minimize wear to the toolholder bore

14

Packaging: Handy toolbox Quantity: 50 picks per toolbox Weight: approx. 15.1 kg per toolbox Dimensions: approx. 26 x 18.5 x 22 cm

Pick W6 H for road milling machines W6 H Part No.: 126696

48

17.5

ø 10.5

ø 19

88

ø 34

The cost-efficient "excavating pick" for large job sites • Long, sturdy carbide tip for all-round use in large milling machines

ø 44

4

• Special hard soldering process to ensure a high-strength joint between the carbide and the steel base

ø 20

• Hardened pick head for optimized pick life • Wear plate with outer diameter of 44 mm for low degree of toolholder wear and optimized pick rotation • Centring function on the wear plate for low wear toolholder bore

Unit of measurement in mm

• Thick-walled, cylindrical R-sleeve for a constant clamping force, even over a long period of service

Our delivery service

• Prestressed R-sleeve for simple and rapid pick assembly • Long R-sleeve to minimize wear to the toolholder bore

Packaging: Handy toolbox Quantity: 50 picks per toolbox Weight: approx. 15.8 kg per toolbox Dimensions: approx. 26 x 18.5 x 22 cm

15

Pick W6 E for road milling machines W6 E Part No.: 158400

48

19.6

ø 10.5

ø 19 ø 34

88

The cost-effective pick for high milling performance • Extremely long carbide tip for long service life

• Extractor groove in the pick head for drawing out the pick with the pick extractor

ø 44

4

• Special hard soldering process to ensure a high-strength joint between the carbide and the steel base

ø 20

• Hardened pick head for optimized pick life • Pick head with ridges for improved asphalt breaking properties and optimized pick rotation

Unit of measurement in mm

• Wear plate with outer diameter of 44 mm for low degree of toolholder wear and optimized pick rotation • Centring function on the wear plate for low wear toolholder bore

Our delivery service

• Thick-walled, cylindrical R-sleeve for a constant clamping force, even over a long period of service • Prestressed R-sleeve for simple and rapid pick assembly • Long R-sleeve to minimize wear to the toolholder bore

16

Packaging: Handy toolbox Quantity: 50 picks per toolbox Weight: approx. 15.2 kg per toolbox Dimensions: approx. 26 x 18.5 x 22 cm

Pick W6 E H for road milling machines

NEW!

W6 E H Bestell-Nr.: 178386

48

19.6

ø 10.5

ø 19

88

ø 34

The pick with an impressive service life • Extremely long carbide tip for long service life

ø 44

4

• Special hard soldering process to ensure a high-strength joint between the carbide and the steel base • Hardened pick head for optimized pick life ø 20

• Pick head with ridges for improved asphalt breaking properties and optimized pick rotation • Wear plate with outer diameter of 44 mm for low degree of toolholder wear and optimized pick rotation

Unit of measurement in mm

• Centring function on the wear plate for low wear toolholder bore

Our delivery service

• Thick-walled, cylindrical R-sleeve for a constant clamping force, even over a long period of service • Prestressed R-sleeve for simple and rapid pick assembly • Long R-sleeve to minimize wear to the toolholder bore

Packaging: Handy toolbox Quantity: 50 picks per toolbox Weight: approx. 16.3 kg per toolbox Dimensions: approx. 26 x 18.5 x 22 cm

17

Pick W6 S for road milling machines W6 S Part No.: 175602

48

17.5

ø 10.5

ø 19

88

ø 37

The high-performance pick with a reinforced steel base for milling and stabilizing work • Long, sturdy carbide tip for all-round use in large milling machines

ø 44

• Hardened pick head for optimized pick life

4

• Special hard soldering process to ensure a high-strength joint between the carbide and the steel base ø 20

• Particularly large pick head for long service life • Wear plate with outer diameter of 44 mm for low degree of toolholder wear and optimized pick rotation

Unit of measurement in mm

• Centring function on the wear plate for low wear toolholder bore • Thick-walled, cylindrical R-sleeve for a constant clamping force, even over a long period of service

Our delivery service

• Prestressed R-sleeve for simple and rapid pick assembly • Long R-sleeve to minimize wear to the toolholder bore Packaging: Handy toolbox Quantity: 40 picks per toolbox Weight: approx. 13.8 kg per toolbox Dimensions: approx. 26 x 18.5 x 22 cm

18

Pick W7 S P for road milling machines

NEW!

W7 S P Part No.: 175603

48

12.5

ø9

ø 20.5

88

ø 34

Extremely economical milling on sites with soft asphalt and heavy wearing of the steel base

ø 44

4

• New carbide technology for particularly low wear to pick heads in soft asphalt

ø 20

• Special hard soldering process to ensure a high-strength joint between the carbide and the steel base • Hardened pick head for optimized pick life • Pick head with ridges for improved asphalt breaking properties and optimized pick rotation

Unit of measurement in mm

• Wear plate with outer diameter of 44 mm for low degree of toolholder wear and optimized pick rotation

Our delivery service

• Centring function on the wear plate for low wear toolholder bore • Thick-walled, cylindrical R-sleeve for a constant clamping force, even over a long period of service • Prestressed R-sleeve for simple and rapid pick assembly

Packaging: Handy toolbox Quantity: 50 picks per toolbox Weight: approx. 14.5 kg per toolbox Dimensions: approx. 26 x 18.5 x 22 cm

• Long R-sleeve to minimize wear to the toolholder bore

19

Pick W7 E H for road milling machines

NEW!

W7 E H Part No.: 146000

48

20.5

ø 11

ø 20.5 ø 34

• Extremely long carbide tip for long service life

88

The pick with an impressive service life thanks to its large carbide tip ø 44

• Hardened pick head for optimized pick life

4

• Special hard soldering process to ensure a high-strength joint between the carbide and the steel base ø 20

• Wear plate with outer diameter of 44 mm for low degree of toolholder wear and optimized pick rotation • Centring function on the wear plate for low wear toolholder bore

Unit of measurement in mm

• Thick-walled, cylindrical R-sleeve for a constant clamping force, even over a long period of service • Prestressed R-sleeve for simple and rapid pick assembly

Our delivery service

• Long R-sleeve to minimize wear to the toolholder bore

Packaging: Handy toolbox Quantity: 50 picks per toolbox Weight: approx. 16.1 kg per toolbox Dimensions: approx. 26 x 18.5 x 22 cm

20

Pick W8 E H for road milling machines

NEW!

W8 E H Part No.: 126336

48

23

ø 11.5

ø 22

88

ø 34

The pick with a particularly robust carbide tip for milling the hardest pavements • Extremely robust carbide tip for milling particularly hard pavements

4

ø 44

• Special hard soldering process to ensure a high-strength joint between the carbide and the steel base • Hardened pick head for optimized pick life

ø 20

• Wear plate with outer diameter of 44 mm for low degree of toolholder wear and optimized pick rotation • Centring function on the wear plate for low wear toolholder bore

Unit of measurement in mm

• Thick-walled, cylindrical R-sleeve for a constant clamping force, even over a long period of service

Our delivery service

• Prestressed R-sleeve for simple and rapid pick assembly • Long R-sleeve to minimize wear to the toolholder bore

Packaging: Handy toolbox Quantity: 50 picks per toolbox Weight: approx. 16 kg per toolbox Dimensions: approx. 26 x 18.5 x 22 cm

21

Pick W1-10 for road milling machines W1-10 Part No.: 134728

48

25.0

ø 10.0

88

ø 27

The robust pick for milling milling concrete pavements with small milling machines • Cylindrical carbide tip for use in hard milling materials, ensuring low cutting forces and a long service life

ø 44

• Extractor groove in the pick head for drawing out the pick with the pick extractor

4

• Special hard soldering process to ensure a high-strength joint between the carbide and the steel base ø 20

• Hardened pick head for optimized pick life • Wear plate with outer diameter of 44 mm for low degree of toolholder wear and optimized pick rotation • Centring function on the wear plate for low wear toolholder bore

Unit of measurement in mm

Our delivery service

• Thick-walled, cylindrical R-sleeve for a constant clamping force, even over a long period of service • Prestressed R-sleeve for simple and rapid pick assembly • Long R-sleeve to minimize wear to the toolholder bore

22

Packaging: Handy toolbox Quantity: 50 picks per toolbox Weight: approx. 14.4 kg per toolbox Dimensions: approx. 26 x 18.5 x 22 cm

Pick W1-13 for road milling machines W1-13 Part No.: 134729

48

25.0

ø 13.0

88

ø 33

The pick with an outstanding price-performance ratio for cutting hard materials • Cylindrical carbide tip for use in hard milling materials, ensuring low cutting forces and a long service life 4

ø 44

ø 20

• Special hard soldering process to ensure a high-strength joint between the carbide and the steel base • Hardened pick head for optimized pick life • Wear plate with outer diameter of 44 mm for low degree of toolholder wear and optimized pick rotation

Unit of measurement in mm

• Centring function on the wear plate for low wear toolholder bore

Our delivery service

• Thick-walled, cylindrical R-sleeve for a constant clamping force, even over a long period of service • Prestressed R-sleeve for simple and rapid pick assembly • Long R-sleeve to minimize wear to the toolholder bore

Packaging: Handy toolbox Quantity: 50 picks per toolbox Weight: approx. 16.5 kg per toolbox Dimensions: approx. 26 x 18.5 x 22 cm

23

Selection table 2005 for road milling machines Used in Machine type soft asphalt

medium-hard asphalt

hard asphalt

concrete

SF 300 C

W 350 / W 350 E

SF 500 C-C/3-C/4 W4 E

W1-10

Part No.: 175592

Part No.: 134728

W 50

W 500

W 50 DC

500 DC

W 600 DC W5 E

W6 E

W1-13

Part No.: 128301

Part No.: 158400

Part No.: 134729

W5 H

W6 E H

Part No.: 121475

Part No.: 178386

SF 1000 C / CBA

W 1000

W 1000 L

24

Used in Machine type soft asphalt

medium-hard asphalt

hard asphalt

concrete

W 1000 F

W 1200 F W6 E

W6

Part No.: 158400

Part No.: 128302

W6 E H

W6 H

W1-13

Part No.: 178386

Part No.: 126696

Part No.: 134729

W6

W7 E H

W8 E H

Part No.: 128302

Part No.: 146000

Part No.: 126336

W 1300 F

1300 - 1500 DC

W7 S P Part No.: 175603

1900 - 2000 DC

W 1500

W 1900

W 2000

2100 DC

W 2100

W 2200

W6 H Part No.: 126696

25

Pick W6 S for cold recyclers and soil stabilizers W6 S Part No.: 175602

48

17.5

ø 10.5

ø 19

88

ø 37

The all-round pick for cold recycling and soil stabilizing • Long, sturdy carbide tip for all-round use in large milling machines ø 44

4

• Special hard soldering process to ensure a high-strength joint between the carbide and the steel base • Hardened pick head for optimized pick life • Particularly large pick head for long service life

ø 20

• Wear plate with outer diameter of 44 mm for low degree of toolholder wear and optimized pick rotation • Centring function on the wear plate for low wear toolholder bore • Thick-walled, cylindrical R-sleeve for a constant clamping force, even over a long period of service

Unit of measurement in mm

Our delivery service

• Prestressed R-sleeve for simple and rapid pick assembly • Long R-sleeve to minimize wear to the toolholder bore Packaging: Handy toolbox Quantity: 40 picks per toolbox Weight: approx. 13.8 kg per toolbox Dimensions: approx. 26 x 18.5 x 22 cm

26

Pick W1-13 for cold recyclers and soil stabilizers W1-13 Part No.: 134729

48

25.0

ø 13.0

88

ø 33

The pick for stabilizing soil studded with rock • Cylindrical carbide tip for use in hard milling materials, ensuring low cutting forces and a long service life

4

ø 44

• Special hard soldering process to ensure a high-strength joint between the carbide and the steel base • Hardened pick head for optimized pick life

ø 20

• Wear plate with outer diameter of 44 mm for low degree of toolholder wear and optimized pick rotation Unit of measurement in mm

• Centring function on the wear plate for low wear toolholder bore

Our delivery service

• Thick-walled, cylindrical R-sleeve for a constant clamping force, even over a long period of service • Prestressed R-sleeve for simple and rapid pick assembly

Packaging: Handy toolbox Quantity: 50 picks per toolbox Weight: approx. 16.5 kg per toolbox Dimensions: approx. 26 x 18.5 x 22 cm

• Long R-sleeve to minimize wear to the toolholder bore

27

Pick W6 / 22 for cold recyclers and soil stabilizers W6 / 22 Part No.: 146004

51

17.5

ø 10.5

ø 19 ø 40

• Long, sturdy carbide tip for all-round use in large milling machines

92

The economical all-round pick for recycling and soil stabilizing ø 44

• Hardened pick head for optimized pick life

5

• Special hard soldering process to ensure a high-strength joint between the carbide and the steel base ø 22

• Particularly large pick head for long service life • Wear plate with outer diameter of 44 mm for low degree of toolholder wear and optimized pick rotation

Unit of measurement in mm

• Centring function on the wear plate for low wear toolholder bore • Thick-walled, cylindrical R-sleeve for a constant clamping force, even over a long period of service

Our delivery service

• Prestressed R-sleeve for simple and rapid pick assembly • Long R-sleeve to minimize wear to the toolholder bore Packaging: Handy toolbox Quantity: 40 picks per toolbox Weight: approx. 16.5 kg per toolbox Dimensions: approx. 26 x 18.5 x 22 cm

28

Pick W8 / 22 for cold recyclers and soil stabilizers W8 / 22 Part No.: 146005

NEW!

51

20

ø 11.5

ø 22

92

ø 40

The robust pick for recycling and soil stabilizing • Extremely robust carbide tip for milling particularly hard pavements

ø 44

5

• Special hard soldering process to ensure a high-strength joint between the carbide and the steel base

ø 22

• Hardened pick head for optimized pick life • Particularly large pick head for long service life • Wear plate with outer diameter of 44 mm for low degree of toolholder wear and optimized pick rotation

Unit of measurement in mm

• Centring function on the wear plate for low wear toolholder bore

Our delivery service

• Thick-walled, cylindrical R-sleeve for a constant clamping force, even over a long period of service • Prestressed R-sleeve for simple and rapid pick assembly • Long R-sleeve to minimize wear to the toolholder bore

Packaging: Handy toolbox Quantity: 40 picks per toolbox Weight: approx. 17.2 kg per toolbox Dimensions: approx. 26 x 18.5 x 22 cm

29

Pick W1-13 / 22 for cold recyclers and soil stabilizers W1-13 / 22 Part No.: 175604

51

25.0

ø 13.0

ø 40

• Cylindrical carbide tip for use in hard milling materials, ensuring low cutting forces and a long service life

92

The pick for stabilizing soil studded with rock

ø 44

• Hardened pick head for optimized pick life

5

• Special hard soldering process to ensure a high-strength joint between the carbide and the steel base ø 22

• Particularly large pick head for long service life • Wear plate with outer diameter of 44 mm for low degree of toolholder wear and optimized pick rotation

Unit of measurement in mm

• Centring function on the wear plate for low wear toolholder bore • Thick-walled, cylindrical R-sleeve for a constant clamping force, even over a long period of service

Our delivery service

• Prestressed R-sleeve for simple and rapid pick assembly • Long R-sleeve to minimize wear to the toolholder bore Packaging: Handy toolbox Quantity: 40 picks per toolbox Weight: approx. 17.4 kg per toolbox Dimensions: approx. 26 x 18.5 x 22 cm

30

Pick W1-17 / 22 for cold recyclers and soil stabilizers W1-17 / 22 Part No.: 146002

51

28.5

ø 17

92

ø 40

The extremely robust pick for soil stabilizing under extreme conditions • Very large and robust cylindrical carbide tip for use with particularly high impact loads

5

ø 44

ø 22

• Special hard soldering process to ensure a high-strength joint between the carbide and the steel base • Hardened pick head for optimized pick life • Particularly large pick head for long service life • Wear plate with outer diameter of 44 mm for low degree of toolholder wear and optimized pick rotation

Unit of measurement in mm

• Centring function on the wear plate for low wear toolholder bore

Our delivery service

• Thick-walled, cylindrical R-sleeve for a constant clamping force, even over a long period of service • Prestressed R-sleeve for simple and rapid pick assembly

Packaging: Handy toolbox Quantity: 40 picks per toolbox Weight: approx. 17.9 kg per toolbox Dimensions: approx. 26 x 18.5 x 22 cm

• Long R-sleeve to minimize wear to the toolholder bore

31

Picks for WR 2000, WR 2500 S and Raco 350

32

Selection table 2005 for recyclers Application

Shank

WR 2000 - WR 2500 - WR 2500 S

20 mm

W6 S

Raco 350

Part No.: 175602

Soil stabilization

W6 / 22

W6 / 22

Part No.: 146004

Part No.: 146004

W8 / 22

W8 / 22

Part No.: 146005

Part No.: 146005

22 mm

20 mm

W1-13 Part No.: 134729

Stabilization of stony soil

W1-13 / 22

W1-13 / 22

Part No.: 175604

Part No.: 175604

W1-17 / 22

W1-17 / 22

Part No.: 146002

Part No.: 146002

22 mm

20 mm

W6 S Part No.: 175602

W6 / 22

Cold recycling

Part No.: 146004

22 mm W8 / 22 Part No.: 146005

33

Picks for Surface Miners 95744 155281

W 47 K15 Locking ring

Part No.: Part No.:

ø 54

ø 17.5

24

28 ø 54

W 47 K22 LE Locking ring

Part No.: 97442 Part No.: 155281

W 47 K24 LE Locking ring

Part No.: 185018 Part No.: 155281

ø 54

77

77

ø 54

ø 11.5

ø 17

20

30

ø 19

28.5

ø 15

70225 155281

48350 155281

77

77

Part No.: Part No.:

Part No.: Part No.:

ø 54

ø 13

ø 22

34

W 47 K17 Locking ring

77

ø 54

W 47 K19 Locking ring

47571 155281

18.7

Part No.: Part No.:

77

W 47 K13 Locking ring

ø 24

Selection table 2005 for Surface Miners Applications The applications listed here are guide numbers. The cuttability, cutting performance and pick wear depend upon the uniaxial pressure strength, the tensile strength, abrasiveness, crevasse formation and inhomogenity.

Machine type

Soft layers

Medium-hard layers

Hard layers

Very hard layers

Sand, clay, marl, lignite

Limestone, bituminous coal, marl, sandstone

Hard limestone, carboniferous sandstone, dolomite

Granite, dolomite, hard limestone

Compressive strength 0 - 20 N/mm2

Compressive strength 20 - 50 N/mm2

Compressive strength 50 - 80 N/mm2

Compressive strength over 80 N/mm2

2100 SM and 2200 SM W47 K22 LE

W47 K13

W47 K15

W47 K17

W47 K19

Part No.: 97442 Part No.: 95744 Part No.: 47571 Part No.: 48350 Part No.: 70225

2500 SM

W47 K13

W47 K15

W47 K17

W47 K19

W47 K24 LE

Part No.: 95744

Part No.: 47571

Part No.: 48350

Part No.: 70255

Part No.: 185018

3700 SM

W47 K15

W47 K17

W47 K19

W47 K24 LE

Part No.: 47571

Part No.: 48350

Part No.: 70255

Part No.: 185018

4200 SM

W47 K15

W47 K17

W47 K19

Part No.: 47571

Part No.: 48350

Part No.: 70255 Part No.: 185018

W47 K24 LE

35

Original Wirtgen quick-change toolholder systems – The standard of quality and economy Optimized systems for picks and toolholders Toolholders are highly stressed components. Almost the entire engine power is converted into cutting performance via the toolholders. When cutting through extremely hard materials, a toolholder must withstand up to five million load cycles during its service life and guarantee optimum rotation of the picks. That is why Wirtgen engineers attach particular importance to using extremely wearresistant materials and optimally designed toolholder systems.

Wirtgen – setting standards in toolholder systems Instead of welding the toolholders onto the drum as in older machines, Wirtgen´s concept was to develop holders which could be replaced quickly and easily. The first generation of Wirtgen quickchange toolholders was ready for series production in 1992 and ensured that worn or damaged toolholders could be replaced in a matter of minutes: on site and without requiring any cut-off or welding machines. The cash value of this advantage was immediately appreciated by the contractors. In addition to being easy to replace, the Wirtgen quick-change toolholder systems are characterized by a long service life, thanks to the elimination of welds and the use of high-quality materials. The success of Wirtgen´s unique quick-change toolholder systems is due not only to the detailed theoretical analyses and computer simulations, but also to exhaustive practical tests by customers on innumerable sites and in extreme special jobs.

Wirtgen's quick-change toolholder systems (HT3 Plus shown here) set new standards for quick pick changes and accurate positioning of the toolholders: on-site replacement is a simple matter.

36

Top quality manufacturing The operating costs of road milling machines and recyclers are largely determined by the service life of the tools subject to wear, meaning the picks and the toolholders. Consequently, these parts must meet the highest quality requirements. Manufacturing by the forging method makes it possible to process quality materials at relatively low cost and achieve extremely high component strengths. Tight tolerances are maintained by subsequent machining to make the precision components required for milling applications such as fine milling. Subsequent heat treatment and hardening of the toolholders is of critical importance. Special methods are used for this step as well, in order to obtain high hardness for low wear, and the necessary toughness. Only in this way can a long service life be achieved under the highly dynamic loads generated by the milling process.

Forging process for the upper part of the quick-change toolholder.

High-precision, automatic machining of the upper part of the quick-change toolholder.

A delight for every contractor and machine operator: the quick-change toolholders from Wirtgen not only cut costs, but are also easy to replace on site.

37

Low operating costs thanks to controlled wear Toolholders that wear evenly produce optimum milling results

ca. 25 mm

Increasingly strict quality requirements imposed on construction companies by road building authorities necessitate continuous improvements in the performance of construction machinery. Wirtgen road milling machines live up to these requirements with their high-precision milling drums and intelligent levelling systems. However, the wear displayed by the individual toolholders on a milling drum differs increasingly as time goes on, which results in uneven surfaces. For this reason, it is very important for machine operators to be able to accurately assess the wear of the individual toolholders, so that an optimum milled surface can be obtained again after changing the upper parts. Controlled wear thus ensures ideal milling results, even after the milling drums and toolholders have been in use for a long time.

20 mm + 12 mm = 32 mm

Different wear patterns on the picks and toolholders cause irregular surfaces.

38

Assessing toolholder wear by means of wear markers

New

20

Toolholder wear is generally influenced by numerous parameters, including the specific characteristics of the machine being used, such as engine output, milling width, milling depth and spacing on the milling drum. Environmental conditions, such as the material to be removed and the temperature at which milling is performed, also play a key role. Therefore, continuously observing wear is of crucial importance for obtaining consistently good milling results. Virtually all Wirtgen toolholder systems now have wear markers that help to accurately assess wear. The markers make it easy to determine the best time to replace a toolholder.

Old

Old

8

New

Unit of measurement in mm

25

Large milling machines max 20

Large milling machines min

15

Small milling machines max Small milling machines average Small milling machines min

Longitudinal wear in mm

Large milling machines average

10

5

0

100 200 300 400 500 600 700 800 Operation hours Longitudinal wear of toolholders in large-volume and small milling machines as a function of operating hours.

900

1000

1200

39

The new Wirtgen HT11 quick-change toolholder Designed to meet practical requirements The new, rugged HT11 quickchange toolholder system After many years of development and extensive testing, the new HT11 quickchange toolholder system for largevolume milling machines will be installed in Wirtgen milling machines as standard equipment starting in 2005. The primary design objective of Wirtgen's engineers was to ensure simple and quick operation and maintenance for machine users. The result of their efforts is a complete system comprising pick, milling drum and milling machine, which has been enhanced by a variety of detail solutions and will further cut operating costs for customers.

40

Wear markers at intervals of 5 mm

Up to 20 percent longer service life of the upper part thanks to System 44

Complete coverage by the upper part provides improved protection of the bottom part Chip breaking web for additional crushing of milled material Optimised shank angle geometry for greater component strength

Protective plug for bolt head

Conical stud for reliable transmission of clamping force

Contact surface between upper and bottom parts increased by 35 percent to prolong the surface life of the bottom part Strong fixing screw with M30x2 thread and 17 mm hexagon socket

Seal between upper and bottom parts for simple and quick assembly/dismantling of the upper part

41

The essential advantages of the new HT11 Strong retaining bolt The retaining bolt is significantly larger than the one used in the HT3 quickchange toolholder system. The external M30x2 thread is now combined with a 17 mm hexagon socket drive, which reliably transfers the necessary torque of 500 Nm. The conical stud can transmit enormous clamping forces and thus minimises any loosening of the upper part on its own.

HT3 HT11

Bottom part covered by upper part Enlargening the contact surface of the upper part to completely cover that of the bottom part ensures an absolutely even and tight fit between the two. As a result, when the upper part needs to be quickly replaced on a job site, the bottom part requires only minimal cleaning, meaning that changes can be made more quickly and easily.

Seal between upper and bottom parts During the milling process fine dirt particles combined with water enter into the gap between upper and bottom part and occasionally cause the shank of the upper part to jam in the bottom part making it more difficult to replace the upper part. In the new HT11 quick-change toolholder system, the bore in the bottom part is protected by a seal against contamination. The seal optimises the position of the upper part in the bottom part, and even further reduces the time required to change parts.

42

The wearing parts of the new HT11 The HT11 quick-change toolholder system for simple operation and maintenance of the milling drum

Retainer screw HT11 M30x2 Torque 500 Nm Part No.: 158501

In designing the new HT11 quickchange toolholder system, priority was given to simple operation and reliable maintenance in rough use at a job site. The result is simple components that together guarantee a long service life for all wear parts and the entire milling drum. As with the HT3 quick-change toolholder system, just a few parts are needed to equip a wide variety of milling drums.

Toolholder HT11 for shaft diameter D20 Part No.: 158500

Toolholder HT11 D22 for shaft diameter D22 Part No.: 158510

Bottom part sealing HT11 Part No.: 158509

Hexagon plug HT11 Part No.: 158508

43

Quick-change toolholder system HT3 Plus The quick-change toolholder system HT3 is a further development of the first generation of Wirtgen’s quick-change toolholders taking practical experience into account. The system was decisively optimized in 2001 when the contact surface of the wear plate was increased by more than 50% to 44 mm, thus reducing wear on both the pick and the toolholder. Since then, the “HT3 Plus” system has been installed on all new milling drums. In addition to the contact surface, the protective cladding on the upper part has also been enlarged. The additional wear volume similarly extends the service life.

Toolholder HT3 plus D20 for shaft diameter D20 Part No.: 128299

44

• Standard upper part for picks with 20 mm shank for - Cold milling machines W 600 DC, W 1000 L, W1000, W 1000 F, W1200 F, W 1300 F, 1300-2000 DC, W 1500, W 1900, W 2000, 2100 DC,W 2100 and W 2200 - recycler WR 2500 and WR 2500 S

Retainer screw HT3 M24x2 Torque 500 Nm Part No.: 79998

• Special upper part for picks with 22 mm shank - for recycler WR 2500, WR 2500 S and soil stabilizer Raco 350 • Dummy upper part to protect the bottom part of the quick-change toolholder in modified pick arrangements for - milling machines with fine milling drums - recycler WR 2500 and WR 2500 S Toolholder HT3 plus D22 for shaft diameter D22 Part No.: 98241

Dummy upper part Part No.: 101472

Hexagon plug HT3 Part No.: 126110

Upper part reliably supported by bottom part

Hexagon plug for screw protection

Large contact surface, Ø 44 mm, for low wear and tear

Wear marker for simple monitoring

Optimized head shape for better wear values

Same upper part for all milling drums

Screw without limiting stop, with self-locking thread

Pentagonal shank for accurate positioning

45

• Standard upper part for picks with 20 mm shank - for milling machines W 1000 F, 1300-2000 DC and 2100 DC • Standard upper part for picks with 20 mm shank - for milling machine W 1000 - for recycler WR 2500

• Correcting upper part with modified square shank for use on milling drums with more than 2000 hours of operation - for milling machines 1300-2000 DC and 2100 DC • Dummy upper part to protect the bottom part of the quick-change toolholder in modified pick arrangements - for milling machines with fine milling drums - for recycler WR 2500

• Special upper part for picks with 22 mm shank - for recycler WR 2500

56

The quick-change toolholder system HT2 was especially developed for a wide variety of machine types and applications.

16

Quick-change toolholder system HT2 (1992 – 1996)

Example of wear: approx. 800 hours of operation with a 2100 DC

Optimum work throughout the whole service life.

56

56

Quick-change toolholder system HT2 – upper parts with 20 mm shank

56

ø2 0

ø 20

ø 20

Correcting toolholder HT2 Part No.: 82755

Toolholder HT2 – 170 Part No.: 74801

Toolholder HT2 Part No.: 49765

46

50

67

Retaining screw HT2 Torque 400 Nm Part No.: 56290 ø 30

M 20 x 2.5

56

56

Quick-change toolholder system HT2 – upper parts with 22 mm shank

ø2 2

ø 22

Dummy upper part Part No.: 89888

Toolholder HT2 - 170 D22 (Optional) Part No.: 97180

Toolholder HT2 D22 (Optional) Part No.: 59308

47

Welded toolholders for road milling machines Small toolholders for miniature pick systems The miniature pick system is used on milling drums or various cutting wheels requiring extremely small installed sizes. Two types are available here: • HT04: Wrought toolholder for miniature picks without positioning. • HT4: Socket-type toolholders for miniature picks with precise positioning in a prepared milling drum tube.

Toolholder HT04 for shaft diameter D13 Part No.: 57629

Toolholders for 20 mm shank diameter These toolholders represent the worldwide standard for the conventional shank diameter of round shank picks for road milling machines. Good weldability and a long service life are due to the use of high-quality materials and special tempering processes. The following types are available: • Toolholder HT02 and HT03: Simple wrought toolholders without positioning.

48

Toolholder HT4 for shaft diameter D13 Part No.: 72258

Toolholder HT03 for shaft diameter D20 Part No.: 5243

Toolholder HT02 for shaft diameter D20 Part No.: 5244

• Toolholder HT01: Tried-and-tested nopped holder with enlarged contact area (diameter 42 mm) and two positioning pins for accurate positioning on the welded helical elements. The toolholders are chamfered for easier welding. • Toolholder HT5: Socket-type toolholders for round shank picks with accurate positioning on a prepared milling drum tube. • Edge protectors: Triple toolholders with preset contact angles. Primarily used in the outer ring areas of milling drums on large machines.

Toolholder HT01 for shaft diameter D20 Part No.: 36780

Toolholder HT5 for shaft diameter D20 Part No.: 74745

Edge protector 3-er for shaft diameter D20 Part No.: 69902

49

Welded toolholders for Surface Miners Highly robust toolholders for Surface Miners The toolholders on Surface Miners are subjected to extremely high stresses, particularly when cutting through hard rock. Unlike the relatively homogeneous structure of an asphalt pavement, the irregular rock formations can cause enormous peak loads on the individual toolholders. For this reason, special systems have been developed in which all the components and their connections on the milling drum are adapted specifically to the loads encountered. • Toolholder HT06: Heavy-duty nopped holder with two positioning pins for accurate positioning on the welded helical elements. The toolholders are chamfered for easier welding. • Toolholder HT6: Socket-type toolholder for round shank picks with precise positioning on the prepared bottom part of the milling drum tube. The toolholder is specially shaped in relation to the bottom part so that high loads can be transmitted, but only small loads are applied to the welds during operation. The increased wall thickness of the toolholder head offers sufficient reserve strength to permit use on machines with higher drive ratings.

Toolholder HT06 for shaft diameter D38-30 Part No.: 78556

Toolholder HT6 for shaft diameter D38-30 Part No.: 95781

50

Ejectors Long-life ejectors Optimally arranged ejectors on the milling drum facilitate the direct transfer of the reclaimed asphalt pavement (RAP) from the drum chamber to the loading conveyor. These ejectors owe their long service life to a special steel alloy containing mixed carbides. • 150 mm wide ejectors for machines W 600 DC, W 1000 L, W 1000, W 1000 F, W 1200 F and W 1300 F. • 250 mm wide ejectors for machines 1300 - 2000 DC, W 1500, W 1900, W 2000, 2100 DC, W 2100 and W 2200.

Ejector width 150 Part No.: 45220

Ejector width 250 Part No.: 44097

51

Milling drums from the market leader The leader in engineering design and production of milling drums Milling drums designed and produced in the Windhagen plant form the central element of the Wirtgen road milling machines known throughout the world. The mere fact that Wirtgen is a market leader in this sector explains the importance of cutting technology within the company. It also explains why Wirtgen has continuously invested in expanding this central area of competence to the benefit of the company’s customers. Both the design of standard milling drums as well as the design of special milling aggregates is done using modern CAD-equipment.

Top quality: proven professionals and modern welding technology in the production hall.

The key to versatile milling machines Operators want to use their milling machines for as many different jobs as possible. That is why Wirtgen supplies a large variety of optional drums as part of its standard range. This allows the customer to engage in a wealth of applications for machining pavements, performing recycling contracts or in the selective extraction of hard rock. The decision to buy a Wirtgen machine is underlined by this versatility. Accuracy: the optimized design data are processed in the CNC-controlled tacking line. This ensures that each toolholder is positioned precisely.

52

Special projects bring proximity to the customer New requirements are repeatedly imposed upon the construction industry and that is why almost never a day passes without Wirtgen receiving at least one enquiry for a solution using milling technology. And solutions have evidently been found, as proved by the numerous special milling drums supplied for machines built by Wirtgen and other companies, as well as for special machines, such as stationary processing plants or even minesweepers.

The engineering design and production departments are equipped with stateof-the-art CAD- and CNC-technology so that these solutions can be realized cost-efficiently. The new product is born on a computer screen and based on decades of experience accumulated by the engineering and production experts. It is then optimized with the aid of intelligent computer programs. Finally, after corresponding simulations and analyzes, and after approval by the competent project manager, the data are transferred online to the production department so that the customer can use his special milling drum on-site in the shortest possible space of time.

Pavement markings are removed quickly and accurately with a special unit.

Milling drum

Fine milling drum

Saw blade

Cutting wheel

Micro fine milling drum

Micro fine milling drum

A choice of different drums for the W 350 showing the various possibilities of the original Wirtgen milling drums.

53

Original Wirtgen fine milling drums for new milling jobs with optimized surface results Fine milling drum LA6x2 Fine milling drum LA8 pick spacing: pick spacing: 6 x 2 mm 8 mm

Milling drum LA15 pick spacing: 15 mm

Fine milling is setting new standards in milling results world-wide By special and precise finishing processes Wirtgen can nowadays design pick spacings up to 3 mm. So milling contractors are offered a multitude of new applications: Their Wirtgen milling machines can work on sites with high quality demands on the surface. The new patented Flexible Cutter System (FCS) makes the milling drum exchange much easier.

The various uses of Wirtgen fine milling drums

Improving the skid resistance of the pavement

Restoring the evenness / levelling

Preparing to apply thin pavement layers

Preparing the pavement for the application of road markings

Milling off resin surfaces / synthetic surfaces in factory halls

Removing surface courses exposed to high traffic loads

54

meanwhile

4.33

Milling

Fine milling

2.31

Pick spacing 15 mm

1.73

Pick spacing 8 mm

1.15

Pick spacing 5 mm

Pick spacing 4 mm 0.87

Micro fine milling

1.44

Pick spacing 6 mm

Pick spacing 3 mm

55

Original Wirtgen milling drums delivery range 2005

Machine

Milling drum

Machine type

Part No.

Type

Milling width*

Pick spacing*

Milling depth*

System Qty.

Part No.

Qty.

300 C

52990

Milling drum

300

15

60

HT03

28

5243

28

4935

Fine milling drum

300

8

40

HT03

43

5243

43

72259

Micro fine milling drum Micro fine milling drum

250 +2x25

4

30

HT04

76

57629

76

300

4

30

HT04

76

57629

76

68850

Milling drum

350

12

100

HT01

36

36780

36

133848

Milling drum

500

12

100

HT01

47

36780

47

105073

Milling drum

200

10

100

HT02

29

5244

29

151642

Milling drum

100

10

100

HT02

16

5244

16

139699

Fine milling drum

450 +2x25

6 x2

30

HT4

164

72258

164

81564

Fine milling drum

300 +2x25

6 x2

30

HT4

116

72258

116

72257

Fine milling drum

350

6 x2

30

HT4

116

72258

116

74737

Fine milling drum

350

6

50

HT5

57

74745

57

129694

Micro fine milling drum Micro fine milling drum Micro fine milling drum

300 +2x25

3

30

HT4

117

72258

117

150 +2x25

3

30

HT4

67

72258

67

350

3

30

HT4

117

72258

117

105487

Cutting wheel

80

160

HT02

18

5244

18

86750

Saw blade

19

100

18

78569

Saw blade

14

100

24

85092 W 350

134590 140808

* Unit of measurement in mm

56

Toolholder

Picks

Original Wirtgen milling drums delivery range 2005

Machine

Milling drum

Machine type

Part No.

Type

Milling width*

Pick spacing*

Milling depth*

System Qty.

Part No.

Qty.

W 50

166076

Milling drum

500

15

160

HT01

50

36780

50

172193

Milling drum

400

12

160

HT01

46

36780

46

172195

Milling drum

300

12

160

HT01

38

36780

38

Fine milling drum

500

6

50

HT5

82

74745

82

300 +2x25

3

30

HT4

117

72258

117

500

3

30

HT5

166

74745

166

15

160

HT5

40

74745

40

160

HT02

24

5244

24

172199

W 50 DC

Picks

179276

Micro fine milling drum Micro fine milling drum

176725

Milling drum (curb)

500

172197

Cutting wheel

80

67920

Milling drum

500

15

160

HT01

50

36780

50

89502

Fine milling drum

500

6

50

HT5

82

74745

82

56855

Cutting wheel

80

220

HT02

24

5244

24

113292

Saw blade

19

120

16

79855

Saw blade

14

120

24

166444

Milling drum

500

15

210

HT01

50

36780

50

178814

Milling drum

400

12

210

HT01

46

36780

46

178815

Milling drum

300

12

210

HT01

38

36780

38

183191

Fine milling drum

450 +2x25

6 x2

30

HT4

164

72258

164

177179

Fine milling drum

500

6

50

HT5

82

74745

82

178362

Micro fine milling drum

500

3

30

HT4

166

72258

166

183119

Cutting wheel

80

210

HT02

24

5244

24

179301

Cutting wheel

80

300

HT02

30

5244

30

172201

W 500

Toolholder

* Unit of measurement in mm

57

Original Wirtgen milling drums delivery range 2005

Machine

Milling drum

Machine type

Part No.

Type

Milling width* Pick spacing*

Milling depth*

System

Qty.

Part No.

Qty.

W 600 DC

185260

Milling drum

600

15

300

HT11

54

158500

66

185276

Milling drum

500

15

300

HT11

46

158500

58

185277

Milling drum

400

15

300

HT11

40

158500

52

185278

Milling drum

300

15

250

HT11

32

158500

56

111335

Cutting wheel

80

250

HT02

36

5244

36

184990

Milling drum

1000

15

250

HT11

80

158500

92

185272

Fine milling drum

1000

8

100

HT11

130

158500

130

71250

Milling drum

1000

15

180

HT01

80

36780

84

184990

Milling drum

1000

15

250

HT11

80

158500

92

185272

Fine milling drum

1000

8

100

HT11

130

158500

130

185280

Milling drum

1000

15

300

HT11

84

158500

102

161484

Fine milling drum

1000

6 x2

30

HT5

340

74745

340

185279

Fine milling drum

1000

8

100

HT11

131

158500

149

185288

FCS-milling drum

1000

15

300

HT11

84

158500

102

185286

FCS-milling drum

900

15

300

HT11

84

158500

102

185296

FCS-milling drum

750

15

300

HT11

66

158500

84

185285

FCS-milling drum

600

12

300

HT11

62

158500

80

185313

FCS-milling drum

500

15

300

HT11

48

158500

72

185309

FCS-milling drum

300

12

300

HT11

31

158500

55

150396

FCS-fine milling drum FCS-fine milling drum FCS-fine milling drum

1000

6 x2

30

HT5

340

74745

340

1000

8

100

HT11

131

158500

149

1000

6

50

HT11

168

158500

168

W 1000 L

W 1000

04.10 W 1000 F

185295 185319

* Unit of measurement in mm

58

Toolholder

Picks

Original Wirtgen milling drums milling drum table HT3 plus (until 2004)

Machine

Milling drum

Machine type

Part No.

Type

Milling width* Pick spacing*

Milling depth*

System

Qty.

Part No.

Qty.

W 600 DC

99250

Milling drum

600

15

300

HT3 plus

54

128299

66

102291

Milling drum

500

15

300

HT3 plus

46

128299

58

104142

Milling drum

400

15

300

HT3 plus

40

128299

52

110917

Milling drum

300

15

250

HT3 plus

32

128299

56

79852

Milling drum

1000

15

250

HT3 plus

80

128299

92

97419

Fine milling drum

1000

8

100

HT3 plus

130

128299

130

79852

Milling drum

1000

15

250

HT3 plus

80

128299

92

97419

Fine milling drum

1000

8

100

HT3 plus

130

128299

130

93480

Milling drum

1000

15

300

HT3 plus

84

128299

102

111304

Fine milling drum

1000

8

100

HT3 plus

131

128299

149

136275

FCS-milling drum

1000

15

300

HT3 plus

84

128299

102

128230

FCS-milling drum

900

15

300

HT3 plus

84

128299

102

148980

FCS-milling drum

750

15

300

HT3 plus

66

128299

84

128225

FCS-milling drum

600

12

300

HT3 plus

62

128299

80

164404

FCS-milling drum

500

15

300

HT3 plus

48

128299

72

162754

FCS-milling drum

300

12

300

HT3 plus

31

128299

55

1000

8

100

HT3 plus

131

128299

149

1000

6

50

HT3 plus

168

128299

168

W 1000 L

W 1000 05.10 W 1000 F

147285 180189

FCS fine milling drum FCS fine milling drum

Toolholder

Picks

* Unit of measurement in mm

59

Original Wirtgen milling drums delivery range 2005

Machine

Milling drum

Machine type

Part No.

Type

Milling width*

Pick spacing*

Milling depth*

System Qty.

Part No.

Qty.

W 1200 F

185290

Milling drum

1200

15

300

HT11

97

158500

115

185284

Fine milling drum

1200

8

100

HT11

156

158500

174

185287

FCS-milling drum

1200

15

300

HT11

97

158500

115

185288

FCS-milling drum

1000

15

300

HT11

84

158500

102

185286

FCS-milling drum

900

15

300

HT11

84

158500

102

185296

FCS-milling drum

750

15

300

HT11

66

158500

84

185285

FCS-milling drum

600

12

300

HT11

62

158500

80

185313

FCS-milling drum

500

15

300

HT11

48

158500

72

185309

FCS-milling drum

300

12

300

HT11

31

158500

55

1200

6 x2

30

HT5

410

74745

410

1200

8

100

HT11

156

158500

174

179345 185297 W 1300 F

Picks

185281

Milling drum

1320

15

300

HT11

105

158500

123

185312

FCS-milling drum

1320

15

300

HT11

105

158500

123

185287

FCS-milling drum

1200

15

300

HT11

97

158500

115

185288

FCS-milling drum

1000

15

300

HT11

84

158500

102

185286

FCS-milling drum

900

15

300

HT11

84

158500

102

185296

FCS-milling drum

750

15

300

HT11

66

158500

84

185313

FCS-milling drum

500

15

300

HT11

62

158500

80

185285

FCS-milling drum

600

12

300

HT11

48

158500

72

185309

FCS-milling drum

300

12

300

HT11

31

158500

55

185308

FCS-fine milling drum

1320

8

100

HT11

170

158500

188

* Unit of measurement in mm

60

FCS-fine milling drum FCS-fine milling drum

Toolholder

Original Wirtgen milling drums milling drum table HT3 plus (until 2004)

Machine

Milling drum

Machine type

Part No.

Type

Milling width* Pick spacing*

Milling depth*

System

Qty.

Part No.

Qty.

W 1200 F

106177

Milling drum

1200

15

300

HT3 plus

97

128299

115

123788

Fine milling drum

1200

8

100

HT3 plus

156

128299

174

128240

FCS-milling drum

1200

15

300

HT3 plus

97

128299

115

136275

FCS-milling drum

1000

15

300

HT3 plus

84

128299

102

128230

FCS-milling drum

900

15

300

HT3 plus

84

128299

102

148980

FCS-milling drum

750

15

300

HT3 plus

66

128299

84

128225

FCS-milling drum

600

12

300

HT3 plus

62

128299

80

164404

FCS-milling drum

500

15

300

HT3 plus

48

128299

72

162754

FCS-milling drum

300

12

300

HT3 plus

31

128299

55

150350

FCS-fine milling drum

1200

8

100

HT3 plus

156

128299

174

115294

Milling drum

1320

15

300

HT3 plus

105

128299

123

163850

FCS-milling drum

1320

15

300

HT3 plus

105

128299

123

128240

FCS-milling drum

1200

15

300

HT3 plus

97

128299

115

136275

FCS-milling drum

1000

15

300

HT3 plus

84

128299

102

128230

FCS-milling drum

900

15

300

HT3 plus

84

128299

102

148980

FCS-milling drum

750

15

300

HT3 plus

66

128299

84

164404

FCS-milling drum

500

15

300

HT3 plus

62

128299

80

128225

FCS-milling drum

600

12

300

HT3 plus

48

128299

72

162754

FCS-milling drum

300

12

300

HT3 plus

31

128299

55

162594

FCS-fine milling drum

1320

8

100

HT3 plus

170

128299

188

W 1300 F

Toolholder

Picks

* Unit of measurement in mm

61

Original Wirtgen milling drums delivery range 2005

Machine

Milling drum

Machine type

Part No.

Type

Milling width* Pick spacing*

Milling depth*

System

Qty.

Part No.

Qty.

1300 DC

185269

Milling drum

1320

15

300

HT11

105

158500

123

185275

Fine milling drum

1320

8

100

HT11

169

158500

187

1500 DC

185268

Milling drum

1500

15

300

HT11

117

158500

135

W 1500

185268

Milling drum

1500

15

300

HT11

117

158500

135

185269

Milling drum

1320

15

300

HT11

105

158500

123

185275

Fine milling drum

1320

8

100

HT11

169

158500

187

185267

Milling drum

1905

15

300

HT11

144

158500

162

185265

Fine milling drum

1905

8

100

HT11

242

158500

260

185266

Milling drum

2010

15

300

HT11

144

158500

162

185264

Fine milling drum

2010

8

100

HT11

256

158500

274

185300

Milling drum

2000

15

300

HT11

144

158500

162

123977

Fine milling drum

2000

6 x2

30

HT5

672

74745

672

185283

Fine milling drum

2000

8

100

HT11

256

158500

274

185301

FCS-milling drum

2000

15

300

HT11

144

158500

162

144986

2000

6 x2

30

HT5

672

74745

672

185298

FCS-fine milling drum FCS-fine milling drum

2000

8

100

HT11

256

158500

274

185300

Milling drum

2000

15

300

HT11

144

158500

162

123977

Fine milling drum

2000

6 x2

30

HT5

672

74745

672

185283

Fine milling drum

2000

8

100

HT11

256

158500

274

185282

Milling drum

2200

15

300

HT11

156

158500

174

185294

Fine milling drum

2200

8

100

HT11

280

158500

298

185301

FCS-milling drum

2000

15

300

HT11

144

158500

162

144986

FCS-fine milling drum FCS-fine milling drum

2000

6 x2

30

HT5

672

74745

672

2000

8

100

HT11

256

158500

274

1900 DC

2000 DC

W 1900

W 2000

185298 * Unit of measurement in mm

62

Toolholder

Picks

Original Wirtgen milling drums milling drum table HT3 plus (until 2004)

Machine

Milling drum

Machine type

Part No.

Type

Milling width* Pick spacing*

Milling depth*

System

Qty.

Part No.

Qty.

1300 DC

96941

Milling drum

1320

15

300

HT3 plus

105

128299

123

102007

Fine milling drum

1320

8

100

HT3 plus

169

128299

187

1500 DC

96939

Milling drum

1500

15

300

HT3 plus

117

128299

135

W 1500

96939

Milling drum

1500

15

300

HT3 plus

117

128299

135

96941

Milling drum

1320

15

300

HT3 plus

105

128299

123

102007

Fine milling drum

1320

8

100

HT3 plus

169

128299

187

96937

Milling drum

1905

15

300

HT3 plus

144

128299

162

96933

Fine milling drum

1905

8

100

HT3 plus

242

128299

260

96935

Milling drum

2010

15

300

HT3 plus

144

128299

162

96931

Fine milling drum

2010

8

100

HT3 plus

256

128299

274

112000

Milling drum

2000

15

300

HT3 plus

144

128299

162

122732

Fine milling drum

2000

8

100

HT3 plus

256

128299

274

123000

FCS-milling drum

2000

15

300

HT3 plus

144

128299

162

155221

FCS-fine milling drum

2000

8

100

HT3 plus

256

128299

274

112000

Milling drum

2000

15

300

HT3 plus

144

128299

162

122732

Fine milling drum

2000

8

100

HT3 plus

256

128299

274

121230

Milling drum

2200

15

300

HT3 plus

156

128299

174

146971

Fine milling drum

2200

8

100

HT3 plus

280

128299

298

123000

FCS-milling drum

2000

15

300

HT3 plus

144

128299

162

155221

FCS-fine milling drum

2000

8

100

HT3 plus

256

128299

274

1900 DC

2000 DC

W 1900

W 2000

Toolholder

Picks

* Unit of measurement in mm

63

Original Wirtgen milling drums delivery range 2005

Machine

Milling drum

Machine type

Part No.

Type

Milling width* Pick spacing*

Milling depth*

System

Qty.

Part No.

Qty.

2100 DC

185274

Milling drum

2200

15

300

HT11

168

158500

186

185270

Milling drum

2100

15

300

HT11

150

158500

168

185263

Milling drum

2000

15

300

HT11

150

158500

168

185273

Fine milling drum

2100

8

100

HT11

270

158500

288

185271

Fine milling drum

2000

8

100

HT11

258

158500

276

185274

Milling drum

2200

15

300

HT11

168

158500

186

185270

Milling drum

2100

15

300

HT11

150

158500

168

185263

Milling drum

2000

15

300

HT11

150

158500

168

185273

Fine milling drum

2100

8

100

HT11

270

158500

288

185271

Fine milling drum

2000

8

100

HT11

258

158500

276

185310

Milling drum

2200

15

350

HT11

170

158500

188

185307

FCS-milling drum

4300

15

350

HT11

317

158500

344

185299

FCS-milling drum

3800

15

350

HT11

288

158500

315

185317

FCS-milling drum

3500

15

350

HT11

268

158500

295

185316

FCS-milling drum

3000

15

350

HT11

230

158500

262

185315

FCS-milling drum

2500

15

350

HT11

201

158500

219

185314

FCS-milling drum

2200

15

350

HT11

170

158500

188

W 2100

W 2200

* Unit of measurement in mm

64

Toolholder

Picks

Original Wirtgen milling drums milling drum table HT3 plus (until 2004)

Machine

Milling drum

Machine type

Part No.

Type

Milling width* Pick spacing*

Milling depth*

System

Qty.

Part No.

Qty.

2100 DC

99042

Milling drum

2200

15

300

HT3 plus

168

128299

186

83810

Milling drum

2100

15

300

HT3 plus

150

128299

168

85860

Milling drum

2000

15

300

HT3 plus

150

128299

168

97711

Fine milling drum

2100

8

100

HT3 plus

270

128299

288

96944

Fine milling drum

2000

8

100

HT3 plus

258

128299

276

99042

Milling drum

2200

15

300

HT3 plus

168

128299

186

83810

Milling drum

2100

15

300

HT3 plus

150

128299

168

85860

Milling drum

2000

15

300

HT3 plus

150

128299

168

97711

Fine milling drum

2100

8

100

HT3 plus

270

128299

288

96944

Fine milling drum

2000

8

100

HT3 plus

258

128299

276

120900

Milling drum

2200

15

350

HT3 plus

170

128299

188

160615

FCS-milling drum

4300

15

350

HT3 plus

317

128299

344

160184

FCS-milling drum

3800

15

350

HT3 plus

288

128299

315

164447

FCS-milling drum

3500

15

350

HT3 plus

268

128299

295

164446

FCS-milling drum

3000

15

350

HT3 plus

230

128299

262

164445

FCS-milling drum

2500

15

350

HT3 plus

201

128299

219

164444

FCS-milling drum

2200

15

350

HT3 plus

170

128299

188

W 2100

W 2200

Toolholder

Picks

* Unit of measurement in mm

65

Original Wirtgen milling drums for cold recyclers and soil stabilizer

Delivery range 2005 Machine

Milling drum

Toolholder

Machine type

Part No.

Type

Milling width* Pick spacing*

Milling depth*

System

RACO 350

185289

Milling drum

2350

16

450

WR 2000

185320

Milling drum

2000

20

185318

Milling drum

2000

WR 2500,

185304

Milling drum

WR 2500 S

185305

185306

Qty.

Picks Part No.

Qty.

HT11 D22 176

158510

208

500

HT11

134

158500

158

20

500

HT11 D22 134

158510

158

2438

30 x2

500

HT11

192

158500

216

Milling drum

2438

30 x2

500

HT11 D22 192

158510

216

Milling drum

3048

37 x2

500

HT11

158500

216

192

* Unit of measurement in mm

Milling drum table HT3 plus (until 2004) Machine

Milling drum

Machine type

Part No.

Type

Milling width* Pick spacing*

Milling depth*

System

Qty.

Part No.

Qty.

RACO 350

139227

Milling drum

2350

16

450

HT3 D22

176

98241

208

WR 2000

173490

Milling drum

2000

20

500

HT3 plus

134

128299

158

173650

Milling drum

2000

20

500

HT3 D22

134

98241

158

WR 2500,

160500

Milling drum

2438

30 x2

500

HT3 plus

192

128299

216

WR 2500 S

160720

Milling drum

2438

30 x2

500

HT3 D22

192

98241

216

160768

Milling drum

3048

37 x2

500

HT3 plus

192

128299

216

* Unit of measurement in mm

66

Toolholder

Picks

Original Wirtgen milling drums for Surface Miner

Machine

Milling drum

Machine type

Part No.

Type

Milling width* Pick spacing*

Milling depth*

System

Qty.

Part No.

Qty.

2100 SM

95819

Milling drum

2000

35

300

HT6

76

95781

76

118216

Milling drum

2000

50

250

HT6

60

95781

60

127333

Milling drum

2200

38

300

HT6

76

95781

76

141663

Milling drum

2200

76

300

HT6

46

95781

46

2200 SM

Toolholder

Picks

* Unit of measurement in mm

67

Original Wirtgen scraper blades for clean milled surfaces Long-life scraper blades The scraper on the rear panel of the milling machine seals the drum chamber so that the reclaimed asphalt pavement can be taken up cleanly. In addition, it smoothes the milled surface by shearing off the higher asphalt ridges. Carbide-tipped scrapers are used for this purpose.

Scraper blades “Type 1”

Scraper blade B100 Part No.: 56731

Scraper blade B145 Part No.: 60117

Scraper blade FB50 Part No.: 8838

Scraper blade B145 R Part No.: 56336

Scraper blade B145 L Part No.: 56335

Scraper blade B248 Part No.: 43408 • Scraper SB 50: Hardmetal elements with a scraper width of 50 mm can be replaced individually. • “Type 1” scraper blades: One-part carbide-tipped scraper blades in different widths can be screwed onto the scraper blade side-by-side in accordance with the working width of the milling machine. Hardmetal elements on the right or left ensure that these scrapers can also be fitted at the edges.

Scraper blade B248 R Part No.: 44638

Scraper blade B248 L Part No.: 44639

68

Scraper blades “Type 2”

Scraper blade B100 Type 2 Part No.: 146459

Scraper blade B145 Type 2 Part No.: 146515

The new scraper blades ensure that the reclaimed asphalt pavement is taken up cleanly and even more efficiently behind the machine. The new “Type 2” scraper blades differ from the previous scraper blades through their outer contours and through the form of the hard-metal elements. Performance has been improved in particular by the optimized position of the hard metal. “Type 2” scraper blades: One-part carbide-tipped scraper blades in different widths are screwed onto the scraper plate side-by-side in accordance with the working width of the milling machine. Hard-metal elements on the right or left ensure that these scrapers can also be fitted at the edges.

Scraper blade B145 R Type 2 Part No.: 146460

Scraper blade B145 L Type 2 Part No.: 146461

Scraper blade B248 Type 2 Part No.: 146456

Scraper blade B248 R Type 2 Part No.: 146457

Scraper blade B248 L Type 2 Part No.: 146458

69

Original Wirtgen wear protection segments for a longer life of the milling drum housing To completely enclose the side of the milling drum housing and prevent material from escaping, the side plate is in full contact with the milled surface and therefore subject to natural wear. Special wear elements are used to minimise this wear and facilitate the replacement of worn parts. The wear elements are made of particularly wearresistant material – partly tungsten carbide – and are easy to replace. The special shape of the front wear runner supports the lifting of the side plate, when the machine travels over edges with the side plate lowered.

Wear protection segments

Protector skid 50 x 625 Part No.: 155630

Protector skid 50 x 490 Part No.: 157828

Protector skid 40 x 180 Part No.: 113001

70

Side plate segments front

Side plate segments rear

Scraper wear segments

Machine type

Description

Qty.

Part No. Description

Qty.

Part No. Description

Qty.

Part No.

W 1500

Protector skid left 50 x 490

1

157828

Protector skid 40 x 180

1

113001

Protector skid right 50 x 625

1

155630

Protector skid 40 x 180

1

113001

W 1900

Protector skid 50 x 625

2

155630

Protector skid 40 x 180

2

113001

W 2000

Protector skid 50 x 625

2

155630

Protector skid 40 x 180

2

113001 Protector skid 40 x 180

8

113001

W 2100

Protector skid 50 x 625

2

155630

Protector skid 40 x 180

2

113001 Protector skid 40 x 180

8

113001

W 2200

Protector skid 50 x 625

2

155630

Protector skid 40 x 180

2

113001 Protector skid 40 x 180

8

113001

The number of the scraper wear segments is valid for the standard milling width of the corresponding milling machine.

71

Original Wirtgen conveyor belts for a high conveyor capacity The milling performance of Wirtgen milling machines is crucially determined by the conveyor belt system. Original conveyor belts from Wirtgen excel in this field, thanks to their very great wear resistance and high running smoothness. The high cleats, which are typical of Wirtgen conveyor belts, permit conveyor capacities of up to 400 tonnes per hour.

Smooth running thanks to special profile

Optimised transverse profile with integrated seal

The highest conveyor capacity thanks to the particularly high cleats

Extremely high tensile strength of up to 800 N per millimetre of belt width

High abrasion resistance plus durable elasticity

Asphalt-resistant upper layer Elastic intermediate layer Tear-resistant polyesterpolyamide textile layers (up to five layers) Base layer with optimised coefficient of friction

72

Continuous connection of cleats and upper layer due to production in one process step

Machine type

Conveyor type

Description

Part No.

W 50

Discharge conveyor

Conveyor belt B400

50002

W 50 DC

Discharge conveyor

Conveyor belt B400

97243

W 500

Discharge conveyor

Conveyor belt B400

50002

W 600 DC, W 1000 L

Discharge conveyor

Conveyor belt B400

97243

W 1000

Discharge conveyor

Conveyor belt B500

71776

W 1000 F, W 1200 F, W 1300 F

Loading conveyor

Conveyor belt B600

90123

Discharge conveyor

Conveyor belt B600

51873

Loading conveyor

Conveyor belt B600

125134

Discharge conveyor

Conveyor belt B600

51873

Loading conveyor

Conveyor belt B800

52890

Discharge conveyor

Conveyor belt B800

57482

Loading conveyor

Conveyor belt B800

52890

Discharge conveyor

Conveyor belt B800

57482

Loading conveyor

Conveyor belt B800

112781

Discharge conveyor

Conveyor belt B800

57482

Loading conveyor

Conveyor belt B1000

53870

Discharge conveyor

Conveyor belt B1000

14920

Loading conveyor

Conveyor belt B1000

53870

Discharge conveyor

Conveyor belt B1000

138316

Loading conveyor

Conveyor belt B1100

116577

Discharge conveyor

Conveyor belt B1100

116578

06.10

W 1000 F, W 1200 F, W 1300 F

07.10

1300 - 2000 DC

05.20

W 1500, W 1900

W 2000

2100 DC

W 2100

W 2200

73

Original Wirtgen drive and return pulleys for reliable conveyor belt drive The high milling performance of Wirtgen road milling machines requires reliable transportation of the milled material. With their special design and fabrication processes, original Wirtgen drive and return pulleys have been specially developed for these very tasks. A reliable power transmission, combined with a high running smoothness, guarantees the high economical efficiency of Wirtgen road milling machines.

A long service life thanks to a special thick-walled, asphalt-resistant rubber mixture Reliable power transmission due to material properties with optimised coefficient of friction

The diamond tread surface design avoids asphalt adhesions

Dependable running smoothness due to steel construction with minimised process tolerances

Precise centring of belt thanks to curved external contour with optimised form

Long service life due to permanent connection of rubber and metal

High running smoothness through use of at least nine supporting ribs

Open design principle avoids asphalt adhesions High service life thanks to supporting ribs made from high-quality steel alloys

74

Durable dimensional stability, even under extremely tough operating conditions, due to the robust steel structure

Machine type

Conveyor type

Description

Part No.

W 500

Discharge conveyor

Drive pulley B400

43231

Discharge conveyor

Return pulley B400

7654

Discharge conveyor

Drive pulley B400

43231

Discharge conveyor

Return pulley B400

7654

Discharge conveyor

Drive pulley B400

43231

Discharge conveyor

Return pulley B400

7654

Discharge conveyor

Drive pulley B400

43231

Discharge conveyor

Return pulley B400

7654

Discharge conveyor

Drive pulley B500

72052

Discharge conveyor

Return pulley B500

72060

Loading and discharge conveyor

Drive pulley B600

90117

Loading and discharge conveyor

Return pulley B600

90059

Loading conveyor

Drive pulley B800

52667

Loading conveyor

Return pulley B800

52666

Discharge conveyor

Drive pulley B800

95865

Discharge conveyor

Return pulley B800

110871

Loading conveyor

Drive pulley B800

52667

Loading conveyor

Return pulley B800

52666

Discharge conveyor

Drive pulley B800

95865

Discharge conveyor

Return pulley B800

110871

Loading and discharge conveyor

Drive pulley B800

95865

Loading and discharge conveyor

Return pulley B800

110871

Loading and discharge conveyor

Drive pulley B1000

15092

Loading and discharge conveyor

Return pulley B1000

38279

Loading and discharge conveyor

Drive pulley B1000

138926

Loading and discharge conveyor

Return pulley B1000

128671

Loading and discharge conveyor

Drive pulley B1100

127761

Loading and discharge conveyor

Return pulley B1100

111225

W 50

W 50 DC

W 600 DC, W 1000 L

W 1000

W 1000 F, W 1200 F, W 1300 F 07.10 1300 - 2000 DC

05.20 W 1500, W 1900

W 2000

2100 DC

W 2100

W 500

75

Original Wirtgen idle pulleys for low wear to conveyor belt Wirtgen conveyor belt systems combine a high conveyor capacity with a low power consumption. Original Wirtgen idle pulleys ensure low-friction circulation of the conveyor belts. High-quality bearings of the pulleys and wear-resistant running surfaces are the essential features. Easily detachable connections make changing idle pulleys a simple task.

The freely moveable individual rollers avoid asphalt adhesions Reduced stressing of the conveyor belt thanks to the generously dimensioned buffer rings

High conveyor capacity as the belt automatically takes on a trough shape in the area of the rollers Fast pulley changing due to easily detachable yet stable connections with a high load-bearing capacity

Highly hardened and tempered connecting elements for the greatest load-bearing capacity of the rollers

Low-friction guiding due to high-quality anti-friction bearings with labyrinth seal

Effective guidance and cleaning of the belt thanks to fully rubberised belt rollers Reliable directional stability due to lateral belt guidance

76

Low wear through use of materials with a minimum coefficient of friction

Machine type

Roller type

W 500

W 50, W 50 DC

W 600 DC, W 1000 L

W 1000

W 1000 F, W 1200 F, W 1300 F

Number of components used in loading conveyor

2 10

8363

Support idler B400

5

8362

Belt roller B400

6

71844

Idle pulley

4

54954

Roller B400

9

171832

Belt roller B400

3

71844

Idle pulley

4

54954

Roller B400

4

99285

Roller B400

6

99286

Belt roller B400

5

71844

Idle pulley

4

54954

Roller B500

4

72068

Roller B500

7

71777

Belt roller B500

6

72067

Idle pulley

2

4

54954

Roller B600

5

4

90120

7

90122

3

6

90121

Idle pulley

4

4

54954

Roller B600

6

4

90120

7

90122

Roller B600 07.10 Belt roller B600 Idle pulley

3

6

90121

4

8

54954

20

111363

Roller B800 Roller B800 05.20 Belt roller B800 W 1500, W 1900

Idle pulley

8 8

4

8

54954

20

111363

8

65967

8

52889

Roller B800 Belt roller B800

2100 DC

4

Idle pulley

4

4

54954

5

10

111363

Belt roller B800

2

Belt cleaning idler B1000

5

111348

6

14919

Idle pulley

2

54954

Cushioned idler B1000

10

40746

Cushioned idler B1000

5

40745

Support idler B1000

18

9352

Support idler B1000

9

15744

3

53907

Idle pulley

4

4

54954

Roller B1000

5

10

138312

Belt roller B1000

2 5

53907

Belt roller B1000 W 2200

52889

Roller B800

Belt roller B1000 W 2100

65967

4

Roller B800

W 2000

54954

Idle pulley

Roller B600

1300-2000 DC

Part No.

Support idler B400

06.10 Belt roller B600 W 1000 F, W 1200 F, W 1300 F

Number of components used in discharge conveyor

Idle pulley Roller B1100

6

Belt roller B1100

2

Belt roller B1100

146073 4

54954

10

116524

5

116747

146072

77

Original Wirtgen water system for effective sprinkling during milling The water system comes complete with pump, filter, supply lines and nozzles. It has been optimised specifically for sprinkling during cold milling. The water system effectively reduces the generation of dust on the conveyor by thoroughly dampening it. In the drum housing, the water system cools the picks and improves their rotation, meaning that it is essential for assisting the milling process. The water system and its individual components are designed to provide high system pressure and a flow rate adapted to respective sprinkling requirements.

Service packages for the water unit including sealing and repair kits, nozzles and nozzle units ensure any time an effective sprinkling.

78

Water pump

Sealing kits and repair kits

Machine type

Series range

Description

Part No.

Description

Part No.

W 350

0001 - 9999

Water pump electric with drive

72845

Sealing kit for pump

48445

W 500

0005 - 0281

Water pump electric with drive

43912

Sealing kit for pump

48445

0282 - 9999

Water pump electric with drive

72845

Sealing kit for pump

48445

W 50

0001 - 9999

Water pump electric with drive

72845

Sealing kit for pump

48445

W 50 DC

0001 - 9999

Water pump electric with drive

168560

Sealing kit for pump

15617

W 600 DC, W 1000 L

0001 - 0034

Water pump electric with drive

1876

Sealing kit for pump

15617

0035 - 0515

Water pump electric with drive

112984

Sealing kit for pump

15617

0516 - 9999

Water pump electric with drive

168560

Sealing kit for pump

15617

0001 - 9999

Water pump hydraulic with drive

72838

Sealing kit for pump

109757

Repair kit for motor

75830

Sealing kit for pump

109757

Repair kit for motor

75830

Sealing kit for pump

109757

Repair kit for motor

75830

Sealing kit for pump

109757

Repair kit for motor

75830

Sealing kit for pump

109757

Repair kit for motor

75830

Repair kit for pump

153824

Clutch pump / motor

178413

W 1000 F

W 1000 F

0001 - 0079

0080 - 9999

1300 - 2000 DC

W 1500, W 1900

W 2000

0026 - 9999

0001 - 9999

0001 - 9999

Water pump hydraulic with drive

Water pump hydraulic with drive

Water pump hydraulic with drive

Water pump hydraulic with drive

Water pump hydraulic with drive

72838

134122

72837

72837

142023

79

Water pump

Sealing kits and repair kits

Machine type

Series range

Description

Part No.

Description

Part No.

2100 DC

0001 - 0140

Water pump hydraulic with drive

38575

Sealing kit for pump

51168

Sealing kit for hydraulik motor

41060

Sealing kit for pump

109757

Repair kit for motor

75830

Repair kit for pump

153824

Clutch pump / motor

178413

Repair kit for pump

153824

Clutch pump / motor

178413

2100 DC

W 2100

W 2200

0141 - 9999

Water pump hydraulic with drive

0001 - 9999

72838

Water pump hydraulic with drive

0001 - 9999

142023

Water pump hydraulic with drive

142023

Sprinkler system drum case

Sprinkler system conveyor

Nozzle unit complete

Single nozzles

Valve for nozzle unit

Single nozzles

Requirement

Requirement

Part No.

Requirement

Part No.

Requirement

2

74328

Machine type

Series range

W 350

0001 - 9999

2

72621

2

15827

W 500

0005 - 9999

4

8667

4

15827

W 50, W 50 DC

0001 - 9999

4

71765

4

15827

W 600 DC

0001 - 9999

6

71765

6

15827

6

74328

W 1000 L

0001 - 0003

8

71765

8

15827

8

74328

0004 - 9999

8

112127

W 1000 F

0001 - 9999

10

71765

10

15827

10

74328

W 1200 F, W 1300 F

0001 - 9999

12

12

15827

12

80

Part No.

Part No.

Sprinkler system drum case

Machine type

Series range

Sprinkler system conveyor

Nozzle unit complete

Single nozzles

Valve for nozzle unit

Single nozzles

Requirement

Requirement

Requirement

Requirement

Part No.

1300 DC

05.20

0026 - 9999

8

1500 DC

05.20

0033 - 9999

9

1900 DC

05.20

0067 - 9999

10

2000 DC

05.20

0038 - 9999

12

W 1500

0001 - 9999

12

W 1900

0001 - 9999

16

W 2000

0001 - 9999

16

2100 DC

71765

12

Part No.

73217

15827

16

12

Part No.

2

7537

74328

20

7537

74328

24

7537

16

16

15827

0001 - 0117

13

38576

2

15827

0118 - 9999

12

73217

3

15827

16

15827

20

111743

W 2100 (FB 2000)

0001 - 9999

16

W 2100 (FB 2100)

0001 - 9999

17

W 2200

0001 - 9999

18

71765

Part No.

112127

17

112127

18

16

16

74328

17

15827

18

21

74328

26

111743

81

The new Wirtgen levelling system: User friendly and highly accurate The automatic levelling system is made up of two separate control loops which operate independently of one another. One is for the grade control on righthand side of the machine and the other for the left-hand side, in respect to each sensor it is connected to.

Control unit with integrated digital controller The control units with integrated digital controller include both the corresponding function keys and the easily legible displays for the preset setpoint and the momentary actual milling depth (in cm or inches). They can be mounted at the top of the operator's platform for the right and left-hand sides of the machine or on the corresponding side of the machine, in which case they are operated from the ground. The controllers are simply connected to the electrohydraulic depth control in the control cabinet and to a sensor via two electrical plug-and-socket connections (directly or via sockets on the machine). Automatic or manual adjustment can be set at the push of a button.

Everything within view: the digital controllers for adjusting the milling depth on the right and left-hand sides of the milling machine can be mounted on the operator's platform.

Alternatively: the digital controllers can also be hooked in and connected at ground level of the corresponding side of the machine.

82

The controller components are hermetically sealed to protect against the elements.

Practical sensor systems with compatible, plug-in sensors The control system for the milling depth is designed to permit connection of a variety of sensors. This ensures that the operator can choose the optimum sensor system for the job at hand. All sensors have compatible plugs, thus making modifications unnecessary. They simply plug in. Cable sensors are used for mechanical scanning on the side plates attached to the drum.

Ultrasonic sensor for scanning without contact

Cable sensor for scanning on the side panel

The non-contact ultrasonic sensors can not only scan the height of the side plate, but also the reference surface beside or in front of the milling drum.

The sonic ski is also a type of ultrasonic sensor which can be used for scanning a grade line, as well as for scanning the height above a reference surface.

Transducing sensors are used to scan a pretensioned grade line.

Multiplex-systems operate with several sensors at the same time and are used for high-precision cutting work.

The slope sensor operates like an electronic pendulum. It is attached to the chassis and operates in combination with a height sensor. Laser sensors operate in combination with a laser transmitter to produce a defined area in space, e.g. in halls.

Transducing sensor Slope sensor for scanning a grade for milling a selected line transverse slope

Laser sensor for milling a physically defined area

Sonic ski sensor for scanning a grade line or a reference surface without contact

Various sensors can be connected to the digital controller. The system is characterized by extremely simple handling and high operational reliability.

S

R

S

S

R N R

S

R

S

Straightforward connection to existing sockets: S = Sensor sockets; R = controller sockets; N = slope controls

S The simple levelling system: plug in and secure.

83

Mechanical levelling via a cable sensor For this type of levelling, the cable sensor is hooked onto the drum panels which glide over the reference surface. The long skid on the side panel compensates any unevenness in its length. When milling the second lane, the panel on one side glides on the milled surface which serves as a reference height.

Scanning reference surfaces: cable sensors on the right and left-hand drum panels.

The cable sensor is robust and operates reliably even in unfavorable weather conditions and in dust clouds.

Scanning a grade line with the transducing sensor A grade line is required when carrying out extensive rehabilitation work, including replacement of several courses and surfacing with the aid of road finishers. This grade line can also be used as a reference line for the milling depth. In this case, the grade line is scanned by the arm of a transducing sensor. A slope sensor or appropriate height sensor is used to control the milling depth on the other side.

In this case, the milling depth on the right-hand side of the machine is controlled via a grade line, while the left-hand side is controlled via a cable sensor on the drum panel.

84

Non-contact scanning with the Digi-Sonic sensor This sensor operates without contact and is therefore not subject to any mechanical problems. It is known as an ultrasonic sensor because of its operating principle. The major advantage of this type of sensor lies not only in its accuracy, but also in the variety of ways in which it can be used for scanning: on the drum panel, beside the drum and also in front of the drum (milling right up to the unpaved roadway edge).

The ultrasonic waves emitted at high frequency reach the reference surface...

...where they are reflected and detected by the sensor. The time between transmission and reception serves as an indicator for the distance between sensor and surface.

The simple and reliable principle underlying an ultrasonic sensor.

The area in front of the drum can be scanned simply by swivelling the holder.

Complex mechanical or hydraulic installation work is not required: the ultrasonic sensor is simply plugged into its holder, the plug inserted in the socket and the sensor plate swung out.

Any sensor position, e.g. when milling alongside pavement deformities.

85

Working with the slope sensor The milling depth on one side can be controlled via the slope sensor. The corresponding side - right or left - can be selected on the control console. The main applications for this type of sensor include specific changes in the transverse grade by milling a roadway, for instance when changing the gradient to ensure that water runs off effectively, or if a height sensor cannot be used when milling up to the unpaved roadway edge.

Milling depth controlled by scanning the height (e.g. with a cable sensor)

Milling depth controlled via a slope sensor

Example for working with a slope sensor: the lhs. of the machine is controlled by scanning a grade line, the rhs. by means of a slope sensor along the unpaved edge.

Levelling surfaces with the laser sensor Adjustment of the milling depth via lasers is a special application. In this case, the reference surface is defined by a rotating laser beam emitted by a transmitter. The milling depth on the right and left-hand sides is adjusted by two receivers on the machine, regardless of the actual pavement geometry. This method is used, for example, in large halls or on large traffic areas, such as airports.

The rotating laser beam is detected by the 5-channel laser sensor mounted on the machine.

Universal sensor for non-contact scanning: the sonic ski The sonic ski is a multiple ultra-sonic sensor permitting even more convenient adjustment of the milling depth and can be used for scanning a grade line, as well as for scanning a reference surface. The five sensors (plus one sensor for temperature compensation) make it easier to drive along the grade line and compensate any unevenness in the pavement to be removed.

Position of the sonic ski for non-contact scanning of a grade line.

Position of the sonic ski for non-contact scanning of a reference surface. Possible uses of the sonic ski.

86

Ideal for fine milling work: the multiplex system When working with the multiplexsystem, three sensors are fitted on one or both sides of the machine to scan the reference surface(s). The controller then forms a mean value from the three measured values in order to compensate any unevenness. The system basically functions in the same way as a very long averaging ski, but is considerably more flexible and very much easier to handle (installation and removal after work). The sensors at the front and rear of the machine are normally ultrasonic sensors and can be ideally positioned with the aid of swivel arms. The sensor alongside the drum may be either an ultrasonic sensor or a cable sensor.

Control unit 3 sensors left

Neigungsregler

3 sensors right Control unit Three sensors are plugged into each side of the machine when working with multiplex. The controllers are mounted at the side of the machine or on the operator's console.

Applications for this system include fine milling (in combination with a fine milling drum) in order to level deformed surface courses, or to allow water to run off and to restore skid-resistant properties. It can also be used to mill off a few millimeters prior to applying thin-layer paving.

A very level milled surface is obtained by scanning three widely spaced points on the reference surface and calculating the mean average height.

Moving arms allow the sensors to be set in the best possible position.

Use of the slope sensor and multiplex-system yields optimum results when changing the grade over several milling lanes.

87

Original Wirtgen levelling system: a versatile, modular system for precision milling depth control Modular concept

Milling depth regulators

Sensors

Suitable for use on all Wirtgen machines, the levelling system for controlling the milling depth comprises one or two milling depth control units and one or more sensors. It is designed to enable connection of several sensors. Thanks to the modular concept, the optimum sensor system can be devised and used for every application.

Milling depth regulators are controller and operating unit in one. An outstanding feature of the units is their user-friendly operation, with clearly arranged, self-explanatory function keys and two easily legible displays.

The Wirtgen levelling system is just as diverse as the job sites on which the machines are used. Different sensors are available for the individual functions and to meet the various requirements imposed on the accuracy and precision of the treated surface.

Ultrasonic sensor for scanning without contact

Cable sensor for scanning on the side panel

The new software release for the milling depth regulator, with its optimised control characteristics, ensures consistently good milling results. The milling depth control units can be mounted on the operator's stand for the left and right sides of the machine, or on the side of the machine.

Transducing sensor Slope sensor for scanning a grade for milling a selected line transverse slope

Sensor system

Height regulation

Operating mode

Ultrasonic sensor

Sonic ski sensor

All sensors can be used with the milling depth regulator, and have compatible plugs: just plug them in and go!

Laser sensor for milling a physically defined area

Sonic ski sensor for scanning a grade line or a reference surface without contact

Slope regulation Cable sensor

Multiplex System (3 or 7)

Transducing sensor

Laser sensor

Slope sensor with height-sensor system

Ground scanning at the front, rear and beside the milling drum Scanning on the side panel Scanning a grade line Scanning a laser signal

88

Increasing precision

Increasing precision x

x

x With additional equipment

x

---

---

x

x

---

x

---

---

---

x

---

x

---

---

x

---

x

---

---

---

---

---

x

x

Description

Part No.

Milling depth regulator

161400

Ultrasonic sensor

58614

Tracer II

110157

Wire rope exchange set II

112024

Tracer III

161455

Wire rope exchange set III

165399

Revolution sensor digital

76309

Slope sensor fluid

157449

Laser sensor

112162

Sonic-Ski sensor

101244

Sensor and power cables are available in various lengths for mounting the sensors and milling depth regulators on the machine in different positions, which considerably increases flexibility for daily tasks. With their spiral design, they save space but are still long enough - cables won't get in the way.

Power cables The power cables connect the milling depth regulators to the machine. They provide a secure electrical power supply and reliably transmit control data for the CAN bus via built-in lines.

Sensor cables The sensor cables connect the individual sensors to the milling depth regulators and transmit the measurement data. The cables and plugs are of highly durable design in order to ensure reliable function despite the rough conditions of constant use on a construction site.

Description

Length spiral / stretched

Part No.

Sensor cable (7-polar)

- / 700

98676

Sensor cable (7-polar)

900 / 3100

74459

Sensor cable (7-polar)

1500 / 5300

102137

Sensor cable, plug one-sided angular (7-polar)

900 / 3100

117835

Power cable, plug one-sided angular (10-polar)

500 / 1750

117833

Power cable (10-polar)

- / 1500

102136

89

Original Wirtgen crawler track units for reliable traction With Wirtgen’s modern milling machines, reliable tractive power transmission goes without saying, even under the toughest conditions on site. Original Wirtgen crawler track units, with their bolted-on track pads, fulfil all requirements such as the greatest strength and stability and long service, even under extreme strain.

Reduction of the number of wearing parts through modular building-block system

Good hinging properties, even with extreme soiling

Hardened and tempered chain pins and chain bushings ensure the highest strain resistance

Optimum wear properties due to induction hardened, curved running surfaces The optimised expansion length ensures the highest dynamic load-bearing capacity of the bolted connection

Special form ensures continuous edge stability

High inherent strength of the crawler links, optimised according to the Finite Elements Method (FEM)

90

Machine type

Description

Part No.

W 1000 F, W 1200 F, W 1300 F

Crawler unit W1 without track pads

131296

Crawler unit W1 including 20 POLY GRIP W1 track pads

131303

Driving gear W1

55602

Crawler unit W1 without track pads

108750

Crawler unit W1 including 24 POLY GRIP W1 track pads

108756

Driving gear W1

55602

Crawler unit W3 without track pads

121236

Crawler unit W3 including 23 POLY GRIP W3 track pads

121235

Driving gear W3

121234

Crawler unit W4 without track pads

43357

Crawler unit W4 including 25 POLY GRIP W4 track pads

43358

Driving gear W4

41346

Crawler unit W4 without track pads

41344

Crawler unit W4 including 24 POLY GRIP W4 track pads

41345

Driving gear W4

41346

Crawler unit W5 without track pads

176322

Crawler unit W5 including 26 POLY GRIP W5 track pads

176321

Driving gear W5

133013

1300 - 2000 DC, W 1500, W 1900

W 2000

2100 DC

W 2100

W 2200

91

Optimized pads from the POLY GRIP series In the tough everyday conditions on job sites, plastic pads prevent the asphalt pavement being damaged by road milling machines. Wirtgen permanently cooperates with one of the world’s leading manufacturers of plastic components to optimize the material properties, form and quality of the pads. The latest result of this cooperation is the POLY GRIP series of pads which sets new standards in terms of service life and machine traction.

Special new polyurethane blend with extremely high resistance to tearing

Longer service life due to 30% higher polyurethane volume Optimized adhesive bond between steel and polyurethane

Logo symbolizes Original Wirtgen part

High-strength pad bolts with rounded head for durable bolt connections

Rounded edges increase the resistance to tearing Heavy-duty square pad nut

Inclined running surface for optimized steering

92

Highly tempered, all-round sandblasted and treated steel plate of special boron steel with good hinging properties

Fine screw thread for reliable bolt connections

Machine type

Description

Part No.

W 1000 F, W 1200 F, W 1300 F,

POLY GRIP track pad W1

150740

1300 - 2000 DC, W 1500, W 1900

Bolt for track pad POLY GRIP W1

18501

Nut for track pad POLY GRIP W1

18502

POLY GRIP track pad kit W1 W 1000 F, W 1200 F, W 1300 F

162455 (includes track pads, bolts and nuts for one crawler unit) POLY GRIP track pad kit W1

1300 - 2000 DC, W 1500, W 1900

85186 (includes track pads, bolts and nuts for one crawler unit)

W 2000

POLY GRIP track pad W3

150821

Bolt for track pad POLY GRIP W3

1861

Nut for track pad POLY GRIP W3

1860

POLY GRIP track pad kit W3 162456 (includes track pads, bolts and nuts for one crawler unit) 2100 VC, 2100 DC, W 2100

POLY GRIP track pad W4

144728

Bolt for track pad POLY GRIP W4

37824

Nut for track pad POLY GRIP W4

37825

POLY GRIP track pad kit W4 2100 VC, 2100 DC

85236 (includes track pads, bolts and nuts for one crawler unit) POLY GRIP track pad kit W4

W 2100

165045 (includes track pads, bolts and nuts for one crawler unit)

W 2200

POLY GRIP track pad W5

144727

Bolt for track pad POLY GRIP W5

43500

Nut for track pad POLY GRIP W5

43499

POLY GRIP track pad kit W5 130346 (includes track pads, bolts and nuts for one crawler unit)

93

Original Wirtgen track rollers for high performance and long service intervals Wirtgen road milling machines achieve high advance speeds even in deep cuts. The crawler units on milling machines and especially the track rollers are exposed to very high load conditions. They have to absorb high machine loads, varying surface conditions and slopes and still provide true in-line tracking. Original Wirtgen track rollers consist of precisely manufactured, high-quality components, which allows the best running performance with long service intervals.

Friction ring seal O-ring made of Viton for high temperature stability

Deflection-free permanent mould casting material with microporosity for reliable oil lubrication

Lapped sealing surfaces

Additional lubrication passages

O-ring seal

High-quality sleeves made of special bronze with rolled friction surfaces

Super-polished axle surface Filled with synthetic, biodegradable lubricant

Reliable axle lock provided by a high tensile strength split pin

94

Extremely hard, high-precision profiled rolling surfaces, complementing the Wirtgen track chains

Machine type

Description

Part No.

Track roller W1 friction bearing

32007

Track roller W1 on roller bearing

90998

2000 VC, 2100 VCL, 2100 DC/L

Track roller W2 friction bearing

41190

W 2000

Track roller W3 friction bearing

118717

2100 VC, 2100 DC, W 2100

Track roller W4 on roller bearing

85700

W 2200

Track roller W5 friction bearing

118719

W 1000 F, W 1200 F, W 1300 F, 1300 - 2000 DC, W 1500, W 1900

W 1000 F, W 1200 F, W 1300 F, 1300 - 2000 DC, W 1500, W 1900

Parts with no. # 90998 and # 32007 can both be used on the above mentioned machines and are compatible to each other. The roller-bearing track rollers provide extended service life under same conditions.

95

Original Wirtgen wheels and tyres made from vulcanized elastomer rubber The smaller milling machines especially require maximum traction to develop their full performance potential. It is very important to use tyres that have been specially designed for corresponding applications and models. Original Wirtgen tyres and wheels have been optimized in years of testing to allow these machines to perform at peak levels. Design features to enhance wear and tear resistance minimize operating costs. Original Wirtgen tyres, made from vulcanized elastomer rubber, are replaceable, reducing operating costs and the impact on the environment. Original Wirtgen tyres and wheels provide high traction and low wear in a combination of unsurpassed quality.

Surface cross-section is specifically matched to each model

Logo symbolizes Original Wirtgen part

Exact tolerances ensure consistent surface to surface contact allowing full transfer of drive system torque

Calm and consistent machine performance due to shock absorbant material properties

Exact fit due to CNC machined surfaces

High tensile strength steel rims comply to highest demands

Longlasting rubber to steel bond

Highly optimized wear and tear resistant vulcanized elastomer rubber compound

96

Clear part numbering in form of Wirtgen Part No.

Machine type

Position

Description

Part No.

W 350

front

Wheel complete

56529

Rubber tyre

57151

rear

Wheel complete

109638

3wheel front + rear

Wheel complete

53348

Rubber tyre

57151

Wheel complete

62602

Rubber tyre

74626

Wheel complete

53348

Rubber tyre

57151

3wheel front

Wheel complete

180726

4wheel front

Wheel complete

180218

3wheel, 4wheel up to m/c 67 rear

Wheel complete

172139

Rubber tyre

171108

3wheel, 4wheel from m/c 68 onwards rear

Wheel complete

180719

3wheel front

Wheel complete

180726

4wheel front

Wheel complete

180218

3wheel, 4wheel up to m/c 50 rear

Wheel complete

173684

Rubber tyre

57151

3wheel, 4wheel from m/c 51 onwards rear

Wheel complete

180719

3wheel up to m/c 32 front

Wheel complete

97720

Rubber tyre

57151

Wheel complete

111868

Rubber tyre

56052

Wheel complete

102476

Rubber tyre

74626

Wheel complete

117051

Rubber tyre

117053

Wheel complete

97720

Rubber tyre

57151

Wheel complete

72790

Rubber tyre

1512

Wheel complete

90040

Rubber tyre

1512

Wheel complete

125782

Rubber tyre

123417

W 500

4wheel front

4wheel rear

W 50

W 50 DC

W 600 DC, W 1000 L

3wheel from m/c 33 onwards front

4wheel up to m/c 106 front

4wheel from m/c 107 onwards front

rear

front + rear

W 1000

front + rear

W 1000 F, W 1200 F, W 1300 F 06.10

front + rear

W 1000 F, W 1200 F, W 1300 F 07.10

97

Original Wirtgen clutches effectively transfer power The clutches in milling machines must be capable of transmitting their high power output and reliably connecting and disconnecting the power in the milling power train. Wirtgen clutches are specially designed for use in the respective power train. They are optimised to handle the stresses generated by the dynamic action of the cutting process.

Based on machine requirements and field experience, Wirtgen has developed individual service packages. The natural wear of the clutch element, toothed ring and outer discs is compensated for. During maintenance work, replacing all the seals included in the seal kit ensures reliable operation.

Service packages for clutches including clutch elements, toothed rings, outer discs and sealing kits guarantee a powerful milling job.

98

Machine type

Description

Series range

RequirePart No. ment

0001 - 0449

1

66626

0450 - 9999

1

148656

0001 - 0449

1

74339

0450 - 9999

1

185025

Toothed Ring

0001 - 9999

1

1556

Outer Disc

0001 - 9999

1

5568

Rotary Duct

0001 - 9999

1

68180

0001 - 0449

1

74338

0450 - 9999

1

185019

Clutch complete

0001 - 9999

1

70196

Clutch element

0001 - 9999

1

76650

Toothed Ring

0001 - 9999

1

1568

Outer Disc

0001 - 9999

2

13882

Rotary Duct

0001 - 9999

1

68180

Sealing Kit

0001 - 9999

1

76651

0001 -0149

1

70196

0150 - 9999

1

138200

Toothed Ring

0001 - 9999

1

1568

Outer Disc

0001 - 9999

2

13882

Rotary Duct

0001 - 9999

1

68180

0001 - 0149

1

76651

0150 - 9999

1

185020

0001 - 0524

1

73213

0525 - 9999

1

101822

0001 - 0524

1

58717

0525 - 9999

1

135110

0001 - 0524

1

59946

0525 - 9999

1

135109

W 350 Clutch complete

Clutch element

Sealing Kit

W 600 DC, W 1000 L, W 1000

W 1000 F, W 1200 F, W 1300 F Clutch complete

Sealing Kit 07.10 1300 - 1500 DC Clutch complete

Clutch element

Toothed Ring 05.20

We recommend to always replace outer disc and toothed ring both together.

99

Machine type

Description

Series range

RequirePart No. ment

0001 - 0524

3

13882

0525 - 9999

3

135108

0001 - 9999

1

66852

0001 - 0524

1

74364

0525 - 9999

1

134277

0002 - 0463

1

80740

0464 - 9999

1

101823

0001 - 0463

1

58717

0464 - 9999

1

135110

0001 - 0463

1

59946

0464 - 9999

1

135109

0002 - 0463

3

13882

0464 - 9999

3

135108

0001 - 9999

1

66852

0001 - 0463

1

74364

0464 - 9999

1

134277

Clutch complete

0113 - 9999

1

159244

Toothed Ring

0113 - 9999

1

133789

Outer Disc

0113 - 9999

2

82243

Rotary Duct

0001 - 9999

1

66852

Sealing Kit

0113 - 9999

1

185024

Clutch complete

0129 - 9999

1

159245

Clutch element

0001 - 9999

1

135110

Toothed Ring

0001 - 9999

1

135109

Outer Disc

0001 - 9999

3

135108

Rotary Duct

0001 - 9999

1

66852

Sealing Kit

0129 - 9999

1

134277

1300 - 1500 DC Outer Disc

Rotary Duct

Sealing Kit 05.20 1900 - 2000 DC Clutch complete

Clutch element

Toothed Ring

Outer Disc

Rotary Duct

Sealing Kit 05.20 W 1500

W 1900

We recommend to always replace outer disc and toothed ring both together.

100

RequirePart No. ment

Machine type

Description

Series range

W 2000, W 2100

Clutch complete

0001 - 9999

1

113902

Clutch element

0001 - 9999

1

156163

Toothed Ring

0001 - 9999

1

133789

Outer Disc

0001 - 9999

2

82243

Rotary Duct

0001 - 9999

1

66852

Sealing Kit

0001 - 9999

1

155377

Clutch complete

0118 - 9999

1

82041

Clutch element

0118 - 9999

1

65601

Toothed Ring

0118 - 9999

1

65598

Outer Disc

0118 - 9999

3

82243

Rotary Duct

0118 - 9999

1

66852

Sealing Kit

0118 - 9999

1

65603

Clutch complete

0001 - 9999

1

116937

Clutch element

0001 - 9999

1

156164

Toothed Ring

0001 - 9999

1

155368

Outer Disc

0001 - 9999

2

155369

Rotary Duct

0001 - 9999

1

66852

Sealing Kit

0001 - 9999

1

155378

Clutch complete

0001 - 9999

1

159871

Clutch element

0001 - 9999

1

185021

Toothed Ring

0001 - 9999

1

59946

Outer Disc

0001 - 9999

3

13882

Rotary Duct

0001 - 9999

1

66852

Sealing Kit

0001 - 9999

1

185022

Clutch complete

0001 - 9999

1

155280

Clutch element

0001 - 9999

1

185026

Toothed Ring

0001 - 9999

1

182696

Outer Disc

0001 - 9999

3

82243

Rotary Duct

0001 - 9999

1

66852

Sealing Kit

0001-9999

1

185023

2100 DC

W 2200

WR 2000

WR 2500 S

We recommend to always replace outer disc and toothed ring both together.

101

Original Wirtgen power belts and belt pulleys for reliable power transmission The power belts and belt pulleys make up a system that reliably transmits power from the engine to the milling drum and dampens disturbing vibrations. In the highly dynamic environment of the milling drum drive, this system is therefore the heart of the machine. The durable power belts and belt pulleys are precisely coordinated and optimised with regard to their coefficients of friction, so as to enable reliable transmission of the high tractive forces. The belt pulleys are made of highprecision casting materials and are dynamically balanced. Their shape has been optimised to dissipate heat at the contact surface between the power belt and the belt pulley.

The V-belt compound unit with several ribs effectively transfer power to the milling drum.

102

Belt Pulley 1 Machine type

V-Belt Compound Unit Diameter

Belt Pulley 2 Part No.

Diameter

Part No.

W 350 (valid up to machine 0594)

77050

150 mm

77052

187 mm

77051

W 350 (valid from machine 0595)

176066

160 mm

175664

200 mm

175665

W 350 E

77050

187 mm

77051

150 mm

77052

W 50

171089

215 mm

170161

230 mm

170170

W 50 DC

171088

215 mm

170161

230 mm

170170

W 600 DC

97153

250 mm

97146

300 mm

97148

W 1000 L

97153

250 mm

97146

280 mm

109646

W 1000

72069

280 mm

52201

250 mm

52203

W 1000 F, W 1200 F, W 1300 F

92815

250 mm

52203

325 mm

90042

1300 - 2000 DC

66894

280 mm

67150

250 mm

67151

W 1500, W 1900

143377

330 mm

142158

280 mm

67150

W 2000

113850

315 mm

72438

280 mm

114274

2100 DC

33142

355 mm

72437

315 mm

72438

W 2100

138901

400 mm

80028

355 mm

72437

W 2200

120650

400 mm

118543

355 mm

118547

WR 2000

173713

315 mm

170796

355 mm

170797

WR 2500, WR 2500 S

33142

400 mm

80028

355 mm

72437

05.20

Belt pulley 1 is the pulley on the engine when shipped; belt pulley 2 is on the drum when shipped.

103

Original Wirtgen filter elements for the highest possible milling performance Wirtgen road milling machines, renowned for their high milling performance, are driven by modern diesel and hydraulic engines. Provided they are regularly maintained, original Wirtgen filter elements form the basis for a high milling performance and long engine service life. Wirtgen has also optimised the adaptation of lubricants and fuels to the requirements of the corresponding filter systems, also guaranteeing the requisite system purity and hence minimising operating costs.

Different oil filters, air and fuel filters ensure smooth operation of your machine and increase the life-span of the engine.

104

Machine type

Description

Series range

W 350

Hydraulic oil filter

0001 - 9999

Replacement interval

RequirePart No. ment

if necessary,

1

74332

at least 1 x p.a.

1

74334

1

5068

every 1000 h, Filling and ventilation filter

Engine oil filter

0001 - 9999 0001 - 0594

every 250 h

1

10877

0595 - 9999

every 250 h

1

175499

1

45287

1

179862

1

35721

if necessary,

1

30294

at least 1 x p.a.

1

36519

1

80741

1

14171

1

56561

1

57299

0001 - 9999 Fuel filter

at least 1 x p.a.

0595 - 9999

every 250 h if necessary,

W 500

Main air filter

0001 - 9999

Hydraulic oil filter

0005 - 9999

Hydraulic oil filter*

0276 - 9999

Filling and ventilation filter

0005 - 9999

Engine oil filter

0005 - 9999

at least 1 x p.a.

if necessary, at least 1 x p.a. every 1000 h,

0005 - 0903 Fuel filter Main air filter Safety air filter Main air filter Safety air filter

0904 - 9999 0005 - 0275

0276 - 9999

at least 1 x p.a. every 250 h every 250 h

2

57299

if necessary,

1

2299

at least 1 x p.a.

1

1942

if necessary,

1

76494

at least 1 x p.a.

1

76495

1

90200

every 1000 h,

1

5068

at least 1 x p.a.

1

179642

every 500 h

1

175499

1

184822

if necessary, W 50

Hydraulic oil filter Filling and ventilation filter Ventilation filter Engine oil filter Fuel filter Preliminary fuel filter Main air filter Safety air filter

W 50 DC

Hydraulic oil filter Filling and ventilation filter Ventilation filter Engine oil filter Fuel filter Preliminary fuel filter (water separator) Main air filter Safety air filter

0001 - 9999

0001 - 9999 0001 - 9999 0001 - 9999

0001 - 9999

at least 1 x p.a.

every 500 h

1

179862

if necessary,

1

170004

at least 1 x p.a.

1

169003

1

90200

every 1000 h,

1

5068

at least 1 x p.a.

1

179642

every 500 h

1

1936

2

1940

if necessary, 0001 - 9999

0001 - 9999 0001 - 9999 0001 - 9999

0001 - 9999

at least 1 x p.a.

every 500 h

1

162055

if necessary,

1

151322

at least 1 x p.a.

1

151321

* This filter is additionally required for the serial numbers mentioned.

105

Machine type

Description

Series range

W 600 DC, W 1000 L

Hydraulic oil filter

0001 - 9999

Replacement interval

RequireBestell-Nr. Part No. ment

if necessary,

1

74332

at least 1 x p.a.

1

45452

1

5068

1

1936

every 1000 h, Filling and ventilation filter

0001 - 9999

Engine oil filter

0001 - 9999

Fuel filter

0001 - 0515

1

1944

Fuel filter

0516 - 9999

2

1940

Preliminary fuel filter (mesh)

0001 - 0269

1

37785

Preliminary fuel filter (water separator)

0270 - 9999

1

122648

if necessary,

1

3181

at least 1 x p.a.

1

34310

if necessary,

1

74332

at least 1 x p.a.

1

45452

1

5068

1

1880

1

77338

1

110563

1

119393

1

74320

1

77339

if necessary,

1

97824

at least 1 x p.a.

1

97825

Main air filter Safety air filter Hydraulic oil filter

W 1000

0001 - 9999

0001 - 9999

at least 1 x p.a. every 500 h

every 500 h

every 1000 h, Filling and ventilation filter

0001 - 9999

Engine oil filter

0001 - 9999

Fuel filter

0001 - 9999

Preliminary fuel filter (water separator)

0357 - 0577

Preliminary fuel filter (water separator)

0578 - 9999

at least 1 x p.a. every 250 h

every 250 h

Main air filter Safety air filter

0001 - 0286

Main air filter Safety air filter

0287 - 0577

Main air filter

0578 - 9999

1

162084

Safety air filter

0578 - 9999

1

162085

Hydraulic oil filter

0001 - 9999

1

90200

Filling and ventilation filter

0001 - 9999

1

5068

Engine oil filter

0001 - 9999

1

1936

1

1944

1

37785

if necessary,

1

3179

at least 1 x p.a.

1

97201

if necessary, W 1000 F, W 1200 F, W 1300 F

every 1000 h,

Fuel filter Preliminary fuel filter (mesh)

0001 - 9999

Main air filter 06.10

Safety air filter

0001 - 9999

* This filter is additionally required for the serial numbers mentioned.

106

at least 1 x p.a.

at least 1 x p.a. every 500 h every 500 h

Machine type

Description

Series range

W 1000 F, W 1200 F,

Hydraulic oil filter

0001 - 9999

Hydraulic oil filter*

0330 - 9999

Filling and ventilation filter

0001 - 9999

Engine oil filter

0001 - 9999

Fuel filter Fuel filter

Replacement interval

RequirePart No. ment

if necessary, 1

90200

1

156576

1

5068

1

1936

0001 - 0559

1

1944

0560 - 9999

2

1940

1

37785

W 1300 F

at least 1 x p.a. if necessary, at least 1 x p.a. every 1000 h,

Preliminary fuel filter (mesh)

0001 - 0074

Preliminary fuel filter (water separator)

0075 - 9999

Main air filter 07.10

Safety air filter

0001 - 9999

at least 1 x p.a. every 500 h

every 500 h

1

122648

if necessary,

1

3179

at least 1 x p.a.

1

97201

5

30294

1

14171

1

40113

2

33023

1

40103

1

84128

every 250 h

1

122648

if necessary,

1

41925

at least 1 x p.a.

1

41924

if necessary,

1

85691

at least 1 x p.a.

1

90980

1

30294

1

118266

1

74334

1

14171

1

145939

1

145940

1

122648

if necessary,

1

85691

at least 1 x p.a.

1

90980

if necessary, 1300 - 2000 DC

Hydraulic oil filter

0001 - 9999

Filling and ventilation filter

0001- 9999

Engine oil filter

0001 - 9999

every 250 h

0001 - 9999

every 250 h

at least 1 x p.a. every 1000 h, at least 1 x p.a.

Fuel filter Preliminary fuel filter Preliminary fuel filter Preliminary fuel filter (water separator)*

0420 - 9999

Main air filter Safety air filter

0001 - 0099

Main air filter 05.20

W 1500, W 1900

Safety air filter

Hydraulic oil filter

0100 - 9999

0001 - 9999

if necessary, at least 1 x p.a. every 1000 h,

Filling and ventilation filter

0001 - 9999

Engine oil filter

0001 - 9999

every 250 h

0001 - 9999

every 250 h

at least 1 x p.a.

Fuel filter Preliminary fuel filter (water separator) Main air filter Safety air filter

0001 - 9999

* This filter is additionally required for the serial numbers mentioned.

107

Machine type W 2000

Description

Hydraulic oil filter

Series range

0001 - 9999

Replacement interval

RequirePart No. ment 1

30294

1

118266

1

74334

1

14171

1

1877

1

119391

1

119393

1

50978

if necessary,

1

85691

at least 1 x p.a.

1

90980

5

30294

6

30294

7

30294

1

14171

1

401113

2

33023

1

40103

1

84128

1

122648

if necessary,

2

41925

at least 1 x p.a.

2

41924

1

30294

1

118266

1

74334

1

14171

if necessary, at least 1 x p.a. every 1000 h,

Filling and ventilation filter

0001 - 9999

Engine oil filter

0001 - 9999

at least 1 x p.a. every 250 h

Fuel filter Preliminary fuel filter (water separator)

0001 - 9999

every 500 h

Preliminary fuel filter (mesh) Main air filter Safety air filter

0001 - 9999

Hydraulic oil filter (DC/SM) 2100 DC

Hydraulic oil filter (DCR)

0001 - 9999

if necessary, at least 1 x p.a.

Hydraulic oil filter (DCR with screed)

every 1000 h, Filling and ventilation filter

0001 - 9999

Engine oil filter

0001 - 9999

Fuel filter

0001 - 9999

Preliminary fuel filter

0001 - 0149

Preliminary fuel filter

0150 - 9999

Preliminary fuel filter (water separator)*

0410 - 9999

Main air filter Safety air filter W 2100

Hydraulic oil filter

0001 - 9999

0001 - 9999

at least 1 x p.a. every 250 h

every 250 h

if necessary, at least 1 x p.a. every 1000 h,

Filling and ventilation filter

0001 - 9999

Engine oil filter

0001 - 0129

every 250 h

1

1877

Engine oil filter

0130 - 9999

every 250 h

2

1877

1

119391

1

119393

at least 1 x p.a.

Fuel filter Preliminary fuel filter (water separator)

0001 - 9999

every 500 h

1

50978

if necessary,

1

85691

at least 1 x p.a.

1

90980

if necessary,

2

182496

at least 1 x p.a.

2

182497

Preliminary fuel filter (mesh) Main air filter Safety air filter Main air filter Safety air filter

0001 - 0129

0130 - 9999

* This filter is additionally required for the serial numbers mentioned.

108

Machine type W 2200

Description

Hydraulic oil filter

Series range

Replacement interval if necessary,

0001 - 9999

at least 1 x p.a. every 1000 h,

Filling and ventilation filter

0001 - 9999

Engine oil filter

0001 - 9999

Fuel filter Preliminary fuel filter (water separator)

0001 - 9999

Main air filter Safety air filter WR 2000

Hydraulic oil filter

0001 - 9999

at least 1 x p.a. every 250 h every 250 h

WR 2500

2

1877

2

119391

90980

1

30294

1

118266

1

74334

1

14171

1

177725

2

145940

1

162055

if necessary,

1

85691

at least 1 x p.a.

1

90980

if necessary,

4

30294

at least 1 x p.a.

4

45452

1

14171

1

40113

2

33023

1

84128

at least 1 x p.a.

0001 - 9999

every 250 h

0001 - 9999

14171

2

every 250 h

Hydraulic oil filter

1

at least 1 x p.a.

0001 - 9999

0001 - 9999

74334

85691

Engine oil filter

Safety air filter

118266

1

119393

0001 - 9999

Main air filter

1

2

Filling and ventilation filter

Preliminary fuel filter (water separator)

30294

1

every 1000 h,

Fuel filter

2

if necessary,

if necessary, 0001 - 9999

RequirePart No. ment

at least 1 x p.a.

every 1000 h, Filling and ventilation filter

0001 - 9999

Engine oil filter

0001 - 9999

every 250 h

0001 - 9999

every 250 h

0150 - 9999

every 250 h

1

122648

if necessary,

2

41925

at least 1 x p.a.

2

41924

1

30294

if necessary,

1

118266

at least 1 x p.a.

1

74332

1

74334

1

14171

1

40113

2

33023

Fuel filter Preliminary fuel filter Preliminary fuel filter (water separator)* Main air filter Safety air filter

0001 - 9999

WR 2500 S Hydraulic oil filter

0001 - 9999

at least 1 x p.a.

every 1000 h, Filling and ventilation filter

0001 - 9999

Engine oil filter

0001 - 9999

Fuel filter Preliminary fuel filter (water separator) Main air filter Safety air filter

0001 - 9999

0001 - 9999

at least 1 x p.a. every 250 h every 250 h

1

162055

if necessary,

2

41925

at least 1 x p.a.

2

41924

* This filter is additionally required for the serial numbers mentioned.

109

Original Wirtgen hydraulic pumps and motors for high-performance machine functions Thanks to their flexibility, power density and easy maintenance, hydraulic drives have proven to be very effective in mobile machines. In Wirtgen machines, they assume a variety of functions: hydraulic drives ensure reliable operation, from advance drive and material transport, all the way to auxiliary functions such as hydraulic cylinder control. The pumps and motors were designed specifically for Wirtgen with an optimised set of characteristics for the individual functions. Based on practical experience, service packages have been developed for these components which ensure long-term, trouble-free operation of a machine, because they

provide for complete replacement of all seals during maintenance work. The pumps and motors for the advance drive have been specifically adapted to the milling function. The highly sensitive, controllable drives have been precisely designed to suit the milling process in terms of power transmission and control response. The compact structural design has been optimised to meet the requirements in Wirtgen milling machines. It allows the components to be installed directly in the crawler unit or the wheel, which significantly improves responsiveness.

The drives for the conveyor have been optimised for the transport of largevolume material flows. The pumps and motors have a high power density in order to guarantee the reliable start-up of a fully-loaded conveyor following work-related interruptions.

110

Sealing kits hydraulic pumps

Machine type

Seriesrange

0766 - 1181

Pump*: 68411 Sealing kit cpl.: 53865 Sealing ring: 58907 Pump*: 110158 Sealing ring: 95832 Pump*: 53603 Sealing kit cpl.: 53865 Sealing ring: 58907 Pump*: 89088 Sealing ring: 95832

1182 - 9999

Pump*: Sealing ring:

W 350 0001 - 0314

0315 - 9999 W 500, 3 wheel 0005 - 0765

0766 - 1198

1199 - 9999

Pump*: Sealing ring:

138833 78164

Pump*: Sealing ring: Pump*: Sealing ring: Pump*: Sealing ring: Pump*: Sealing ring: Pump*: Sealing kit cpl.: Pump*: Sealing ring: Pump*: Sealing ring: Pump*: Sealing kit cpl.: Pump*: Sealing ring: Pump*: Sealing ring: Pump*: Sealing kit cpl.:

170046 95832 170044 78164 93856 95832 93857 95832 14975 23589 93856 95832 93857 95832 14975 23589 138837 95832 138840 95832 14975 23589

0005 - 0765

W 50 DC

138829 95832

Pump*: Sealing kit cpl.: Sealing ring: Pump*: Sealing ring:

W 500, 4 wheel

W 50

Advance drive

0001 - 9999 0001 - 9999

W 600 DC, W 1000 L

0001 - 0224

0225 - 0294

0295 - 9999

53603 53865 58907 89086 78164

Conveyor belt drive

Fan drive

Cylinder Pump: Sealing kit cpl.:

80714 64797

Pump: Sealing kit cpl.: Pump: Sealing kit cpl.:

80714 64797 47964 40913

Pump: Sealing kit cpl.: Sealing ring:

47964 40913 42020

Pump: Sealing kit cpl.: Sealing ring:

36965 40913 42020

Pump: Sealing kit cpl.: Sealing ring:

36965 40913 42020

Pump: Sealing kit cpl.:

47964 40913

Pump: Sealing kit cpl.:

47694 40913

36965 Pump: Sealing kit cpl.: 40913 42020 Sealing ring: 36965 Pump: Sealing kit cpl.: 40913 42020 Sealing ring: 171599 Pump: Sealing kit cpl.: 78033 30975 Pump:

171599 Pump: Sealing kit cpl.: 78033

36965 Pump: Sealing kit cpl.: 40913 42020 Sealing ring: 36965 Pump: Sealing kit cpl.: 40913 42020 Sealing ring: 171599 Pump: Sealing kit cpl.: 78033 171597 Pump:

Pump: Sealing kit cpl.:

93858 39302

Pump: Sealing kit cpl.:

93858 39302

Pump: Sealing kit cpl.:

96368 39302

Pump: Sealing kit cpl.:

96368 39302

Pump: Sealing kit cpl.:

96368 39302

Pump: Sealing kit cpl.:

96368 39302

* Position of drive pump: different assembly position

111

Sealing kits hydraulic pumps

Machine type

Seriesrange

W 1000

0001 - 0556

0557 - 0577

0578 - 9999

W 1000 F, W 1200 F, W 1300 F 06.10 W 1000 F, W 1200 F, W 1300 F 07.10

0001 - 9999 0001 - 0556 0557 - 9999 0001 - 0049

1300 - 2000 DC

0050 - 9999 5.20 W 1500, W 1900

Pump*: Sealing kit cpl.: Pump*: Sealing ring: Pump*: Sealing kit cpl.: Pump*: Sealing ring: Pump*: Sealing kit cpl.: Pump*: Sealing ring: Pump*: Sealing ring: Pump*: Sealing ring: Pump*: Sealing ring: Pump*: Sealing kit cpl.:

78036 78033 69896 78164 78036 78033 156587 87708 78036 78033 152240 87708 92601 102948 92601 102948 138842 87708 36964 40846

Conveyor belt drive

0001 - 0185

Pump: Sealing kit cpl.:

78035 78033

Pump: Sealing kit cpl.:

78034 78033

Pump: Sealing kit cpl.:

78035 78033

Pump: Sealing kit cpl.:

78034 78033

Pump: Sealing kit cpl.:

90144 64797

Pump: Sealing kit cpl.:

78035 78033

Pump: Sealing ring:

92602 78164

Pump: Sealing kit cpl.:

90144 64797

92603 Pump: Sealing kit cpl.: 103330

Pump: Sealing ring:

92602 78164

Pump: Sealing kit cpl.:

90144 64797

92603 Pump: Sealing kit cpl.: 103330

Pump: Sealing kit cpl.: Sealing ring: Pump: Sealing ring:

58086 62649 42975 80026 87708

Pump: Sealing kit cpl.:

64795 23649

Pump: Sealing kit cpl.: Sealing ring: Pump: Sealing kit cpl.:

Pump: Sealing kit cpl.: Pump: Sealing kit cpl.:

141745 135152 151331 135152

Pump: Sealing kit cpl.:

15543 23649

Pump*: Sealing ring:

84389 88774

Pump*: Sealing ring:

137165 88774

Pump: Sealing ring:

137167 87708

Pump*: Sealing ring:

113993 88774

Pump: Sealing ring:

113994 87708

2100 DC

Pump*: Sealing ring:

137165 88774

0001 - 0094

0095 - 0117

Pump: Sealing ring: Pump: Sealing kit cpl.:

Pump*: Sealing kit cpl.:

36964 40846

0118 - 0256

Pump: Sealing kit cpl.: Sealing ring:

137167 87708

84389 88774

Pump: Sealing ring:

80026 87708

Pump*: Sealing ring: 0001 - 0050 Pump*: W 2200 Sealing ring: 0051 - 9999 Pump*: Sealing ring: 0001 - 9999 Pump*: WR 2000 Sealing ring: * Position of drive pump: different assembly position

138885 92082 115181 92082 138885 92082 167036 92082

Pump: Sealing ring: Pump: Sealing ring: Pump: Sealing ring:

137166 135969 113994 87708 137167 87708

112

0001 - 9999

Pump: Sealing kit cpl.: Pump: Sealing ring:

Pump: Sealing kit cpl.:

40445 43733

Pump: Sealing kit cpl.:

71477 23649

58086 62649 42975

Pump*: Sealing ring:

W 2100

Pump: Sealing ring:

36965 40913 42020 84388 47741 123347 129382

51890 40913 123347 129382

36967 40847

0257 - 0282 0283 - 9999

Cylinder

78034 78033

0186 - 0210 0211 - 9999

Fan drive

Pump: Sealing kit cpl.:

0001 - 0091 0092 - 9999

W 2000

Advance drive

Pump: 94907 Sealing kit cpl.: 135152 Pump: 15543 Sealing kit cpl.: 23649 Pump: Sealing ring: Pump: Sealing kit cpl.:

Pump: Sealing kit cpl.: Sealing ring:

36965 40913 42020

Pump: Sealing kit cpl.:

84388 47741

Pump: Sealing ring:

123347 129382

123238 129382

Pump: Sealing ring:

123347 129382

31291 23649

Pump: Sealing ring:

154412 129382

Sealing kits hydraulic pumps Sealing kits hydraulic motors Machine type

Seriesrange

W 2500

0001 - 0041

0042 - 0109

0110 - 0259

0260 - 9999

W 2500 S 0001 - 9999

Advance drive

Conveyor belt drive

Fan drive

Cylinder 71477 23649

Pump: Sealing kit cpl.:

79129 47741

Pump: 94907 Sealing kit cpl.: 135152

Pump: Sealing kit cpl.:

79129 47741

Pump: 94907 Sealing kit cpl.: 135152

Pump: Sealing kit cpl.:

79129 47741

Pump: 94907 Sealing kit cpl.: 135152

Pump: Sealing kit cpl.:

79129 47741

Pump:

Pump: Sealing ring:

Pump*: Sealing ring: Pump*: Sealing Kit kpl.: Sealing ring: Pump*: Sealing ring: Pump*: Sealing kit cpl.: Sealing ring: Pump*: Sealing kit cpl.: Sealing ring: Pump*: Sealing kit cpl.:

80019 29986 80020 20231 29986 80019 29986 80020 20231 29986 80020 20231 29986 112624 20231

Pump: Sealing kit cpl.:

Pump*: Sealing ring: Pump*: Sealing ring: Pump*: Sealing ring: Pump*: Sealing ring:

149739 78164 149740 78164 154408 78164 154409 78164

161467

154412 129382

* Position of drive pump: different assembly position

Machine type

Seriesrange

W 350 0001 - 0058

0059 - 0314

0315 - 9999

Advance drive motor Motor*: Sealing kit cpl.: Sealing ring: Motor*: Sealing kit cpl.: Sealing ring: Motor*: Sealing kit cpl.: Sealing ring:

0005 - 0236

0431 - 9999 W 50 W 50 DC

0001 - 9999 0001 - 9999

Motor*: Sealing kit cpl.: Sealing ring:

Fan motor

23397 20258 43711 76498 73602 80607 90051 130618 80607

W 500

0237 - 0430

Conveyor belt motor

24316 53867 43011

Motor**: Sealing kit cpl.:

43270 48360

Motor**: Sealing kit cpl.:

62926 62752

Motor**: Sealing kit cpl.:

51659 62752

Motor**: Sealing kit cpl.: Motor**: Sealing kit cpl.:

51659 62752 51659 62752

Motor: Sealing kit cpl.:

44617 25451

* Advance drive motor: with / without Pick up or right / left machine side; ** Conveyor belt motor: Primary conveyor / discharge conveyor

113

Sealing kits hydraulic motors

Machine type

Seriesrange

W 600 DC, W 1000 L 0001 - 9999 W 1000 0001 - 0010

0011 - 0374

0375 - 9999 W 1000 F, W 1200 F, W 1300 F

Advance drive motor Motor*: Sealing kit cpl.: Sealing ring: Motor*: Sealing kit cpl.: Sealing ring: Motor*: Sealing kit cpl.: Sealing ring: Motor*: Sealing kit cpl.: Sealing ring:

90051 130618 80607 23397 20258 43711 76498 73602 80607 90051 130618 80607

Conveyor belt motor Motor**: Sealing kit cpl.:

51659 62752

Motor**: Sealing kit cpl.:

72082 62752

0001 - 0054 0055 - 0329

0001 - 0317

0318 - 9999 05.20 W 1500, W 1900 0001 - 9999 W 2000 0001 - 0479

0480 - 9999

W 2100 0001 - 0099

0100 - 9999

2100 DC

Motor: Sealing kit cpl.:

48051 51204

Motor**: Sealing kit cpl.:

43643 39929

Motor*: Sealing kit cpl.: Sealing ring: Motor*: Sealing kit cpl.: Sealing ring:

76496 73602 80607 110028 130618 80607

Motor**: Sealing kit cpl.:

14711 23592

Motor**: Sealing kit cpl.:

41685 23592

Motor*: Sealing kit cpl.: Sealing ring:

110028 130618 80607

Motor**: Sealing kit cpl.: Motor**: Sealing kit cpl.:

14711 23592 41685 23592

Motor: Sealing kit cpl.: Sealing ring:

89818 24159 68759

Motor*: Sealing ring: Motor*: Sealing ring: Motor*: Sealing ring: Motor*: Sealing ring: Motor*: Sealing ring: Motor*: Sealing ring: Motor*: Sealing ring: Motor*: Sealing ring:

114879 80607 114163 80607 172614 80607 114163 80607 147121 129396 147120 129396 172615 129396 147120 129396

Motor**: Sealing kit cpl.:

41685 23592

Motor: Sealing ring:

2209 68759

Motor**: Sealing kit cpl.:

126430 152960

Motor: Sealing kit cpl.: Sealing ring:

89818 24159 68759

Motor**: Sealing kit cpl.:

126430 152960

Motor: Sealing kit cpl.: Sealing ring:

89818 24159 68759

Motor**: Sealing kit cpl.: Motor**: Sealing kit cpl.: Motor**: Sealing kit cpl.: Motor**: Sealing kit cpl.:

14711 23592 41685 23592 13526 22734 41685 23592

Motor: Sealing kit cpl.:

38192 53880

Motor: Sealing kit cpl.:

38192 53880

Motor*: Sealing kit cpl.: Sealing ring:

38450 20258 43711

Motor*: Sealing kit cpl.: Sealing ring:

38450 20258 43711

0022 - 0117 0118 - 0120

90196 78241 132565 78241 44617 254541

90051 130618 80607

0001 - 0008 0009 - 0021

Motor: Sealing kit cpl.: Motor: Sealing kit cpl.: Motor: Sealing kit cpl.:

Motor*: Sealing kit cpl.: Sealing ring:

0330 - 9999 1300 - 2000 DC

Fan motor

* Advance drive motor: with / without Pick up or right / left machine side; ** Conveyor belt motor: Primary conveyor / discharge conveyor

114

Sealing kits hydraulic motors

Machine type

Seriesrange

2100 DC 0118 - 0120

0121 - 0176

0177 - 0282

0283 - 0355

0356 - 9999

W 2200 0001 - 0127

0128 - 9999

WR 2000

0001 - 9999

WR 2500 0001 - 0041

0042 - 9999

WR 2500 S 0001 - 0071

0072 - 9999 * Advance drive motor: with / without

Advance drive motor Motor*: Sealing kit cpl.: Sealing ring: Motor*: Sealing kit cpl.: Sealing ring: Motor*: Sealing kit cpl.: Sealing ring: Motor*: Sealing kit cpl.: Sealing ring: Motor*: Sealing kit cpl.: Sealing ring: Motor*: Sealing kit cpl.: Sealing ring: Motor*: Sealing kit cpl.: Sealing ring: Motor*: Sealing kit cpl.: Motor*: Sealing kit cpl.: Motor*: Sealing ring: Motor*: Sealing ring: Motor*: Sealing ring: Motor*: Sealing ring: Motor*: Sealing ring: Motor*: Sealing ring: Motor*: Sealing ring: Motor*: Sealing ring: Motor*: Sealing ring: Motor*: Sealing ring: Motor*: Sealing ring: Motor*: Sealing ring: Motor*: Sealing ring: Motor*: Sealing ring: Motor*: Sealing ring:

43460 20258 43711 72618 73602 80607 73086 73602 80607 76496 73602 80607 76497 73602 80607 76496 73602 80607 76497 73602 80607 110028 130618 110039 130618 115302 129396 115303 129396 115302 129396 172616 129396 179857 84805 179858 84805 179859 84805

Conveyor belt motor Motor**: Sealing kit cpl.:

13526 23592

Motor**: Sealing kit cpl.:

41685 23592

Motor**: Sealing kit cpl.:

13526 23592

Motor**: Sealing kit cpl.:

41685 23592

Motor**: Sealing kit cpl.:

13526 23592

Motor**: Sealing kit cpl.:

41685 23592

Motor**: Sealing kit cpl.:

13526 23592

Motor**: Sealing kit cpl.: Motor**: Sealing kit cpl.:

Fan motor Motor: Sealing kit cpl.:

38192 53880

Motor: Sealing kit cpl.:

38192 53880

Motor: Sealing kit cpl.:

38192 53880

Motor: Sealing kit cpl.: Sealing ring:

89818 24159 68759

41685 23592 13526 23592

Motor: Sealing kit cpl.: Sealing ring:

89818 24159 68759

Motor**: Sealing kit cpl.:

44871 22734

Motor: Sealing ring:

123237 29703

Motor**: Sealing kit cpl.:

44871 22734

Motor: Sealing ring:

123237 29703

Motor: Sealing kit cpl.:

155626 163338

80022 38192 Motor: 84805 53880 Sealing kit cpl.: 80023 84805 80022 89818 Motor: 84805 24159 Sealing kit cpl.: 80023 68759 Sealing ring: 84805 80023 89818 Motor: 84805 24159 Sealing kit cpl.: 80022 68759 Sealing ring: 84805 170608 89818 Motor: 84805 24159 Sealing kit cpl.: 80022 68759 Sealing ring: 84805 Pick up or right / left machine side; ** Conveyor belt motor: Primary conveyor / discharge conveyor

115

Original Wirtgen hydraulic cylinders for precision responsiveness and accurate positioning Hydraulic cylinders are used whenever linear movements requiring high power must be executed. They are used in Wirtgen milling machines for numerous purposes, e.g. to swing the conveyor, for steering, for the side plate, and for height adjustment.

On some sites, material contact is unavoidable. In such instances, the hydraulic cylinders are exposed to increased wear due to contact with dirt. Two solutions are available for maintenance: if the cylinder displays mechanical damage, it is advisable to replace it in order to ensure full operability. If the cylinder material is intact, a Wirtgen service package can be used, which contains all the seals required to allow continued, reliable use of the cylinder for an extended period of time.

Wirtgen hydraulic cylinders are adapted and optimised for individual applications and operating conditions. They reliably transmit high forces and provide for exact positioning in any situation thanks to their precision responsiveness. Wirtgen hydraulic cylinders are characterised by high mechanical strength and corrosion resistance. As a result, machines are guaranteed to remain operational even over a long period of time.

116

Side plate

Scraper

Machine type

Series range

Cylinder

Sealing Kit

W 500

0001-9999

61124

76301

W 50

0001-0067

172087

76301

Cylinder

Depressor Sealing Kit

Cylinder

Belt tensioner Sealing Kit

8814

6395

100429

6395

172087

76301

172087

76301

Cylinder

Sealing Kit

Side plate right 173624

76301

0068-9999 Side plate left 172087

76301

W 50 DC

0001-9999

173624

76301

100429

6395

W 600 DC, W 1000 L

0001-9999

90224

76301

100429

6395

57301

38870

W 1000

0001-9999

61124

76301

8814

6395

57301

38870

W 1000 F, W 1200 F,

0001-9999

90224

76301

8813

6395

52280

55808

34144

6394 106527

106530

113317

113317

62603

55812

57301

38870

3266

6394

57301

38870

106530

3266

6394

57301

38870

106530

16689

6395

57301

38870

57301

38870

W 1300 F 1300 - 2000 DC

0001-0226 05.20 0227-9999

W 1500, W 1900

0001-9999

113565

74376

W 2000

0001-0519

113565

74376

0520-9999

163871

55812 Milling depth 300

2100 DC

3265 0001-9999

34144

6394

38737

6395

6400 Milling depth 400

W 2100

W 2200

0001-0106

113565

74376

0107-9999

163871

55812

0001-0123

Milling width 2200 113565

16689

6395

113317

106530

16689

6395

57301

38870

132596

132067

45450

6395

57301

38870

74376

Milling width 3800 34144 0001-0055

SM 113565

0056-0123

0124-9999

6394

74376

SM 34144

6394

163871

55812

117

Original Wirtgen electrical accessories for continuously reliable and safe machine operation Electrical Service Kit for machine operators Minor faults in the electrical system, such as blown fuses or failed relays, can seriously impede work on a job site. The Electrical Service Kit for machine operators is a handy case with all the tools and parts required to get a machine up and running again on site without wasting a lot of time and effort.

included for electrical tests, adjustments and other service tasks. The contents of the Electrical Service Kit enable a machine operator to remedy minor problems on his own.

The service kit contains a variety of electrical parts, such as relays, fuses, valve connectors, auxiliary switches and front elements. A simple multimeter with instrument leads is also

Machine type

Series range

Part No.

W 350, W 350 E

0001 - 9999

147320

W 500

0001 - 9999

147320

W 50, W 50 DC

0001 - 9999

148616

W 1000

0001 - 0577

147320

0578 - 9999

148616

0001 - 0164

147320

0165 - 9999

148616

W 1000 F

1300 - 2000 DC

05.20

0001 - 9999

147320

W 1500, W 1900

08.20

0001 - 9999

148616

0001 - 0215

147320

0216 - 9999

148616

0001 - 0011

147320

0012 - 9999

148616

0001 - 0059

147320

0060 - 9999

148616

WR 2000

0001 - 9999

148616

WR 2500

0001 - 9999

147320

WR 2500 S

0001 - 9999

148616

W 2000

W 2100

W 2200

118

Electrical Service Kit for workshop staff The rough use of Wirtgen milling machines, frequently under difficult conditions, makes routine maintenance of the electrical system necessary in order to ensure availability of a machine at all times. The Electrical Service Kit for workshop staff contains the most common and essential hardware for servicing a machine, all neatly arranged in a case: relays, blade-type fuses, wire end sleeves, flat plugs, proximity switches, auxiliary switches, front elements and much more. It contains over 100

different parts totalling more than 1,000 items. The variety of electrical hardware in this service kit greatly facilitates the work of service and maintenance staff. A perfect match for this service kit is the Electrical Test Kit (tools).

Machine type

Series range

Part No.

W 350, W 350 E

0001 - 9999

83980

W 500

0001 - 9999

83980

W 50, W 50 DC

0001 - 9999

161003

W 1000

0001 - 0577

83980

0578 - 9999

161003

0001 - 0164

83980

0165 - 9999

161003

W 1000 F

1300 - 2000 DC

05.20

0001 - 9999

83980

W 1500, W 1900

08.20

0001 - 9999

161003

0001 - 0215

83980

0216 - 9999

161003

0001 - 0011

83980

0012 - 9999

161003

0001 - 0059

83980

0060 - 9999

161003

WR 2000

0001 - 9999

161003

WR 2500

0001 - 9999

83980

WR 2500 S

0001 - 9999

161003

W 2000

W 2100

W 2200

119

Original Wirtgen electrical accessories for continuously reliable and safe machine operation Worklights Work is performed round-the-clock on a lot of job sites, and many types of work can only be done at night. Optimum illumination of the site is essential for such tasks. To meet these demands, Wirtgen offers an extensive range of worklights that can be used flexibly for a variety of jobs. The lamps can be mounted in existing fixtures at various points on a machine, or entirely as needed at other spots. The lamps are easy to disassemble and store to prevent vandalism and theft.

Xenon worklights Xenon worklights are particularly suitable for demanding lighting situations. The ultramodern Xenon lamps are very bright, providing ideal illumination of a construction site. The mounting options and connections are fully compatible with the conventional worklight system.

Safety equipment Wirtgen machines conform to the highest European and international safety standards. To maintain this prescribed level of safety on a permanent basis, individual pieces of safety equipment must be complete and fully functional, even when subjected to extensive use. If their operation is impaired, for example because of damage, the corresponding parts must be replaced.

120

Description

Part No.

Work light

10906

Work light with cable and plug

31926

Work light with spiral cable and plug

37013

Work light with quick fastening

57775

Work light with magnetic bracket

117676

Bulb for work light

9778

Work light Xenon

144623

Work light Xenon with spiral cable and plug

161026

Work light Xenon with magnetic bracket

146979

Bulb for work light Xenon

144624

Patrol light yellow

68407

Bulb for patrol light

16224

Horn

8015

Reversing alarm

19836

121

Original Wirtgen tools for everyday use Extractor for picks Part No.: 28812

Ejector drift for picks Part No.: 45275

Pneumatic ejector drift for picks Part No.: 84252

Pneumatic driver for picks Part No.: 84251

122

Ejector drift for picks Part No.: 82747

Copper hammer for driving in the picks Part No.: 5442

Pneumatic hammer set with driver and ejector drift Part No.: 60604

Rapid replacement of picks

3/4” extension Part No.: 10747

Hexagon socket, 17 mm for HT2 Part No.: 11886

Pick changes mean machine stoppages. The milling drums on all Wirtgen machines are easily accessible to keep these downtimes short. The next step is to drive out the worn picks and insert the new ones. Wirtgen can offer suitable tools for this purpose: manual ejector drifts and extractors, copper hammers for driving in the new picks and pneumatic tools for changing picks.

Assembly tools for quickchange toolholder systems

Ratchet 3/4” Part No.: 97204

In addition to the standard tool kit supplied with every machine, special tools are required for the optional milling drums with quick-change toolholders. These tools have been carefully selected by Wirtgen. Hexagon socket, 14 mm for HT3 Part No.: 11151

Assembly tools for Surface Miner picks Special pliers are available from Wirtgen for mounting and dismounting the locking rings.

Torque wrench up to 700 Nm Part No.: 68273

Assembly pliers for locking rings Part No.: 5447

Locking rings for Surface Miner picks Part No.: 155281

Adapter for thread cutter Part No.: 169132

Thread cutter for HT3 M 24 x 2 Part No.: 101772

123

Original Wirtgen Test Kits ensure the performance of your machine Regular maintenance of Wirtgen machines greatly increases their service life and enhances their performance. To carry out maintenance and service work professionally, Wirtgen has put together two test kits for service staff, which contain all the tools required to test and adjust electrical and hydraulic components.

Hydraulic Test Kit Part No. 12782 The Hydraulic Test Kit contains a variety of tools required to carry out

124

hydraulic pressure tests and perform adjustments and service work on Wirtgen machines. The main items include pressure gauges for different pressure ranges, hydraulic fittings and manometer adapters. Other tools are also available, such as different double open-ended spanners, a set of metric hex wrenches with ball end, and a set of SAE hex wrenches. The kit is rounded out by sets of seals for several different valves, and O-rings in the most common sizes.

Electrical Test Kit Part No. 89900 The Electrical Test Kit contains a variety of high-quality tools required to take electrical measurements and perform adjustments and service work on Wirtgen machines. The test kit's basic equipment includes a high-quality multimeter with an extensive set of accessories, such as instrument leads, test probes, clip-type probes and test adapters. These are supplemented by a wire stripper, a crimping tool for wire end sleeves, diagonal side cutters, needle-nose pliers and a set of screwdrivers.

Service Master Test Kit Part No. 156825 Wirtgen machines offer a variety of innovative functions with different settings to help the machines operate at full potential and ensure optimum productivity. The Service Master Test Kit was developed to support the corresponding diagnostic and service work. It can be used to take hydraulic, thermal and electrical measurements, or to perform adjustments and service work.

The standard equipment includes a hand-held test unit, pressure sensors, temperature probes, an rpm speed sensor, an electronic module and sufficient instrument leads. Pressure, flow rate, temperature, rpm speed (frequency), current and voltage can be tested with the kit. Six channels are available to simultaneously record the test data. With the help of the software provided, the test data can be transferred via the integrated RS232 interface directly to a PC or printer for further processing or printing.

125

Original Wirtgen tools for an effective service Vacuum Kit Part No. 95304 When working on the hydraulic system, it is important to prevent hydraulic fluid from escaping. Special precautionary measures should be taken particularly on a job site to comply with environmental regulations. Using the Vacuum Kit can effectively help prevent excessive amounts of fluid from escaping when disconnecting a hydraulic hose or dismantling a valve. For this purpose, the vacuum pump from the kit is connected to the

126

hydraulic tank using one of the adapters provided. The pump then generates a vacuum in the air space above the hydraulic fluid, which minimises fluid leakage.

Spanners for slotted nuts on conveyor system Part No. 161468/161472 To secure the return roller of the conveyor unit in the correct axial position, the slotted round nuts with tensioner bushes are fixing the return roller. For tightening and loosening the slotted round nuts without damaging them, the original Wirtgen spanners are required.

Machine type

Part No.

W 1000 F, W 1200 F, W 1300 F

161468

1300 - 2000 DC

05.20

161468

W 1500, W 1900

161468

W 2000

161472

W 2100

161472

W 2200

161472

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Original Wirtgen vibrators for maximum compaction and reliability Wirtgen Slipform Pavers cover a variety of applications for high-quality offset slipforming and roadway paving, all of which centre on the compaction of concrete. The structural design and model features of the Wirtgen vibrators used for compaction are adapted to the various applications and optimised with regard to form and function. Their most outstanding feature is maximum compaction combined with maximum reliability. Other characteristics include durability, high efficiency and long service life, which enable economical use.

An additional smooth protection hose prevents concrete sticking

Shock proved plug which is unbreakable even at low temperatures

Changed geometry of the inner vibrator prevents the protection hose rubbing against its own suspension

High efficiency by using high quality 3-phase asynchronous motors

Bigger effective diameter and higher compaction performance due to increased unbalance

Completely casted connections for protection against mechanical damage, improved insulation safety and better heat rejection

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Long life due to special roller bearings

Offset applications For offset pavement, which usually involves the paving of a profile, the mould is located alongside of the actual machine. During offset paving, the vibrators are positioned directly in the moulds and arranged such that the concrete is evenly distributed and compacted even in small or complex moulds. Straight vibrators are generally used in the offset process. The number and arrangement of the vibrators depends on the shape of the profile and the volume of concrete placed.

Road pavement When it comes to road pavement, curved vibrators are usually used, which are submerged in the concrete in front of the slipform pan. The vibrators are distributed across the paving width in such a way that optimum compaction is achieved. In the case of two-layer paving, “Tvibrators” are used to compact the second layer. For other applications, e.g. profiled surfaces, the various vibrators can be flexibly combined to ensure the best possible results for concrete paving.

Vibrator electric Application

Description

Part No.

Offset application

Vibrator straight D66

180705

Offset application

Vibrator bent D66

145963

Road pavement 1. Layer

Vibrator bent D66

145963

Road pavement 1. Layer

Vibrator bent D76

145961

Road pavement 2. Layer

T-vibrator D76

180706

Vibrator hydraulic Application

Description

Part No.

Offset application

Vibrator straight (hydraulic)

75721

Offset application

Vibrator bent (hydraulic)

75722

Road pavement

Vibrator bent (hydraulic)

75722

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Telefon: 0 26 45 /131- 0 Telefax: 0 26 45 /131- 397 E-Mail: [email protected] Internet: www.wirtgen-group.com

Wirtgen GmbH Hohner Straße 2 53578 Windhagen · Deutschland Telefon: 0 26 45 /131- 0 Telefax: 0 26 45 /131- 397 E-Mail: [email protected] Internet: www.wirtgen.de

Joseph Vögele AG Neckarauer Straße 168 - 228 68146 Mannheim · Deutschland Telefon: Telefax: E-Mail: Internet:

06 21/ 81 05 - 0 06 21/ 81 05 - 463 [email protected] www.voegele-ag.de

Hamm AG Hammstraße 1 95643 Tirschenreuth · Deutschland Telefon: 0 96 31/ 80- 0 Telefax: 0 96 31/ 80- 120 E-Mail: [email protected] Internet: www.hammag.com

Abbildungen sind unverbindlich. Technische Änderungen bleiben vorbehalten. Leistungsdaten sind abhängig von den Einsatzbedingungen. – Nr. 40-10 / 186038 DT 11/04 © by Wirtgen GmbH 2004 Printed in Germany

Wirtgen Group Hohner Straße 2 53578 Windhagen · Deutschland