Compact and heavy-duty high-performance

cold milling machine.

W 220 F i
Cold Milling Machine

US RELEASE
02
03

Compact and heavy-duty high-

performance cold milling machine.

The heavy-duty cold milling machine handles a wide range of applications, from surface layer rehabilitation to
complete pavement removal and fine milling.
Rapid milling drum assembly changes and particularly fast milling drum changes for milling widths of 7 ft 3 in
(2.2 m), 8 ft 2 in (2.5 m), or 12 ft 6 in (3.8 m) thanks to the MCS (Multiple Cutting System) further expand the
machine’s wide range of applications.
In automatic mode, the innovative MILL ASSIST machine control system always selects the best ratio between
performance and costs – in addition, an operating mode can be selected based on cost, performance, or
quality.
Thanks to the unique DUAL SHIFT powershift transmission with extended milling drum speed, the W 220 F i is
the perfect choice for particularly demanding milling tasks.
The new LEVEL PRO ACTIVE leveling system built directly into the machine control system optimizes p
­ recision
in height control and machine positioning.
 Highlights of the
Cold Milling Machine at a Glance
04
05
Operation Quality
1| EXCEPTIONAL COMFORT ON THE OPERATOR’S 3|  HIGH-PRECISION, VERSATILE
PLATFORM ­LEVEL PRO ACTIVE LEVELING SYSTEM
> Excellent view of important working areas > New, easy-to-use LEVEL PRO ACTIVE operating
> High-performance LED lighting concept
> Generously sized storage space > Numerous additional and automatic functions
> Powerful heater for operator’s platform > Optimized 3D and laser leveling
> Variable, vertically adjustable weather canopy > Leveling boom with Sonic-Ski sensor on both sides
> SMART KEY to save user-specific machine parameters > Optimized multiplex system

2| INTUITIVE MMI – MAN MACHINE INTERFACE 4| HIGH RELIABILITY

> Flexible control panel concept for maximum machine control > Groundbreaking diagnostic concept
> 2" control panel with favorites buttons > Redundant machine control
> 5" control panels for leveling > Robust, reliable CAN network
>7 " control panels conveniently display important information > Reliable vandalism protection
> Heavy-duty, high-quality camera / monitor system with 10" control > Time-saving service and maintenance concept
panel

10 | 2|
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4|
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9|

8|

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5|
Milling
5| ONE-OF-A-KIND CUTTING TECHNOLOGY 6| INNOVATIVE MILL ASSIST
> Rapid milling drum changes thanks to MCS BASIC > MILL ASSIST automatic mode for maximum cost
> Simple milling drum assembly changes ­efficiency
> Optimized protection against milling drum assembly > Additional pre-selection of an operating strategy in
wear automatic mode
> Extremely wear-resistant HT22 quick-change toolholder > Clear pre-selection of constant milling pattern quality
system > Innovative efficiency indicator
> New HT22 PLUS toolholder upper part with increased > New DUAL SHIFT powershift transmission
service life

7|

Cost-Effectiveness
Performance 9| REDUCED DIESEL CONSUMPTION
7| MAXIMUM MILLING PERFORMANCE > 2-speed powershift transmission for a wide
range of usable milling drum speeds
>P  owerful diesel engine > Automatic stop feature for the diesel engine
> Increased ballasting flexibility > Maximum performance in the low speed
> Large scraper lift with high setting depth range
> Flexible and powerful loading of milled material > Automatic start-stop feature of the milling
> ACTIVE CONVEYOR for swinging the discharge drum
­conveyor relative to the steering angle > Dual fan concept for optimum cooling

8| INFORMATIVE WPT – WIRTGEN 10 | ENVIRONMENTALLY FRIENDLY

­PERFORMANCE TRACKER MACHINE TECHNOLOGY
>F  ield-tested WITOS FleetView telematics system > Maximum exhaust gas purification for low
>O  ptional additional equipment WPT for clear exhaust emissions
­documentation of milling performance > Reduced noise emissions during relocation
> Automatically generated measurement reports > Optimized VCS extraction system
> Job site tracking via satellite map display > Start-stop engine function via external control
>D  ocumentation of consumables to calculate operating panel
costs > Efficient water management
 CONNECTED MILLING
06
07

COLD MILLING
MACHINE

CONNECTED
MILLING

MACHINE
OWNER
 An efficient flow of information is the MILL ASSIST can be used to assess
key to making processes easier, faster, relevant information such as engine
and more cost-effective. WIRTGEN load, milling drum type, milling
has been committed to this approach depth, or traveling pressure, for
for many years and refers to the topic example, in order to set the optimum
in the field of milling technology as milling drum speed. In addition, the
­CONNECTED MILLING. machine operator can pre-select a
work strategy with respect to costs,
CONNECTED MILLING refers to the performance, or quality.
innovative, diverse flow of informa-
tion between the machine and its The WIRTGEN PERFORMANCE
various components, the machine TRACKER uses a laser scanner to
operator, the service workshop, and measure the cross-sectional profile
the scheduling offices. This available to be milled. Surface milling perfor-
data and information can be used to mance and milling volume are then
make milling operations even more precisely measured using GPS posi-
efficient and further increase machine tioning and other sensors. Afterwards,
reliability. an automatically generated report
is created that documents the daily
In the new generation of large milling performance, including all
milling machines, the latest, in- consumables, a precise site plan, and
novative ­CONNECTED MILLING a wealth of other information, which is
features include the MILL ASSIST then sent to the machine dispatcher,
intelligent assistance system and the for example. The machine operator
­WIRTGEN PERFORMANCE TRACKER receives important information direct-
high-precision milling performance ly via the control panel display.
measurement system.
In WIRTGEN’s new genera-
tion of large milling machines,
­CONNECTED ­MILLING becomes
even more important for machine
operators.

MACHINE
OPERATOR
 Operation
Exceptional Comfort on the
08
09
­Operator’s Platform
EXCELLENT VIEW OF IMPORTANT WORKING AREAS panel lighting, lighting for the milling drum assembly
The large milling machine’s intelligently designed visibil- including auxiliary working lights for tool changes, and
ity concept makes the operator’s work much easier and optional LED lighting balloons. This guarantees optimum
results in precise milling results. For example, the opera- machine illumination, even in difficult lighting conditions.
tor’s platform can be extended to the right by more than
7.9 in (20 cm) beyond the edge of the machine to guar- GENEROUSLY SIZED STORAGE SPACE
antee that the operator has an unobstructed view of the The W 220 F i offers plenty of storage space for leveling
area to be milled and the loading of the milled material. In sensors, pick ejectors, and tool buckets. The 428-gallon
addition, the narrow chassis is designed with a wasp waist (1,620-liter), additional and optional XXL storage com-
at the front left and right as well as at the back right. This partment at the rear of the machine can hold up to 72
means that the operator always has a good view of the pick buckets, while another 70-gallon (265-liter) storage
crawler unit and milling edge. compartment on the operator’s platform can also be used
as an option.
HIGH-PERFORMANCE LED LIGHTING
The W 220 F i has particularly powerful LED working lights
all around the machine, lighting for the operator’s plat-
form, and “welcome and go home” lighting for comfort-
able access. In addition, the machine also features control

1|
1 | Ergonomically
2|
designed operator’s
platform.

2 | Optimum heating
for the operator’s
hands and feet.

3 | Individually,
vertically height-­
adjustable weather
canopy.

4 | Weather canopy
in transport position.

3| 4|

POWERFUL HEATER FOR OPERATOR’S with window wipers. Exterior canopy panels
PLATFORM that can be moved independently of each other
The cold milling machine is equipped with a provide additional protection in the event of
high-performance heater for the operator’s rain. The operator’s platform railings are also
platform. Intelligently arranged air vents equipped with wind and weather protection
positioned near the operator’s hands and feet elements.
guarantee an excellent heating effect. In addi-
tion, the generated heat is effectively kept close SMART KEY
to the operator by lateral wind and weather The SMART KEY fob can be used to save indi-
protection elements and the lowerable weather vidually adjustable machine parameters such
canopy. as the display configuration or the assignment
of favorites buttons. The user-specific data can
VARIABLE, VERTICALLY ADJUSTABLE be saved on five different key rings and easily
WEATHER CANOPY transfered to other cold milling machines.
The height of the hydraulically height-ad-
justable weather canopy can be individually
adjusted based on the respective operating and
weather conditions. The height of the canopy
can be adjusted at the touch of a button during
milling operation, e.g. to avoid low-hanging
branches on a street lined with trees. In addi-
tion, the heavy-duty windshields are equipped
 Operation
Intuitive MMI –
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11
Man Machine Interface
The new control panel concept makes it possible to 5" CONTROL PANELS FOR LEVELING
combine different control panels to meet specific cus- For leveling with the LEVEL PRO ACTIVE leveling system,
tomer requirements. The comprehensive and clear status, up to two additional 5" control panels on the right and left
diagnostics, and informational display for the machine of the machine can be optionally fitted for ground crews.
operator was an essential requirement for the WIRTGEN
development engineers. The new, easy-to-understand, 7" CONTROL PANELS CONVENIENTLY DISPLAY
intuitive control panel concept optimally meets these ­IMPORTANT INFORMATION
requirements. Whether up top on the operator’s platform or at the
lower operating positions, the new control panel concept
2" CONTROL PANEL WITH FAVORITES BUTTONS provides comprehensive and clear information. As such,
In addition, up to two 2" control panels can be added to the 7" control panel offers all of the machine operators the
the operator’s platform. In this context, the position of the following displays, for example: Machine load conditions,
panel on the left and right external railings of the opera- temperatures, hydraulic pressures, diesel and water levels,
tor’s platform makes operation easier and more effective. leveling control, status and diagnostic messages, and gen-
It can be programmed with up to 21 individually selected eral information such as the current time.
functions, such as swinging the discharge conveyor.

1|
1 | Individual,
2|
user-friendly panel
layout.

2 | Overview of the
different control
panels and their Control panel – operator’s
positions. platform middle

Control panel – opera- Control panel – opera-

tor’s platform left tor’s platform right

2" control panel 2" control panel

7" control panel 10" control panel

2" control panel

Control panel – external Control panel – external

operation operation

7" control panel 7" control panel

= Standard
control panels
5" control panel = Optional
5" control panel
control panels
 Operation
Intuitive MMI –
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13
Man Machine Interface
HEAVY-DUTY, HIGH-QUALITY CAMERA / MONITOR screen. The heavy-duty camera / monitor systems provide
SYSTEM WITH 10" CONTROL PANEL the operator a clear view of important working areas, such
A two-camera, four-camera, or eight-camera system is as where the material is loaded onto trucks or the milled
also optionally available. In the two-camera system, the surface behind the scraper.
camera images are displayed on the 7" control panel on
the operator’s platform. The four-camera and eight-cam-
era systems also come with a 10" control panel that can
display several camera images simultaneously via split

1|
1 | 10" control panel
with split screen to 2|
simultaneously dis-
play several camera
images.

2 | Optional 5" con-

trol panel to display
leveling information
to ground crews.

3 | Various camera
systems to provide a
clear view of import-
ant areas.

3|
Two-camera system:
Camera for rear area / camera for loading situation

Four-camera system:
Two-camera system plus additional cameras on the right and left sides of the machine facing
forwards

Eight-camera system:
Four-camera system plus additional cameras on the right and left sides of the machine
facing the rear / camera at the scraper / camera in front of milling drum
 Quality
High-Precision, Versatile ­LEVEL
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15
PRO ACTIVE Leveling System
NEW, EASY-TO-USE LEVEL PRO ACTIVE OPERATING can be selected on the control panel. This also speeds up
CONCEPT work processes. This means the entire machine can be
The new LEVEL PRO ACTIVE leveling system especial- lifted quickly and easily to drive over a manhole cover, for
ly developed for cold milling machines and featuring example.
innovative operating panels is intuitive and easy to
operate. Fully integrated into the machine control sys- OPTIMIZED 3D AND LASER LEVELING
tem, it enables a high degree of automation because The drastically simplified method of attaching laser sen-
important machine functions are directly linked to each sors to the cold milling machine’s weather canopy makes
other, guaranteeing precise milling results. In addition, it easier to use 3D systems.
­LEVEL PRO ACTIVE offers a simple and field-tested 3D
system interface with the 3D kit. LEVELING BOOMS ON THE RIGHT AND LEFT WITH
SONIC-SKI SENSOR
NUMEROUS ADDITIONAL AND AUTOMATIC The new leveling booms with Sonic-Ski sensor make the
­FUNCTIONS contactless scanning of a string line or a reference surface
The LEVEL PRO ACTIVE leveling system offers many au- on both sides at a distance of up to 6 ft 3 in (1,900 mm)
tomatic and additional functions that make the operator’s from the milling edge possible. In this context, the boom
job easier. All of the connected sensors are displayed and can be adjusted hydraulically from the operator’s ­platform

1|
7" LEVEL PRO ACTIVE
control panel

Machine control system

Hydraulic side plate cylinder with

Cross-slope sensor built-in displacement sensor
 2|

by up to 2 ft 9 in (840 mm) to the outside using the Son-

ic-Ski sensor during milling operation; and a mechanical
adjustment offers an additional 2 ft 11 in (880 mm) of
telescopic travel.

OPTIMIZED MULTIPLEX SYSTEM

The multiplex system consists of two ultrasonic sensors 3|
attached to flexibly adjustable swing legs on each side
of the machine. Benefits of the system include the large
adjustment range for a wide variety of leveling applica-
tions and the low weight of the individual units. The swing
legs can be easily folded together onto the machine for
machine transport.

4|

5|
1 | W 220 F i with
standard leveling
sensors.

2 | Multiplex system
with up to four ultra-
sonic sensors.

3 | Scanning in front
of the milling drum.

4 | 3D leveling /
laser leveling.

5 | Telescoping
­leveling boom.
 Quality
Exceptional Reliability
16
17
GROUNDBREAKING DIAGNOSTIC CONCEPT on the operator’s platform and outside for ground crews
The new diagnostic concept guides the operator easily can be interchanged variably while maintaining all of the
and intuitively through the troubleshooting process. Any machine’s functions.
potential malfunction is clearly indicated to the operator
on the display, including a description of the fault. The ROBUST, RELIABLE CAN NETWORK
operator can then locate the malfunction using optimized, A backup CAN bus has been installed in important areas
easy-to-understand color graphics. Finally, detailed as- and can be switched to if necessary. The main control
sistance in writing ensures that the operator can begin to elements are equipped with two-channel signal transmis-
correct the error. sion, meaning that they can still be used if one signal fails.
Information about a signal failure is also displayed to the
REDUNDANT MACHINE CONTROL operator.
Three control computers built into the machine can be
interchanged variably in order to ensure that the machine
is always operational in the event that one of the three
computers fails. In addition, the two 7" control panels

1|
1 | Images are direct-
ly forwarded from 2|
the error message to
the diagnostics with
clear localization.

2 | Easy access to
the service points,
shown here on the
W 220 F i.

3 | Secure and fast

protection of control
panels.

3|

RELIABLE VANDALISM PROTECTION TIME-SAVING SERVICE AND MAINTENANCE

The innovative vandalism protection system CONCEPT
protects the control panels against the use of The W 220 F i stands out thanks to significantly
force or theft. This means that the control pan- simplified access to the service points. As such,
els on the left and right side of the operator’s the air, hydraulic oil, and engine oil filters are all
platform can simply be pushed into the main easily accessible from the operator’s platform
control panel and locked. The linearly arranged when the engine cover is open, for example.
control panels on the operator’s platform can The diesel particulate filters are readily ac-
be folded and secured by means of a special cessible from the ground for maintenance. In
mechanism via the centrally positioned control addition, all relevant machine components are
panel. All in all, the simple method of securing quickly and easily accessible.
the control panels also makes it possible to
quickly prepare the machine for transport.
 Milling
One-Of-A-Kind
18
19
Cutting Technology
RAPID MILLING DRUM CHANGES THANKS TO This simplified process has many advantages:
MCS BASIC Rapidly changing milling drums with differ-
Milling drums can now be changed even faster ent tool spacings to meet specific application
thanks to the new generation of MCS milling requirements increases machine productivity.
drums. The milling drum rotation device can Changing the milling drum at short notice and
be used to release just one central screw at the using the ideal drum for the job reduces wear
push of a button. The only thing the operator costs. In addition, this systems guarantees max-
has to do afterwards is simply pull out the mill- imum flexibility for the ever-changing require-
1 | Milling drum
changes are now ing drum. The MCS side panel can be opened ments during day-to-day operations.
even faster with quickly and effortlessly using the hydraulic
the new MCS
cylinder drive.
BASIC milling drum
system.

2 | Large selection
of different MCS
milling drums.

1|
 2|

SIMPLE MILLING DRUM ASSEMBLY CHANGES ECO Cutter

Milling width: 7 ft 3 in (2,200 mm)
The new quick-change milling drum assembly allows Milling depth: 0 – 14 in (0 – 350 mm)
different milling widths of 7 ft 3 in (2.2 m), 8 ft 2 in (2.5 m), Tool spacing: 1 in (25 mm)
11 ft 6 in (3.5 m), or 12 ft 6 in (3.8 m) to be selected. With
the help of the simplified quick-change system, milling
drum assemblies of different working widths can be
changed in less than an hour. The significantly increased
stroke of the machine height adjustment makes work
much easier. In addition, only one electrical plug connec-
tion, four hydraulic quick couplings, and one water hose
need to be connected. Standard Milling Drum
Milling width: 7 ft 3 in (2,200 mm)
Milling depth: 0 – 14 in (0 – 350 mm)
Tool spacing: 0.7 in (18 mm)

Standard Milling Drum

Milling width: 7 ft 3 in (2,200 mm)
Milling depth: 0 – 14 in (0 – 350 mm)
Tool spacing: 0.6 in (15 mm)

Fine Milling Drum

Milling width: 7 ft 3 in (2,200 mm)
Milling depth: 0 - 3.9 in (0 – 100 mm)
Tool spacing: 0.3 in (8 mm)

Micro-Fine Milling Drum

Milling width: 7 ft 3 in (2,200 mm)
Milling depth: 0 - 1.2 in (0 – 30 mm)
Tool spacing: 6 x 0.1 in (6 x 2 mm)
 Milling
One-Of-A-Kind
20
21
Cutting Technology
OPTIMIZED PROTECTION AGAINST MILLING DRUM NEW HT22 PLUS TOOLHOLDER UPPER PART WITH
ASSEMBLY WEAR INCREASED SERVICE LIFE
The side plates are equipped with extremely wear-resis- The new HT22 PLUS quick-change toolholder upper
tant protective skids on both sides. Additional optional part features innovative centering marks on the tool
rollers attached to the side plates prevent scratches contact surface. In combination with the new X² genera-
on the asphalt. In addition, the material depressor on tion of picks, this reduces toolholder wear by up to 25%
rollers gently glides over the surface. and also optimizes the rotation behavior of the picks.
The new upper part offers considerable benefits such
EXTREMELY WEAR-RESISTANT HT22 QUICK-CHANGE as higher milled surface quality and longer intervals
TOOLHOLDER SYSTEM between changes.
The milling drums of the W 220 F i are equipped with
the HT22 quick-change toolholder system, making
them perfect for highly demanding milling tasks. In
addition, the heavy-duty milling drum design enables
the upper parts of the quick-change toolholders to be
changed quickly on site, if required.

1|
1 | Extremely
wear-resistant HT22 2|
quick-change tool- W 220 F i with 7 ft 3 in (2.2 m) milling drum assembly
holder system.

14 in
(350)
2 | 7 ft 3 in (2.2 m),
8 ft 2 in (2.5 m),
11 ft 6 in (3.5 m),
and 12 ft 6 in
(3.8 m) milling Standard Milling Drum
drum ­assemblies. Milling width: 7 ft 3 in (2,200 mm)
4 ft 6 in
Milling depth: 0 – 14 in (0 – 350 mm)
(1,375)
Tool spacing: 0.6 in (15 mm)
10.6 in (270)
7 ft 3 in (2,200) 5 in (128)
9 ft 4 in (2,840)

W 220 F i with 8 ft 2 in (2.5 m) milling drum assembly

14 in
(350)

Standard Milling Drum

4 ft 6 in Milling width: 8 ft 2 in (2,500 mm)
(1,375) Milling depth: 0 – 14 in (0 – 350 mm)
1 ft 10 in (570) Tool spacing: 0.6 in (15 mm)

8 ft 2 in (2,500) 5 in (128)
10 ft 4 in (3,140)

W 220 F i with 11 ft 6 in (3.5 m) milling drum assembly

14 in
(350)

Standard Milling Drum

Milling width: 11 ft 6 in (3,500 mm)
4 ft 6 in
Milling depth: 0 – 14 in (0 – 350 mm)
(1,375)
Tool spacing: 0.6 in (15 mm)
2 ft 6 in (770)
11 ft 6 in (3,500) 5 in (128)
13 ft 1 in (4,000)

W 220 F i with 12 ft 6 in (3.8 m) milling drum assembly

14 in
(350)

Standard Milling Drum

4 ft 6 in Milling width: 12 ft 6 in (3,800 mm)
(1,375) 3 ft 6 in Milling depth: 0 – 14 in (0 – 350 mm)
(1,070) Tool spacing: 0.6 in (15 mm)

12 ft 6 in (3,800) 5 in (128)
14 ft 1 in (4,300)
 Milling
Innovative MILL ASSIST
22
23
MILL ASSIST AUTOMATIC MODE ADDITIONAL PRE-SELECTION OF AN OPERATING
In automatic mode, the innovative MILL ASSIST machine STRATEGY IN AUTOMATIC MODE
control system always selects the operating strategy with The operator can also pre-select one of three working
the best balance between performance and costs. In strategies for the next application: “cost-optimized,”
doing so, the process optimization automatically adjusts “performance-optimized,” or “milling pattern quality.” The
the speed of the diesel engine and milling drum, the machine then automatically adjusts the main parameters
travel drive, the water system, and the machine’s advance based on the selected operating strategy.
speed. This significantly reduces the operator’s workload
while improving machine performance and considerably
reducing diesel consumption, CO2 emissions, and noise.

OPERATOR MACHINE
Operating Strategy Operating Parameters
> Cost-optimized Such as:
> Performance-optimized >M illing width
> Milling pattern quality >M illing depth
>M illing drum / picks
>…

AUTOMATIC ADJUSTMENT INFORMATION DISPLAYED

OF MACHINE SETTINGS
>E
 fficiency
> Machine settings >M
 illing pattern
> Milling speed >S
 uggested optimizations
> Engine speed
> Water injection rate
> …
CLEAR PRE-SELECTION OF CONSTANT MILLING NEW DUAL SHIFT POWERSHIFT TRANSMISSION
­PATTERN QUALITY The new two-speed DUAL SHIFT selector gearbox
The operator can preset the required milling pattern ­controlled via MILL ASSIST can also be shifted under load.
quality by simply pre-selecting from a scale from 1 to 10. DUAL SHIFT offers an extremely wide range of milling
This then automatically sets the milling drum rotation drum speeds and makes the machine perfect for a wide
speed and the milling speed, taking the milling drum range of cost-effective milling applications. Low milling
type into account. drum speeds reduce diesel consumption. High milling
drum speeds make it possible to achieve maximum mill-
INNOVATIVE EFFICIENCY INDICATOR ing speeds during fine milling, for example.
The machine operator can constantly monitor the
­machine’s status via an efficiency indicator. Changes to
the milling parameters that could potentially improve
efficiency are also displayed on the control panel.
 Performance
Maximum Milling Performance
24
25
POWERFUL DIESEL ENGINE LARGE SCRAPER LIFT WITH HIGH SETTING DEPTH
The engine’s enormous power combined with its high The increased scraper lift makes greater milling depths
maximum torque makes the machine even more powerful possible and thus expands the machine’s range of
and versatile. applications when milling without material loading. This
also allows a milling depth of up to 1 ft (310 mm) to be
INCREASED BALLASTING FLEXIBILITY achieved as soon as the machine enters the position to
The additional weights weighing 3,307 lbs (1,500 kg) can begin milling. At the same time, reduced material accu-
be quickly and easily installed or removed from the rear mulation minimizes wear on the milling drum housing
of the machine in two increments. This allows the desired and the milling drum. Different scraper contact pressure
machine transport weight to be adjusted even more levels can also be selected quickly and conveniently at
precisely. the touch of a button via the 7" control panel, depending
on the requirements and application.

W 220 Fi COLD MILLING MACHINE ENGINE CHARACTERISTICS

M [Nm] P [kW]
4000 800
3500 700
3000 600
2500 500
2000 400
1500 300
1000 200
500 100
0 0
1100 1300 1500 1700 1900 2100 [1/min]

= Engine power
= Torque
1 | The discharge
1|
conveyor has a large
swing range.
65°
2 | Increased scraper
stroke for a wider
65
range of milling °
applications and
reduced wear.

2|

FLEXIBLE AND POWERFUL LOADING OF be adjusted at the touch of a button, and the
MILLED MATERIAL hydraulically folding discharge conveyor further
Extremely wide conveyor swing angles of 65° increase flexibility on the job site.
to both sides make it possible to load material
even in difficult situations, e.g. in intersections ACTIVE CONVEYOR
or turning areas. Pressing the “Booster” button When repositioning the discharge conveyor in
on one of the two main control panels tempo- difficult job site situations, the semi-automatic
rarily increases the belt speed by 20% and the ACTIVE CONVEYOR swing angle control system
loading capacity of the discharge conveyor by assists the operator in the best possible way –
20% in order to temporarily transport milled such as when milling in intersections or bypass-
material particularly high or far onto a truck ing road installations.
bed. Two swing speeds, the belt speed that can
 Performance
WPT – The Informative WIRTGEN
26
27
Performance tracker
FIELD-TESTED WITOS FLEETVIEW TELEMATICS ­SYSTEM OPTIONAL ADDITIONAL EQUIPMENT WPT FOR CLEAR
The WITOS FleetView telematics system consists of the DOCUMENTATION OF MILLING ­PERFORMANCE
control unit (TCU) with a GPS receiver and a license to use The additional equipment WPT also tracks the machine’s
the WITOS FleetView web application. The web interface actual milling performance and provides consumption
provides a compact overview of the machine status with and position data in a clear, automatically generated
consumption data, operating hours, position data, error report. Milling cross-sections measured by a laser scanner
messages, and service intervals. are converted for the purpose of calculating the milling
volume. The current milling volume and truck tonnage
are constantly displayed to the operator on the 7" control
panel during the milling process.

1|
AUTOMATICALLY GENERATED SITE SURVEY REPORTS
Milling performance data is continuously transmitted to a
data server via a cellular connection. After completing a
milling job, a site survey report is automatically generated
in both Excel and PDF formats and sent by e-mail to the
machine operator’s job management office, for example.
The site survey report contains precise information on the
milling volume, milled area, and milling depth with the
corresponding GPS position.

2|

JOB SITE TRACKING VIA SATELLITE MAP DISPLAY

The site survey reports contain easy-to-read satellite map
images detailing the completed milling work. In this con-
text, the milled areas are shown in different c­ olors based
on the various milling depth classes.

DOCUMENTATION OF CONSUMABLES
The site survey report contains valuable information on
consumables such as diesel, water, and picks. Information
such as the number of loaded trucks is also displayed, if
confirmed by the machine operator. This makes it possi-
ble to calculate operating costs quickly and easily.

1 | The operator is
always aware of the
current machine
and application
parameters – at the
end of the workday,
the data is transmit-
ted to the machine
owner.

2 | The actual, cur-

rently active milling
width is scanned by
a laser scanner and
clearly displayed on
the operating panel.
 Cost-Effectiveness
Reduced Diesel Consumption
28
29
TWO-SPEED POWERSHIFT TRANSMISSION FOR A AUTOMATIC STOP FEATURE FOR THE DIESEL ENGINE
WIDE RANGE OF USABLE MILLING DRUM SPEEDS The diesel engine is automatically switched off in idle
The new two-speed DUAL SHIFT powershift transmission mode after an appropriate cooling time. The engine
makes it possible to operate the machine at efficient stopping time is displayed on the control panels during
engine speeds while maintaining powerful milling drum the cooling phase.
speeds. DUAL SHIFT offers the unbeatable advantages
of low diesel consumption, reduced noise emissions, and
unmatched milling performance.

1|
1 | Compact engine
drive station, shown 2
here on the W 220 Fi.

2 | Significantly
expanded range WIRTGEN W 220 F i cold milling machine with two-speed DUAL SHIFT powershift transmission
of milling drum
speeds for reduced
diesel consump-
tion and tool wear, Engine speed (rpm)
shown here for the 1300 1400 1500 1600 1700 1800 1900 2000
W 220 F i.

Transmission level 1

Transmission level 2

1300 1400 1500 1600 1700 1800 1900 2000

Engine speed (rpm)

60 65 70 75 80 85 90 95 100 105 110 115 120 125 130 135

Milling drum rotation speed (rpm)

= diesel consumption

MAXIMUM PERFORMANCE IN THE LOW INTELLIGENT DUAL FAN CONCEPT

SPEED RANGE Two separate speed-controlled and intelligent-
The built-in MILL ASSIST machine control ly positioned fans cool the diesel engine and
system ensures that the diesel engine of the hydraulic system as required. As a result, the
W 220 F i primarily runs at lower speeds while cooling system also helps efficiently reduce
simultaneously delivering high performance diesel consumption.
and low diesel consumption.

AUTOMATIC START-STOP FEATURE OF

THE MILLING DRUM
The start-stop feature temporarily switches
off the milling drum after a few seconds when
the milling operation has stopped, like when
waiting for a truck, further reducing diesel con-
sumption. The milling drum is then automatical-
ly switched on again when milling is resumed.
 Cost-Effectiveness
Environmentally Friendly
30
31
Machine Technology
Minimizing exhaust fumes, noise, and dust on road con- Speed ranges that optimize consumption during milling
struction sites while maintaining maximum performance operation, engine speeds that adapt to the advance rate,
and productivity is more important than ever. Innovative and engine temperature-controlled fan speeds all help
WIRTGEN technologies play an extremely active role to protect the environment and conserve resources. In ad-
in protecting the environment and conserving natural dition, the milled material is a valuable recycled construc-
resources. tion material and is completely reused in the production
of asphalt mixes.

MAXIMUM EXHAUST GAS PURIFICATION

FOR LOW EXHAUST EMISSIONS
The state-of-the-art, fuel-efficient diesel engine of
the W 220 F i offers maximum engine power with
­exceptionally high torque. In this con-
text, the engine technology used in the
W 220 F i meets the requirements of
highest US EPA Tier 4f emissions stan-
dard for minimum exhaust emissions.

REDUCED NOISE EMISSIONS

DURING RELOCATION
The cold milling machine has a travel speed of up to
288.7 ft / min (88 m / min). At the same time, only low
engine speeds are required – with reduced diesel
consumption and lower noise emissions.
 OPTIMIZED VCS EXTRACTION SYSTEM
VCS improves air quality and visibility in the
machine operator’s and ground crew’s working
area. In addition, the optimized design of the
more easily accessible VCS suction channel
reduces the amount of cleaning required.

EFFICIENT WATER MANAGEMENT

Four separate water spray bar segments that can be
activated electrically from the operator’s platform
allow the optimum amount of water to be added to
the milling process, such as when milling only half
the width of a lane. Automatic activation and deacti-
vation of the water system as well as water injection
on the basis of milling performance considerably
reduce water consumption.

START-STOP ENGINE FUNCTION VIA EXTERNAL CONTROL PANEL

The diesel engine can also be switched on and off effortlessly by
ground crews via the external control panel, making it possible
to further reduce diesel consumption and noise emissions.
 Technical Specifications
W 220 F i
32
33
Milling drum

Milling width 7 ft 3 in (2,200 mm)

Milling depth *1 0 – 14 in (0 – 350 mm)

Cutting diameter 3 ft 9 in (1,140 mm)

Engine

Manufacturer Caterpillar

Type C18 ATAAC

Cooling Water

Number of cylinders 6

at 1,950 rpm
Rated power
597 kW / 801 hp / 812 PS

at 1,700 rpm
Maximum power
597 kW / 801 hp / 812 PS

Displacement 4.8 gal (18.1 l)

Fuel consumption at rated power | during a mixture 39.6 gal / h | 15.9 gal / h
of job site operations (150 l / h | 60 l / h)

Emissions standard US EPA Tier 4f

Electrical system

Power supply 24 V

Tank capacities

Fuel tank 343.4 gal (1,300 l)

Hydraulic oil tank 31.7 gal (120 l)

Water 1,096.3 gal (4,150 l)

Driving performance

Max. travel and milling speed 0 – 288.7 ft / min (3.3 mph) (0 – 88 m / min (5.3 km / h))

Crawler units

Crawler units front / back (L x W x H) 6 ft 7 in x 15 in x 2 ft 6 in (2,000 x 370 x 750 mm)

Loading of milled material

Belt width of primary conveyor 3 ft 7 in (1,100 mm)

Belt width of discharge conveyor 3 ft 3 in (1,000 mm)

Theoretical capacity of discharge conveyor 722 yd³/h (552 m³/h)

*1 = The maximum milling depth may deviate from the value indicated due to tolerances and wear.
 Base machine weight

Empty weight of machine without fluids 75,839 lbs (34,400 kg)

Operating weight, CE *2 81,792 lbs (37,100 kg)

Maximum operating weight (full tanks, full range of equipment) in FB2200 96,783 lbs (43,900 kg)

Weight of tank contents

Water 9,149 lbs (4,150 kg)

Fuel (6.9 lbs / gal (0.83 kg / l)) 2,381 lbs (1,080 kg)

Additional weight

Operator and tools

Machine operator 165 lbs (75 kg)

5 pick containers 276 lbs (125 kg)

Vehicle tool kit 66 lbs (30 kg)

Optional milling drum units instead of standard

Milling drum assembly MCS BASIC FB2200 1,433 lbs (650 kg)

Milling drum assembly MCS BASIC FB2500 3,638 lbs (1,650 kg)

Milling drum assembly MCS EXTEND FB3500 7,716 lbs (3,500 kg)

Milling drum assembly MCS EXTEND FB3800 9,921 lbs (4,500 kg)

Optional milling drums instead of standard

Milling drum FB2200 HT22 LA18 with 156 picks -463 lbs (-210 kg)

Optional MCS milling drums instead of standard

Milling drum MCS BASIC FB2200 HT22 LA15 with 182 picks 221 lbs (100 kg)

Milling drum MCS BASIC FB2200 HT22 LA18 with 156 picks -243 lbs (-110 kg)

Milling drum MCS BASIC FB2200 HT22 LA15 with 18 standard picks and 180 PKD cutting tools 331 lbs (150 kg)

Milling drum MCS BASIC FB2500 HT22 LA15 with 196 picks 860 lbs (390 kg)

Milling drum MCS EXTEND FB3500 HT22 LA15, multi-part with 294 picks 4,453 lbs (2,020 kg)

Milling drum MCS EXTEND FB3800 HT22 LA15, multi-part with 314 picks 5,401 lbs (2,450 kg)

Optional additional equipment

Operator’s platform with functional standing seat and large storage compartment 176 lbs (80 kg)

Operator’s platform with functional standing seat, large storage compartment, and weather canopy 1,323 lbs (600 kg)

Operator’s platform with high-quality comfort cabin 1,874 lbs (850 kg)

Two additional weights with a total weight of 3,307 lbs (1,500 kg) 3,307 lbs (1,500 kg)

Large storage compartment at the rear of the machine for 72 pick buckets 441 lbs (200 kg)

Extension of MCS BASIC with one hydraulically opening side panel for FB2200 / FB2500 110 lbs (50 kg)

VCS extraction system 309 lbs (140 kg)

Extension of LEVEL PRO ACTIVE with leveling booms and a Sonic-Ski sensor 176 lbs (80 kg)

Extension of LEVEL PRO ACTIVE with two ultrasonic sensors for multiplex scanning 88 lbs (40 kg)

Extension of LEVEL PRO ACTIVE with four ultrasonic sensors for multiplex scanning 176 lbs (80 kg)
*2 = Machine weight, half-full tanks, vehicle tool kits, machine operator, excluding optional equipment
 Dimensions
W 220 F i
34
35

54 ft 6 in (16,620)

51 ft 6 in (15,700)

44 ft 11 in (13,700)

31 ft 8 in (9,660)

Weather canopy in
transport position

4,690 (15 ft 5 in)

13 ft (3,975)
9 ft 10 in
(3,000)

3 ft 3 in 7 ft 8 in 9 ft 10 in 3 ft 5 in
2 ft 5 in
(980) (2,350) (3,000) (1,050)
1 ft 10 in (740)
13 ft 8 in (4,160) (550)

Machine’s center of gravity *

65
°
FB
A

3 ft 3 in

4 ft 9 in
(1,000)

(1,450)
°
65

FB A
7 ft 3 in (2,200) 9 ft 4 in (2,840)
8 ft 2 in (2,500) 10 ft 4 in (3,140)
11 ft 6 in (3,500) 13 ft 1 in (4,000)
12 ft 6 in (3,800) 14 ft 1 in (4,300)

Dimensions in American standard and mm

* Based on operating weight, CE with conveyor folded out
 FB
2
FB 200
:
FB 2500 Rmin
3
FB 500 : Rmi = 41
FB 38 : n
00 Rmin = 2 ft 12
FB 2200 :R = 3 f in (
mi t 7 12
FB 2500 : Rm n =
in ,8
FB 3500 : Rm in = 8 18 19 (7 00
38 i ft 8 ft (5 ,200 )
00 : Rmi n = 7 ft 2 i
:R n= f n in ,8 )
mi 6 f t 3 in (2,5 (5, 00)
n = 70
5 f t 7 in (2,2 00) 0)
t7 0
in (2,00 0)
(1,
70 )0
0)
FB
FB 2200
FB 2500 : Rmi
n
n
FB 3500 : Rmi = 8 f
38 t
00 : Rmin = 8 f 2 in
:R =5 t2 (
mi ft in 2,50
n =
5 f 7 in (2,50 0)
t7 (
in 1,70 0)
(1,
70 0)
0)

Milling radius at milling depth of 5.9 in (150 mm), dimensions in American standard and mm
65
° 60
°
 Standard Equipment
W 220 F i
36
37
Basic machine

Basic machine with engine

Machine frame featuring a single wasp waist at the rear right, and a dual wasp waist at the front

DUAL SHIFT two-speed powershift transmission for efficient engine speeds combined with powerful milling drum speeds

Automatic pressure adjustment of the cylinder pump in accordance with performance requirements for reduced diesel consumption

Hydraulically opening, soundproof engine cowling

Air compressor system

Battery-operated hydraulic unit for auxiliary drive

Two cooling fans to minimize power consumption of the cooling system

Milling drum unit

Adjustment of material depressor contact pressure via the control panel or automatically via the MILL ASSIST feature
to reduce chunk formation

Electrical adjustment of scraper contact pressure via the control panel

Automatically controlled locking feature of scraper

Milling drum rotation device with electro-hydraulic milling drum drive for slowly turning the milling drum during pick replacement

Single-piece water spray bar in the milling drum unit for reliable pick cooling and to prevent dust development

Automatic control of the water quantity via the MILL ASSIST feature

Height adjustment stroke increased by 7.9 in (200 mm) to facilitate pick replacement and the exchange of milling drum units

Pre-fitting to allow the quick exchange of milling drum units

Hydraulically lifting side plates, clearance right 18 in (450 mm), clearance left 13 in (330 mm)

Milling drum housing FB2200 (7 ft 3 in)

Milling drums

Milling drum FB2200 (7 ft 3 in) HT22 LA15 with 188 picks

Loading of the milled material

Increased conveyor slewing angles of 65° each to the left and right

Discharge conveyor with adjustable conveying speed and two slewing speeds for precise loading

Boost feature for a temporary increase of the belt speed and conveying performance of the discharge conveyor by 20%

Water spray system in the primary conveyor

Larger conveyor pump for a constant belt speed even at a low engine speed of 1,300 rpm

Discharge conveyor, 26 ft 9 in (8,150 mm) long, 3 ft 3 in (1,000 mm) wide

Machine control and leveling system

User-friendly control panel including 7" color screen

LEVEL PRO ACTIVE leveling system with numerous automated and complementary features relieving the operator
of a part of his workload

LEVEL PRO ACTIVE – automatic height control in transport mode

LEVEL PRO ACTIVE – ramp milling and auto-start feature for the second milling cut

= Standard equipment
= Standard equipment, can be replaced with optional equipment if desired
= Optional equipment
Machine control and leveling system

RAPID SLOPE cross-slope sensor for LEVEL PRO ACTIVE leveling system

MILL ASSIST assistance system for automatic adjustment of the milling drum speed in accordance with the main area of application
and the parameters selected in terms of engine load, advance rate, milling volume and quality of the milling pattern

Automatic start-stop feature of the milling drum to reduce diesel consumption

Comprehensive machine diagnostics on the control panel including, for example, a diagnostic system for the CAN bus

Voltmeter integrated into the control panel for voltage measurement in the event of a malfunction

Two control panels for operating functions performed by ground crew

Operator’s platform

Convenient access to the operator’s platform, right and left

Anti-vibration mounted operator’s platform across the full width of the machine including fold-out railing, right

Electrical control cabinet on the operator's platform for optimum accessibility and fast troubleshooting

Electrical level indicator for the water tank on the external control panels

Time display on the main control panel and on the exterior control panels

Two mirrors at the front, one mirror at the rear of the machine

Operator's platform with functional stand-up seat

Track unit and height adjustment

PTS – automatic alignment of the machine parallel to the pavement surface

ISC – intelligent track speed control including hydraulic four-track drive

Fourfold full-floating axle for high machine stability

High travel speed of up to 288.7 ft / min (88 m / min) at low engine speeds (1,350 rpm), reduced diesel consumption
and low noise emissions

Miscellaneous

"Welcome" and "Go home" lights feature in the area of the operator's platform and access

Large storage compartment on the machine for pick containers

High-pressure water system with automatic on/off function, 261 psi (18 bar), 17 gal/min (67 l/min)

Good accessibility to all maintenance points on the engine station

Pneumatic hammer with pick extractor/inserter

Comprehensive toolkit in lockable toolbox

A total of six EMERGENCY STOP switches in appropriate positions on the machine

Pre-fitting for installing the WITOS FleetView control unit

European design type certification, EuroTest mark and CE conformity

Water tank filling from rear of machine

Standard painting in RAL 9001 (cream)

WITOS FleetView – professional telematics solution for machine operation and service optimization

Standard LED lighting system with 19,700 lumens

= Standard equipment
= Standard equipment, can be replaced with optional equipment if desired
= Optional equipment
 Optional Equipment
W 220 F i
38
39
Milling drum unit
Milling drum housing MCS BASIC FB2200 (7 ft 3 in)
Milling drum housing MCS BASIC FB2500 (8 ft 2 in)
Milling drum housing MCS EXTEND FB3500 (11 ft 6 in)
Milling drum housing MCS EXTEND FB3800 (12 ft 6 in)
Extension of MCS BASIC with a hydraulically opening side door for FB2200/FB2500 (7 ft 3 in / 8 ft 2 in)
Electrically switchable sectional water spray bar for FB2200 (7 ft 3 in)
Electrically switchable sectional water spray bar for FB2500 (8 ft 2 in)
Electrically switchable sectional water spray bar for FB3500/3800 (11 ft 6 in / 12 ft 6 in)
Wear protection rollers for side plates
Transport carriage for milling drum units from FB2200 (7 ft 3 in) to FB4400 (14 ft 5 in)
Milling drum mounting and transport carriage FB1500 (4 ft 11 in) to FB2500 (8 ft 2 in)
Transport roller set for simplified milling drum unit change (FB1500 – FB3800)
Quick-change milling drum assembly FB2200 (7 ft 3 in) MCS BASIC
Quick-change milling drum unit FB2500 (8 ft 2 in) MCS BASIC
Quick-change milling drum unit FB3800 (12 ft 6 in) MCS EXTEND
Milling drums
Milling drum FB2200 (7 ft 3 in) HT22 LA18 with 156 picks
Milling drum MCS BASIC FB2200 (7 ft 3 in) HT22 LA15 with 182 picks
Milling drum MCS BASIC FB2200 (7 ft 3 in) HT22 LA18 with 156 picks
Milling drum MCS BASIC FB2500 (8 ft 2 in) HT22 LA15 with 196 picks
Milling drum MCS EXTEND FB3500 (11ft 6 in) HT22 LA15, multi-part, with 294 picks
Milling drum MCS EXTEND FB3800 (12 ft 6 in) HT22 LA15 MCS milling drum, multi-part, with 314 picks
Milling drum MCS BASIC FB2200 (7 ft 3 in) HT22 LA8 with 297 picks
Milling drum MCS BASIC FB2200 (7 ft 3 in) HT22 LA25 with 121 picks
Milling drum MCS BASIC FB2200 (7 ft 3 in) HT5 LA6X2 with 740 picks
Milling drum MCS BASIC FB2200 (7 ft 3 in) HT22 LA8 with 18 standard picks and 298 PCD tools
Milling drum MCS BASIC FB2200 (7 ft 3 in) HT22 LA15 with 18 standard picks and 180 PCD tools
Milling drum MCS BASIC FB2500 (8 ft 2 in) HT5 LA6X2 with 840 picks
Milling drum MCS BASIC FB2500 (8 ft 2 in) HT22 LA8 with 335 picks
Milling drum MCS BASIC FB2500 (8 ft 2 in) HT22 LA25 with 148 picks
Loading of the milled material
Discharge conveyor, 26 ft 9 in (8,150 mm) long, 3 ft 3 in (1,000 mm) wide, with hydraulic folding device
Mounting aid for lifting out the primary conveyor when changing the milling drum unit
VCS extraction system
Signal lights for visual "Stop" and "Go" instructions to the truck driver
ACTIVE CONVEYOR slewing angle control for discharge conveyor
Support device for discharge conveyor
Machine control and leveling system
Actual milling depth measurement and display on the LEVEL PRO ACTIVE panel
Overload sensors installed on the scraper
Active floating position for the side plates, left and right
5" control panel for controlling the leveling system
7" control panel for displaying the machine control system and for contolling the leveling system
2” control panel including "Favourites" keys
Two 2” control panels including "Favourites" keys
User-specific storage of machine settings via SMART KEY fob
= Standard equipment
= Standard equipment, can be replaced with optional equipment if desired
= Optional equipment
Machine control and leveling system
Extension of LEVEL PRO ACTIVE with leveling booms and one Sonic Ski sensor
Extension of LEVEL PRO ACTIVE with one hydraulic sensor mounted on the right
Extension of LEVEL PRO ACTIVE with two hydraulic sensors mounted on the right and left
Extension of LEVEL PRO ACTIVE with two ultrasonic sensors for multiplex scanning
Extension of LEVEL PRO ACTIVE with four ultrasonic sensors for multiplex scanning
Extension of LEVEL PRO ACTIVE with two ultrasonic sensors for multiplex scanning (FB3500/FB3800) (11 ft 6 in / 12 ft 6 in)
Extension of LEVEL PRO ACTIVE with four ultrasonic sensors for multiplex scanning (FB3500/FB3800) (11 ft 6 in / 12 ft 6 in)
Extension of LEVEL PRO ACTIVE with pre-fitting for 3D leveling for machines without canopy
Extension of LEVEL PRO ACTIVE with pre-fitting for 3D leveling for machines with canopy
Extension of LEVEL PRO ACTIVE with pre-fitting for 3D leveling for machines with cabin
Extension of LEVEL PRO ACTIVE with two laser receivers
Operator´s platform
Operator's platform with functional stand-up seat, large storage compartment
Operator's platform with functional stand-up seat, a large storage compartment and weather protection canopy
Operator’s platform with a high-quality comfort cabin
Warm air heating close to the operator´s hands and feet
Additional stand-up seat for operator’s platform
2-fold camera system
4-fold camera system with 10" control panel
8-fold camera system with 10" control panel
Miscellaneous
Hydraulically operated filling pump for water refilling
Standard film coating in RAL 9001 (cream)
Painting in one special color (RAL)
Film coating according to the customer’s wishes
Model without WITOS FleetView
WIRTGEN PERFORMANCE TRACKER including WITOS FleetView – precise tracking of the milling performance
Extended LED lighting system with 43,600 lumens
High-performance LED lighting system with 93,000 lumens, including LED lighting balloon
Two-piece additional weight totaling 3,307 lbs (1,500 kg)
Large storage compartment at the rear of the machine for 72 pick containers
Storage compartment close to the rear track units for 10 pick containers
Powerful high-pressure water cleaner, 2,175 psi (150 bar), 4 gal / min (15 l / min)
One hydraulic pick extractor
Two hydraulic pick extractor
Dual starter system
Electrical diesel suction and pressure pump including 24 ft 7 in (7.50 m) suction hose
License plate holder with LED lighting
Drawbar eye attached to the rear of the machine with a maximum permitted horizontal load of 50 kN

= Standard equipment
= Standard equipment, can be replaced with optional equipment if desired
= Optional equipment
 WIRTGEN AMERICA Inc.
6030 Dana Way · Antioch, TN 37013, USA
Phone: (615) 501-0600 · Fax: (615) 501-0691
Internet: www.wirtgen-group.com/america

All details, illustrations and texts are non-binding and may include optional additional fittings. Subject to technical modifications.
Performance data dependant upon operational conditions. © WIRTGEN GmbH 2019. Printed in USA. No. 2808605 US-12/19 – V2 (01/20)