WR 240 Instruction Manual

INSTRUCTION MANUAL
WR 240
07WR_ _ _ _
Series
Issue date
2244971_V02_en
Order number
© Wirtgen GmbH 2012 07WR0001-9999

Publisher Wirtgen GmbH
Reinhard-Wirtgen-Strasse 2
53578 Windhagen
Germany
Phone: +49 (0) 2645 / 131 - 0
http://www.wirtgen.de
Document name BAL_07WR_2244971_V02_en

Translation of the original instruction manual
Date of first issue 31.07.2012
Date of amendment 25.02.2014
Copyright © Wirtgen GmbH 2012

Distribution and copying of this document, usage and communication of its con-
tent are forbidden, unless specifically permitted. Infringements will result in the
obligations to pay damages. All rights reserved in case of a patent, utility model
or registration of a design.
2 / 370 BAL_07WR_2244971_V02_en © Wirtgen GmbH 2012

General instructions on the instruction manual
GENERAL INSTRUCTIONS ON THE INSTRUCTION MANUAL
The instruction manual is divided into 6 main groups:
Main group 1 =
GENERAL
General instructions, safety instructions, sound/vibration information, stickers,
machine identification, etc.
Main group 2 =
DESCRIPTION
Overview and arrangements of the control panels, explanation of the controls
and their position on/in the machine, etc.
Main group 3 =
OPERATION
General operating instructions for startup, on-site operation, shutting-down,
transport, etc.
Main group 4 =
MAINTENANCE
General maintenance instructions, specific description of all maintenance points
in the machine such as checks, oil changes, lubrication work with the corre-
sponding maintenance intervals, etc.
Main group 5 =
TABLES
Service and maintenance chart, technical data, fuels / lubricants, tightening
torques, operating state messages, etc.
Main group 6 =
INSTRUCTIONS, SET-UP TASKS
General instructions for setting up the machine before starting on-site operation,
etc.
© Wirtgen GmbH 2012 BAL_07WR_2244971_V02_en 3 / 370

4 / 370
Contents
CONTENTS
1 General.................................................................................... 13
1.01 Preface / introduction.................................................... 13
1.01.01 Introduction..................................................................................... 13
1.01.02 Changes / caveats..........................................................................14
1.01.03 Packaging / storage........................................................................14
1.01.04 Markers and symbols..................................................................... 14
1.01.05 Documentation................................................................................15
1.01.06 CE declaration of conformity.......................................................... 16
1.02 Use...................................................................................17
1.02.01 Correct use..................................................................................... 17
1.02.02 Incorrect use...................................................................................17
1.02.03 Residual risks................................................................................. 17
1.03 Climatic conditions........................................................18
1.03.01 Climatic conditions..........................................................................18
1.04 Safety instructions.........................................................19
1.04.01 Environmental protection................................................................19
1.04.02 Disposal.......................................................................................... 19
1.04.03 Machine-specific safety instructions...............................................20
1.04.04 Danger zones................................................................................. 24
1.05 Noise / vibration............................................................. 25
1.05.01 Noise / vibration data..................................................................... 25
1.06 Labelling......................................................................... 25
1.06.01 Colours............................................................................................25
1.06.02 Signs / stickers............................................................................... 26
1.06.03 Nameplate (machine)..................................................................... 30
1.06.04 Nameplate (ROPS/FOPS)..............................................................32
1.06.05 Machine identification..................................................................... 33
2 Description.............................................................................. 35
2.00 General............................................................................35
2.00.01 Overview of control panels.............................................................35
2.00.02 Description of function....................................................................37
2.01 Chassis / safety devices............................................... 45
2.01.01 Chassis controls............................................................................. 45
2.01.02 Lighting / warning device................................................................45
2.01.03 Cover panel / storage boxes / maintenance flaps.......................... 46

Contents
2.01.04 Fire extinguishers........................................................................... 47

2.02 Operator's stand............................................................ 48
2.02.01 Cabin control panels...................................................................... 48
2.02.02 Operator's seat right control panels............................................... 51
2.02.03 Operator's seat left control panels................................................. 53
2.02.04 On-board computer display............................................................ 55
2.02.05 On-board computer symbols.......................................................... 55
2.02.06 Operator's cabin............................................................................. 70
2.02.07 Operator's seat............................................................................... 70
2.02.08 Air conditioner.................................................................................71
2.02.09 Radio / printer................................................................................. 72
2.02.10 Camera / monitor system............................................................... 73
2.03 Milling drum unit............................................................74
2.03.01 Tool exchange / milling drum rotation device control panels..........74
2.03.02 Milling drum.................................................................................... 75
2.03.03 Milling drum scraper front / rear..................................................... 75
2.04 Engine / motor group.................................................... 76
2.04.01 Diesel engine..................................................................................76
2.04.02 Fuel supply..................................................................................... 77
2.04.03 Cooling system............................................................................... 77
2.04.04 Air filter........................................................................................... 78
2.04.05 Control panel diesel engine diagnosis........................................... 79
2.05 Hydraulic oil feed...........................................................80
2.05.01 Hydraulic oil feed............................................................................80
2.05.02 Hydraulic pump drive..................................................................... 81
2.06 Electrical system........................................................... 81
2.06.01 Batteries..........................................................................................81
2.06.02 Electrical cabinet / fuses................................................................ 82
2.08 Advance drive................................................................ 82
2.08.01 Advance drive gearbox / wheels.................................................... 82
2.08.02 Engine load control........................................................................ 83
2.08.03 Device for towing away.................................................................. 84
2.09 Steering system............................................................. 84
2.09.01 Steering...........................................................................................84
2.11 Levelling system............................................................ 85
2.11.01 Sensors...........................................................................................85
2.12 Water system..................................................................85
2.12.01 Water supply...................................................................................85

Contents
2.13 Cleaner unit.................................................................... 86

2.13.01 High pressure cleaner.................................................................... 86
2.16 Binder unit...................................................................... 87
2.16.01 On-board computer display dosing unit......................................... 87
2.16.02 Spraying beams..............................................................................87
2.16.03 Pipe connectors..............................................................................88
2.16.04 Test nozzle..................................................................................... 88
2.17 Compressed air system and accessories................... 89
2.17.01 Compressed air tank / defroster unit..............................................89
3 Operation.................................................................................91
3.00 General............................................................................91
3.00.01 General instructions........................................................................91
3.00.02 Startup............................................................................................ 91
3.00.03 On-site operation............................................................................ 91
3.00.04 Shutting down.................................................................................92
3.00.05 Transportation.................................................................................93
3.01 Programmable logic control (PLC).............................. 94
3.01.01 Operator guidance (on-board computer)........................................94
3.01.02 Operating state messages SPN/FMI (diesel engine)................... 104
3.01.03 Operating state messages flash code (diesel engine)................. 105
3.01.04 Operating state messages (machine).......................................... 109
3.01.05 Operating state messages flash code (machine).........................112
3.01.06 Diagnostic system........................................................................ 114
3.01.07 Job data........................................................................................115
3.01.08 Printer........................................................................................... 117
3.02 Diesel engine................................................................118
3.02.01 Starting the diesel engine............................................................ 118
3.02.02 Switching off the diesel engine.................................................... 120
3.02.03 Starting with jump leads...............................................................121
3.03 Operator's stand.......................................................... 123
3.03.01 Cabin / air conditioner / heater..................................................... 123
3.03.02 Exterior lighting.............................................................................128
3.03.03 Camera / monitor system............................................................. 130
3.04 Milling drum unit..........................................................137
3.04.01 Milling drum rotation speed..........................................................137
3.04.02 Milling drum scraper rear............................................................. 142
3.04.03 Milling drum scraper front............................................................ 144

Contents
3.04.04 Automatic starting/lifting-out function........................................... 145

3.04.05 "0" position....................................................................................149
3.04.06 Milling depth................................................................................. 151
3.04.07 Milling drum drive......................................................................... 152
3.04.08 Milling drum rotation device......................................................... 153
3.05 Travelling / steering..................................................... 154
3.05.01 Travelling...................................................................................... 154
3.05.02 Engine load control (ELC)............................................................157
3.05.03 Steering.........................................................................................158
3.05.04 Towing away.................................................................................165
3.06 Height adjustment / levelling...................................... 175
3.06.01 Lifting / lowering machine.............................................................175
3.06.02 Slope regulation............................................................................180
3.06.03 Ground clearance......................................................................... 182
3.07 Dosing unit................................................................... 183
3.07.01 Basic settings............................................................................... 183
3.07.02 Dosing unit I (operation)...............................................................190
3.07.03 Dosing unit II (operation)..............................................................193
3.07.04 Dry run sensor..............................................................................196
3.07.05 Foam bitumen consistency sample..............................................197
3.07.06 Operation with tank truck............................................................. 198
4 Maintenance.......................................................................... 201
4.00 General..........................................................................201
4.00.01 General maintenance instructions................................................201
4.00.02 General instructions on winter service......................................... 202
4.00.03 General instructions on welding work.......................................... 204
4.00.04 General instructions on the short maintenance instruction...........205
4.00.05 General instructions on the maintenance flaps............................ 205
4.01 Chassis / safety devices............................................. 212
4.01.01 Checking safety devices.............................................................. 212
4.01.02 Lighting / warning device..............................................................214
4.01.03 Cleaning........................................................................................215
4.02 Operator's stand.......................................................... 221
4.02.01 Operator's cabin........................................................................... 221
4.02.02 Air conditioner...............................................................................222
4.03.01 Milling drum gearbox....................................................................225

Contents
4.03.02 Changing the picks.......................................................................228

4.03.03 Quick-change toolholder system.................................................. 231
4.03.04 Wear patterns............................................................................... 236
4.03.05 Front turntable.............................................................................. 239
4.03.06 Milling drum bearing.....................................................................240
4.03.07 Drive belts.....................................................................................242
4.03.08 Drive belt pulleys..........................................................................247
4.04 Engine / motor group.................................................. 255
4.04.01 Diesel engine in general.............................................................. 255
4.04.02 Diesel engine fuel system............................................................ 257
4.04.03 Diesel engine oil...........................................................................262
4.04.04 Diesel engine air filtering..............................................................265
4.04.05 Diesel engine cooling system...................................................... 270
4.05 Hydraulic oil feed.........................................................274
4.05.01 Hydraulic oil tank..........................................................................274
4.05.02 Hydraulic oil filter..........................................................................277
4.05.03 Cooler (hydraulic oil + hydraulic pump drive - flushing)............... 281
4.05.04 Hydraulic pump drive................................................................... 282
4.06 Electrical system..........................................................284
4.06.01 Batteries / electrical power supply................................................284
4.08 Advance drive.............................................................. 286
4.08.01 Advance drive gearbox................................................................ 286
4.08.02 Wheels / tyres...............................................................................287
4.12 Water system................................................................288
4.12.01 Water tank.................................................................................... 288
4.12.02 Water filter.................................................................................... 292
4.16 Binder unit.................................................................... 293
4.16.01 Bitumen water pump.................................................................... 293
4.16.02 Binder pumps............................................................................... 295
4.16.03 Cleaning of the dosing unit.......................................................... 296
4.16.04 Bitumen filter.................................................................................300
4.17 Compressed air system and accessories................. 303
4.17.01 Compressed air tank.................................................................... 303
4.17.02 Defroster unit................................................................................ 304
4.18 Lubrication unit............................................................307
4.18.01 Lubrication points......................................................................... 307

Contents
5 Charts.................................................................................... 319
5.01 Maintenance................................................................. 319
5.01.01 Service and maintenance chart....................................................319
5.02 Technical data.............................................................. 323
5.02.01 Dimensions / weights / performance............................................ 323
5.03 Fuels / lubricants......................................................... 329
5.03.01 Filling capacities........................................................................... 329
5.03.02 Fuels / lubricants comparison table - 03.2014............................. 329
5.03.03 Fuels / lubricants selection diagrams - 11.2013...........................332
5.04 Tightening torques...................................................... 335
5.04.01 Screws / nuts (metric standard thread)........................................ 335
5.04.02 Screws / nuts (metric fine thread)................................................ 335
5.04.03 Screws / nuts (inch standard thread UNC).................................. 336
5.04.04 Screws / nuts (inch fine thread UNF)........................................... 336
5.05 Frost protection........................................................... 337
5.05.01 Diesel engines - 10.2013............................................................. 337
5.05.02 Milling drum / water system......................................................... 338
5.06 Operating state messages.......................................... 338
5.06.01 Machine........................................................................................ 338
5.06.02 Diesel engine SPN code and flash code..................................... 343
5.07 Calculation examples / formulas................................346
5.07.01 Water / emulsion...........................................................................346
5.07.02 Foam bitumen...............................................................................347
6 Installation, assembly and conversion instructions, set-up

tasks.......................................................................................349
6.00 General..........................................................................349
6.00.01 General instructions......................................................................349
6.01 Programmable logic control (PLC)............................ 349
6.01.01 Display brightness / date / programme language.........................349
6.01.02 IPR code.......................................................................................351
6.02 Diesel engine................................................................351
6.02.01 Prior to starting the diesel engine................................................ 351
6.03 Operator's stand.......................................................... 356
6.03.01 Operator's cabin........................................................................... 356
6.03.02 Operator's seat unit...................................................................... 358
6.03.03 Mirrors...........................................................................................362

Contents
6.03.04 Camera / monitor system............................................................. 363

6.04.01 Milling drum shell......................................................................... 366
6.05 Dosing unit................................................................... 369
6.05.01 Foam bitumen consistency...........................................................369
6.05.02 Water tank / additional water tank................................................370

12 / 370
General
Preface / introduction
1 GENERAL
Follow the remarks in your safety manual during all work!
1.01 Preface / introduction

1.01.01 Introduction
In this section, as the operator you will find important remarks on the operation
of the machine and the usage of this instruction manual.
This WIRTGEN machine is a product from the wide range of WIRTGEN road-
building machinery.
WIRTGEN's extensive experience as well as the latest production and test meth-
ods ensure the maximum reliability of your machine. The instruction manual is a
part of the machine!
This instruction manual is only valid in conjunction with the safety manual
and the transportation instructions. Please note:
This instruction manual was written for the operators/maintenance personnel.
This instruction manual is intended to make you able to operate the machine
safely and to exploit the possibilities it offers.
It also provides you with information on the function of important assemblies and
systems.
During this process certain terms are used in this instruction manual. To avoid
misunderstandings, you should always use the same terms.
Only qualified, instructed and trained personnel are allowed to work on this ma-
chine.
The instruction manual, the safety manual, the transportation instructions and
the stipulations and regulations applicable in the place of use must be followed
(for example health and safety regulations).
The usage of this instruction manual will make it easier for you:
 To become familiar with the machine
 To avoid faults due to incorrect operation
Following the instruction manual will:
 Help you to avoid hazards
 Increase reliability during usage on the construction site
 Increase the service life of the machine
 Reduce maintenance costs and downtimes
Always keep this instruction manual at hand, for example in the tool box on the
machine or in the holder provided for this purpose.
If you should receive further information for the machine from us (for example
additional technical information), these instructions are also to be followed and
added to the instruction manual.
If you do not understand the instruction manual or individual sections, you
should ask us before you start the related activity.
WIRTGEN GmbH is not liable for the safe function of the machine:
 In the case of use other than normal.

General
You cannot make claims under the warranty in case of:

 Operating errors.
 Inadequate maintenance.
 Use of unsuitable fuels / lubricants.
 Use that is not listed in the instruction manual.
The warranty conditions and liability stated in the general terms and conditions
of WIRTGEN GmbH are not modified by these instructions.
We reserve the right to make changes without notice in the context of technical
development.
This instruction manual also describes optional equipment which may not be fit-
ted to your machine.
The information and illustrations contained in this instruction manual must not be
copied, distributed or used for competitive purposes.
Although all translations have been carried out as meticulously as possible No li-
ability can be accepted for translation errors or any resulting consequences; also
not in the case that the translation was made by us or was commissioned by us.
The original German text is binding for all warranty and liability claims.
All rights expressly reserved in accordance with the law on copyright.
We wish you every success with your WIRTGEN machine!
1.01.02 Changes / caveats

We make every effort to ensure this instruction manual is correct and up to date.
To maintain our technological lead, it may be necessary to make changes to the
product and its operation without notice. For faults, failures and resulting dam-
age, we accept no liability.
Please also pay attention to any additional information supplied.
1.01.03 Packaging / storage

To ensure adequate protection during shipping, the products have been care-
fully packaged. On receipt of the goods, the packaging and the goods should be
checked for damage.
In case of damage, the unit is not allowed to be placed in operation. Damaged
cables and connectors are also a safety risk and must not be used. In this case,
please contact your WIRTGEN supplier.
If the units are not placed in operation immediately after unpacking, they must be
protected against moisture and soiling.
1.01.04 Markers and symbols

The markers and symbols in this manual are intended to help you to use the unit
quickly and safely. NOTE
REMARK
The remark provides information on the most effective and most practical usage
of the unit and this manual.
MARGIN
Actions
The defined sequence of actions will make it easier for you to use the unit cor-
rectly and safely.
MARGIN
Result
Here you will find a description of the result of a sequence of actions.

General
[] Position numbers in the individual illustrations are marked in the text with square
brackets [].
1.01.05 Documentation
A copy of this manual must be available to the authorised operators/mainte-
nance personnel at all times.
Before you use the machine, you must read this manual carefully and under-
stand it.
This manual is intended to make you familiar with the basic tasks/activities on
the machine.
This manual contains important instructions on the safe and correct use of the
machine.
Following it will help:

 To avoid hazards.
 To reduce repair costs and down times.
 To increase the reliability and service life of the machine.
Notwithstanding this manual, the laws, ordinances, directives and standards ap-
plicable in the country and place of use must be observed.
The usage of the machine is described in this manual. This instruction manual is
only valid in conjunction with the safety instructions manual and the transporta-
tion instructions from Wirtgen.
A safety instructions manual and the transportation instructions must be accessi-
ble for the operators/maintenance personnel at all times.

General
1.01.06 CE declaration of conformity

The declaration of conformity is part of the documentation provided separately
by Wirtgen GmbH and will be provided to you on the delivery of the machine.
The CE marking of the machine forms part of the nameplate.
MARGIN
The pictogram indicates conformity with the applicable EU directives that affect
the product – that is the machine – and that specify a CE marking.

General
Use
1.02 Use
1.02.01 Correct use
The machine corresponds to the technical state-of-the-art as well as the applic-
able safety stipulations at the time it is placed on the market in the context of its
correct use.
The machine is designed:

 exclusively for mixing filler, cement, lime hydrate, emulsion, hot bitumen etc.
with natural soil or fill material in order to improve the natural properties of the
soil and for milling off unstable asphalt and asphalt concrete road surfaces up
to a maximum thickness of 20 cm.
The machine is only intended to be used commercially on enclosed construction
sites.
The machine must be operated by trained service staff/maintenance personnel
in accordance with the specifications in the technical documentation.
Any incorrect operation or activities on the machine not described in this manual
represent misuse outside the limits of the manufacturer's statutory liability.
1.02.02 Incorrect use

In particular, the machine is not allowed to be used:
 To carry people who are not personnel for operating the machine
 As lifting equipment
 For milling or removing tracks, pipes, manhole covers and other objects set
into the road surface
1.02.03 Residual risks

The residual risks were analysed and evaluated prior to the start the design and
planning of the machine.
Information on existing residual risks is given in the documentation.
You can avoid existing residual risks by the practical implementation and compli-
ance with these requirements, for example:
 The special warnings on the machine.
 The general safety instructions in this manual and in the safety manual.
 The special warnings in this manual.
 The instructions in the safety manual.
 The operating organisation's instructions.
Mortal danger/risk of injury for personnel can arise on the machine, for example
due to:
 Incorrect usage.
 Incorrect handling.
 Incorrect transport.
 Missing protective devices.
 Faulty or damaged components.
 Handling/usage by personnel who have not been trained and instructed.

General
Climatic conditions
Hazards for the environment due to the machine can arise for example due to:
 Incorrect disposal of lubricants and fuel.
 Noise emission.
Damage to the machine can occur for example due to:
 Failure to comply with operating and maintenance requirements.
Damage to other assets in the operating area of the machine can occur for ex-
ample due to:
 Incorrectly performed repairs.
The machine's performance or functionality may be limited for example due to:
 Incorrect maintenance and repair.
1.03 Climatic conditions

1.03.01 Climatic conditions
Low ambient temperature
In cold weather, the starting behaviour and the operation of the diesel engine de-
pend on the following points:
 For fuels used, see Fuels - lubricants selection tables.
 For engine oil viscosity, see Fuels - lubricants selection tables.
 State of the battery.
Advice for operation in cold weather:
 After starting, leave the diesel engine to run on low load until the temperature
gauge indicates increasing values.
 After the diesel engine is switched off, the cooling and lubrication systems
take time to cool down. This means that the diesel engine can be shut down
for a few hours and then restarted without problems.
 Below 0 °C use winter fuel.
 Prior to the cold season, fill in the correct lubricant.
 Check all parts made of rubber (hoses, V-belts etc.).
 Check all electrical cables and connections for chafing and damage to the in-
sulation.
 Keep battery charged and warm.
 Re-fill fuel tank at the end of each shift.

General
Safety instructions
WARNING
Injuries and damage may be caused by the usage of alcohol or other starting
aids.
Do not use aerosol starting aids, for example ether.
In these cases there is a risk of explosion and injury.
High ambient temperature, high altitude

At increasing altitude or ambient temperature, the maximum power of the en-
gine, the exhaust quality, the temperature level and, under extreme circum-
stances, the starting behaviour are impaired.
In case of operation in the following conditions, the amount of fuel injected must
be reduced:
 Above an altitude of 1000 m
 Above an ambient temperature of 30°C
NOTE
In electronically controlled engines, the fuel quantity is adapted automatically.
Hydraulic system
The acceleration and braking behaviour of the machine are affected by viscous
hydraulic oil. In low outdoor temperatures, wait a few minutes after starting the
diesel engine before pulling away. During the warming-up phase only drive the
machine at moderate speed and low load until the oil in the hydraulic system has
warmed up to approx. + 40°C.
1.04 Safety instructions

1.04.01 Environmental protection
Packaging material, cleaning agents and used or left-over fuels / lubricants are
to be sent for recycling, as per the regulations for the protection of the environ-
ment in the place of use.
1.04.02 Disposal
The protection of the environment is an urgent task. Correct disposal will avoid
negative effects on man and the environment and enable valuable raw materials
to be reused.
Fuels / lubricants
Dispose of fuels / lubricants as per the related specifications and the related na-
tional regulations.
Materials (metals, plastics)

To be able to dispose of materials correctly, they must be sorted by type. Clean
materials of other adhering substances. Dispose of materials in accordance with
the related national regulations.
Electrics / electronics
The electrical/electronic components are not subject to the WEEE directive
2002/96/EC and the related national laws (in Germany e.g. ElektroG). The elec-
trical/electronic components must be sent to a specialised recycling organisa-
tion.

General
Safety instructions
1.04.03 Machine-specific safety instructions

The maximum theoretical lateral tilt of the machine must not exceed 8° (14%)
from the horizontal plane.
DANGER
Risk of injury!
Lateral tilt values can be reduced drastically, depending on the application con-
ditions, especially for an unstable sub-base.
 In case of doubt, always secure the machine against tipping.
Maximum longitudinal tilt on the machine during milling = 30° (57%).

In case of milling work on steeper inclines / declines than the above mentioned
values, or an unstable sub-base, the machine must be secured with a suitably
dimensioned winch (tow truck).
Especially when using the machine with a coupled tanker, the allowed lateral
and longitudinal tilt depends on the conditions of the construction site. Ensure
that unsafe operating conditions do not arise.
‎On travelling / transferring / transporting the machine, attention is to be paid to
sufficient pendulum stroke.
On travelling / transferring / transporting the machine, it must be horizontal in the
lateral direction and raised to the highest point.
WARNING
Risk of losing control
The machine operator can loose control of the machine.
 Start and operate the machine only from the driver / operator position.
WARNING
Working with hot bitumen, bitumen emulsion, binder, lime, cement and sol-
vents:
The above mentioned binders can be a health hazard and can cause life-threat-
ening illness.
 Avoid contact with the skin - wear protective clothing (hard helmet with neck
protector, safety shoes, heat resistant gloves, etc.).
 Trouser legs are to be worn over the shoes; jacket arms are to worn over the
glove sleeves.
 Avoid contact with the eyes - wear a face visor.
 Do not inhale fumes - wear a dust protection mask.
 Accumulation of emulsion puddles, etc. must be removed immediately - risk
of slipping.
 Solvents must be applied in such a way that they cannot penetrate into the
soil.
 Any pressure is to be released before disconnecting the rapid-action connec-
tors.
 If the machine is not equipped with a cabin, the operator must wear a dust
protection mask under dusty operational conditions.
 Caution with hot system parts - risk of burning.

General
Safety instructions
First aid - measures for:

Scalding with hot bitumen
 Immediately flush the eyes for at least 15 minutes with sufficient cold water.
Never rub the eyes dry.
 Immediately flush the skin with plenty of cold water for at least 10 minutes.
 Do not remove the bitumen from skin after it has cooled, since it forms a ster-
ile covering over the wound. The bitumen normally comes off by itself after a
few days.
Contact with bitumen emulsion

 Immediately flush the skin with sufficient cold water and soap.
 Remove any saturated clothing.
Contact with cement / lime / suspension

 If inhaled, ensure sufficient fresh air.
 Immediately flush the skin with sufficient cold water and soap.
 Remove any saturated clothing.
 If swallowed, immediately flush out the mouth with sufficient cold water (only
when conscious) and then give sufficient cold water to drink.
 Do not induce vomiting.
 If necessary, an opthalmic specialist or other medical specialist or
ahospital must be consulted immediately.
Inspections
NOTE
For filling level check or for topping up fuels / lubricants, use secure ladders.
Do not climb onto the machine or use parts of the machine as climbing aids.
Risk of falling!

General
Safety instructions
Safety supports
NOTE
During work inside or under the machine, the safety supports must be fitted to all
lifting columns, and the chassis supported on them.
Fire extinguishers
NOTE
Observe national and / or local regulations and retrofit a fire extinguisher, if re-
quired.
The provided mounting position was specified by WIRTGEN.

General
Safety instructions
ROPS-FOPS cabin
WARNING
Visual check
The frame of the cabin is configured as a ROPS (roll-over protective structure).
The roof of the cabin is configured as a FOPS (falling objects protective struc-
ture).
Refer to the separate nameplate in the cabin to find the standards that have
been complied with.
All screw connections must be in accordance with the prescribed specifications
and be firmly screwed on.
The supporting elements of the cabin frame and the roof are not allowed to have
any rust, damage, hairline cracks or breakage points; neither are they allowed to
be warped or bent.
Any change to the supporting elements (e.g. drilling, welding, etc.) is prohibited,
as are repairs / straightening.
MARGIN
The safety belt must be worn (only with ROPS cabin or ROPS roll-over bar)
Danger due to being flung out if the machine tips over, can lead to serious or
even fatal injuries.
Wear the safety belt.

General
Safety instructions
1.04.04 Danger zones
During on-site operation and during transport, there must not be any people in
the machine's danger zone.
Entry to the danger zone is only allowed for maintenance and cleaning work:
 With the machine stationary and secured
 For authorised personnel

General
Labelling
1.05 Noise / vibration

1.05.01 Noise / vibration data
Noise data in accordance with 98/37/EC and 2006/62/EC
The measurement was made in accordance with EN 500-3 at a diesel engine
operating speed of
1850 r.p.m.
performed.
The machine emits a noise level of

LwA = 110 dB(A)
At the operator position a sound pressure level of

LpA = 76 dB(A)
is emitted.
Vibration specifications according to 91/368/EEC:

Hand / arm vibration.
In case of correct use, the weighted effective values for the acceleration in rela-
tion to hand / arm oscillations of
ahw = 2.5 m/s2
are not exceeded.
Total body oscillations

In case of correct use, the weighted effective values for the acceleration in rela-
tion to total body oscillations of
aw = 0.5 m/s2
are not exceeded.
1.06 Labelling
1.06.01 Colours
Signs / stickers
Colour Designation Instructions - information
Prohibition Dangerous behaviour
Danger Stop, evacuation
Warning Attention, caution, check
Help, rescue Doors, exits, routes, stations, compartments

Safety Return to the normal state
Instruction Specific behaviour or activity. (e.g. obligation to

wear personal protective equipment)

General
Labelling
Pilot lights / light emitting diodes (LED) / status bar of the on-board
computer
Colour Designation Explanation Instructions / informa-
tion for the operator
Emergency Critical state Immediate action neces-
sary to react to the dan-
gerous state (e.g. press
EMERGENCY STOP)
Abnormal Abnormal state; Monitor or take action to
critical state immi- suppress the abnormal
nent state (e.g. restart an inter-
rupted automatic process)
Normal Normal state Ready for operation or
function active
Imperative State that requires Reset function (e.g. con-

action by the oper- firm)
ator
Neutral Other state Monitoring or general func-
tions (e.g. milling drum
START/ON, water pump
START/ON etc.) or operat-
ing state of a component
(e.g. milling drum rotating,
belt conveyor motor rotat-
ing etc.)
1.06.02 Signs / stickers NOTE
Refer to the safety manual for the description of safety-relevant stickers.

MARGIN
GS mark
WIRTGEN machines are subject to a type examination by a notified body and
have the GS mark.
MARGIN
Approval certificate
WIRTGEN machines are subject to an inspection by an expert in accordance
with EU directives and have an approval sticker.
MARGIN
Patent information

General
Labelling
MARGIN
Information box
For information leaflets.
(located in the cab under the emergency seat)
MARGIN
Transportation Instructions
Information on storage location for the related transportation instructions.
MARGIN
Key fob
On parking the machine the electrical power supply is to be switched off and the
key removed.
MARGIN
Diesel fuel tank

Use diesel with a sulphur content of less than 0.5%.
Pay attention to standards.
MARGIN
Bleeding the diesel line

It is essential to comply with the description in the instruction manual
MARGIN
Fill in water
MARGIN
Drain water

General
Labelling
MARGIN
Diesel engine oil
MARGIN
Hydraulic oil tank
MARGIN
Diagnose socket
MARGIN
Storage location for technical documentation and tools
MARGIN
Emergency exit
MARGIN
Welding work
Prior to welding work, disconnect electrical devices such as battery, alternator,
sensors, controllers, etc. - danger of irreparable damage!
12350 Attach earth clamp as close as possible to the welding point.

General
Labelling
MARGIN
Milling drum rotation speed

Arrangement of the drive belt pulleys for the corresponding milling drum rotation
speed.
MARGIN
Lubrication instructions
Only use stipulated lubricant.
MARGIN
Instructions on lifting points.
MARGIN
Instructions on lashing point.
MARGIN
"no" lashing point.
MARGIN
Air conditioner / window

As long as the air conditioner is in operation, leave the cabin window closed.
MARGIN
Front lubrication points
MARGIN
Rear lubrication points

General
Labelling
MARGIN
"Multi-function" joystick - short instruction

(transparent adhesive foil on the side window)
MARGIN
"Height adjustment" joystick - short instruction

(transparent adhesive foil on the windscreen)
1.06.03 Nameplate (machine)

General
Labelling
[a] Name and address of the man- [b] Description according to the
ufacturer Machinery Directive
[c] Stipulated markings (for EU [d] Series and type designations
countries the CE mark)
[e] Year of construction [f] Serial number
[g] Operating weight in kg [h] Engine rated output in kW
[i] Allowed axle load in kg (for [k] Curb weight in kg
wheeled machines only)
NOTE
The entire marking represents an official document and must not be altered or
effaced.
Additional explanations of the nameplate:

(e) Year of construction
The year of construction is the year during which the manufacturing process was
concluded.
It is not allowed to pre-date or post-date the year of construction of the machine
when applying the CE marking.
(g) Operating weight

The weight of the basic machine with all standard fittings, with or without driver
cabin, with a driver (75 kg) and half-filled fuel tank and all fluid systems, if applic-
able, with half-filled water spray tank.
Additionally for crawler machines (e.g. specification from - to):
The operating weight with all components which are required for the installation
of the equipment on the basic machine (e.g. ballast weight and all possible ac-
cessories) and a full water spray tank.
(h) Engine rated output

Diesel engine rated output in kW according to ISO 14396.

General
Labelling
(i) - Allowed front / rear axle load

The axle load is the maximum axle load stated by the manufacturer incl. all ad-
ditional features, tanks filled to the maximum and a supplement of 75 kg for the
operator.
(Obligation for wheel machines)
(k) Curb weight

The curb weight of the machine with basic equipment, with filled oil tanks, with-
out tools, with empty tanks and without the weight of the co-driver.
1.06.04 Nameplate (ROPS/FOPS)

General
Labelling
[a] Name and address of the manufac- [b] Standards complied with
turer
[c] Material number / part number [d] Year of construction
[e] Machine series and type [f] Machine serial number
[g] Test weight in kg
NOTE
The entire marking represents an official document and must not be altered or
effaced.
1.06.05 Machine identification
All WIRTGEN machines are identified by the serial number. The serial number is
on the nameplate and the chassis of your machine.
Example:
07 WR 0004 = Serial number
07 WR= Series code for the WR 240
0004 = Sequential machine number

34 / 370
Description
General
2 DESCRIPTION
2.00 General
2.00.01 Overview of control panels
[1] Lighting control panel [2] Diesel engine diagnosis control panel
[3] Foam-bitumen sample control panel [4] High-pressure cleaner control panel

Description
General
[1] On-board computer display (cameras) [2] Control panel (diesel engine control)
[3] On-board computer display (work) [4] Control panel (window wiper / air conditioner /
heater)
[5] Control panel (window wiper / heater) [6] Control panel (driving machine)
[7] Control panel (milling drum) [8] Control panel (height adjustment)
[9] Control panel (dosing)
[1] Control panel (tool exchange / open milling drum [2] EMERGENCY STOP switch
scraper)
[3] Control panel (milling drum rotation device) [4] Control panel (cleaning spraying nozzles)

Description
General
2.00.02 Description of function
All binder pumps are driven hydraulically. This allows the feed quantity to be ad-
justed continuously. Feed quantities are captured electronically.
Feed quantity control comprises a computer which controls the various oper-
ational modes and continuously calculates the relative flow-through quantity,
based on advance speed and input data like width, depth and density. It allows
automatic adaptation of the feed volume according to advance speed.
Available spraying units

Water or emulsion / water and emulsion / foam bitumen / water (1800 l
pump) / suspension

Description
General
Schematic representation (water or emulsion)
NOTE
The supply (water or emulsion) comes from tank trucks and via the water spray-
ing beam position B

Description
General
Schematic representation (water + emulsion)
NOTE
The supply (water) comes from tank trucks and via the water spraying beam po-
sition B
The supply (emulsion) comes from tank trucks and via the emulsion spraying
beam position A

Description
General
Schematic representation (foam bitumen + water)
NOTE
sition B
The supply (bitumen) comes from tank trucks and via the bitumen spraying
beam position A

Description
General
Schematic representation (water 1800 litres)
NOTE
sition B

Description
General
Schematic representation (suspension)
NOTE
The supply (suspension) comes from an external preparation plant (e.g. WM

1000) ad via the suspension spraying beam position B.

Description
General
MARGIN
• A precise pre-setting of depth, width and density is a prerequisite for an exact

calculation.
MARGIN
• A = Automatic mode (milling depth) - The milling depth is measured con-

tinuously and the spray volume is automatically adapted for the calculated
milling depth.
• M = Manual mode (milling depth) - The spray volume is adapted to the rele-
vant milling depth setting

Description
General
MARGIN
• A = Automatic mode (spraying width) - The spray volume is automatically

adapted to the number of opened spraying nozzles
• M = Manual mode (spraying width) - The spray volume is adapted to the
relevant milling width setting
MARGIN
• Milling depth, setting of the milling drum scrapers, travelling speed (speed)
and added binder volumes (depending on the equipment of the machine, e.g.
water, bitumen, bitumen water, emulsion or suspension) are displayed per-
manently.

Description
Chassis / safety devices
2.01 Chassis / safety devices

2.01.01 Chassis controls
[1] Foam-bitumen sample ON / OFF [2] Area lighting ON / OFF

[3] Clean spraying beam ON / OFF [4] High-pressure cleaner ON / OFF
2.01.02 Lighting / warning device
[1] Floodlight [2] Mirrors

[3] Patrol light [4] Floodlights (mobile)

Description
2.01.03 Cover panel / storage boxes / maintenance flaps
[1] Cover panels [2] Storage compartment

[3] Maintenance flap [4] Maintenance flap
[5] Storage compartment [6] Storage compartment

Description
2.01.04 Fire extinguishers
[1] Fire extinguisher position

Description
Operator's stand
2.02 Operator's stand

2.02.01 Cabin control panels
Diesel engine control panel
[1] Diesel engine speed control [2] LED preglow diesel engine
[3] LED diesel engine ready for start [4] Diesel engine STOP
[5] Diesel engine START [6] Electrical power supply OFF / ON / tool ex-
change ON
[7] Diagnosis (machine control I + II) [8] General fault message
[9] Spraying unit OFF / ON [10] OFF / lighting stage I ON / lighting stage II ON

Description
Operator's stand
Wiper / heater control panel
[1] Front window wiper / front window washer [2] Side window wiper / side window washer
[3] Rear window wiper / rear window washer [4] Patrol light
[5] Fan MIN / MAX [6] Temperature MIN / MAX

Description
Operator's stand
Wiper / air conditioner control panel
[1] Front window wiper / front window washer [2] Side window wiper / side window washer
[3] Rear window wiper / rear window washer [4] Patrol light
[5] Activation of manual operational mode selec- [6] Increase nominal temperature; increase blower
tion; changeover between heating and air-con- speed
ditioning operational modes; in dehumidification
mode: air-conditioner function OFF / ON
[7] Manual air-conditioning mode active [8] Device OFF / ON
[9] Reduce nominal temperature; reduce blower [10] Automatic blower control active
speed
[11] Bar display for blower speed with manual blower [12] Manual blower control active
control
[13] Service mode [14] there is at least one confirmed error
[15] manual heating mode active [16] 4-digit seven-segment display for nominal tem-
perature, errors, etc.
[17] Switch between manual and automatic blower [18] no function
operation; activate manual blower adjustment
[19] Dehumidify operation active [20] Dehumidify operation OFF / ON
[21] Activation of fully automatic operation (automatic
operational mode selection as well as automatic
blower control)

Description
Operator's stand
2.02.02 Operator's seat right control panels
[1] Front steering [2] COORDINATE steering

[3] CRAB steering [4] Maximum travelling speed
[5] Low travelling speed [6] Maximum working speed
[7] Low working speed [8] Parking brake
[9] Move cabin [10] Differential lock
[11] Multi-function joystick [12] Warning horn
[13] Milling drum rotation speed selector switch

Description
Operator's stand
[1] lift complete / lower complete / roll right / roll left [2] Speed limiter ON / OFF
[3] Switch over camera display (depending on op- [4] Switch travelling gears continuously
tion)
[5] Travelling RELEASE (1) / travelling FOR- [6] Steering rear left / right
WARDS / REVERSE (2)
[7] Lift / lower milling drum [8] Steering modes: OFF (front only) / COORDI-
NATE / CRAB / straight (rear only)
[9] Activate automatic starting/lifting-out function [10] Green LED (automatic starting/lifting-out func-
(1) / automatic starting/lifting-out function (2) tion)
[11] "Multi-function joystick" sticker (side window)

Description
Operator's stand
2.02.03 Operator's seat left control panels
[1] Height adjustment joystick [2] Front milling drum scraper LIFT
[3] Front milling drum scraper LOWER [4] Rear milling drum scraper LIFT
[5] Rear milling drum scraper LOWER [6] Rear milling drum scraper (floating position)
[7] Left slope regulation [8] Right slope regulation
[9] Favourite I [10] Favourite II (spare)
[11] Spraying nozzles 1/1 OPEN / 1/2 OPEN [12] Bitumen heater
[13] Display for rotary button [14] Rotary button HOME / ESC
[15] Pumps manual operational mode [16] Pumps automatic operational mode
[17] Dosing units I, II, II or I-III [18] Spraying nozzles symbol manual operational
mode
[19] Spraying nozzles manual / automatic / off [20] Spraying nozzles symbol automatic operational
mode

Description
Operator's stand
[1] Button (additional function LIFT) [2] Button (additional function LOWER)
[3] both buttons not pressed (see no. 4) [4] LIFT complete machine / ROLL right or left side
about the longitudinal central axis / LOWER
completely
[5] Front button pressed (see no. 6) [6] LIFT machine front / LIFT right or left side / LIFT
rear
[7] Rear button pressed (see no. 8) [8] LOWER machine front / LOWER right or left
side / LOWER rear
[9] "Height adjustment joystick" sticker (front win-
dow)

Description
Operator's stand
2.02.04 On-board computer display
[1] Dial/pushbutton [2] Display

[3] Diagnostics quick access [4] Camera display (cameras 1 to 4)
[5] Favourites button [6] Function keys
[7] Light intensity sensor [8] Confirm / display operating state messages
[9] General fault [10] HOME key (return to start screen)
[11] ESC key (return to previous screen)
2.02.05 On-board computer symbols

Status symbols
Depending on the selected function or operating state, various symbols are shown on the on-board computer dis-
play.
RED Malfunction
ORANGE Function active
GREEN Function OK
GREY Function inactive
Symbol Description Symbol Description
Compressed air inactive (grey) Compressed air active (orange)

Description
Operator's stand
Automatic inactive (grey) Automatic active (orange)
Speed control inactive (grey) Speed control active (orange)
Low working speed (orange) Maximum working speed (orange)
Low travelling speed (orange) Maximum travelling speed (orange)
Heater inactive (grey) Heater active (orange)
Manual inactive (grey) Manual active (orange)
Engine load control inactive (grey) Engine load control active (orange)
Milling mode inactive (grey) Milling mode active (orange)
Automatic / manual inactive (grey)
Adaptive speed control inactive (grey) Adaptive speed control active (orange)
Traction control system inactive (grey) Traction control system active (orange)
Drive mode inactive (grey) Drive mode active (grey)

Description
Operator's stand
Side plate – "Fast travelling" mode inactive Side plate – "Fast travelling" mode active
(grey) (orange)
Status bar symbols

Armrest opened Milling drum gearbox temperature too high
Maintenance EMERGENCY STOP switch pressed
Tool exchange
Diesel engine warming-up phase Diesel engine malfunction
Fuse has tripped
General
Actual value set to "0"
Automatic Buzzer
calibrate Date table
Machine ID EMERGENCY STOP

Description
Operator's stand
Caution not confirmed
Minutes / minimum Maximum
Maintenance Manual
Fan Operational hours
Time Pump
Sensitivity Nominal value
Action performed (green) Action failed (red)
Left Right
Warning horn Confirmed
Caution Hour
Towing away Patrol light
Stop Tank

Description
Operator's stand
Value can be changed Call customer service
Setup Logical operation of inputs
Nominal value
Operator's stand
Camera Front window washer
Front window wiper Rear window washer
Rear window wiper Side window washer
Side window wiper Up / Down
Cabin Move cabin
Move cabin left Move cabin right
Cabin in parked position

Description
Operator's stand

Turn cabin to the left Turn cabin to the right
Cabin door open Washer unit for side window
Washer unit windscreen Window wiper for windscreen
Window wiper for side window Seat
Heater Lamp
Favourite Favourite I
Favourite II Area (job data)
Distance (job data) Density (job data)
Set density (job data) Volume (job data)
Weight of the material (job data) Working depth (job data)
Set working depth (job data) Working width (job data)

Description
Operator's stand

Set working width (job data) Number of truck journeys (job data)
Weight of material per truck (job data) Fold rear-view mirror
Mirror left Mirror right
Contrast for daytime operation Contrast for night operation
Display illumination
Milling drum unit

Pick extractor Milling drum width
Front milling drum scraper UP / DOWN Milling drum scraper hydr. pressure floating
position
Rear milling drum scraper UP / DOWN Rear milling drum scraper UP
Rear milling drum scraper floating position Milling drum
Milling drum drive Milling drum rotation speed Level 1
Milling drum rotation speed Level 2 Milling drum rotation speed Level 3

Description
Operator's stand

Milling depth Set milling depth
Milling width Set milling width
Milling drum position in relation to milling Milling drum housing position in relation to
drum housing ground
Electric motor
Engine / motor group

Diesel engine Diesel engine air filter
Diesel engine charge air pressure Diesel engine charge air temperature
Diesel engine coolant filling level Diesel engine coolant temperature
Diesel engine general fault Diesel engine load control
Diesel engine torque Diesel engine oil pressure
Diesel engine oil temperature Diesel engine START
Diesel engine operational hours Diesel engine electrical power supply

Description
Operator's stand

Preglow diesel engine Diesel engine speed
Fuel tank Fuel tank filling level
Fuel tank filling level low Diesel engine engine load control sensitivity
Diesel engine engine load control level 1 Diesel engine engine load control level 2
Diesel engine engine load control level 3
Hydraulic oil feed

Hydraulic travelling pressure Hydraulic system
Hydraulic oil pressure Valve
Hydraulic oil temperature Hydraulic leakage oil filter
Hydraulic pressure filter Hydraulic pressure filter inactive or not

present
Hydraulic return flow filter Hydraulic oil filling level
Hydraulic oil filter Hydraulic drum pressure

Description
Operator's stand

Hydraulic drive pressure discharge conveyor Hydraulic drive pressure primary conveyor
Hydraulic pressure conveyor system
Electrical system
Acceleration ramp Deceleration ramp
Electrical power supply Electrical switch
Electrical current Fuse
Generator Electrical power supply ON
Max. current Min. current
Electrical power supply OFF Patrol light
Relays Regulation parameters
Valve Regulation parameters
Exterior lighting Working lights

Description
Operator's stand

Working lights circuit 1 Working lights circuit 2
Electric motor Pressure switch
Height adjustment
Height adjustment inactive Height adjustment completely active
Front height adjustment active Front left height adjustment active
Front right height adjustment active Left side height adjustment active
Rear height adjustment active Rear left height adjustment active
Rear right height adjustment active Right side height adjustment active
Lower Fast lower
Lift Fast lift
Lowering speed - automatic PTS automatic

Description
Operator's stand
Advance drive
Travelling REVERSE Travelling FORWARDS
Travelling FORWARD / REVERSE Parking brake
Slow Fast
Speed control Speed max.
Differential lock (flow distributor) Traction control
Adaptive travel speed control Cruise control
Crawler unit tighten chain / slacken chain Milling or drive mode
Steering system
Steering Steering angle
Front left steering Front right steering
Rear left steering Rear right steering
COORDINATE steering CRAB steering

Description
Operator's stand

Front steering Rear steering
Steering CRAB / COORDINATE Steering (rear) – AUTOMATIC mode
Rear steering straight
Levelling system
Slope inactive Left slope active
Right slope active Scanning in front of the milling drum
Cleaner unit
High pressure cleaner Compressor
Binder unit
Area Distance
Density Set density
Volume Volume weight

Description
Operator's stand

Spraying beam general Spraying beam I
Spraying beam II Spraying beam II+
Spraying beam nozzles open / ½ number

open
Dry run protection Milling width reference / job data
Heater Flow-through meter
Bitumen pressure Filling level bitumen water
Information message print job data Printer
Dosing
Compressed air inactive Compressed air active
Automatic inactive Automatic active
Manual inactive Manual active
Heater inactive Heater active

Description
Operator's stand
Spraying beam cleaning Automatic / manual inactive
Spraying beam inactive Spraying beam ½ automatic inactive
Spraying beam ½ manual inactive Spraying beam automatic active
Spraying beam automatic spraying active Spraying beam manual spraying active
Water spraying beam inactive Water spraying beam ½ automatic inactive
Water spraying beam ½ manual inactive Water spraying beam automatic active
Water spraying beam automatic spraying ac- Water spraying beam manual spraying ac-
tive tive
Programmable logic controller (PLC)

Display lighting daytime operation Display lighting nighttime operation
Programmable logic controller (PLC) Programmable logic controller 1
Programmable logic controller 2 Programmable logic controller 2 inactive or

not present
Lighting keypads

Description
Operator's stand
2.02.06 Operator's cabin
[1] Window wiper (side window) [2] Window wiper (window front / rear)
[3] Mirrors [4] Cabin (movable)
2.02.07 Operator's seat
[1] Monitor cameras [2] Steering wheel

[3] turn complete seat [4] Monitor operation machine
[5] Armrest left [6] Armrest right
[7] Operator's seat

Description
Operator's stand
2.02.08 Air conditioner
[1] Air conditioner (air flow nozzles) [2] Air conditioner (control)
[3] Air conditioner (air filter)
[1] Cooler (air conditioner) - folding

Description
Operator's stand
2.02.09 Radio / printer
[1] Printer (job data) [2] Radio

Description
Operator's stand
2.02.10 Camera / monitor system
[1] Camera (outside area left) [2] Camera (milling drum / milling drum scraper
front area)
[3] Camera (milling drum / milling drum scraper rear [4] Camera (area behind the machine / reverse
area) travel)
[5] Monitor (in the cabin)
[5] Monitor for various camera positions (in the

cabin)

Description
Milling drum unit
2.03 Milling drum unit

2.03.01 Tool exchange / milling drum rotation device control panels
[1] Turn milling drum to left (milling drum rotation [2] Turn milling drum to right (milling drum rotation
device control panel) device control panel)
[3] Socket for milling drum rotation device / pick ex- [4] Tool exchange OFF / ON / rear milling drum
tractor (in rear tool box) scraper LIFT (rear crossmember)
[5] Electrical power supply OFF / ON / tool ex- [6] Hydr. coupling for pick extractor (in rear tool
change ON (diesel engine control panel - cabin) box)

Description
Milling drum unit
2.03.02 Milling drum
[1] Milling drum [2] Pick extractor (pneumatic)

[3] Pick extractor (hydraulic) [4] Pick support
[5] Picks
2.03.03 Milling drum scraper front / rear
[1] Milling drum scraper rear [2] Milling drum scraper front

Description
2.04 Engine / motor group

2.04.01 Diesel engine
Diesel engine
Diesel particulate filter
[1] Diesel particulate filter [2] Control panel diesel particulate filter

Description
2.04.02 Fuel supply
[1] Shut-off tap (fuel pre-filter) [2] Fuel filler port

[3] Fuel main filter [4] Fuel pre-filter
[5] Fuel hand pump
2.04.03 Cooling system
[1] Coolant filler port [2] Coolant filling level

[3] Cooler (coolant) [4] Cooler (charge air)

Description
2.04.04 Air filter
[1] Air filter

Description
2.04.05 Control panel diesel engine diagnosis

Diagnosis (in the electrical cabinet behind the cabin)
[1] Button - diagnosis start ON / OFF - LED in but- [2] Diesel engine stop light (red LED)
ton lights up when the button is set to ON
[3] Diesel engine warning light (yellow LED) [4] Button - ENTER (next flash code)
[5] Button - raise diesel engine speed (only for [6] Button - reduce diesel engine speed (only for
emergency mode) - LED in button lights up emergency mode)
when the maximum speed is reached

Description
Hydraulic oil feed
2.05 Hydraulic oil feed

2.05.01 Hydraulic oil feed
[1] Hydraulic return flow filter [2] Filler filter and ventilation filter
[3] Hydraulic pressure filter [4] Hydraulic combination filter (return flow / suction
filter)
[5] Hydraulic oil level indicator
[1] Cooler (hydraulic pump drive) [2] Cooler (hydraulic oil)

Description
Electrical system
2.05.02 Hydraulic pump drive
[1] Ventilation valve [2] Oil filler port

[3] Maintenance flap oil drain [4] Oil drain
[5] Dipstick
2.06 Electrical system

2.06.01 Batteries
[1] Battery [2] Battery main switch

[3] Battery

Description
Advance drive
2.06.02 Electrical cabinet / fuses
[1] Foam bitumen unit fuses (generator) [2] Trip-switches foam bitumen unit (heater circuits)
[3] Main electrical cabinet (behind the cabin) [4] Diesel engine emergency mode module
2.08 Advance drive

2.08.01 Advance drive gearbox / wheels
[1] Tyres [2] Advance drive gearbox

Description
Advance drive
2.08.02 Engine load control
[1] Engine load control ON / OFF [2] Adjust sensitivity

[3] Set engine load limit speed 1 [4] Set engine load limit speed 2
[5] Set engine load limit speed 3
The engine load control detects speed reductions of the diesel engine due to in-
creasing load.
As a consequence the pressurisation speed for the 3 milling speeds is limited
and as a result the travelling speed of the machine reduced.
The machine operator can concentrate completely on the other machine func-
tions.
The engine load limit speed and the sensitivity can be adjusted by the machine
operator via the on-board computer.

Description
Steering system
2.08.03 Device for towing away
[1] Brake release device [2] Pressure gauge connection

[3] Hydraulic coupling towing away / travelling [4] Switching electro-hydraulic unit on/off
[5] Hand pump
2.09 Steering system

2.09.01 Steering
[1] Steering wheel (front wheels) [2] Multi-function joystick (rear wheels / steering
mode)

Description
Water system
2.11 Levelling system

2.11.01 Sensors
[1] Sensor (lateral tilt)
2.12 Water system

2.12.01 Water supply
[1] Water filler port [2] Water filter

[3] Water drain

Description
Cleaner unit
2.13 Cleaner unit

2.13.01 High pressure cleaner
[1] Cleaning ON / OFF [2] Connection high-pressure cleaner

[3] Position high-pressure cleaner (behind the right
front wheel)

Description
Binder unit
2.16 Binder unit

2.16.01 On-board computer display dosing unit
[1] On-board computer display for setting / reading

off dosing data
2.16.02 Spraying beams
[1] Spraying beam position "A" (here foam bitumen) [2] Spraying beam position "B" (here water / emul-
sion / suspension)

Description
Binder unit
2.16.03 Pipe connectors
[1] Connection for water (1800 litres) [2] Connection for water / emulsion (1st pump)
[3] Connection for suspension [4] Connection for water / emulsion (2nd pump)
[5] Connection for hot bitumen (foam bitumen)
2.16.04 Test nozzle

Test nozzle foam bitumen sample
[1] Test nozzle for taking foam-bitumen samples [2] Test bucket with hook for foam-bitumen samples
[3] Test nozzle ON / OFF

Description
Compressed air system and accessories
2.17 Compressed air system and accessories

2.17.01 Compressed air tank / defroster unit
[1] Defroster unit [2] Compressed air tank

[3] Compressed air connection

90 / 370
Operation
General
3 OPERATION
3.00 General
3.00.01 General instructions
All activities described in Group Norm 6 "INSTALLATION, ASSEMBLY and
CONVERSION INSTRUCTIONS, SET-UP TASKS" (depending on the equip-
ment of the machine) before starting-up the machine and before on-site opera-
tion. Otherwise the machine may be damaged or the results may be unsatisfac-
tory.
3.00.02 Startup
 Set up cabin in working position
 Set up operator's seat in working position.
 Adjust mirrors.
 Adjust cameras.
 Start diesel engine.
 Lift the machine completely.
 Lift the milling drum up to the highest point.
3.00.03 On-site operation

 Select required travelling speed and steering mode.
 Drive machine to start position.
 couple the tank truck hose pipes if necessary.
 select required dosing unit type (I, II, III).
 open / close the shut-off valves of the dosing unit if necessary.
 Pre-heat the foam bitumen unit.
 Switch on the dosing unit.
 Set the required milling depth.
 Lower the machine completely.
 Set the milling drum scrapers as required.
 Switch on milling drum drive.
 Lower milling drum to milling depth.
 Move the machine slowly forwards.
 Set required working speed.

Operation
General
3.00.04 Shutting down

 Stop the machine.
 Lift the milling drum up to the highest point.
 Switch off the dosing unit.
 Switch off milling drum drive.
 Close all shut-off valves of the dosing unit.
 Uncouple the tank truck hose pipes.
 Lift the machine completely.
 Close the rear milling drum scraper.
 Drive machine to parking position.
 Lower the machine completely.
 Place wooden beams under milling drum and lower milling drum onto them.
 Switch off diesel engine. Set the electrical power supply to OFF, pull out the
key, set the main switch to OFF, remove the toggle.
 Lock the cabin.
 Lock boxes, storage compartments, patrol lights, etc. theft-proof.

Operation
General
3.00.05 Transportation
Before the machine is loaded onto a low loader or similar transportation vehicle,
it absolutely must be positioned on a level, solid sub-base. ready for loading .
Requirements:
 The machine must be freed of coarse contamination.
 The patrol light and working lights must be dismantled and packed securely
for transport - dust caps must be slid open.
 All parts protruding beyond the transportation height/width must be removed
and packed securely for transport on the machine; there must not be any
loose objects on the machine.
 The transportation height/width must not be exceeded under any circum-
stances.
 Move the cabin to the left to the end point.
 Fold mirrors.
 Close the front milling drum scraper.
 Close the rear milling drum scraper - set the switch to FLOATING position.
 Lift the milling drum up to the stop position.
 Lower the machine completely to the stop position.
 The starter batteries must be charged.
 There must be enough fuel in the fuel tank.
 The hand-over of keys (key for electrical power supply, key for the control
panels, toggle for the main switch) must be ensured.
 The driver of the transport vehicle must be informed about the location of the
"INFO BOX" and the transportation instructions contained therein.

Operation
Programmable logic control (PLC)
3.01 Programmable logic control (PLC)

3.01.01 Operator guidance (on-board computer)
Starting the on-board computer
MARGIN
 The on-board computer starts automatically after the electrical power supply
is switched on
 . . . the WIRTGEN symbol appears
 . . . the version with the machine type in question appears
 . . . a system test is performed
 . . . the working screen appears, from which it is possible to select all operat-
ing and setup screens

Operation
Selecting the selection menu
MARGIN
 Press the rotary button to leave the current screen - the selection menu ap-
pears.
 Turn the rotary button to the right or left and scroll to the required menu (here
e.g. 7 - Dosing) - press rotary button - the submenu appears.
 Turn the rotary button to the right or left and scroll to the required submenu
(here e.g. 7.1 - Overview) - press rotary button - the required selection screen
appears (here e.g. 7.1.1 - Dosing unit I).
 Press an "F" key (here e.g. F1) to enter or change values.
MARGIN
 Press the "ESC" key = change from the current screen to the previous
screen.
MARGIN
 Press the "HOME" key = change from the current screen to the main screen.

Operation
1 - Operation
2 - Service
3 - Setup
4 - Diagnosis

Operation
5 - Cameras
6 - Job data
7 - Dosing unit

Operation
Select screens (1 - Operation)
MARGIN
 To leave the current screen and scroll further, turn the rotary button to the
right or left.
Select screens (2 - Service)

Operation
MARGIN
 The working menu shows a separate window with the message when the
next maintenance is due (here, for example, in 8 hours).
pears.
e.g. 2 - Service) - press rotary button - the submenu appears.
(here e.g. 2.1 - Settings) - press rotary button - the selection screen appears
(here e.g. 2.1.1 - Next maintenance).
 Scroll to the submenu (here 2.1.2 - Service).
 Press F2 and confirm the maintenance - the hours until the next maintenance
are shown in "2.1.1 - Next service".
NOTE
Once the maintenance has been done and confirmed, a green smiley appears
on "2.1.2 - Service".
Once the maintenance has been done and confirmed, a green smiley appears
on "2.1.2 - Service".
Select screens (3 - Setup)

Operation
MARGIN
pears.
e.g. 3 - Setup) - press rotary button - the submenu appears.
(here e.g. 3.1 - Milling drum) - press rotary button - the submenu appears.
(here e.g. 3.1.1 - General) - press rotary button - the required selection
screen appears (here e.g. 3.1.1.1 - Milling depth automatic mode).
 Press the rotary button and enter the required value.
Selecting IPR code
MARGIN
 Turn the rotary button to the right or left and scroll to the required screen
(here e.g. 3.1.1.4 - Milling drum housing mode) - the input box is marked with
a lock indicating that the specific value can only be changed if an IPR code is
entered.
 Pressing the rotary button produces an IPR request code which can be sent
to WIRTGEN Service, which will then allocate a release code to you.
Select screens (4 - Diagnosis)

Operation
MARGIN
pears.
e.g. 4 - Diagnosis) - press rotary button - the submenu appears.
(here e.g. 4.1 - Milling drum) - press rotary button - the required selection
screen appears (here e.g. 4.3.0 - Milling drum).
(here e.g. 4.3.1 - Milling drum clutch) - press rotary button - the required se-
lection screen appears (here e.g. 4.3.1.1 - Milling drum clutch ON/OFF).
 Read off the required data.
Select screens (5 - Cameras)
MARGIN
pears.
e.g. 5 - Cameras) - press rotary button - the submenu appears.
(here e.g. 5.1 - Camera 1).
 Press the rotary button and allocate the required camera to the 2nd monitor.

Operation
Select screens (6 - Job data)
MARGIN
pears.
e.g. 6 - Job) - press rotary button - the submenu appears.
(here e.g. 6.1 - Job data detail) - press rotary button - the required selection
screen appears (here e.g. 6.1.1 - Distance).
 Alternative method: Press the F4 key = jump directly from the current
screen to the selection screen (here e.g. 6.1.1 - Distance).
 Read off the required value.
 Press the F5 key = print out job data.

Operation
Select screens (7 - Dosing)
MARGIN
pears.
e.g. 7 - Dosing) - press rotary button - the submenu appears.
(here e.g. 7.1 - Overview) - press rotary button - the required selection screen
appears (here e.g. 7.1.1 - Water).
 Alternative method: Press the F5 key = jump directly from the current
screen to the selection screen (here e.g. 7.1.1 - Water).
 Press the rotary button and enter the required value.

Operation
"F" - function keys
MARGIN
 Press the "F1" key - a selection window appears for entering the milling
depth.
 Press the "F2" key - a selection window appears for entering the contact
pressure for the rear milling drum scraper.
 Press the "F3" key - a selection window appears for entering the slope.
 Press the "F4" key - a selection window (6.1.1 - Job data) appears for read-
ing off the processed distance. Turn the rotary button to the right or left and
navigate to the next selection screen (6.1.2 to 6.1.10 - Job data) in order to
read off the processed area, volume, quantity, milling width, milling depth,
etc.
 Press the "F5" key - a selection window (7.1.1 - Dosing unit overview) ap-
pears for reading off the water settings. Turn the rotary button to the right
or left and navigate to the next selection screen (7.1.2 to 7.1.3 - Dosing unit
overview) to read off settings for emulsion, binder, etc.
NOTE
The assignment of function keys F1 to F5 changes both depending on the dis-

played screen and the status of the machine.
3.01.02 Operating state messages SPN/FMI (diesel engine)

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

Operation
If there is a fault:
 A warning horn sounds for 5 seconds,
 the red LED [1] lights up,
 the red CAUTION key [2] lights up,
 if the red LED [3] lights up on the engine control unit control panel,
 an SPN____ / FMI____ number appears on the display.
 Establish the cause of the fault.
 Rectify fault, if necessary contact WIRTGEN customer service.
The message on the display is confirmed by pressing any key

 the text message on the large reporting window disappears, the red
CAUTION key [2] goes out and the red LED [1] remains lit as long as the
malfunction has not been rectified.
 the SPN___/FMI___ message is no longer displayed,
 the red CAUTION key [2] goes out,
 the red LED [1] lights up if the malfunction returns and it goes out as soon as
the malfunction has been rectified,
 the red LED [3] lights up on the engine control unit control panel if the mal-
function continues and it goes out as soon as the malfunction has been recti-
fied.
3.01.03 Operating state messages flash code (diesel engine)

The diesel engine is equipped with a monitoring system.
After switching on the electrical power supply, starting the diesel engine, or dur-
ing on-site operation, messages on the state of the diesel engine can be dis-
played.

Operation
[1] Button - diagnosis start ON / [2] Diesel engine stop light (red
OFF - LED in button lights up LED)
when the button is set to ON
[3] Diesel engine warning light [4] Button - ENTER (next flash
(yellow LED) code)
[5] Button - raise diesel engine [6] Button - reduce diesel engine
speed (only for emergency speed (only for emergency
mode) - LED in button lights up mode)
when the maximum speed is
reached
Diesel engine "WARNING" (Possible to continue working for a short period)

MARGIN
 Yellow LED is illuminated - red LED is off
 Switch off diesel engine / switch on electrical power supply.

MARGIN
 Press the DIAG button - the yellow LED lights up.
MARGIN
 Yellow and red LED illuminate

 Short pause

Operation
MARGIN
 Yellow and red LED switch off

 Short pause
MARGIN
 The red LED outputs the flash code for the fault (here e.g. 4-3-5 = engine oil
pressure sensor)
Example:
 Determine the cause of the fault (see "Table" SPN/FMI and flash code
(diesel engine) - read off the corresponding message.
MARGIN
 To read other flash codes, press the button briefly.
Diesel engine "STOP" (No longer possible to continue to work)

MARGIN
 Yellow LED is off - red LED is illuminated
 Switch off diesel engine / switch on electrical power supply.

Operation
MARGIN
 Press the DIAG button - the yellow LED lights up.
MARGIN
 Yellow and red LED illuminate

 Short pause
MARGIN
 Yellow and red LED switch off

 Short pause
MARGIN
 the red LED outputs the flash code for the fault (here e.g. 2-3-5 = coolant
level too low)
Example:
 Determine the cause of the fault (see "Table" SPN/FMI and flash code
(diesel engine) - read off the corresponding message.

Operation
MARGIN
3.01.04 Operating state messages (machine)

The machine is equipped with a monitoring system.
After switching on the electrical power supply, starting the diesel engine, or during on-site operation, messages on
the state of the machine can be displayed.
The cause of the message is to be determined in every case and, if necessary, the fault or the error rectified.
 A warning horn sounds for 5 seconds,
 the red LED [1] lights up,
 the red CAUTION key [2] lights up,
 if the red LED [3] lights up on the engine control unit control panel,
 an SPN____ / FMI____ number appears on the display.
 Establish the cause of the fault.
The message is confirmed by pressing a key

 the text message on the large reporting window disappears, the red CAUTION key [2] goes out and the red LED
[1] remains lit as long as the malfunction has not been rectified.
 the SPN___/FMI___ message is no longer displayed,
 the red CAUTION key [2] goes out,
 the red LED [1] lights up if the malfunction returns and it goes out as soon as the malfunction has been rectified,
 the red LED [3] lights up on the engine control unit control panel if the malfunction continues and it goes out as
soon as the malfunction has been rectified.

Operation
Categories / priorities (P) of fault messages

P Name Definition Example / remarks Consequences for the
operator
White message Developer message Not used None
Blue message Blue messages indicate Lifting column front right is Mandatory action:
(protection signal) malfunctions that display completely extended Blue messages indicate a
a problem with a machine -> the operator no longer machine state that requires
system, and do not neces- has pendulum stroke avail- action by the operator; e.g.
sarily relate to the electron- able reset functions or acknowl-
ics edge message
Yellow message Yellow messages indicate Position measuring sen- Abnormal state:
(alarm signal) malfunctions of a machine sor of the side plate cylin- Yellow messages indi-
system; the machine does der has failed -> the ma- cate an abnormal state as
not have to be stopped im- chine can continue to be well as an imminent critical
mediately operated using emergency state of the machine. This
mode means this state must be
monitored and/or the oper-
ator must intervene in order
to stop the abnormal state
Red message Red messages indicate Diesel engine temperature Emergency: Red mes-
(machine STOP malfunctions of a machine is too high sages indicate a critical
signal) system in which the signifi- -> Diesel engine must be state of the machine which
cance of the malfunction is shut down immediately requires immediate action
so serious as to justify an by the operator in response
immediate stop of the ma- to this critical state (e.g.
chine press EMERGENCY STOP
switch)
Examples of fault message categories / priorities
Fault message category 1 - white

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

Operation
Fault message category 2 - blue

Press the red CAUTION key - the corresponding text message appears in the large message window with a blue
symbol
Fault message category 3 - yellow

Press the red CAUTION key - the corresponding text message appears in the large message window with a yellow
symbol
Fault message category 4 - red

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

Operation
View fault message list
Select "Operating state messages" box

Press the pushbutton - a list of all fault messages appears NOTE
Once all fault messages have been confirmed, the list with the operating state
messages can also be opened with the CAUTION key.
View fault message text
Select required field

Press pushbutton - the corresponding text message appears in the large message window
3.01.05 Operating state messages flash code (machine)

The machine is equipped with a monitoring system.
After switching on the electrical power supply, starting the diesel engine, or dur-
ing on-site operation, messages on the state of the machine can be displayed.

Operation
MARGIN
 A warning horn sounds for 5 seconds,
NOTE
If no text message appears (e.g. if the on-board computer display is defective or

the on-board computer has been removed) then the fault messages can also be
read out using a flash code.
MARGIN
 As soon as the red LED 1 lights up, this indicates a fault has been found on
control unit 1.
MARGIN
 As soon as the red LED 2 lights up, this indicates a fault has been found on
control unit 2.
Example:
 BLOCK [A]
LED 1 blinks 7 times
Pause 1.5 seconds.
Pause 1.5 seconds.
The LED lights for a period of 5 seconds between the blocks [A] and [B].

Operation
 BLOCK [B]
Pause 1.5 seconds.
LED 1 blinks 6 times NOTE
The relevant LED flashes 10 times for an output of the number "0".
Error code 713-16 (air filter) was determined in the example.
 Determine the cause of the fault (see "Table" flash code (machine) - read off
the corresponding message.
MARGIN
NOTE
The flash code for control unit 2 (red LED 2) is read out accordingly with the
same working procedure.
3.01.06 Diagnostic system

Symbol Colour Status
Inputs of the on-board gray Inactive
computer
green Active
red Fault
Outputs of the on-board gray Inactive

computer
green Active
red Fault
yellow Short circuit
red, green Cable break, output active
yellow, green Short circuit, output active

Operation
e.g. milling drum clutch MARGIN
 Select the adjacent screen (4.3.1).
MARGIN
 Press the rotary button - the adjacent screen appears (4.3.1.1 - Milling drum
clutch ON/OFF).
 Diagnosis-specific data can be read out in the "Inputs / outputs" field.
NOTE
Turn the rotary button to the right or left to display additional information.
Rectify any fault, if necessary contact WIRTGEN customer service.
3.01.07 Job data

Job data (detail / total)
Display milling width / milling depth
MARGIN
 Select the adjacent screen (3.6.1 - Job data selection milling width).
 Select preset milling width of the corresponding dosing unit for calculating the
job data.
Job data detail

Operation
NOTE
"Job data detail" shows values that are displayed during daily on-site operation
(optionally also in US standard measurements):
 1 = Distance driven in metres (m).
 2 = Milled surface in square metres (m²).
 3 = Milled material in cubic metres (m³).
 4 = Milled amount in tonnes (t).
 5 = Milling width in millimetres (mm).
 6 = Milling depth in millimetres (mm).
 7 = Density in kilograms per cubic metre (kg/m³).
 8 = Milled quantity for dosing unit "I" in percent / litres (% / l).
 9 = Milled quantity for dosing unit "II" in percent / kilograms (% / kg) - with
emulsion in litres (l).
 10 = Milled quantity for dosing unit "II+" in percent / litres (% / l).
Job data total
NOTE
"Job data total" shows cumulative values for the entire operating time (option-
ally also in US standard measurements):
 1 = Distance driven in metres (m).
 2 = Milled surface in square metres (m²).
 3 = Milled material in cubic metres (m³).
 4 = Milled amount in tonnes (t).
 5 = Milling width in millimetres (mm).
 6 = Milling depth in millimetres (mm).
 7 = Density in kilograms per cubic metre (kg/m³).
 8 = Milled quantity for dosing unit "I" in litres (l).
 9 = Milled quantity for dosing unit "II" in kilograms (kg) - with emulsion in litres
(l).
 10 = Milled quantity for dosing unit "II+" in litres (l).

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

 The area, the volume and the weight are calculated.
 The accuracy of these calculated values significantly depends on the input
values for the milling depth, milling width and density of the material to be
milled.
3.01.08 Printer
If required, work-specific data (job data) can be printed.
Activate printer MARGIN

 Use the rotary button to select the "Information messages on/off" field.
 Switch on messages (activate).
MARGIN

 Select the "Printer" field with the rotary button.
 Switch on printer (activate).
MARGIN
Start printing
 Select screen.
 Switch on printer.
 Set to "Print job data" to "yes" and start printing.

Operation
Diesel engine
 Example of a printout of specific job data.
3.02 Diesel engine

3.02.01 Starting the diesel engine MARGIN
 Before starting the diesel engine, it is essential to make sure that the
shut-off valve in the fuel line is opened.
MARGIN
 Switch on the electrical power supply - insert key and place in central posi-
tion.

Operation
Diesel engine
MARGIN
The yellow LED and the green LED light up.
MARGIN
The diesel engine is ready to be started, as soon as the yellow LED is switched
off.
MARGIN
 Sound acoustic warning signal.
MARGIN
 Press the green pushbutton and start the diesel engine.
NOTE
• Multiple attempts at starting will discharge the battery.

• Leave diesel engine to run for approx. 3 to 5 minutes at low idle speed
MARGIN
Increase / reduce diesel engine speed

 Moving the multi-function joystick from the "0" position forwards or backwards
automatically increases the diesel engine speed, and adjusts it to the speed
of the machine.
 Moving the multi-function joystick to the "0" position automatically reduces
the diesel engine speed to the specified idling speed.

Operation
Diesel engine
Alternatively, the diesel engine speed can be adjusted using the "Engine control
unit" control panel. MARGIN
 Press the right button and increase the speed.
MARGIN
 Press the right button and reduce the engine speed.
NOTE
 Observe the display instruments during the warming-up phase.

 Perform visual checks for leaks.
 If there is a malfunction, a fault message appears on the on-board computer
display. The red LED on the "Diesel engine control" control panel lights up
and an alarm buzzer sounds. Identify the fault, rectify the fault immediately or
inform WIRTGEN Customer Service
3.02.02 Switching off the diesel engine MARGIN
 Move the multi-function joystick to "0" (the diesel engine speed drops to idling
speed) and let the engine run without load in order to cool down.
NOTE
If the engine is switched off immediately after running at full load, it can over-
heat, resulting in increased wear of parts.
Excessive temperatures in the middle part of the turbocharger result in carbonis-
ing of oil.
MARGIN
 Press the red diesel engine STOP button and hold until the diesel engine has
stopped.

Operation
Diesel engine
MARGIN
 Set electrical power supply to "OFF".

 Remove the ignition key.
NOTE
Only turn key to OFF position and remove with diesel engine shut down.
MARGIN
EMERGENCY STOP switches must only be used in case of an emergency and

not for normally switching off the engine.
NOTE
If the diesel engine is switched off with the EMERGENCY STOP button:
 Mechanical components are exposed to increased wear.
 Electrical and hydraulic components may be damaged.
3.02.03 Starting with jump leads

1. Preparation MARGIN
 Ensure that the batteries have same nominal voltage.

 Use jump leads with insulated pole clamps and a cross section of at least 25
mm².
 The pole clamps of one cable must not touch those of the other cable.
 Do not disconnect a discharged battery from the electrical system of the vehi-
cle.
 The vehicle providing the jump start and the vehicle receiving the jump start
must not touch each other.

Operation
Diesel engine
2. Connecting the cables

 Set the electrical power supply of the vehicle receiving the jump start to OFF.
 First connect the positive cable to the positive terminal [+] on the external
power source.
 Connect the other end of the positive cable to the positive connection [+] pro-
vided (pull off protective cap).
 Then connect the negative cable to the negative terminal [+] on the external
power source.
 Connect the other end of the negative cable to the negative connection [ - ]
provided. NOTE
Do not connect the [ - ] pole clamp to the negative pole of the discharged battery
(risk of explosion), but as far away from the discharged battery as possible.
Position the cables so that they will not be seized by rotating parts and can be
removed later when the diesel engine is running.
3. Starting
 Start the diesel engine of the vehicle providing the jump start and run it at
medium engine speed.
 Start the diesel engine of the vehicle receiving the jump start after about 5
minutes.
 Let both diesel engines run for at least 3 minutes at medium engine speed
with connected jump leads.

Operation
Operator's stand
4. Removing the jump leads
 In order to prevent overloads in the electrical system before removing the

jump leads, switch on an electrical load on the vehicle receiving the jump
start (e.g. headlight, fan).
 Remove the jump leads in the same way in the opposite working procedure.
 After the jump leads have been removed, return the protective cap to the
positive connection [ + ].

3.03.01 Cabin / air conditioner / heater
Air-conditioning/ventilation/ The air conditioner functions as a ventilation system. Fresh air is always sup-
heating system plied via the heater. The best cooling effect is achieved if doors and windows of
the cabin are closed.
WIRTGEN recommends an air temperature of approximately 22°C within the
cabin. For extremely high ambient temperatures the internal temperature should
not be lower than 6°C below ambient temperature (e.g. for an ambient tempera-
ture of 32°C the internal temperature should not be cooled to lower than 26°C).
The cabin door should be opened for 2 - 3 minutes before the air conditioner is
switched on in order to allow warm air (accumulated heat) to escape from the
cabin. Close the door subsequently.
MARGIN
Device
 Press the button = device ON
 Press the button again = device OFF

Operation
Operator's stand
MARGIN
Air conditioner / heater

 Press the button = activate manual operational mode - change over between
heating and air-conditioning operational modes (in re-heat mode, air condi-
tioner OFF / ON)
 Press the button again = activate heater operation
MARGIN
Fan
 Press the button = change over from manual to automatic blower operation
(activate manual blower adjustment)
 Press the button again = change over from automatic to manual blower oper-
ation
MARGIN
Nominal temperature / blower speed

 Press the top button = increase nominal temperature / blower speed
 Press the bottom button = reduce nominal temperature / blower speed

Operation
Operator's stand
MARGIN
Re-heat (dehumidify)
 Press the button = re-heat operation ON
 Press the button again = re-heat operation OFF
MARGIN
Air conditioner/blower control

 Press the button = activate fully automatic operational mode (automatic oper-
ational mode selection as well as automatic blower control)
MARGIN
Air flow nozzles

 Adjust the air flow nozzles such that air does not blow directly onto the ma-
chine operator.

Operation
Operator's stand
MARGIN
Front window wiper

 Press the top of the rocker switch = window wiper ON
 Press the top of the rocker switch again = window wiper OFF
MARGIN
Front window washer

 Press and hold the bottom of the rocker switch = window washer ON
 Release the bottom of the rocker switch = window washer OFF
MARGIN
Side window wiper


Operation
Operator's stand
MARGIN
Side window washer

MARGIN
Rear window wiper

MARGIN
Rear window washer


Operation
Operator's stand
Cabin heater (without air

conditioner)
MARGIN
Fan
 Rotary knob to MIN = weak air flow
 Rotary knob to MAX = strong air flow
MARGIN
Heater (heating power)

 Set rotary knob to MIN = no heating power
 Set rotary knob to MAX = maximum heating power
3.03.02 Exterior lighting

Operation
Operator's stand
MARGIN
 Press the rocker switch stage 1 = lighting circuit 1 ON (lamps for cabin front
top, lamps for wheel consoles rear)
MARGIN
 Press the rocker switch stage 2 = lighting circuit 2 ON (lamps for cabin front
top, lamps for wheel consoles rear, lamps for chassis rear right/left, lamps for
chassis front right/left)
MARGIN
 Press the rocker switch left = lighting circuits 1 and 2 completely OFF
Welcome & go home light MARGIN
 Press the button = lighting "X" ON (lamp in cabin, lamp in front area lifting
columns, lamp in rear area lifting columns)
 Press the button again = lighting "X" OFF
NOTE
The "welcome & go home light" remains lit for max. 2 minutes (even when the
electrical power supply is switched off).

Operation
Operator's stand
[1] Camera (outside area left) [2] Camera (milling drum / milling drum scraper
front area)
[3] Camera (milling drum / milling drum scraper rear [4] Camera (area behind the machine / reverse
area) travel)
WARNING
Danger of injury
Camera and monitor systems must not be used as safety devices to detect per-
sons or obstacles.
A system of this kind is only allowed to be used for observing the front and rear
milling drum scrapers (CAM 2+3), the left side of the machine (CAM 1) and/or for
quality control of the working result, or during reverse travel (CAM 4).
During reverse travel (CAM 4), the machine outlines can project beyond the dis-
played lines depending on the situation.
Persons or obstacles could be overlooked. Risk of fatal injury.
 Use an assistant to monitor danger areas.
 Camera and monitor systems must not be used to safeguard the danger
area.

Operation
Operator's stand
 Adjust the monitor so that no reflections occur.
Camera 4 (rear area) Reversing camera / reversing assistant

Operation
Operator's stand
MARGIN
 This camera supplies pictures of what is happening behind the machine.

 The picture from camera 4 is shown automatically on the display during re-
verse travel.
 As assistance for the driver, orientation lines (reversing assistants) are also
projected onto the reversing picture.
 The long orientation lines (A) in the travel direction are an extension of the
machine transport width (rear area of the machine) by approx. 9 m to the
rear.
 The short orientation lines (B1 … B3) crossways to the travel direction are
used for estimating distances; line B1 is about 1 m behind the machine. Line
B2 is about 3 m behind the machine and line B3 is about 9 m behind the ma-
chine.
 Depending on the set steering mode and the selected steering angle, the ori-
entation lines display the path of the machine in the travel direction. It should
be noted that the accuracy of the orientation lines directly behind the machine
(B1) is greater and declines correspondingly with increasing distance (B3).
 The orientation lines are only displayed in the automatic steering modes
(CRAB, FRONT, COORDINATE).
 The orientation lines are hidden during manual steering of the rear wheels.
 After the rear wheels have driven through the obstacle or the bottleneck, ob-
serve further passage of the entire machine through the bottleneck (e.g. us-
ing the rear-view mirrors).
 Familiarise yourself with the function of the reversing assistant in a safe area.
The lighting and visibility conditions should be good.

Operation
Operator's stand
MARGIN
 scanned area
MARGIN
 non-scanned area
NOTICE
 Camera 4 does not record the area under the machine, in particular it does
not capture the area between the milling drum housing and the rear wheels.
 The reversing assistant is not a safety device for detecting people or obsta-
cles.
 Appoint a look-out in order to monitor areas that cannot be viewed, or for
which visibility is poor.
 The reversing assistant does not replace the requirement for the operator to
remain attentive. Responsibility during reverse travel and comparable ma-
noeuvres lies exclusively with the operator.
 The operator must always keep the entire area around the vehicle in view, in-
cluding by use of the rear-view mirrors.
 The reversing camera and reversing assistant should only be used as assis-
tance when they provide a good, clear image. Oncoming light, darkness or
dirt can impair the image, for example.
 If the position or the installation angle of the camera is changed (e.g. dam-
age) then the reversing assistant is no longer allowed to be used (for rea-
sons of safety). The system must then be checked by trained Wirtgen Service
technicians.

Operation
Operator's stand
NOTICE
Objects can appear nearer or further away in the display, if:
 The vehicle is reversing from a horizontal surface down or up a slope.
 The vehicle is reversing towards projecting objects (e.g. objects that are not
touching the ground, such as trailer couplings, etc.).
NOTICE
The accuracy of the orientation lines is reduced if:
 Objects are further back behind the machine.
 The camera does not provide a reliable image (poor visibility conditions, cont-
aminated lens, etc.).
 The image cannot be seen due to sunshine falling on the display or the lens
at an unfavourable angle.
Camera 3 (area of rear milling

drum scraper)
MARGIN
 This camera shows when obstacles in the track have been overcome, and is
used for assessing the quality of the placed material.

Operation
Operator's stand
Camera 2 (area of front

milling drum scraper)
MARGIN
 This camera shows obstacles or binder spread in front, and allows accurate
overlapping with the working edge as well as precise starting.
Camera 1 (area of left side of

the machine)
MARGIN
 This camera is used for precisely approaching limits at the side, for example.

Operation
Operator's stand
Camera positions
It is possible to switch over between the different camera areas on the monitor
display
. . . either MARGIN
 Press the "Camera" button on the monitor and change over to the required
viewing area
or . . . MARGIN
 Press the "Camera" button on the multi-function joystick and change over to
the required viewing area

Operation
Milling drum unit

3.04.01 Milling drum rotation speed
Overview screen (milling Depending on the working conditions, the milling drum rotation speed can be
drum rotation speed sticker) changed by varying the arrangement of drive belt pulleys as well as the diesel
engine speed.
For the individual speeds, please refer to the sticker affixed in the cover.
The outlined arrangement of drive belt pulleys and the rotation speeds refer to
the basic setting.

Operation
Milling drum unit
Exchanging drive belt pulleys Basic requirement:

 The milling drum is not allowed to have any ground contact.
 The diesel engine is switched off and safeguarded against unauthorised
starting (withdraw ignition key).
 Open the front cover.
 Open the middle cover.

Operation
Milling drum unit
 Remove the protective cover at the rear (loosen and remove the screws).
 Removing drive belts

Operation
Milling drum unit
 Change drive belt pulleys to achieve required speed.

NOTE
When loosing the screws, use the supplied installation pin "X" to prevent the
drive belt pulleys from turning.
 Fit drive belts NOTE
It is essential to ensure proper seat of the drive belts.

Operation
Milling drum unit
Adjusting the tensioner roller stopper
 Undo counter nut and adjust tensioner roller using the adjusting screw such
that the drive belts cannot touch the cover or jump out of the grooves in the
untensioned state.
 Tighten counter nut.
 Install the protective cover at the rear (screw in and tighten the screws).

Operation
Milling drum unit
 Close and lock the middle and front covers.
3.04.02 Milling drum scraper rear NOTE
The rear milling drum scraper can be operated in 2 operational modes:

Milling drum scraper "locked"
Milling drum scraper "floating"
MARGIN
Milling drum scraper "locked"

 Press the button until the green LED goes out.
 After opening or closing the milling drum scraper remains in the respective
position and is secured.
 Application: e.g. tool exchange, other maintenance work on the milling drum.
MARGIN
Milling drum scraper "floating"

 Press the button until the green LED lights up.
 The milling drum scraper is always driven towards the "closed" position due
to the set cylinder pressure, but can open independently if corresponding
counter pressure from the material is experienced. Application: e.g. automatic
smoothing / planing of ground or mixed material.
Setting the pressure MARGIN
 Select the adjacent screen (3.1.1.5).

 Select the "Nominal pressure milling drum scraper" field with the adjuster.
 Set contact pressure 0-100%.

Operation
Milling drum unit
NOTE
Work in the milling drum area must only be performed if both switches "Tool
exchange" (diesel engine control panel / tool exchange control panel) are
switched to ON.
MARGIN
MARGIN
 Move both key switches to "Tool exchange ON"
NOTE
The milling drum scraper is only allowed to be opened or closed when locked.
MARGIN
MARGIN
Opening the milling drum scraper

 Press the button and hold it until the required position has been reached.
MARGIN
Closing the milling drum scraper

 . . . or during on-site operation.

Operation
Milling drum unit
MARGIN
 . . . Set the milling drum scraper to "Floating" (the green LED lights up).
MARGIN
The respective position of the milling drum scraper can be seen on the display.
3.04.03 Milling drum scraper front MARGIN
Opening the milling drum scraper

NOTE
A crusher bar is activated when the front milling drum scraper is closed. The
closer the bar is moved to the milling drum, the smaller the particles will be.
MARGIN
Closing the milling drum scraper

MARGIN
The respective position of the milling drum scraper can be seen on the display.

Operation
Milling drum unit
3.04.04 Automatic starting/lifting-out function

Set the automatic starting
function Milling depth MARGIN

 Select the "Milling depth starting" field with the adjuster.
 Set milling depth.
Milling drum scraper front MARGIN

 Select the "Front milling drum scraper starting position" field with the adjuster.
 Set position for starting.
Milling drum scraper rear MARGIN

 Select the "Rear milling drum scraper starting position" field with the adjuster.
 Set position for starting.
Set the automatic lifting-out

function Front milling drum scraper (forwards travel)
MARGIN

 Select the "Front milling drum scraper lifting out forwards" field with the ad-
juster.
 Set position for lifting out.
Rear milling drum scraper (forwards travel)

MARGIN

 Select the "Rear milling drum scraper lifting out forwards" field with the ad-
juster.

Operation
Milling drum unit
Distance (forwards travel) MARGIN

 Select the "Distance automatic lifting-out function forwards" field with the ad-
juster.
 Set required distance for lifting out.
Front milling drum scraper (reverse travel)

MARGIN

 Select the "Front milling drum scraper lifting out backwards" field with the ad-
juster.
Rear milling drum scraper (reverse travel)

MARGIN

 Select the "Rear milling drum scraper lifting out backwards" field with the ad-
juster.
Distance (reverse travel) MARGIN

 Select the "Distance automatic lifting-out function backwards" field with the
adjuster.
 Set required distance for lifting out.
Front milling drum scraper (automatic end)

MARGIN

 Select the "Front milling drum scraper automatic end" field with the adjuster.
 Set position for ending automatic.
Rear milling drum scraper (automatic end)

MARGIN

 Select the "Rear milling drum scraper automatic end" field with the adjuster.
 Set position for ending automatic.

Operation
Milling drum unit
Operation of the automatic The automatic starting function is used to easily achieve a pre-defined milling
starting function depth when the machine is applied to a new job.
First of all, the machine goes down rapidly, and the front and rear milling drum
scrapers move to the preselected positions. When the lifting columns are in the
working position, the milling drum is moved down into the ground until reaching
the programmed working depth. Pressing the joystick forwards causes the ad-
vance movement to be released.
MARGIN
 The 3 indicators on the working screen appear with an orange background.
MARGIN
 Press the automatic starting/lifting-out function button - the green LED

flashes . The automatic starting function is in stand-by for 5 seconds.
MARGIN
 The 3 indicators in the working screen now change to a white background.
MARGIN
 Press the bottom of the rocker switch within the 5 seconds and hold - whilst
the rocker switch is being held, the green LED lights continuously.
 The machine moves down to the lower end position - at the same time,
the milling drum scrapers move to the preset position.

MARGIN
 The 3 indicators in the working screen now change from a white to an orange
background - depending on the current position of the individual elements
(progress bar).
MARGIN
 When the milling drum is lowered to the preset milling depth with the joystick,
the rear milling drum scraper is automatically at FLOATING - the green LED
lights up.

Operation
Milling drum unit
MARGIN
 Continue to hold the rocker switch - the green LED continues to be lit.
 The milling drum is lowered to the preset milling depth.
MARGIN
 When the preset milling depth is reached, the green LED goes out.
MARGIN
 Once all elements have reached the present position, the 3 indicators in the
working screen appear with an orange background.
Operation of the automatic The automatic lifting-out function is used for closing the incision that is produced
lifting-out function at the end of each track in the area of the milling drum.
The milling drum scrapers move to the required positions, depending on whether
lifting out is taking place forwards or backwards.
A milling drum scraper closes the incision completely while the machine con-
tinues to move for a few metres. At the same time, the milling drum is lifted out
slowly and the lifting columns move the machine to the transport position.
MARGIN
 The 3 indicators on the working screen appear with an orange background.
MARGIN
 Press the automatic starting/lifting-out function button - the green LED

flashes . The automatic lifting-out function is in stand-by for 5 seconds.
MARGIN
 The 3 indicators in the working screen now change to a white background.

Operation
Milling drum unit
MARGIN
 Press the top of the rocker switch within 5 seconds - the green LED is contin-
uously lit.
MARGIN
 Move the machine forwards or in reverse - depending on the situation on site.

 The milling drum scrapers remain in the preset position.
 The milling drum is lifted out of the cut over the predefined travel.
 Once the milling drum is in the uppermost position, the height adjustment
moves to the upper end position and the milling drum scrapers move to the
"auto end" position.
MARGIN
 The 3 indicators in the working screen now change from a white to an orange
background - depending on the current position of the individual elements
(progress bar).
MARGIN
 Once all elements have reached the present position, the 3 indicators in the
working screen appear with an orange background.
3.04.05 "0" position

Setting up the zero setting
NOTICE
The machine must be standing on a level sub-base, horizontal in the lateral and
longitudinal directions.
Switch on the milling drum drive
WARNING
Milling drum drive must only be switched on with the milling drum lifted and run-
ning free.
Milling drum drive must only be switched on with engine speed at MIN.

Operation
Milling drum unit
MARGIN
(minimum speed)
 Turn the button to the right until the LED in question lights up.
Lower the machine MARGIN
 Press the rocker switch down and hold it until the machine has lowered com-
pletely.
Lowering the milling drum MARGIN
 Turn the rotary button forwards and hold it until the milling drum lightly
scrapes the surface to be milled on both sides.
Zero the milling depth value MARGIN
MARGIN
 Press key F2 "SET".

 Set value to "0".

Operation
Milling drum unit
End setting-up MARGIN
 Turn the rotary button to the rear and hold it until the milling drum has
reached the required height.
MARGIN
Switching off the milling drum drive

 Turn the button to the left until the LED in question goes out
MARGIN
 Press the rocker switch up and hold it until the machine has moved up com-
pletely.
3.04.06 Milling depth NOTE
If you do not want the milling depth to selected using the automatic starting/lift-
ing-out function then the milling drum can be raised/lowered manually.
Raise/lower the milling drum MARGIN
 Turn the rotary button to the front and hold it until the milling drum has
reached the required depth.
 Turn the rotary button to the rear and hold it until the milling drum has
reached the required height.

Operation
Milling drum unit
3.04.07 Milling drum drive

Switch on the milling drum
drive
WARNING
Milling drum drive must only be switched on with the milling drum lifted and run-
ning free.
Milling drum drive must only be switched on with engine speed at MIN.
MARGIN
(maximum speed)
 Turn the button to the right until the LED in question lights up
MARGIN
(medium speed)
MARGIN
(minimum speed)
MARGIN
Switching off the milling drum drive

 Turn the button to the left until the LED in question goes out

Operation
Milling drum unit
3.04.08 Milling drum rotation device NOTE
The control panel is fitted with a magnetic clamp and should be positioned within
reach of the operator.
After completing the check of the milling drum or changing the picks, the control
panel must be dismantled and stowed away properly.
The "Milling drum rotation device" control panel is only active approximately 20
seconds after switching on tool exchange (via the "diesel engine control" control
panel and via the "tool exchange" control panel).
MARGIN
Turn milling drum to the right

 Press the button - the milling drum turns for a maximum of 4 seconds, there-
after the button must be pressed again.
MARGIN
Turn milling drum to the left

 Press the button - the milling drum turns for a maximum of 4 seconds, there-
after the button must be pressed again.
MARGIN
Turn the milling drum with the pick ejector drift

MARGIN
various functions of the two buttons

 press the left button (in machines with a milling drum rotation device):
 The milling drum turns slowly "anti-clockwise".
 press the right button (in machines with a milling drum rotation device):
 The milling drum turns slowly "clockwise".
 press both buttons at the same time (depending on the machine equipment):
 The diesel engine is switched off.

Operation
Travelling / steering
3.05 Travelling / steering

3.05.01 Travelling
Set the speed limit MARGIN

 Select the "Speed limit" field with the adjuster.
 Set speed limit in %.
NOTE
Shifting gears between "Low working speed" <--> "Maximum working speed" or
"Low travelling speed" <--> "Maximum travelling speed" can be done while trav-
elling.
Shifting gears between "Maximum working speed" <--> "Low travelling speed"
should only be done when the machine is stationary.
Machine accelerates / decelerates automatically.
Select travelling speed MARGIN
 Press the rocker switch and set the required travelling gear (see the particu-
lar green LED).
MARGIN
Low working speed = green LED "tortoise 1" lights up.

Maximum working speed = green LED "tortoise 2" lights up.
Low travelling speed = green LED "hare 3" lights up.
Maximum travelling speed = green LED "hare 4" lights up.

Operation
MARGIN
 The joystick is equipped with an electrical central position lock.

 For travelling, the interlock key must be pressed and held until the joystick
has been pushed forward or pulled backward out of the "0" position. The in-
terlock key can be released as soon as the joystick is out of the "0" position.
 The further the joystick is pushed forward or pulled backward from the central
position, the faster the machine travels.
 The joystick does not automatically return to the central position.
Travelling forward MARGIN
 Press the interlock key and push the joystick forward until the required speed
is reached.
 The diesel engine speed automatically adjusts to the selected joystick posi-
tion during travel.
 If the joystick is in the "0" position then the diesel engine speed drops to
"idling speed".
 If the joystick is in the "0" position, the parking brake is activated - the "P"
symbol lights up red; if the joystick is moved out of the "0" position, the park-
ing brake is deactivated - the "P" symbol goes out.

Operation
Travelling reverse MARGIN
 Press the interlock key and pull the joystick backwards until the required
speed is reached.
 The diesel engine speed automatically adjusts to the selected joystick posi-
tion during travel.
 If the joystick is in the "0" position then the diesel engine speed drops to
"idling speed".
 If the joystick is in the "0" position, the parking brake is activated - the "P"
symbol lights up red; if the joystick is moved out of the "0" position, the park-
ing brake is deactivated - the "P" symbol goes out.
Using speed control MARGIN
 Press the button = speed control active.

 Press the button gain = speed control inactive.
NOTE
Travelling on open ground

When working or travelling on extremely uneven open ground, the machine must
be lowered at the front to approximately 150 mm (+100) below maximum height
in order to allow sufficient pendulum stroke.
MARGIN
Before starting on a downhill route, the advance drive must absolutely be

switched to WORKING SPEED, e.g.: during normal hill descent at Maximum
working speed = green LED "tortoise 2" lights up. . .
. . . or
. . . during extreme hill descent at Low working speed = green LED "tortoise 1"
lights up. The speed must be adapted to the conditions of the open ground.

Operation
Moving off forward on steep ground

The parking brake can be used in order to prevent the machine from rolling
backward when moving off on steep ground.
MARGIN
 Press and hold the button - the parking brake is activated - the "P" symbol
lights up red; press the locking button at the same time and carefully push the
joystick forward. As soon as the machine moves, release the button - the "P"
symbol goes out.
Set differential lock (flow distributor)

MARGIN
 Press the button = differential lock active (the green LED lights up).
MARGIN
 Press the button again = differential lock inactive (the green LED goes out).
3.05.02 Engine load control (ELC)

Setting the engine load limit
speed Switch on/off MARGIN

 Select the "Engine load control" field with the adjuster.
 Switch engine load control on (activate box) or off (deactivate box).

Operation
Sensitivity MARGIN

 Select the "ELC sensitivity" field with the adjuster.
 Set sensitivity.
Engine load limit speed MARGIN

 Select the "ELC speed 1" field with the adjuster.
 Set engine load limit speed 1.
MARGIN

MARGIN

NOTE
If the diesel engine is forced below the set speed, the speed is automatically re-
duced until the diesel engine again runs at the set speed.
3.05.03 Steering
Set the fine tuning at rear MARGIN

 Select the "Fine tuning at rear straight running" field with the adjuster.
 Set fine tuning for straight running (rear wheels) in degrees °.
Set the steering speed MARGIN

 Select the "Steering speed" field with the adjuster.
 Set steering speed manually in %.

Operation
Front wheels
MARGIN
 Steering the front wheels with the steering wheel.
Rear wheels (manual) MARGIN
 Push the joystick to the right.

 The rear wheels steer for a right-hand curve.
MARGIN
MARGIN
 Push the joystick to the left.

 The rear wheels steer for a left-hand curve.

Operation
"Steering FRONT" function MARGIN
MARGIN
MARGIN
 Press the rocker switch forwards (the corresponding green LED lights up).
 The rear wheels automatically turn to straight ahead. When steering the
front wheels with the steering wheel, the rear wheels remain in the straight
ahead position.
 After manual steering of the rear wheels with the joystick, they swivel back
to the straight-ahead position.

Operation
"COORDINATE" function MARGIN
MARGIN
MARGIN
 Press the rocker switch to the left (the corresponding green LED lights up).
 When steering the front wheels with the steering wheel, the rear wheels
steer in the opposite direction.
 After manual steering with the joystick, these return to the position of the
set steering mode.

Operation
"CRAB" function MARGIN
MARGIN
MARGIN
 Press the rocker switch to the right (the corresponding green LED lights up).
 When steering the front wheels with the steering wheel, the rear wheels
steer parallel to the front wheels.
 After manual steering with the joystick, these return to the position of the
set steering mode.

Operation
"Automatic off" function MARGIN
MARGIN
 Press the rocker switch backwards (all green LEDs go out) - steering of the
front and rear wheels is independent of one another.
 After manual steering of the rear wheels with the joystick, they remain in the
steered-to position.

Operation
Steering beyond the end Depending on the operating conditions, the machine can be steered beyond the
position (rear wheels) perceived stop (e.g. manoeuvring in a field with restricted dimensions, etc.).
Basic requirement:
COORDINATE steering mode is switched on.
MARGIN
 Depending on the situation, turn the steering wheel to the right or left as far
as the perceived stop - by applying increased force, it is now possible to
steering the rear wheels beyond the position.

Operation
3.05.04 Towing away NOTE
In an emergency, in particular for recovery, the machine can be towed out of the
danger zone. For this purpose the machine's disc brakes must be released.
 The machine is allowed to be towed max. 300 m.
 The maximum towing speed is 5 m/min.
Safety instructions During towing the applicable safety regulations and the health and safety regula-
tions must be followed.
On towing away a machine without brakes, a rigid connection, e.g. towing bar,
must be used. The machine is only allowed to be moved by another vehicle
once it is securely connected to the towing vehicle. The usage of loose objects
for pushing, such as plungers, bolts, is not allowed.
Requirements  The machine operator is at the operator's stand.

 The operator of the towing vehicle, the machine operator and any necessary
assistants must remain in visual contact during the entire towing process.
 The diesel engine is not in operation.
 The hydraulic system (hoses, pumps, motors etc.) is correctly filled with hy-
draulic oil.
 A suitable towing vehicle is available.
 Towing bars with adequate strength are to be used.
 The milling drum is to be raised such that it will not come into contact with the
ground during the entire towing process.
NOTICE
If the diesel engine is switched off, the machine can only be steered using
the optional electro-hydraulic unit.
Operation of the electro-hydraulic unit

MARGIN
 Switch on electrical power supply
MARGIN
 Select screen (4.4.0) - press key F1 - the adjacent indicator must light up
green = electro-hydraulic unit is switched on.
MARGIN
 Change the position of the ball cock on the electro-hydraulic unit (as shown).

Operation
MARGIN
 Move the steering wheel - slowly -; as soon as the steering wheel is moved,
the electro-hydraulic unit switches itself on automatically.
NOTE
In addition, all "zero stroke" functions can be operated:

- Height adjustment
- Milling drum up / down
- Milling drum scraper up / down
MARGIN
Unlocking advance drive Unlocking the advance drive and releasing the wheel brakes is only allowed to
be done after the machine has been secured against unintentional rolling away.
The brakes of the machine are released with the following steps. First check
whether the machine has been attached to a towing vehicle.
WARNING
Warning about risk of crushing
Inactive brakes. An inadequately secured machine may become detached from
the towing vehicle.
Machine may hit people. Risk of serious injury with mortal consequences.
 Therefore first check whether the machine is securely fastened to a towing
vehicle.

Operation
Starting the towing process Step 1
 Unlatch the cover panel, open it up to the stop and secure it.

Operation
Step 2
 Connect the pressure gauge contained in the scope of supply of the machine
to the mini measuring connector.
Step 3
 Remove the dust caps from the hydraulic connections and connect the hy-
draulic hoses together.

Operation
Step 4
 Press in brake release device.
Step 5a
 Open all high-pressure valves of the advance pump (2 valves).

 The following step describes the opening of a high pressure valve. Opening
of the other valve is done accordingly with the same working procedure.

Operation
Step 5b
 Unscrew the counter nut using a 32 mm open-end wrench.

 Unscrew the high-pressure valve using a 36 mm open-end wrench approx.
2-3 turns.
 Tighten the counter nut again.
Step 6
 Operate hand pump several times until a pressure of min. 25 to max. 40 bar
is reached (can be read off on the pressure gauge).
 The machine can now be pulled out of the danger zone.

Operation
Completing the towing Step 1a

process
 Close all high-pressure valves of the advance pump (2 valves).

 The following step describes the closing of a high pressure valve. Closing of
the other valve is done accordingly with the same working procedure
Step 1b
 Unscrew the counter nut using a 32 mm open-end wrench.

 Screw in the high-pressure valve using a 36 mm open-end wrench as far as
the stop, and tighten.
 Tighten the counter nut again.

Operation
Step 2 (if the diesel engine cannot be started)
 Pull out brake release device.

NOTE
Only disconnect the coupling with the towing vehicle if the brake release device
has been removed.
The brake release device automatically jumps back to its original position if the
diesel engine can be started.
Observe the pressure gauge. The pressure must drop off, otherwise the brakes
will not function.
Step 3
 Decouple the hydraulic hoses and close the hydraulic connections with the
dust caps.

Operation
Step 4
 Disconnect the pressure gauge from the mini measuring connector.

Operation
Step 5
 Lift the cover panel slightly and unlock, fold it closed and lock.
MARGIN
 Select screen (4.4.0) - press key F1 - the adjacent indicator must light up
grey = electro-hydraulic unit is switched off.

Operation
Height adjustment / levelling
MARGIN
 Switch off the electrical power supply
3.06 Height adjustment / levelling

3.06.01 Lifting / lowering machine
Set the stroke limitation All crawler units (top) MARGIN

 Select the "Stroke limitation top" field with the adjuster.
 Set new limit position.
Lifting the machine

completely
 Push the joystick forward and hold it until the required height has been
reached. NOTE
After releasing the joystick, the machine remains at the set level.

Operation
Raise the machine at the

front on both sides only
 Push button (1); at the same time, push the joystick forward and hold it until
the required height has been reached.
NOTE
Lower the machine at the

front on both sides only
 Push button (2); at the same time, push the joystick forward and hold it until
the required lowering has been achieved.
NOTE
Lowering the machine

completely
 Pull the joystick backwards and hold it until the required lowering has been
reached. NOTE

Operation
Raise the machine at the rear

only
 Push button (1); at the same time, pull the joystick backward and hold it until
the required height has been reached.
NOTE
Lower the machine at the rear

only
 Push button (2); at the same time, pull the joystick backward and hold it until
the required lowering has been achieved.
NOTE
Roll the machine to the left

about the middle longitudinal
axis
 Push the joystick to the left and hold it until the required position has been
reached. NOTE

Operation
Raise the machine on the left

only
 Push button (1); at the same time, push the joystick to the left and hold it until
the required position has been reached.
NOTE
Lower the machine on the left

only
 Push button (2); at the same time, push the joystick to the left and hold it until
the required position has been reached.
NOTE
Roll the machine to the right

about the middle longitudinal
axis
 Push the joystick to the right and hold it until the required position has been
reached. NOTE

Operation
Raise the machine on the

right only
 Push button (1); at the same time, push the joystick to the right and hold it
until the required position has been reached.
NOTE
Lower the machine on the

right only
 Push button (2); at the same time, push the joystick to the right and hold it
until the required position has been reached.
NOTE

Operation
Overrunning the end position Depending on the operating conditions, the machine can be raised beyond the
electrically interlocked end position (e.g. for loading onto a low-loader).
NOTICE
The pendulum stroke is inoperative in this case.
 Push the joystick forwards and hold it for about 5 seconds until the machine
is completely raised. NOTE
3.06.02 Slope regulation

Set slope MARGIN

 Select the "Zero slope nominal value" field with the adjuster.
 Set value to "0".
MARGIN

 Select the "Slope nominal value" field with the adjuster.
 Enter required value in %.

Operation
Milling depth regulation with

slope sensor
Slope left MARGIN
 Press the SLOPE button to the left (the green LED lights up) = slope left ac-
tive.
 The machine operates with the preset slope on the left side and with the
preset milling depth on the right side.
MARGIN
 Press the SLOPE button to the left again (the green LED goes out) = slope
left inactive.

Operation
Slope right MARGIN
 Press the SLOPE button to the right (the green LED lights up) = slope right
active.
 The machine operates with the preset slope on the right side and with the
preset milling depth on the left side.
MARGIN
 Press the SLOPE button to the right again (the green LED goes out) = slope
right inactive.
 The actual slope value is displayed on the working screen in "%".
3.06.03 Ground clearance

Adjust ground clearance
(bottom - working position) Front (left bottom) MARGIN

 Select the "End position front bottom left" field with the adjuster.

Operation
Dosing unit
Front (right bottom) MARGIN

 Select the "End position front bottom right" field with the adjuster.
Rear (bottom) MARGIN

 Select the "End position rear bottom" field with the adjuster.
Adjust ground clearance (top

- transport position) Front and rear (both sides) MARGIN

 Select the "Stroke limitation top" field with the adjuster.
3.07 Dosing unit

3.07.01 Basic settings
Before starting on-site operation, various basic settings must be per-
formed.
1. Pre-setting nominal values (e.g. depth, width, density, etc.) - specified by the
client.
2. Pre-setting the binder addition rate (in % by weight) - specified by the client.
3. Pre-setting the spraying nozzles (open or close the spraying nozzles accord-
ing to the required working width).

Operation
Dosing unit
General MARGIN
 Set the dosing unit switch (engine control unit panel) to ON
MARGIN
 The on-board computer display changes from the entry screen (1.1.0) to the
dosing unit screen (7.1.1).
MARGIN
 Press key F4.
MARGIN
 Screen (3.5.1.1) appears.

 Select the "Density ground" field with the adjuster.
 Set density in kg/m3.
MARGIN

 Select the "Milling depth auto mode" field with the adjuster.
 Switch automatic milling depth on (activate box) or off (deactivate box).
MARGIN
 Select the adjacent screen (3.5.1.3) - if the automatic milling depth function is
switched off.
 Select the "Milling depth manual" field with the adjuster.
 Set milling depth.

Operation
Dosing unit
Pre-setting for water injectionMARGIN
 Press the ESC key.
MARGIN
 Screen (7.1.1) appears again.
MARGIN
 Press key F1.
MARGIN
 Screen (7.2.1) appears.

 Select the "Nominal value automatic" field with the adjuster.
 Enter the required feed volume of water in % (if you want to work in auto-
matic mode).
MARGIN

 Select the "Nominal value manual" field with the adjuster.
 Enter the required feed volume of water in % (if you want to work in manual
mode).
MARGIN

 Select the "Milling width mode" field with the adjuster.
 Select automatic mode (the spraying width is calculated automatically based
on the opened spraying nozzles).
 . . . or (select manual mode if the milling width is specified manually)
MARGIN

 Select the "Milling width" field with the adjuster.
 Enter the milling width (if the spraying width should not be calculated auto-
matically).

Operation
Dosing unit
MARGIN

 Select the "Option 800 litres" field with the adjuster.
 Activate the box (if you want to work with the 800 litre pump).
 . . . or
MARGIN

 Select the "Option 1800 litres" field with the adjuster.
 Activate the box (if you want to work with the 1800 litre pump).
NOTE
"Option 1800 litres" means that the machine is equipped with a large
pumping system.
Please check which system is fitted in your machine.
Pre-setting for bitumen spraying

MARGIN
 Press the ESC key.
MARGIN
 Screen (7.1.1) appears again.
MARGIN
 Press key F2.
MARGIN
 Screen (7.3.1) appears.

 Select the "Nominal value automatic" field with the adjuster.
 Enter the required feed volume of bitumen in % (if you want to work in auto-
matic mode).

Operation
Dosing unit
MARGIN

 Select the "Nominal value manual" field with the adjuster.
 Enter the required feed volume of bitumen in % (if you want to work in man-
ual mode).
MARGIN

 Select the "Bitumen water" field with the adjuster.
 Enter the required feed volume of bitumen water in %.
MARGIN

 Select the "Milling width mode" field with the adjuster.
 Select automatic mode (the spraying width is calculated automatically based
on the opened spraying nozzles).
 . . . or (select manual mode if the milling width is specified manually)
MARGIN

 Select the "Milling width" field with the adjuster.
 Enter the milling width (if the spraying width should not be calculated auto-
matically).
MARGIN
 Press key F2.
MARGIN
 Switch the heater on/off.
NOTE
The heater should be switched on at least 1/2 hour before startup.

Operation
Dosing unit
MARGIN
 Press key F3.
MARGIN
 Switch the compressed air on/off.
NOTE
The spraying nozzles should be cleaned before the dosing units are
started up.
To do this, it is essential to switch off the milling drum drive.
MARGIN
 Press key F4.
MARGIN
 Carry out the cleaning procedure several times.
NOTE
It is also a good idea to give the spraying nozzles a visual check.
Pre-setting of the spraying nozzles

The spraying nozzles (depending on the equipment of the machine) must be
opened or closed according to the required spraying position for every dosing
unit.
NOTE
Press a button to operate a pair of spraying nozzles.

Press button 1x (depending on the required spraying nozzle) = automatic spray-
ing function is active.

Operation
Dosing unit
NOTE

Press button 2x (depending on the required spraying nozzle) = manual spraying
function is active.
NOTE

Press button 3x (depending on the required spraying nozzle) = spraying function
is inactive.
MANUAL mode
The spraying volume does not change with the advance speed.
Spraying starts immediately (irrespective of the position of the advance drive
lever) when a required value for binder dosing is set.
AUTOMATIC mode
The spraying volume changes with the advance speed.
Spraying (depending on the pre-set binder dosing value) starts immediately
when the milling drum drive is switched on and the advance drive lever is moved
forward from the "0" position.NOTE
On-site operations are normally performed in AUTOMATIC mode - MANUAL

mode should only be used for special assignments.

Operation
Dosing unit
3.07.02 Dosing unit I (operation)

Basic requirements:
 The basic settings have been carried out.
 Machine is in working position.
 The diesel engine is running at operating speed.
 The external filling device for water supply (800 litres) or (1800 litres) is cou-
pled.
 Nominal values for milling depth, milling width, density have been preset.
 The spraying nozzles are opened or closed according to the required working
width / spraying position.
 The milling drum is running.
 The switch ADVANCE DRIVE is set to low or maximum working speed
NOTE
The setting of shut-off valves, connectors of pumps to the spraying beams and
any possible binder addition combinations can be found in the "Description of
function" chapter.
Spraying pump operation MARGIN
 Press button "I" = dosing unit I is active (the green LED lights up).
 . . . or
MARGIN
 Press buttons "I - III" = all preset dosing units are active (the green LED lights
up).

Operation
Dosing unit
Spraying nozzles MARGIN
 Automatic mode (the selected spraying nozzles open as soon as the milling
drum is running and the machine is travelling)
MARGIN
 Manual mode (the selected spraying nozzles open as soon as the button for
the required spraying nozzle is pressed)
MARGIN
 Depending on the operating conditions, the spraying beam can be set to full
spraying width (1/1) or half spraying width (1/2) with the F1 key.
Pumps operational mode MARGIN
 Press the AUTOMATIC button = automatic operational mode ON (the green

LED lights up) - press the button again = automatic OFF.
. . . or MARGIN
 Press the MANUAL button = manual operational mode active (the green LED
lights up) - press the button again = manual OFF.
NOTE
The pump in question starts up as soon as the MANUAL key is pressed.

Operation
Dosing unit
On-site operation MARGIN
 Activate automatic starting function.

 The milling drum moves down to the preset milling depth and, at the same
time, spraying starts.
MARGIN
NOTE
Travelling speed should be at least 3 m/min.
MARGIN
 Milling depth, setting of milling drum scrapers, travelling speed and added
binder volumes are displayed permanently.
 Compare the displayed actual values with the preset nominal nominal values;
check the system if necessary.
End of on-site operation MARGIN
 Activate automatic lift-out function.

 Stop the machine and reverse.
 During the reverse travel, the milling drum is lifted slowly out of the area be-
ing processed, in accordance with the set values.

Operation
Dosing unit
3.07.03 Dosing unit II (operation)

Basic requirements:
 The basic settings have been carried out.
 Machine is in working position.
 The diesel engine is running at operating speed.
 The external filling device for emulsion or bitumen (800 litres) is coupled up.
 Nominal values for milling depth, milling width, density have been preset.
 The spraying nozzles are opened or closed according to the required working
width / spraying position.
 The milling drum is running.
 The switch ADVANCE DRIVE is set to low or maximum working speed
NOTE
The setting of shut-off valves, connectors of pumps to the spraying beams and
any possible binder addition combinations can be found in the "Description of
function" chapter.
Spraying pump operation MARGIN
 Press button "II" = dosing unit II is active (the green LED lights up).
 . . . or
MARGIN
 Press buttons "I - III" = all preset dosing units are active (the green LED lights
up).

Operation
Dosing unit
Spraying nozzles MARGIN
 Automatic mode (the selected spraying nozzles open as soon as the milling
drum is running and the machine is travelling)
MARGIN
 Manual mode (the selected spraying nozzles open as soon as the button for
the required spraying nozzle is pressed)
MARGIN
 Depending on the operating conditions, the spraying beam can be set to full
spraying width (1/1) or half spraying width (1/2) with the F1 key.
Bitumen nozzles MARGIN
 Press button 1x = each opened spraying nozzle operates (the left green LED
lights up).
MARGIN
 Press button 2x = only every other opened spraying nozzle operates (the
right green LED lights up).
NOTE
This setting is a good idea when adding small binder quantities or if the bi-
tumen pressure is low.

Operation
Dosing unit
Pumps operational mode MARGIN
 Press the AUTOMATIC button = automatic operational mode ON (the green

LED lights up) - press the button again = automatic OFF.
. . . or MARGIN
 Press the MANUAL button = manual operational mode active (the green LED
lights up) - press the button again = manual OFF.
NOTE
The pump in question starts up as soon as the MANUAL key is pressed.
Bitumen heater MARGIN
 Press the button = bitumen heater active (the green LED lights up).
NOTE
When working with foam bitumen, the unit must be at operational temperature
before startup.
On-site operation MARGIN
 Activate automatic starting function.

 The milling drum moves down to the preset milling depth and, at the same
time, spraying starts.
MARGIN
NOTE
Travelling speed should be at least 3 m/min.

Operation
Dosing unit
MARGIN
 Milling depth, setting of milling drum scrapers, travelling speed and added
binder volumes are displayed permanently.
 Compare the displayed actual values with the preset nominal nominal values;
check the system if necessary.
End of on-site operation MARGIN
 Activate automatic lift-out function.

 Stop the machine and reverse.
 During the reverse travel, the milling drum is lifted slowly out of the area be-
ing processed, in accordance with the set values.
3.07.04 Dry run sensor

Dosing unit I or II
MARGIN
The system is fitted with a dry run sensor, which is activated in case of too little
or no fluid at the flow-through meter.
The operator is informed by means of a text message on the relevant screen of
the on-board computer, switching on of the red LED and the sounding of a warn-
ing buzzer.
(here e.g. dosing unit II)
Automatic mode MARGIN
After 3 seconds, the text message appears in the preset programme language.
The pump switches off automatically after 3 seconds.

Operation
Dosing unit
Manual mode MARGIN
After 30 seconds, the text message appears in the preset programme language.
The pump switches off automatically after 30 seconds.
3.07.05 Foam bitumen consistency sample

The unit has been fitted with a separate spraying nozzle for taking foam-bi-
tumen samples in order to achieve the correct foam bitumen consistency
during on-site operation. If required, samples can be taken by means of
pre-selected values by pressing a button and can be collected in an exter-
nal container (metal bucket).
Sample extraction during on-site operation:

MARGIN
 Stop the machine (advance drive lever in "0" position).

Operation
Dosing unit
MARGIN
 Place the container for taking samples (metal bucket) underneath the spray-
ing nozzle.
 Open the maintenance flap next to the front access ladder.
 Press the button and hold until the required sample volume has been col-
lected in the bucket.
NOTE
If the foam bitumen consistency does not comply with the specification, the per-
centage bitumen / bitumen water feed must be set again or changed (e.g. bitu-
men parameters or temperature, etc.).
3.07.06 Operation with tank truck
The following remarks must absolutely be taken into consideration when

working with a tank truck (stockpiling and supply of water, bitumen emul-
sion, hot bitumen, etc.):
 Connect the tank truck with the Wirtgen recycler, using a connecting rod, in
order to maintain a constant distance between the two units. The tank truck
must be pushed by the Wirtgen recycler as a matter of principle. There must
be a free run from the tank truck to the Wirtgen recycler.
 The pump of the tank truck must not be used (also not during operation).
Wirtgen recyclers convey via own pumps.
 The hose connector between the tank truck and the Wirtgen recycler must be
form-fitting and suitable for the application.
 The hose must be empty and de-pressurised when connecting and discon-
necting.
 The length of the hose must be chosen such that it does not drag on the
ground or is kinked when cornering.
It is recommended to use hoses which can be ordered from Wirtgen in var-

ious lengths. These hoses comply with the requirements regarding pres-
sure and heat resistance.
If other hoses are used, they must at least comply with the specifications accord-
ing to EN 13482:2001.

Operation
Dosing unit
Specification EN 13482:2001 Operational pressure:

7 bar at 200°C or 10 bar at 40°C
Test pressure:
10.5 bar
Hot bitumen resistance:

168 hours in bitumen at 200°C (submersion test)
Fracture pressure including fittings:

40 bar
Fittings:
Nominal pressure 25 bar
NOTE
Only press fittings or fittings with screwed press connectors must be used.

200 / 370
Maintenance
General
4 MAINTENANCE
4.00 General
4.00.01 General maintenance instructions NOTE
Only regularly serviced machines are reliable!
WARNING
• Unless different information is given in the description, it is not permitted for
maintenance work to be carried out unless the diesel engine is stopped.
• Attach a warning notice in the operator's stand before starting maintenance
work.
MARGIN
A machine takes between 50 and 100 operational hours to run in. During this
time the machine must not be operated at maximum performance.
The following conditions must be met during all filling level checks:
 The machine must be parked on a level sub-base and must be level both in
the lateral and longitudinal direction.
MARGIN
In the maintenance manual you will find instructions on the correct care and
maintenance of your machine. It is imperative the work listed in the following is
carried out and that it is carried out carefully.
The illustrated instructions are arranged by maintenance groups. Maintenance
work that is not subject to fixed intervals is listed with "AS REQUIRED".
The main group "CHARTS" contains a service and maintenance chart, arranged
according to maintenance groups, in order to ease the search for illustrated in-
structions.
Only the fluids stipulated by WIRTGEN or those with an equivalent classification
are allowed to be used in the machine.
Oils with different specifications are not allowed to be mixed.

Pay attention to absolute cleanliness, clean connections and fittings prior to un-
doing. Only use fluff-free cloths. Cover all openings and connections or seal with
plugs.
Do not fill the oil filter with oil before fitting it (risk of engine damage due to conta-
mination).
Do not fill the fuel filter with fuel before fitting it (risk of engine damage due to
contamination).
Only undertake oil changes with the engine at operating temperature. Never
start engine with hydraulic oil drained. Only undertake checks and measure-
ments on the hydraulic system with the hydraulic oil at operating temperature (at
least 40°C). Prior to filling the hydraulic system with new hydraulic oil, the oil is
to be filtered.
Only use pressure gauge with adequate measuring range for the pressure test
on the hydraulic system. Have pressure gauge checked at extended intervals.
Thoroughly clean all grease nipples prior to the application of lubricant.

Maintenance
General
MARGIN
Unauthorised modification or changes to the machine are not allowed. Pressure

relief valves and regulators must not be adjusted without the agreement of the
manufacturer.
It is not allowed to weld or bolt on any additional components, or to drill any
holes in the machine without agreement of the manufacturer.
Safety could be adversely affected!
We explicitly inform you that spare parts and additional equipment not supplied
by us have not been tested or approved. The installation/use of such compo-
nents can degrade the machine’s performance and adversely affect its active
and/or passive safety.
All liability on the part of the machine manufacturer is excluded for damage re-
sulting from the use of non-original spare parts or additional equipment.
The manufacturer is not liable for damage/injury resulting from unauthorised
modifications or changes to the machine!
4.00.02 General instructions on winter service

During extended interruptions in use (e.g. storage over winter), the following pro-
tective measures are to be taken. These protective measures will provide protec-
tion for approx. 6 - 12 months depending on the weather.
After an interruption in use of more than 6 months, the engine oil is to be
changed. For oil volume and specified engine oil, refer to the filling capacity
table. NOTE
It is imperative that you follow the original instruction manual from the engine
manufacturer.

Maintenance
General
Measures for overwintering / protecting the machine

 It is imperative that a machine with a diesel engine to which protection mea-
sures have been applied is marked using an appropriate sign!
 Thoroughly clean exterior and interior of the machine and park in a place that
is well ventilated and dry as far as possible.
 Fill fuel tank completely.
 Fill AdBlue® / DEF tank to approx. 25%.
 Spray exterior of diesel engine with commercial cleaning agent and clean.
 Lubricate all lubrication points as per the information in the maintenance
booklet.
 Remove V-belt, spray the grooves on the V-belt pulleys with corrosion protec-
tion oil.
 Carefully seal openings on the air filter and the exhaust system.
 Check coolant for adequate frost protection.
 On machines without a cabin, the control panel is to be treated or covered
with commercial protection agents.
 LCD displays must be protected against temperatures below -25°C by park-
ing the machine in an adequately heated building. Alternatively, the LCD dis-
plays are to be removed and stored in a suitable place. Openings in control
panels or electrical cabinets are to be covered.
 Remove batteries; grease terminals with acid-protection grease and re-
charge in accordance with the information from the manufacturer. The batter-
ies should be stored in a dry, temperature-controlled, well ventilated room.
 If air tanks are fitted, the condensation water is to be drained and the anti-
freeze tanks for the compressed air system are to be filled with suitable anti-
freeze.
 Close all sockets with the protective caps provided.
Following systems must be completely drained:

 Water tank
 High pressure cleaner
 Water system
Measures for placing the machine back in operation
 Prior to placing back in operation, the corrosion protection oil is to be re-
moved from the V-belt pulleys.
 Re-fit V-belt and tension.
 Fit the battery (batteries) and check charge state and acid level.
 Check oil levels in diesel engine, gearbox and other oil tanks.
 Check coolant level and frost protection.
 After a lengthy non-operational period (approx. 6 months), check the AdBlue®
/ DEF quality.
 Check function of the electrical system.
 Open intake opening on the air filter and on the exhaust opening.
 Start diesel engine; check oil pressure; check hoses and other lines for leaks
and porosity.
 Check the function of the brakes and steering.

Maintenance
General
4.00.03 General instructions on welding work NOTE
Welding work is only allowed to be carried out by qualified personnel.

No welding work is allowed to be performed on ROPS/FOPS protective devices.
Welding work is only allowed to be carried out on tanks and pressurised compo-
nents by specially trained personnel.
Suitable fire extinguishing devices must be kept in readiness, e.g. fire extin-
guisher, fire blanket, etc.
Proceed as follows to avoid damage to the machine, and in particular to

protect the electronic components:
1. Electrical power supply

 Set electrical power supply to "0" or "OFF".
 Remove and take away the key.
2. Starter battery
 Disconnect negative terminal first; then the positive terminal.
3. Plug connections, e.g. of electronic devices and controllers

 Disconnect the plugs of electronic controllers (e.g. on-board computer, etc.).
 Pull out the plugs of the engine control unit and the alternator.
 Pull out the plugs of all monitors, displays and cameras.
 Pull out the plugs of all electronic components (also sensors, angle encoder
and position measuring systems in cylinders).
4. Important precautionary measures

 Connect the earth terminal directly to the component to be welded, and at the
shortest possible distance from it.
 Never connect using rotary elements or loose metallic parts.
 Make sure there is a good current transition without any coats of paint or lay-
ers of rust.
 Do not lay welding cables parallel to electrical cables.
NOTE
Failure to comply can result in components possibly becoming fused together or

else damaged by stray currents.
5. Electronic housings, electrical cabinets, cables, hoses, rubber and

plastic parts
 Never touch housings for electronic components or electrical cables with the
welding electrode or the welding wire.
NOTE
Electronic housings, electrical cabinets, cables, hoses, rubber and plastic parts
can be damaged by the effects of heat.
6. Fuel and hydraulic system

 Take suitable precautions to protect the fuel and hydraulic systems (e.g. re-
move or cover).
7. Diesel engine
 Always adhere to the original instruction manual from the engine manufac-
turer.

Maintenance
General
4.00.04 General instructions on the short maintenance instruction

A short maintenance instruction is included with each machine.
The following maintenance activities are given there:
 Check on safety devices.
 Filling level checks.
 Check on filters.
 Changing filters.
 Changing fluids.
 Lubrication or greasing of lubrication points.
[1] Chapter numbers from the in- [2] Symbols for maintenance work
struction manual
[3] Operational hours [4] Maintenance work
[5] "Instruction manual" symbol
NOTE
The instruction manual contains a large amount of additional maintenance work

and is definitive for the correct maintenance of the machine.
4.00.05 General instructions on the maintenance flaps.

NOTE
Use the maintenance flaps provided for all maintenance work on the diesel en-
gine, the hydraulic system, the milling drum drive, the compressed air system,
etc. These must be opened and secured correctly, and then locked again cor-
rectly at the end of the maintenance work..

Maintenance
General
NOTE
Prior to all maintenance work on the machine (cooler system cover, hydraulic
filtering), it is necessary to erect and secure the safety barrier correctly before
stepping on the closed engine cover.

Maintenance
General
NOTE
After the maintenance work on the machine (cooler system cover, hydraulic fil-
tering), it is necessary to fold in and secure the safety barriers correctly.

Maintenance
General
Air filtering / pump splitter

gearbox / batteries, etc.
 Unlatch the cover panel, open it up to the stop and secure it.

Maintenance
General
 Lift the cover panel slightly and unlock, fold it closed and lock.

Maintenance
General
Cooling system / hydraulic

filtering
 Unlock the cover on the right and left and open as far as the stop.
Diesel engine filtering /

hydraulic filtering / frost
monitor
 Unlock the maintenance flap and open it as far as the stop.

Maintenance
General
Drive belts / drive belt pulleys
 Unlock and open the cover in the middle and front.
Water filter
 Unlock and open the cover.

Maintenance
4.01 Chassis / safety devices

4.01.01 Checking safety devices
The following illustrations and descriptions show the position of the most impor-
tant safety devices, e.g., EMERGENCY STOP switches, engine STOP buttons,
warning horns etc. NOTE
 You must pay special attention to the safety devices installed in the machine.
 They must always be checked for correct function.
DANGER
If the safety devices do not function or function incorrectly, you are not al-
lowed to operate the machine.
Functional check Daily before starting on-site operation
Engine STOP button MARGIN
Check:
 With diesel engine running (idling speed), press button.
 Diesel engine must stop.
EMERGENCY STOP switch MARGIN
Check:
a) Unlock all EMERGENCY STOP switches on the machine.
b) Start diesel engine and set to idling speed.
c) Press an EMERGENCY STOP switch.
 Diesel engine must stop immediately.
 Check all other EMERGENCY STOP switches one after the other using steps
a), b) and c).
Warning horn MARGIN
Check:
 Press button with electrical power supply switched on.
 Horn must sound.

Maintenance
Reversing horn MARGIN
Check:
 Pull back the advance drive lever with the diesel engine running (machine
travels in reverse).
 The horn must sound intermittently.
Patrol light MARGIN
Check:
 Press the top of the switch with electrical power supply switched on.
 Patrol light must flash.
Parking brake MARGIN
Check (only with stationary machine):

MARGIN
 Select low travelling speed

Maintenance
MARGIN
 Press and hold the parking brake button - the red "P" symbol lights up
. . . and at the same time

MARGIN
 Gently push the advance drive lever forward

 The parking brake is OK if the advance drive is blocked.
NOTE
If it is possible to drive despite the parking brake being activated, the brake discs
must be checked or replaced immediately and WIRTGEN Service must be in-
formed, if applicable.
4.01.02 Lighting / warning device NOTE
With light removed, the mounting is always to be sealed water-tight using the
rubber bushing.
Visual inspection Every 50 operating hours

MARGIN
Patrol light
 Check contacts.
 If necessary, clean contacts or spray with contact spray.
MARGIN
Working light
 Check contacts every 50 operational hours.
 If necessary, clean contacts or spray with contact spray.

Maintenance
4.01.03 Cleaning
Cleaning of the machine Daily after on-site operation
 Using an external high-pressure cleaner
 Or using the machine's high-pressure cleaner.
NOTE
The high-pressure cleaner comprises a hydraulically driven pump, hose and

cleaner lance. It is used to completely clean the machine after on-site operation
using the machine's supply of water or an external water supply.
NOTE
• Caution on cleaning plastic parts and small parts. Risk of irreparable dam-
age.
• Electrical cabinets, electrical couplings, electrical connectors etc. are not al-
lowed to be cleaned using high pressure. An insulation fault may occur if wa-
ter penetrates the wiring.
• If a camera/monitor system is fitted, the monitor is only allowed to be cleaned
with a damp cloth if contaminated.
• When cleaning, never point the water jet into the exhaust pipe, otherwise the
exhaust system could be damaged.
 Pick up lance with high-pressure hose.

Maintenance
 Connect the high-pressure hose to the connector.
 Open the main water shut-off valve.

MARGIN
 Start diesel engine and run it at minimum speed.

Maintenance
 Press and hold the "high-pressure cleaner" button until the high-pressure
pump remains in operation.
 Press the lever on the cleaning lance, hold it and clean the machine.
NOTE
After 15 minutes without further operation, the high-pressure cleaner switches it-
self off automatically.

Maintenance
 Switch off the high-pressure pump after completion of the cleaning process.
MARGIN
 Switch off diesel engine.
 Close the main water shut-off valve.

 Disconnect the high-pressure hose, roll it up and stow it away.
NOTICE
Do not kink the high-pressure hose.

Maintenance
Cleaning the cabin Daily after on-site operation

 With the machine's own compressed air system.
 Open the maintenance flap behind the cabin.

 Connect the compressed air gun to the connector on the hose.
MARGIN
 Start diesel engine and run it at minimum speed.

Maintenance
 Clean the cabin with compressed air.

 Then uncouple the compressed air hose and stow it away; close the mainte-
nance flap.
MARGIN

Maintenance
Operator's stand

4.02.01 Operator's cabin
Visual inspection for Every 50 operational hours
contamination (heater fresh
air)
 Clean or change the filter element if required but at least once a year.
Visual inspection for Every 50 operational hours

contamination (heater
recirculating air)
 Clean or change the filter element if required but at least once a year.

Maintenance
Operator's stand
Filling level check (window Every 50 operational hours

washer)
 Fill the container with water when required. Mix with commercial anti-freeze
(for window washers) in cold weather.
4.02.02 Air conditioner

The following maintenance tasks and safety regulations are general specifica-
tions.
For other special maintenance and safety information, contact WIRTGEN to ob-
tain the original instruction manual from the air conditioner manufacturer.
NOTE
Safety regulations
The refrigeration circuit is filled with R134A safety refrigerant.
Never use hot steam to clean the system components.
Use nitrogen.
Alternatively, dry compressed air can be used.
Heating parts of the enclosed refrigerant circuit gives rise to high pressure in the
system, which can lead to damage or cause an explosion.
Therefore, welding and soldering or brazing work is not permitted on the system
or in the immediate vicinity.

Maintenance
Operator's stand
Switching on the air Every 250 operational hours

conditioner
 operate the air conditioner approximately 5 to 10 minutes (outside of the cool-

ing season and during extended non-operational periods).
NOTE
This regular operation procedure is required for the seal on the crankshaft of the
compressor to be lubricated. The crankshaft seal only seals properly if it is lubri-
cated sufficiently.

Maintenance
Operator's stand
Check air filter Every 50 operational hours
 If necessary, however at least once every six months, clean or change conta-
minated air filters.
Changing the dryer cartridge At least 1x yearly NOTE
This work is only allowed to be performed by qualified workers who have good
knowledge of refrigeration technology.

Maintenance
Milling drum unit
Check the condenser Every 50 operational hours
 if necessary, fold up the condenser and clean it on both sides.
Check the vaporizer At least 1x yearly

 clean if necessary. NOTE
Set the pressure reducer on the nitrogen bottle, the compressed air bottle or on
the air compressor to a low pressure value, in order to avoid damaging the slats.
Visual inspection (electrical At least 1x yearly

connectors, hose and pipe
connections)
 Check electrical connectors, hose and pipe connections for chafe marks.
 Retighten hose connections, if required.
 Check electrical connectors for proper contact (solid seat).

4.03.01 Milling drum gearbox
Visual inspection for leaks Daily

Maintenance
Milling drum unit
Filling level check Every 50 operational hours
 Use the hand crank, milling drum rotation device or the electrical pick ex-
tractor to turn the milling drum until the filling / drain plug is approx. in the 3
o'clock position.
 Remove filler / drain plug.
 Oil level must be up to the opening - top up oil if necessary.
 Close opening.

Maintenance
Milling drum unit
Oil change 1st change during runing-in period after 50 operational hours, then every 500
operational hours but at least 1x yearly.
 Loosen and remove the filling / drain plug.

 Use the hand crank, milling drum rotation device or the electrical pick extrac-
tor to turn the milling drum until the opening is pointing downwards.
 Collect oil in a suitable container.

Maintenance
Milling drum unit
Fill in oil
tor to turn the milling drum until the check opening is approx. in the 3 o'clock
position.
 Fill in new oil
 Oil must lightly discharge from the opening.
 Close opening.
4.03.02 Changing the picks

Check on the picks Daily (frequently)
 Repeated checks for wear and tear - change picks, if necessary.

tor to turn the milling drum until the picks / pick supports are accessible.
NOTE
It must always be ensured that the milling picks are in immaculate condition in
order to achieve optimal utilisation of machine capacity.
Cleaning the milling drum Daily

 Thorough cleaning of the milling drum with a high-pressure cleaner.

Maintenance
Milling drum unit
Changing the picks . . . either

 Set engine speed to MIN.
. . . or
 Use the electro-hydraulic unit
 Lift the milling drum completely up to the end point.

 Fully lift machine to the end point.
 Fit safety supports.
 Lower machine onto the safety supports.
 Open the REAR milling drum scraper up to its highest position.
 Set the TOOL EXCHANGE switch to "I" and remove the key (tool exchange
control panel).
 Remove damaged or worn picks using an electrical pick extractor, pneumatic

pick extractor or a hammer and drift.

Maintenance
Milling drum unit
 Hammer in new picks with copper/plastic hammer or pneumatic pick driver.

NOTE
Ensure proper seating of the millilng picks (it must be possible to turn the picks
freely by hand).
MARGIN
 Use the hand crank, milling drum rotation device or the hydraulic pick extrac-
tor to turn the milling drum until all picks can be checked and/or changed.

Maintenance
Milling drum unit
4.03.03 Quick-change toolholder system

Check on the pick supports Daily (frequently)
 Repeatedly check for signs of wear and firm seating.

 If necessary, replace pick supports.
 Position milling drum using milling drum rotation device (hand crank if neces-
sary) such that the picks / pick supports are accessible.
NOTE
It is imperative to ensure the pick supports are in good condition.
Changing the pick supports
 Clean access hole for Allen screw.

 Remove hex plug.

Maintenance
Milling drum unit
 Carefully clean hex socket.

 Undo Allen screw by hand using a suitable Allen key.
 Completely unscrew Allen screw and remove.
NOTE
The full depth of the Allen key must be available.

Do not use worn tools!
 Remove pick support.

Maintenance
Milling drum unit
 Check for damage to the threaded hole and the cylindrical guide of the bot-
tom part of the pick support welded onto the milling drum.
 Provide good contact surface.NOTE
There is not allowed to by any milled material in the bottom part after cleaning.
The contact surfaces between the top and bottom parts must make fully fitting
contact with one another, without a gap.
The surface of the bottom part of the holder must be smooth and undamaged.
An uneven surface leads to further damage to the bottom and top parts.
 Pull on a new bottom part seal.

Maintenance
Milling drum unit
 Grease pick support shaft using temperature-resistant grease.

 Grease a new Allen screw using temperature-resistant grease. Do not use
worn screws.
 Fit pick support.
 Insert the Allen screw.
 Screw in the screw approx. 3 turns by hand. If it is only possible to screw in
the Allen screw using a large amount of force, the thread of the bottom part
must be re-cut using a tap.
 Screw in Allen screw by hand and tighten to a torque of 650 Nm.

NOTE
Only use a manually-operated torque wrench for tightening the Allen screws.

Maintenance
Milling drum unit
 By hitting the pick support with a hammer (1 kg copper hammer) check

whether the pick support settles further (sound test).
 Then tighten Allen screw to a torque of 650 Nm again.
 Fit new hex plug.
Tighten the Allen screws Every 250 / 500 operational hours

It is imperative the Allen screws are re-tightened after the 1st on-site operation
(approx. 10 operational hours) to 650 Nm, then every 250 or 500 operational
hours. If a screw can be tightened by more than one turn, the bottom piece must
be checked.
 HT 3 every 250 operational hours.

Maintenance
Milling drum unit
4.03.04 Wear patterns MARGIN
Good pick rotational behaviour = low wear

For this reason pay attention to:
 Clean pick support bore
 Adequate water cooling
Normal pick wear stages
Reduction in cutting depth  Wear travel at the pick support:

due to different wear states HT3 = 12 mm
HT11 = 16 mm
HT22 = 30 mm
 Wear travel at the pick:
Depending on type: from 9 mm to 20 mm

Maintenance
Milling drum unit
Optimum wear MARGIN
Pick with cap-shaped carbide tip.

Exchange recommended.
MARGIN
Pick with cap-shaped carbide tip and chamfered wear disc.

Exchange recommended.
MARGIN
Pick with cylindrical carbide tip.
Unwanted wear MARGIN
Pick with cap-shaped carbide tip.

The wear disc is heavily worn and does not provide adequate protection for the
pick support.
The pick body (with tip) is only one third worn.
Optimum rotation behaviour overall.
MARGIN
Pick with cap-shaped carbide tip:

Carbide fracture - mechanical overload due to hard objects/materials that cannot
be cut or broken;
e.g. reinforcing steel rods, boulders or manhole covers in the surfaces or materi-
als to be milled.
Thermal overload by excessive temperature in the cutting process and inade-
quate water supply.
MARGIN

Steel object erosion - overload by excessive feed rate.
Steel object erosion - due to working in soft milled material.

Maintenance
Milling drum unit
MARGIN

Excessive lengthways wear. No more carbide is visible.
The wear was detected too late.
The maximum pick life has been exceeded.
MARGIN

Clamping sleeve and wear disc worn.
MARGIN

Poor rotation - strong, one-sided wear on the pick head and on the carbide tip.
Contamination of the pick support hole - inadequate water supply.
This is also possible if the pick support is heavily worn.
Optimum pick support = low wear

For this reason pay attention to:
 Clean pick support shaft
 adequate water sprinkling
MARGIN
New pick support.

Monitor the wear condition of the pick supports with reference to the markings.
MARGIN
Normal wear after approx. 800 operational hours.

Maintenance
Milling drum unit
4.03.05 Front turntable

Turntable bolts Retighten bolts during run-in period after 50 operational hours, thereafter every
250 operational hours
 Open the left maintenance flap and retighten the bolts to 250 Nm (torque
wrench).
 Open the right cover and retighten the bolts to 250 Nm (torque wrench).

Maintenance
Milling drum unit
4.03.06 Milling drum bearing

 Undo inspection screw and remove.

 Oil level must be up to the opening - top up oil if necessary.
 Close opening.

Maintenance
Milling drum unit
 Loosen and remove the drain plug.

 Loosen and remove inspection screw to bleed the system.
 Close openings.

Maintenance
Milling drum unit

 Fill with new oil.
 Oil must run out of the opening.
 Close opening.
4.03.07 Drive belts

WARNING
Taking off and putting on drive belts.
Danger of crushing limbs.
• take suitable safety precautions.
• Only take off / put on drive belts using a suitable tool.

Maintenance
Milling drum unit
Check (tensioner roller) Every 250 operational hours
 Check tensioner roller stopper (measure) and re-adjust if necessary.
Check (drive belts) Every 250 operational hours
 Check drive belts (wear) and replace, if necessary.

NOTE
Before new drive belts are fitted, the drive belt pulleys must be checked for wear
and, if necessary, replaced with new pulleys.

Maintenance
Milling drum unit
Replacing drive belts MARGIN
MARGIN
 Turn the rotary button to the front and hold it until the milling drum is not in
contact with the ground.
MARGIN
 Press the Engine Stop button and hold until the diesel engine has stopped.
MARGIN
 Switch electrical power supply OFF and safeguard against unauthorised

switch-on (remove key).

Maintenance
Milling drum unit
 Remove the cover at the rear (loosen and remove the screws).
 Removing drive belts

Maintenance
Milling drum unit
 Fit new drive belts. NOTE
It is essential to ensure proper seat of the drive belts.
Adjusting the tensioner roller

stopper
 Undo counter nut and adjust tensioner roller using the adjusting screw such
that the drive belts cannot touch the cover or jump out of the grooves in the
untensioned state.
 Tighten counter nut.

Maintenance
Milling drum unit
 Install the cover at the rear.
4.03.08 Drive belt pulleys

WARNING
Taking off and putting on drive belt pulleys.
Danger of crushing limbs.
• take suitable safety precautions.
• Only take off / put on drive belt pulleys using a suitable tool.
 Remove the cover at the rear (loosen and remove the screws).

Maintenance
Milling drum unit
Wear check Every 250 operational hours
 Change drive belt pulleys if necessary.

NOTE
Faulty drive belt pulleys will result in premature wear and failure of the drive
belts. Wear is due to abrasion during operation or the inclusion of foreign bodies
(dust, rust etc.).
To ensure reliable operation, all drive belt pulleys must be renewed from the
same set. It is essential to ensure proper seat of the drive belt pulleys.
On changing the drive belt pulleys, it is imperative to ensure the drive belts are
correctly re-fitted.
Step 1
Insert test gauge - as shown - in the profile on the drive belt pulley.
If the test gauge fits in the profile, the drive belt pulley is OK.
Step 2
Rotate test gauge by 180° and insert - as shown - in the profile on the drive belt
pulley.
If the test gauge is in contact with the outer diameter of the profile, the drive belt
pulley must be replaced.

Maintenance
Milling drum unit
Aids for replacing drive belt pulleys:
A = installation bolt (for clamping and securing the loosened drive belt pulleys).
NOTE
After completion of the replacement work, the installation bolt must be removed
from the relevant drive belt pulley and be securely screwed into the receptacle of
the cover.
B = screw holder (for depositing the loosened screws of a drive belt pulley).
NOTE
There must not be any screws left in the screw holder after completion of the re-
placement work.

Maintenance
Milling drum unit
Changing the front drive belt

NOTICE
pulley
Before unfastening the hydr. pressure pipe, suitable measures must be taken to
cover the drive belt pulley.
It is essential to make sure that no oil drips onto the drive belt pulley.
 1 = Unfasten and pull off the hydr. pressure pipe.

 2 = Loosely screw hydr. pressure pipe onto the weld-in screw connection.
 3 = Close the hydraulic screw connection with the plug.

Maintenance
Milling drum unit
 4 = Screw in the installation bolt up to the stop in the clamping hole.

 5 = Loosen screws and deposit them in the screw holder.
 6 = Unscrew the installation bolt and screw it into one of the top tap holes up
to the stop.

Maintenance
Milling drum unit
 7 = Screw two of the screws into the force-off holes.

 8 = Screw in both screws evenly until the drive belt pulley has been loosened
and freely rests on the installation bolt.
 9 = Remove drive belt pulley and place on one side.
NOTICE
Before screwing on the hydr. pressure pipe correctly, suitable measures must be
taken to cover the drive belt pulley.
It is essential to make sure that no oil drips onto the drive belt pulley.
 Fit new drive belt pulley and tighten cross-wise with the required torque ac-
cording to similar workflow.
 Screw the hydr. pressure pipe back on correctly.

Maintenance
Milling drum unit
Changing the centre drive

belt pulley
 1 = Screw in the installation bolt up to the stop in the clamping hole.

 3 = Unscrew the installation bolt and screw it into one of the top tap holes up
to the stop.

 5. Remove drive belt pulley and place on one side.
 Fit new drive belt pulley and tighten cross-wise with the required torque
according to similar workflow.

Maintenance
Milling drum unit
Changing the rear drive belt

pulley

 2 = Screw the installation bolt into one of the top tap holes up to the stop.
 5 = Remove drive belt pulley and place on one side.
 Fit new drive belt pulley and tighten cross-wise with the required torque
according to similar workflow.

Maintenance
 Install the cover at the rear (screw in and tighten the screws).
 Close all maintenance flaps of the drive belt box.
4.04 Engine / motor group

4.04.01 Diesel engine in general NOTE
All the maintenance work listed in the following is general information.

For further maintenance work on the diesel engine, please refer to the original
instruction manual from the engine manufacturer.
Diesel engine - contamination Daily

check  Check diesel engine externally for contamination and leaks; clean if neces-
sary.
 Also check the vicinity of the fuel injection pump for contamination; clean if
necessary.

Maintenance
Hoses and fuel lines Check every 500 operational hours.
 Check hoses for damage.

 Renew leaking or damaged hoses.
Hose clamps Check during run-in period after 50 operational hours, thereafter every 500 oper-
ational hours.
 Check for loose hose clamps and re-tighten.
V-belts / poly-V-belts Tension check during run-in period after 50 operational hours, thereafter every
500 operational hours.
 Re-tension or renew V-belts / poly-V-belts if necessary.

Maintenance
4.04.02 Diesel engine fuel system NOTE

Filling level check Daily (frequently)
If the filling level is too low:

 The red LED lights up (diesel engine control panel)
 A text message appears on the display of the on-board computer.
Top-up fuel
 Remove the tank lid.

 Insert fuel hose and fill the tank.
 Replace the tank lid.

Maintenance
Draining water from the fuel At least 1x yearly

tank
 Unscrew cover lid.

 Screw on special hose (included in the items supplied) and collect fuel in a
suitable container.
 Monitor fluid flowing out and remove hose on the transition from water to fuel.
 Tighten cover lid. NOTE
In case of truck transport via public roads, the fuel tank must not contain more
than 1,000 litres of diesel. Else the transport is subject to the GGVS (Germany
only)

Maintenance
Changing the fuel filter 1st change during running-in period after 50 operational hours, then every 500
operational hours but at least 1x every six months.
 Loosen filter element with suitable tool and remove it.

 Lightly oil O-ring seal.
 Fit new filter element and tighten by hand.

Maintenance
Changing the fuel pre-filter 1st change during running-in period after 50 operational hours, then every 500
 Close the shut-off valve (fuel line).

 Remove the sensor cable.
 Loosen water collection dish (4) with suitable tool and remove it.
 Loosen filter element (2) with suitable tool and remove it.
 Lightly oil and insert O-ring seals (1+3).
 Fit new filter element (2) and tighten by hand.
 Fit water collection dish (4) and tighten by hand.
 Connect sensor cable.
 Open the shut-off valve (fuel line).

Maintenance
Dewatering the fuel pre-filter Daily
 Close the shut-off valve (fuel line).

 Place collecting container under the water separator.
 Loosen the drain plug, observe the draining fluid and tighten again when it
changes from water to fuel.
 Open the shut-off valve (fuel line).
 Check for tightness after restarting the diesel engine.

Maintenance
Fuel lines Bleed (only after filter change). . .

For bleeding, the solenoid valve in the supply line must be opened (LED on
the connector housing of the solenoid valve lights up)
 Place collecting container under the fuel pre-filter.

 Loosen bleeder screw.
 Switch on the electrical power supply => the solenoid valve opens for about 3
minutes (LED lights up).
 Operate the fuel hand pump until fuel is discharged without air bubbles from
the bleeder screw.
 Tighten the bleeder screw. NOTE
If the bleeding procedure has not finished within the 3 minutes (LED is no longer
lit) and the diesel engine does not start, press the "Engine STOP" button => the
solenoid valve opens for another 3 minutes (LED lights up); perform the bleeding
procedure again.
4.04.03 Diesel engine oil NOTE


Maintenance
Engine oil filling level check Daily (before starting on-site operation)
 The dipstick must indicate a level between MIN and MAX; top up engine oil, if
necessary.

Maintenance
Changing the engine oil 1st change during running-in period after 50 operational hours, then every 500
 Undo cover and remove.

 Screw on special hose (included in the items supplied) and collect engine oil
in a suitable container.
 Remove hose.
 Tighten cover lid.
 Fit the cover correctly.

Maintenance
 Fill in new engine oil.
Changing the oil filter 1st change during running-in period after 50 operational hours, then every 500
 Place the collecting tray under the filter element.

 Remove the collecting tray.
4.04.04 Diesel engine air filtering NOTE


Maintenance
Air filter Daily
 Check for contamination (display message, pay attention to the display on

the "diesel engine" control panel (cabin) and mechanical display on the front
right lifting column) - red LED on the "diesel engine" control panel is not al-
lowed to light up, mechanical display is not allowed to point to the red area.
 Clean or change the filter element if necessary.

Maintenance
Changing the filter elements When required but at least 1x yearly
NOTE
This describes opening and changing the filter elements on one air filter unit.
Maintenance on the second air filter unit is performed accordingly with the same
working procedure.
 Unlock cover and remove.

Maintenance
 Raise the main filter element slightly at the front (as shown), take it out and
replace it with a new filter element.
NOTE
If a new filter element is temporarily unavailable during on-site operation, it is

possible to extend the service interval by a minimal amount by lightly tapping the
filter element or blowing dry compressed air through it opposite to the flow direc-
tion.

Maintenance
 The safety element must be removed and changed as well on the third occa-
sion that the main filter element is changed, if not before.
NOTE
The air filter unit is assembled in the same way in the opposite working proce-
dure.

Maintenance
NOTE
When assembling the air filter unit, make sure that the main filter element is in-
stalled in the correct orientation, otherwise the cover cannot be locked correctly.
4.04.05 Diesel engine cooling system NOTE


Maintenance
Diesel engine radiator / Daily

intercooler
 Continuously check radiator fins for contamination (particularly in case of

dusty conditions).
 If necessary, spray radiator fins with a suitable cleaning agent, leave to act
and clean with a jet of water. MARGIN
Danger due to escaping contaminated water

Lack of care might result in contaminated water spilling onto the ground. Risk of
pollution.
 Collect escaping contaminated water and dispose of correctly.
Coolant filling level check Daily
If the filling level is too low:

 The red LED lights up (diesel engine control panel).

Maintenance
 Check the coolant level before starting on-site operation and top up coolant if
necessary.
 If necessary, change coolant, however at least 1x yearly.

Maintenance
Changing the coolant
 Undo cover and remove.

 Unscrew the lid.
 Screw on special hose (included in scope of supply) and collect coolant in a
suitable container.
 Remove hose.
 Screw on the lid.
 Fit the cover correctly.

Maintenance
Hydraulic oil feed
Replacing the coolant filter 1st change during running-in period after 50 operational hours, then every 1000
 Close shut-off valve.

 Open shut-off valve.
4.05 Hydraulic oil feed

4.05.01 Hydraulic oil tank
Filling level check Daily
If the hydraulic oil level is too low:


Maintenance
Hydraulic oil feed
 Sight glass must be filled at least halfway; top up hydraulic oil if necessary.
Changing hydraulic oil Every 1000 operational hours, but at least 1x yearly.
 Open the cover.

 Screw on special hose (included in the items supplied) and collect oil in a
suitable container.
 Remove hose.
 Close the cover.

Maintenance
Hydraulic oil feed
MARGIN
 Loosen and remove the lid of the filler / ventilation filter.
MARGIN
 Remove the filter element, thoroughly clean the filter housing; change filter el-
ement if necessary.
MARGIN
 Fill in new hydraulic oil and check the oil level in the sight glass.
Changing the filter element When required, but at least 1x yearly.

MARGIN
 Fit new filter element.
MARGIN
 Position the lid of the filler and breather filter and tighten lightly.

Maintenance
Hydraulic oil feed
4.05.02 Hydraulic oil filter

Checking filter contamination Daily (frequently)
If a filter element is contaminated:

All hydraulic filter elements 1st change during runing-in period after 50 operational hours, then every 500
Changing filter elements

(pressure filters)
MARGIN
 1 = loosen bottom part of filter with open-end wrench and unscrew.

Maintenance
Hydraulic oil feed
MARGIN
 2 = remove filter element and replace with new one.
NOTE
The filter is assembled in the same way in the opposite working procedure.
Before reassembling filter top and bottom part, clean thoroughly.
Lightly oil O-ring seal.

(combination filters)
MARGIN
 1 = loosen and remove the filter top part screws.
MARGIN
 2 = lift off the filter top part.
MARGIN
 3 = loosen the entire filter element, lift with the separation plate and remove.

Maintenance
Hydraulic oil feed
MARGIN
 4 = loosen separation plate and remove from the filter element.
MARGIN
 5 = pull out filter element further, together with the filter screen.
MARGIN
 6 = loosen contaminated filter element, pull out of the filter screen and dis-
pose of properly.
MARGIN
 7 = pull out filter screen and clean.
MARGIN
 8 = clean separation plate and coarse filter.
MARGIN
 9 = assemble new filter element, filter screen and separation plate and insert
into filter housing.
MARGIN
 10 = position the filter top part.

Maintenance
Hydraulic oil feed
MARGIN
 11 = insert and tighten the filter top part screws.
NOTE
MARGIN
12 = bleed the filter

 Loosen the bleeding screw and let any air escape until hydraulic oil is dis-
charged from the bleeding screw.
 Tighten bleeding screw.
NOTE
The filter housing must be bled after every filter change.

(return flow filters)
MARGIN
 1 = loosen the filter top part with an open-end wrench.
MARGIN
 2 = unscrew the filter top part.

Maintenance
Hydraulic oil feed
MARGIN
 3 = remove filter element and replace with new one.
NOTE
4.05.03 Cooler (hydraulic oil + hydraulic pump drive - flushing)

Contamination check Daily (frequently)
 Continuously check the cooler fins for contamination (especially in case of

heavy dust and leaves).
 Clean cooler fins if necessary.
Cleaning  Spray cooler fins with a suitable cleaning agent, allow to soak and clean off
with water jet. MARGIN
Danger due to escaping contaminated water

Lack of care might result in contaminated water spilling onto the ground. Risk of
pollution.
 Collect escaping contaminated water and dispose of correctly.

Maintenance
Hydraulic oil feed
4.05.04 Hydraulic pump drive

Filling level check Every day (before starting on-site operation - before the diesel engine is started)
 Pull out dipstick, clean and insert again.

 Pull out dipstick again.
 The dipstick must indicate a level between MIN and MAX; top up oil, if neces-
sary.
 Insert dipstick.

Maintenance
Hydraulic oil feed
 Open the cover.

 Screw on special hose (included in the items supplied) and collect oil in a
suitable container.
 Remove hose.
 Close the cover.
 Undo filler plug and remove.

 Fill in new oil.
 Check filling level on dipstick.
 Close opening.

Maintenance
Electrical system
4.06 Electrical system

4.06.01 Batteries / electrical power supply
Battery acid level Every 500 operational hours
 Check acid level.

 Unscrew all lids, the acid level must be approx. 10 - 15 mm above the top of
the plates.
 If necessary, top-up with distilled water.
 Re-fit lids.
Grease the battery terminals Every 500 operational hours
 Remove the battery terminal caps.

Maintenance
Electrical system
 Grease +/- terminal (only use special battery terminal grease).
 Put on the battery terminal caps.

Maintenance
Advance drive
4.08 Advance drive

4.08.01 Advance drive gearbox

 Oil level must be up to the opening - top up oil if necessary.
 Close opening.

 Loosen and remove inspection screw to bleed the system.
 Close openings.

Maintenance
Advance drive

 Fill with new oil.
 Oil must run out of the opening.
 Close opening.
4.08.02 Wheels / tyres

Check for wear Daily
 Check tyre profile for wear; change tyres if necessary.

Maintenance
Water system
Checking tyre pressure Daily
 Check air pressure = 4.0 bar; inflate tyres to specified air pressure if neces-
sary.
4.12 Water system

4.12.01 Water tank
WARNING
Danger due to service water
Danger due to service water. Service water can contain frost protection, rust,
etc. and is not suitable for human consumption.
• Do not drink water.
• Never fill drink bottles or similar containers with this water.

Maintenance
Water system
Filling level check Daily (frequently)
 Check water level.

 Fill up water if necessary. NOTE
At low temperatures the water must be drained from the entire water system -
(drain water pump and water filter separately) - or a suitable anti-freeze added to
prevent the water and the entire water system freezing.
Filter screen
 The condition of the filter screen in the filler port must always be checked be-
fore filling.
 Clean filter screen if necessary.

Maintenance
Water system
Drain water
 Open the shut-off valve.

 Collect water in a suitable container.
 Close the shut-off valve.

Maintenance
Water system
Changing the tank protection Every 1000 operational hours, but at least 1x yearly.
cartridge
WARNING
Danger due to caustic substances
Injury (skin and eyes).
 Wear safety glasses.
 Wear gloves.
 Drain water tank.

 Remove filter screen.
 Remove spent tank protection cartridge and insert new cartridge.
 Insert filter screen
 Put on tank lid.

Maintenance
Water system
4.12.02 Water filter

Contamination check Daily
 Close shut-off valve (lever must be across the direction of flow).
 Remove the covering hood.

 Remove filter element; check for contamination.
 Clean filter element if necessary.
Cleaning MARGIN
 Thoroughly clean filter element with a jet of water.

 Insert filter element and put on cover lid.

Maintenance
Binder unit
 Open shut-off valve (lever must be in direction of flow).
4.16 Binder unit

4.16.01 Bitumen water pump
 The sight glass must be filled at least halfway.

 Top up oil if necessary.

Maintenance
Binder unit
 Remove the protective cover over the pump.

 Loosen and remove check screw to bleed the system.
 Close openings.
 Reinstall protective cover.

Maintenance
Binder unit
 Undo check screw and remove.

 Fill in new oil.
 Check oil volume in the sight glass.
 Close opening.
4.16.02 Binder pumps

Check for leakages Daily
 When the pump is running, approximately 1 drop per second should be dis-
charged from the shaft seal.
 If necessary, the packing must be tightened or loosened until the required
leakage is reached.
 Change worn packings. (see original instruction manual of the pump manu-
facturer).

Maintenance
Binder unit
4.16.03 Cleaning of the dosing unit

WARNING
Risk of trapping by rotating milling drum.
People may be drawn into the rotating milling drum. Risk of serious injury with
mortal consequences.
 Work in the area of the milling drum must only be performed at a sufficient
safety distance.
Check for material clogging Daily (frequently)
 After on-site operation open the cover of the right hand milling drum housing
and check for major material clogging.
 If clogging exists, which can be removed with the normal cleaning function of
the spraying nozzles, lift the milling drum until it does not contact the ground
any more.
 Switch on milling drum drive.
 Run the milling drum until the clogging has been removed.

Maintenance
Binder unit
 Wait for at least 30 seconds after switching off the milling drum drive.
 Press the CLEANING button.
 The openings between the spraying beam and the roll housing are auto-
matically cleaned for approximately 10 seconds.
WARNING
Danger posed by cleaning agents
For all cleaning and flushing processes discharged cleaning agents must ab-
solutely be collected in a suitable container.
• Do not allow any cleaning agent to soak into the soil.

Maintenance
Binder unit
Cleaning the emulsion unit Daily (after on-site operation)
 Open the left half of the nozzles.

 Siphon cleaning agent from an external container.
 Flush lines.
 Open the right half of the nozzles.
 Flush lines.

Maintenance
Binder unit
Cleaning the suspension unit Daily (after on-site operation)

 Draw in water from a container using an external pump, or connect the water
pipe from the WM 1000 and activate the pump on the WM 1000.
 Flush lines.
 Draw in water from a container using an external pump, or connect the water
pipe from the WM 1000 and activate the pump on the WM 1000.
 Flush lines.

Maintenance
Binder unit
Cleaning the foam bitumen Daily (after on-site operation)

unit

 Flush lines.
 Flush lines.
4.16.04 Bitumen filter NOTE
Check can only be performed on a unit that is ready for operation. The pump is
switched off.

Maintenance
Binder unit
Contamination check Daily
 Visual check; clean bitumen filter if necessary.

 Loosen two locks.
 Fold away two locks.

Maintenance
Binder unit
 Pull out bitumen filter.
WARNING
Danger posed by cleaning agents
For all cleaning and flushing processes discharged cleaning agents must ab-
solutely be collected in a suitable container.
• Do not allow any cleaning agent to soak into the soil.
Cleaning
 Place bitumen filter in a container and treat with a suitable cleaning agent
and allow to drip off until the filter screen allows acceptable flow again.
 Fit the bitumen filter properly again.

Maintenance
Bitumen water nozzles Every day (test) MARGIN
MARGIN
 Press the F1 key - an automatic flow rate test is initiated.

 Visual check of the display, clean any blocked nozzle (marked in colour).
4.17 Compressed air system and accessories

4.17.01 Compressed air tank
Checking compressed air Daily
connector
 Check for contamination; clean if necessary.

Maintenance
Compressed air tank Blow off condensation water every 50 operational hours.
 Switch off diesel engine

 Operate the bleeder valve until the compressed air has escaped completely.
 The condensation water is automatically drained as the compressed air
escapes.
4.17.02 Defroster unit NOTE
The defroster unit must be activated in order to prevent freezing of the conden-
sation water in the compressed air system at low temperatures.
Activation When required or at low temperatures.
 Press in the locking handle to the stop and latch by turning it 90°.

Maintenance
 Carefully loosen the dipstick and wait for any possible compressed air to es-
cape.
 Completely loosen the dipstick and pull it out.
 Fill in ethyl alcohol (methylated spirits).

Maintenance
 Loosely insert the dipstick, pull out and check the filling level.
 Top up with ethyl alcohol if necessary.
 Screw in the dipstick again and unlatch the locking handle.
NOTE
Defroster unit locking handle pressed in and locked = Summer setting

Defroster unit locking handle pulled out and unlocked = Winter setting
Cleaning the wick At least 1x yearly
 Undo plug screw.

 Remove wick and clean using ethyl spirit (methylated spirits).
 Fit wick.
 Tighten plug screw.

Maintenance
Lubrication unit
4.18 Lubrication unit

4.18.01 Lubrication points NOTE
In general all lubrication points, unless expressly stated otherwise, are lubri-
cated with a few pumps of a grease gun (the grease should escape slightly at
the side).
All nipples and spindles must be cleaned thoroughly prior to the lubrication
process.
During all lubrication work the diesel engine is to be shut down (exceptions are
specifically stated).
If the machine is cleaned with a high-pressure cleaner (hot or cold), in general
all lubrication points are to be lubricated afterwards.
Lubricate Grease Operational hours
Guide columns - front right and left
 Lubricate bearings (1 lubrication point each)

Maintenance
Lubrication unit
Guide columns - rear right and left
Guide columns - front and rear
 Grease

Maintenance
Lubrication unit
Milling drum unit - left connecting rod
 Lubricate bearings (2 lubrication points each)
Milling drum unit - right connecting rod

Maintenance
Lubrication unit
Milling drum unit - left and right turntable cylinders
Milling drum unit - turntable top left and right

Maintenance
Lubrication unit
Milling drum unit - turntable bottom left
Milling drum unit - turntable bottom right

Maintenance
Lubrication unit
Milling drum scraper - front left + right (hydraulic cylinder)
Milling drum scraper - rear left + right (hydraulic cylinder)

Maintenance
Lubrication unit
Milling drum scraper - rear left + right (articulation points)
Milling drum scraper - rear (holder)

Maintenance
Lubrication unit
Front steering cylinder
 Lubricate bearings (1 lubrication point)
Rear steering cylinder

Maintenance
Lubrication unit
Drive belts - tensioning device
 Lubricate bearings (2 lubrication points)
Drive belts - tensioner roller

NOTE
Only use WIRTGEN GROUP Clutch Grease or a similar grease.

Maintenance
Lubrication unit
Drive belts - middle drive belt pulley

NOTE
Milling drum clutch

 approximately 2-3 pump strokes -> turn drive belt pulley -> approximately 2-3
pump strokes -> turn drive belt pulley -> approximately 2-3 pump strokes -
approximately 8-10 pump strokes in total
NOTE

Maintenance
Lubrication unit
All socket joints
 Lubricate
All bolts
 Grease
All locking bars
 Lubricate

Maintenance
Lubrication unit
All hinges
 Lubricate

Charts
Maintenance
5 CHARTS
5.01 Maintenance
5.01.01 Service and maintenance chart
Symbol Description
◆ Service interval (e.g. every 10 h, every 250 h. . .)
✰ Service interval during the running-in period
½ Maintenance every 6 months (½-yearly)
1 Maintenance every 12 months (yearly)
2 Maintenance every 2 years
3 Maintenance every 3 years
01 CHASSIS / SAFETY DEVICES

An- As Check
Elements Activity 10 h 50 h 100 h 250 h 500 h 1000 h
nual required OK
Safety devices Check function prior to starting on-site
operation ◆
Ensure correct function ◆
Lighting - warning Check contacts ◆
device
Clean contacts ◆
Cleaning Complete machine with high-pressure ◆
cleaner
Cabin with compressed air ◆
02 OPERATOR'S STAND
An- As Check
nual required OK
Heater Check filter element (fresh air) ◆
Filter element cleaning / changing 1 ◆
Check filter element (recirculating air) ◆
Filter element cleaning / changing 1 ◆
Window washer Check water filling level ◆
Top up water ◆
Fill in anti-freeze ◆
Air conditioner Switch on the unit ◆
Check filter elements ◆
Clean / change filter elements ½ ◆
Change dryer cartridge (specialist 1
company)
Change refrigerant (specialist com- 1
pany)
Check / clean condenser ◆ ◆
Check / clean vaporizer 1 ◆
Check connectors 1
Tighten hose connections ◆

Charts
Maintenance
03 MILLING DRUM UNIT

An- As Check
nual required OK
Milling drum gear- Visual inspection for leaks ◆
box
Check oil level ◆
Top-up oil ◆
Change oil ✰ ◆ 1
Milling drum Cleaning ◆
Pick change Check picks - frequently ◆
Change picks ◆
Quick-change Check pick supports ◆
toolholder system
Change pick supports ◆
Retighten bolts (HT 3, HT 11) ✰ ◆
Retighten bolts (HT 22) ✰ ◆
Front turntable ◆ 1
Retighten screws (250 Nm) ✰
(right and left)
Milling drum bear- Check oil level ◆
ing (right)
Top-up oil ◆
Drive belts Check tensioner roller stopper ◆

Adjust tensioner roller stopper ◆
Check drive belts ◆
Replace drive belts ◆
Drive belt pulleys Check drive belt pulleys ◆
Renew drive belt pulleys ◆
04 ENGINE / MOTOR GROUP

An- As Check
nual required OK
Diesel engine in Check diesel engine for contamina-
general tion / leakages ◆
Clean diesel engine ◆
Check hoses and fuel lines ◆
Change hoses and fuel lines ◆
Check hose clamps ✰ ◆
Re-tighten hose clamps ◆
Check V-belts ✰ ◆
Replace V-belts ◆
Diesel engine fuel Check fuel level - frequently ◆
system
Top-up fuel ◆
Drain water from fuel tank 1
Change fuel filter ✰ ◆ ½
Bleed fuel lines (only after filter
change) ◆
Change fuel pre-filter ✰ ◆ ½
Drain water from fuel pre-filter ◆ ◆

Diesel engine oil Check oil level ◆

Charts
Maintenance
An- As Check
nual required OK
Top-up oil ◆
Change oil ✰ ◆ ½
Change oil filter ✰ ◆ ½
Diesel engine air Check air filter ◆

filtering
Clean / change air filter elements 1 ◆
Diesel engine Check diesel engine radiator/ inter-
cooling system cooler ◆
Clean cooler fins ◆
Check coolant level ◆
Top-up coolant ◆
Change coolant 1 ◆
Replacing coolant filter ✰ ◆ 1
▲ For information ▲ Checking the radiator fan ◆ ◆

about the mainte-
nance steps listed ▲ Checking the charge air lines ◆ ◆
here, please refer ▲ Checking the crankcase ventilation
to the original in- hose ◆
struction manual
▲ Checking the coolant additive ◆
from the engine
(SCA) and antifreeze concentration
manufacturer
▲ Checking/renewing the coolant filter 1
head
▲ Checking the air intake and exhaust ◆ 1
system
▲ Checking the engine wiring harness ◆ 1
▲ Checking the cold start aid (e.g. 2
heater flange, temperature sensors,
etc.)
▲ Cleaning the diesel engine with a 2
steam cleaner
▲ Checking the diesel engine attach- 2
ment
▲ Inspecting the vibration dampers 2
on the crankshaft to see if they can be
reused
▲ Performing the cylinder head ad- 2
justment jobs (valves, etc.)
▲ Renewing the internal crankcase 2
breather
▲ Changing the V-belt pulleys 5
▲ Checking the air compressor pres- 5
sure pipe
05 HYDRAULIC OIL FEED

An- As Check
nual required OK
Hydraulic oil tank Check oil level ◆
Top-up oil ◆
Change oil ◆ 1
Clean / change filter element ◆ 1 ◆

Hydraulic oil filter Check contamination - frequently ◆
Change filter element ✰ ◆ 1 ◆

Charts
Maintenance
An- As Check
nual required OK
Cooler hydraulic Check cooler fins - frequently ◆
oil + hydraulic
pump drive - Clean cooler fins ◆
flushing
Hydraulic pump Check oil level ◆
drive
Top-up oil ◆
06 ELECTRICAL SYSTEM
An- As Check
nual required OK
Batteries Check acid level ◆
Rennelar Top up water ◆
Grease battery terminals ◆
08 ADVANCE DRIVE
An- As Check
nual required OK
Advance drive Check oil level ◆
gearbox
Top-up oil ◆
Wheels Check tyres ◆

Replace tyres ◆
Check air pressure ◆
Adjust air pressure ◆
12 WATER SYSTEM
An- As Check
nual required OK
Water tank Check water level - frequently ◆
Top up water ◆
Fill in anti-freeze ◆
Check filter screen ◆
Clean filter screen ◆
Change tank protection cartridge ◆ 1
Water filter Check filter element ◆

Clean filter element ◆
16 BINDING UNIT
An- As Check
nual required OK
Bitumen water Check oil level ◆
pump
Top-up oil ◆
Binder pumps Check packings ◆

Adjust packings ◆
Change packings ◆

Charts
Technical data
An- As Check
nual required OK
Cleaning Check milling drum housing material
clogging - frequently ◆
Clean milling drum housing ◆
Clean dosing unit ◆
Bitumen filter Check bitumen filter ◆
Clean bitumen filter ◆
Bitumen water Test through-flow ◆
nozzles
Cleaning the nozzle ◆
17 COMPRESSED AIR SYSTEM

An- As Check
nual required OK
Compressed air Check compressed air connector for
tank contamination ◆
Clean compressed air connector ◆
Drain condensation water ◆
Defroster unit Activation (summer / winter) ◆
Fill in ethyl spirit ◆
Clean wick 1
18 LUBRICATION
An- As Check
nual required OK
Lubrication points Lubricate / grease ◆ ◆ ◆
5.02 Technical data

5.02.01 Dimensions / weights / performance
Machine dimensions
All dimensions in mm.
*1 = with spraying unit
*2 = machine centre of gravity (in relation to operating weight, CE)

Charts
Technical data

Charts
Technical data
Rear dimensions

Charts
Technical data
Turning circle

Charts
Technical data
DIESEL ENGINE
Manufacturer CUMMINS
Type QSX 15
Cooling Water
Number of cylinders 6
Rated power output at 2100 kW / 447/600/608
r.p.m. HP / PS
Maximum power output at 1900 kW / 455/610/619
r.p.m. HP / PS
Displacement cm3 15000
Fuel consumption (full load) l/h 120
Fuel consumption (in construc- l/h 60
tion site mix)
Exhaust emissions category EU Stage 3a / US Tier 3
TRAVERSING CHARACTERISTICS
Working speed / travelling speed max. 0 - 210
m/min
max. km/h 0 - 12.6
Lateral tilt max. ° 8
Ground clearance mm 400
TYRES
Tyre size front 28 L 26
Tyre size rear 28 L 26
FILLING CAPACITIES
Fuel tank l 1500
Hydraulic oil tank l 320
Water tank l 500
ELECTRICAL SYSTEM
Voltage V 24
*1 = Maximum milling depth can differ form the specified value due to tolerances and wear.
MILLING DRUM
Working width (max.) mm 2400
Working depth * 1 mm 0 - 510
Tool spacing mm 20
Number of milling tools 170

Charts
Technical data
MILLING DRUM
Cutting circle diameter mm 1480
TRANSPORT DIMENSIONS
Dimensions truck transport (L x mm 9230x3000x3000
W x H)
Shipping dimensions (L x W x H) mm 9400x3200x3200
*1 = Basic machine with standard equipment without filling substances.

*2 = Machine with standard equipment, half full water tank, half full fuel tank, driver (75 kg), tools.
*3 = Machine with max. equipment, fully fuelled, with ESP (spraying unit) "foam bitumen".
MACHINE WEIGHTS
Curb weight *1 kg 28400
Operating weight CE * 2 kg 29400
Service weight * 3 max. kg 32000
WEIGHTS FILLING SUBSTANCES

Water tank filling kg 500
Fuel tank filling kg 1245
ADDITIONAL WEIGHTS IN RELATION TO CURB WEIGHT (OPTIONAL EQUIPMENT)

ESP single: kg 380
Spraying unit for water or bitu-
men emulsion
ESP double: kg 710
Spraying unit for water and bitu-
men emulsion
ESP foam bitumen: kg 1400
Spraying unit for water and foam
bitumen
ESP 1800 l: kg 350
Spraying unit for water up to
1800 l/min
Additional water tank (empty) kg 440
Additional water tank filling kg 950

Charts
Fuels / lubricants
5.03 Fuels / lubricants

5.03.01 Filling capacities
System Stipulated fuels - lubricants Litre *) U.S. Brit.
gallons *) gallons *)
Milling drum shell Water 420.00 110.96 92.39
(water/coolant 60/40%) WIRTGEN 280.00 73.98 61.59
Antifreezing Compound
Milling drum (gearbox) WIRTGEN GROUP 20.00 5.28 4.40
Milling Drum Oil
VG 150
Milling drum bearing WIRTGEN GROUP 1.30 0.34 0.29
Milling Drum Oil
VG 150
Fuel tank DIESEL EN 590 1500.00 396.30 329.96
(Cetan min. 49)
Diesel engine WIRTGEN GROUP 47.00 12.42 10.34
Engine Oil 15W-40
Diesel engine (cooling system) Water 52.00 13.74 11.44
(water/coolant 50/50%) WIRTGEN 52.00 13.74 11.44
Antifreezing Compound
Hydraulic oil system WIRTGEN GROUP 450.00 118.89 98.99
Hydraulic Oil
HVLP 46
Hydraulic pump drive WIRTGEN GROUP 10.60 2.80 2.33
Gear Oil 85W-90
Advance drive gearbox WIRTGEN GROUP 4.00 1.06 0.88
Gear Oil 85W-90 (4x) (4x) (4x)
Water tank 500.00 132.10 109.99
Additional water tank 950.00 250.99 208.97
Water pump WIRTGEN GROUP 0.30 0.08 0.07
(Bitumen water) Engine Oil 15W-40
Lubrication points WIRTGEN GROUP
(General) Multipurpose Grease
Lubrication points WIRTGEN GROUP
(Special) Clutch+Remixer Grease
*) All quantities listed here are approximate
5.03.02 Fuels / lubricants comparison table - 03.2014

Only use the "stipulated fuels / lubricants" (see "Filling capacities" chapter).
Wirtgen Group fuels / lubricants Specification
WIRTGEN GROUP SAE 5W-40
Engine Oil ACEA E5/E4/E3,
5W-40 API CI-4 plus,
MB 228.5,
CAT ECF-1,
Cummins CES 20072/20071

Charts
Fuels / lubricants

WIRTGEN GROUP SAE 10W-30 "Low SAPS"
Engine Oil "Low SAPS" ACEA E9/E7,
10W-30 API CJ-4,
Deutz DQC III-10 LA,
CAT ECF-3,
Cummins CES 20081,
MB 228.31
Engine Oil ACEA E7/E5,
10W-40 API CF,
Deutz DQC III-05,
MB 228.5
WIRTGEN GROUP SAE 10W-40 "Low SAPS"
Engine Oil "Low SAPS" MB ACEA E6/E7, E4-99
10W-40 API CI-4,
MB 228.51
Engine Oil ACEA E7/E5,
15W-40 API CI-4 plus,
MB 228.3,
CAT ECF-1,
Cummins CES 20078/7/6/2/1
WIRTGEN GROUP SAE 75W-90 with EP additives
Gear Oil API GL-5
75W-90
WIRTGEN GROUP SAE 85W-90 with EP additives
Gear Oil API GL-5,
85W-90 MB 235.0,
ZF-TE-ML 05A/07A/12A/16C/17B
WIRTGEN GROUP *** Synthetic polyglycol gear oil
High-Performance Gear Oil PGLP 150 DIN 51517- 3 group CLP,
VG 150 ISO 6743-6 category CKS/CKT
High-Performance Gear Oil PGLP 220 DIN 51517-3 group CLP,
VG 220 DIN 51502 group PGLP,
ISO 6743-6 category CKS/CKT
High-Performance Gear Oil PGLP 460 DIN 51517-3 group CLP,
VG 460 DIN 51502 group PGLP,
ISO 6743-6 category CKS/CKT
WIRTGEN GROUP Hydraulic oil HVLP ISO-VG 32 with EP additives
Hydraulic Oil DIN 51524 part 3 type HVLP,
HVLP 32 ISO 6743/4 HV
Hydraulic Oil DIN 51524 part 3,
HVLP 46 Type HVLP ISO 6743/4 HV
Hydraulic Oil DIN 51524 part 3 type HVLP,
HVLP 68 ISO 6743/4 HV
WIRTGEN GROUP *** Bio hydraulic oil ISO-VG 46 with EP additives
Bio Hydraulic Oil Type HVLP HEES ISO 15380
VG 46

Charts
Fuels / lubricants

WIRTGEN GROUP *** Bio hydraulic oil ISO-VG 68 with EP additives
Bio Hydraulic Oil Type HVLP HEES ISO 15380
VG 68
WIRTGEN GROUP KPF 2 K-25 with EP additives
Multipurpose Grease (lithium-saponified)
DIN 51825
ISO 6743-9: L-XBFIB 2
WIRTGEN GROUP KP 3 P-20
Clutch+Remixer Grease (lithium-saponified)
DIN 51825
WIRTGEN GROUP Flow grease of mineral oil base with EP additives
Flow Grease (lithium based) (lithium-saponified)
KP/GP 00-30 DIN 51502
WIRTGEN GROUP Heat transmission oil ISO-VG 22 (32)
Heat Transmission Oil DIN 51522-Q for forced circulation systems up to 320 °C
VG 22
WIRTGEN Corrosion-protection agent, coolant and anti-freeze
Antifreezing Compound Free from nitrites, amines, phosphates and silicates acc.
to ASTM D4985-05 and MB 325.3
Check compatibility if using other diesel engine coolants
WIRTGEN Corrosion-protection agent, coolant and anti-freeze
Antifreezing Compound MB Free from nitrites, amines, phosphates and borates
acc. to Mercedes Benz regulations MB 325.5 DM (for
diesel engines)
Check compatibility if using other diesel engine coolants
AdBlue® Highly pure urea solution AUS 32
DEF (Diesel Exhaust Fluid) DIN 70070 / ISO 22241-1 / ASTM D7821
AUS 32 (Aqueous Urea Solution)
ARLA 32
(***) Cannot be mixed with mineral oil

Charts
Fuels / lubricants
5.03.03 Fuels / lubricants selection diagrams - 11.2013

Engine oil selection table The lubricating oil viscosity in accordance with the SAE class is selected as per
the following table.
The ambient temperature defines the selection. Dropping below the tempera-
ture limit may adversely affect the cold starting ability, but will not cause engine
damage. The temperature limit should not be exceeded for an extended period
to avoid a reduction in the lubrication.
For all-year round usage we recommend using multigrade oils.
Diesel fuel selection At low temperatures, blockages may occur in the fuel system and cause faults
due to paraffin precipitation. Below 0°C outdoor temperature use winter diesel
(down to -20°C).
 Special diesel fuels can be used for arctic climate zones down to -44 °C.
NOTE
It is not permitted to add petrol or paraffin, or to add additional free-flow addi-

tives.

Charts
Fuels / lubricants
Diesel properties required:

– Flash point, min. 55 °C.
– Water-content, max. 200 mg/kg
– Sulphur content, max. 10 mg/kg (0.001%)
– Lubricating capacity, "wear scardiameter" max. 460 μm
– Cetane rating for moderate climate, min. 49....51
– Cetane rating for arctic climate, min. 47....49
– Use diesel in accordance with the European standard EN 590 or US diesel
in accordance with ASTM D 975 grade no.1-D and 2-D.
NOTE
 If it is necessary to use fuel with a high sulphur content (more than 0.5 per-
cent by weight / 5000 mg/kg), the maintenance intervals must be halved.
 It is imperative that the original documentation from the engine manufacturer
(instruction manual, operating manual and maintenance manual etc.) is fol-
lowed.

Charts
Fuels / lubricants
Hydraulic oil selection table
W= Winter conditions in central Europe

S= Summer conditions in central Europe or buildings
T= Tropical conditions or hot areas
U= Excessively hot (e.g. due to combustion engines)
X= Hydraulic fluid temperature range
νopt = Optimal operating viscosity range
1000 Max. permissible viscosity (short duration)
=
II = 10 mm2/s (tmax= +90°C) . . . 1000 mm2/s (tmin= -25°C)

Charts
Tightening torques
5.04 Tightening torques

5.04.01 Screws / nuts (metric standard thread)
Dimension Tightening torque
[mm] Ma [Nm]
8.8 10.9 12.9
Tightening torques for metric bolts and M3 1,1 1,6 ---
nuts with normal thread pitch in steel: M4 2,6 3,9 4,2
Calculated with µ = 0.10 for bolt grade 8.8
and 10.9 up to M16 and with µ = 0.09 for bolt M5 5,2 7,6 8,3
quality 10.9 from M16 and for 12.9 as av- M6 9 13,2 14,3
erage coefficient of friction in the thread as M8 21,6 31,8 34,5
well as between bolt head and component,
M10 43 63 67,5
dry, 90% utilisation of the elastic limit in ac-
cordance with VDI 2230. M12 73 108 117
M14 117 172 186
M16 180 240 285
M18 259 340 400
M20 363 480 562
M22 495 650 760
M24 625 820 962
M27 915 1200 1406
M30 1246 1635 1916
M33 1679 2205 2578
M36 2164 2840 3325
M39 2791 3660 4283
5.04.02 Screws / nuts (metric fine thread)

[mm] Ma [mm]
8.8 10.9 12.9
Tightening torques for metric bolts and M8x1 22,8 33,5 36,2
nuts with fine pitch thread in steel: M10x1.25 44 65 71
Calculated with µ = 0.10 for bolt grade 8.8
and 10.9 up to M16 and with µ = 0.09 for bolt M12x1.25 79 116 125
quality 10.9 from M16 and for 12.9 as av- M14x1.5 124 182 196
erage coefficient of friction in the thread as M16x1.5 189 256 299
well as between bolt head and component,
M18x1.5 283 370 433
dry, 90% utilisation of the elastic limit in ac-
cordance with VDI 2230. M20x1.5 392 512 599
M22x1.5 529 690 808
M24x1.5 686 894 1046
M24x2 666 871 1019
M27x2 967 1264 1478
M30x2 1343 1751 2050
M33x2 1794 2338 2735
M36x2 2345 3054 3573

Charts
Tightening torques
5.04.03 Screws / nuts (inch standard thread UNC)

The SAE strength classes of bolts
with UNC/UNF thread are stated on
the head.
Strength class 5 corresponds to 8.8,
strength class 8 corresponds to
10.9.
Class 5 Class 8

[inch x turns Ma [Nm]
over 1"]
Class 5 Class 8
Tightening torques for Imperial (inch) 1/4"x20 11 17
bolts and nuts with normal thread pitch 5/16"x18 24 32
(UNC) in steel:
Calculated with µ = 0.125 as average coef- 3/8"x16 42 62
ficient of friction in the thread as well as be- 7/16"x14 69 97
tween bolt head and component, dry, 90% 1/2"x13 104 152
utilisation of the elastic limit in accordance
9/16"x12 152 207
with SAE.
5/8"x11 190 300
3/4"x10 360 525
7/8"x9 430 810
1"x8 870 1220
1-1/8"x7 1100 1740
1-1/4"x7 1520 2470
1-3/8"x6 1980 3220
1-1/2"x6 2600 4280
5.04.04 Screws / nuts (inch fine thread UNF)

The SAE strength classes of bolts
with UNC/UNF thread are stated on
the head.
Strength class 5 corresponds to 8.8,
strength class 8 corresponds to
10.9.
Class 5 Class 8

over 1"]
Class 5 Class 8
Tightening torques for Imperial (inch) 1/4"x28 14 19
bolts and nuts with fine thread pitch 5/16"x24 26 35
(UNF) in steel:
Calculated with µ = 0.125 as average coef- 3/8"x24 48 69
ficient of friction in the thread as well as be- 7/16"x20 76 111
tween bolt head and component, dry, 90% 1/2"x20 124 166
utilisation of the elastic limit in accordance
9/16"x18 166 235
with SAE.
5/8"x18 250 332
3/4"x16 415 581

Charts
Frost protection

over 1"]
Class 5 Class 8
7/8"x14 650 895
1"x12 960 1360
1-1/8"x12 1200 1950
1-1/4"x12 1640 2710
1-3/8"x12 2280 3690
1-1/2"x12 2980 4830
5.05 Frost protection

5.05.01 Diesel engines - 10.2013
Coolant concentrate
The recommended mixing ratio is 50/50, provided frost protection below -37°C is not required.
The portion of the coolant concentrate in the coolant is not allowed to drop below 48 % by volume in operation.
Frost protection up to °C Coolant concentrate Remark
portion in % by volume
- 35°C 48 % by vol. Engine operation permitted.
Recommendation: increase
concentration to 50%.
- 37°C 50 % by vol. Recommended concentration.
- 40 °C 52 % by vol. Engine operation not permitted.
Only permitted for storage.
Increased requirements are placed on the coolant for diesel engines. Coolant concentrates in accordance with
DAIMLER CHRYSLER specification 325.3 and in accordance with ASTM D4985 are approved.
Specification ARAL ARTECO BASF BP CATERPILLAR
ASTM D4985 Antifreeze Havoline AFC-An- Glysantin G48, ProCool DEAC - Diesel
Silikatfrei tifreeze / Coolant Glysantin G30 Engine An-
tifreeze / Coolant
ESSO/ EXXON HÄRTOL SHELL TEXACO TOTAL
MOBIL
Mobil An- Frostox SF-D12 Glycoshell Havoline XLC GLACELF Plus /
tifreeze LL2000 GLACELF
Auto Supra
Coolants can only be mixed together to a limited degree. Due to different additive technologies, the additives can
mutually degrade each other, render each other ineffective or adversely affect the functionality of the cooling sys-
tem due to sedimentation. Damage due to mixing or incorrect usage of coolant is not covered by the warranty.
Requirements on water
The water for making up the coolant should be distilled or fully demineralised.
Specification in ac- Analysis figures
cordance with ASTM
Upper limit
D512, D4327 Chlorine (Cl) 40 mg/l • 2.4 grains/US gall.
D516 Sulphate (SO4) 100 mg/l • 5.9 grains/US gall.
D1126 Total hardness 170 mg/l (17°dH) • 10 grains/US gall.
D1888 Total solids 340 mg/l • 20 grains/US gall.

Charts
Operating state messages
Specification in ac- Analysis figures

cordance with ASTM
Upper limit
D1293 Acidity pH value from 6.5 to 8.5
Cooling system cleaning agents

Cooling system cleaning agents are designed to free the system of damaging scale and corrosion. Mineral de-
posits, corrosion products, light oil contamination and sludge deposits are dissolved using the cooling system
cleaning agents.
Always clean the cooling system if the coolant is contaminated or sludge forms in the coolant.
The cooling system cleaning agent must be thoroughly flushed out of the cooling system.
5.05.02 Milling drum / water system

At low temperatures, water must be mixed with a suitable anti-freeze to prevent
frost damage.
Do not use more than 52 % by volume (= max. frost protection) corrosion protec-
tion / anti-freeze.
Ensure you only use environmentally friendly anti-freeze!
Frost protection up to °C Portion of anti-
freeze in % by volume
- 10 °C 21 % by vol.
- 15 °C 28 % by vol.
- 21 °C 34 % by vol.
- 25 °C 40 % by vol.
- 30 °C 44 % by vol.
- 35 °C 48 % by vol.
- 40 °C 52 % by vol.
5.06 Operating state messages

5.06.01 Machine
Operating state messages - 03.2014
Group Number Description
Fuse fault 113 01..n F 1..Fn
Voltage monitoring 115 11 Electrical power supply Vss 2 (10V) PLC 1 failed
115 12 Electrical power supply Vss 2 (10V) PLC 2 failed
121 15 Rear steering cylinder
121 16 Front steering cylinder
121 17 Travelling pressure
121 18 Fuel filling level
121 19 Hydraulic oil temperature
121 26 Joystick armrest right
121 27 Milling depth cylinder
121 28 Drum flap, front
121 29 Drum flap, rear
121 30 Height cylinder, front-right
121 31 Height cylinder, front-left

Charts

121 32 Height cylinder, rear-right
121 33 Height cylinder, rear-left
121 34 Drum flap, rear, downward pressure
121 36 Temperature sensor, heating circuit 1
121 46 Charge air temperature sensor engine 1
121 52 Bitumen pressure sensor
121 53 Milling drum gearbox temperature sensor
Sensor frequency signal fault 125 11 Speed of left front advance motor
125 12 Speed of right front advance motor
125 13 Speed of left rear advance motor
125 14 Speed of rear right advance motor
125 16 Milling drum gearbox speed sensor
Sensor digital signal fault 127 11 Sense of rotation of left front advance motor
127 12 Sense of rotation of right front advance motor
127 13 Sense of rotation of left rear advance motor
127 14 Sense of rotation of right rear advance motor
131 17 Rear left control unit
131 18 Rear right control unit
131 19 Control panel cabin
Unexpected switching status 201.. 01..n IN_1..IN_n
299
Short circuit exit 301.. 01..n OUT_1..OUT_n
399
Cable fracture exit 401.. 01..n OUT_1..OUT_n
499
Short-to-battery voltage exit 501.. 01..n OUT_1..OUT_n
599
CAN Node fault 613 01..n Node_1..Node_n
615 16 Can 1
615 17 Can 2
615 18 Can 3
615 19 Can 4
615 21 Steering unit CAN 3 - CAN 4 interchanged
615 22 Control 1 -> TCU
Communication failed 621 11 TCU
713 12 J1939 SPN / FMI

Charts

713 13 J1939 Communication
713 14 Coolant level
713 16 Air filter
713 28 Starter
713 29 Charge control D+
713 30 Water in fuel
713 32 DPF filling level high
713 33 Signal fault engine running
713 34 DPF fault
713 35 DPF filling level full (SPN:3251 FMI:0)
713 36 DPF filling level low / medium (SPN:3251 FMI:15)
713 37 DPF filling level high (SPN: 3251 FMI:16)
713 38 Engine stop
713 39 Fuel pressure (SPN:94)
713 41 Air intake pressure (SPN:102)
713 42 Fuel pressure line (SPN:157)
713 43 Water in fuel (SPN:97)
713 44 Engine oil pressure (SPN:100)
713 45 Engine coolant temperature (SPN:110)
713 46 Air intake temperature (SPN:105)
713 47 Engine start relay
713 48 Engine stop relay
713 49 Alternator
713 51 SCR/DEF filling level low |====<|
713 52 SCR/DEF filling level low |===<_|
713 53 SCR/DEF filling level low |==<__|
713 54 SCR/DEF filling level low |=<___|
713 55 SCR/DEF filling level low |<____|
713 56 SCR/DEF insufficient quality |====<|
713 57 SCR/DEF insufficient quality |===<_|
713 58 SCR/DEF insufficient quality |==<__|
713 59 SCR/DEF insufficient quality |=<___|
713 61 SCR/DEF insufficient quality |<____|
713 62 SCR/DEF unit manipulation |====<|
713 63 SCR/DEF unit manipulation |===<_|
713 64 SCR/DEF unit manipulation |==<__|
713 65 SCR/DEF unit manipulation |=<___|
713 66 SCR/DEF unit manipulation |<____|
713 67 SCR unit fault
Hardware fault 717 11 Rotation transducer steering unit CAN 3
717 12 Rotation transducer steering unit CAN 4
717 13 Brake steering unit CAN 3 inactive
717 14 Steering unit CAN 3 - CAN 4 interchanged

Charts

717 31 Valve fault lime dosing conveyor
717 32 Valve fault lime auger left
717 33 Valve fault lime auger right
717 34 Valve fault lime scraper conveyor
813 24 Emergency stop wiring PLC1
813 27 Steering unit
813 28 Joystick travelling armrest right
813 39 Emergency stop wiring PLC2
Multiple fault 815 11 Milling drum flap ground relay
815 14 Dosing conveyor blocked
815 15 Auger right blocked
815 16 Auger left blocked
815 17 Scraper conveyor blocked
815 18 Uncontrolled advance movement of machine
815 19 Engine stop without function
815 21 ground relay Control 2
815 22 Uncontrolled operation of the machine
Hydraulics fault 821 11 Pressure filter monitoring
821 12 Return filter monitoring
821 13 Leak oil filter monitoring
821 14 Hydraulic oil temperature too high
821 16 Hydraulic oil filling level too low
821 18 Monitoring combination filter
821 19 Milling drum clutch pressure too low
821 21 Milling drum gearbox temperature high
821 22 Milling drum gearbox temperature too high
821 23 Hydraulic feed pressure too low
Calibration fault 831 11 Rear steering cylinder
831 12 Front steering cylinder
835 16 Milling drum ON locked
835 19 Tool change active
835 21 Engine warm-up phase active
835 23 Gearbox switch-over blocked
913 12 Fuel filling level
913 27 Exhaust gas temperature high
913 28 DPF regeneration locked -> diagnostic module
913 29 DPF regeneration locked -> operator's stand
913 31 Generator fault
913 32 Dry run protection spraying 1
913 33 Dry run protection spraying 2
913 34 Function fault advance motor front left
913 35 Function fault advance motor front right
913 36 Function fault advance motor rear left

Charts

913 37 Function fault advance motor rear right
913 38 Stop diesel engine
913 41 Bitumen emergency operation selected
913 42 Dry run protection bitumen water
913 43 Bitumen water filling level <20%
913 44 Gearbox switch-over 1st gear no return signal
913 45 Gearbox switch-over 2st gear no return signal
913 46 Gearbox switch-over no return signal
913 47 Bitumen temperature >210°C circuit 1
913 58 Bitumen temperature >230°C
913 61 Milling drum gearbox temperature too high
Remarks 925 11 Lime dosing conveyor has achieved max. speed
925 12 Lime container advance warning empty
925 13 Lime container empty
925 14 Lime container full
925 15 Lime filling level sensor 100% does not switch off
925 16 Lime filling level sensor 50% does not switch off
925 17 Lime filling level sensor 50% does not switch on
925 18 Lime filling level sensor 0% left does not switch on
925 19 Lime filling level sensor 0% left does not switch on
925 21 Lime filling level sensor 0% right does not switch on
925 22 Lime filling level sensor 0% right does not switch on
925 23 Lime filling level sensor left does not switch off
925 24 Lime filling level sensor left does not switch on
925 25 Lime filling level sensor centre-left does not switch off
925 26 Lime filling level sensor centre-left does not switch on
925 27 Lime filling level sensor centre-right does not switch off
925 28 Lime filling level sensor centre-right does not switch on
925 29 Lime filling level sensor right does not switch off
925 31 Lime filling level sensor right does not switch on
925 32 Lime filling level sensor behind auger left does not switch off
925 33 Lime filling level sensor behind auger left does not switch on
925 34 Lime filling level sensor behind auger right does not switch off
925 35 Lime filling level sensor behind auger right does not switch on

Charts

925 36 Empty pipe detection (EPD)
5.06.02 Diesel engine SPN code and flash code

SPN = Suspect Parameter Number
SPN FMI code Flash code Description
code
84 2 2-4-1 Wheel-based Vehicle Speed
91 8 1-4-7 Accelerator pedal position 1
91 3 1-3-1 / 5-1-5 Accelerator pedal position 1
91 4 1-3-2 / 5-1-6 Accelerator pedal position 1
94 16 4-4-9 Fuel supply pressure
97 15 4-1-8 Water-in-fuel display
100 4 1-4-1 Engine oil pressure
100 2 435 Engine oil pressure
102 3 1-2-2 Pressure of engine intake pipe 1
102 4 1-2-3 Pressure of engine intake pipe 1
103 16 5-9-5 Speed from engine/turbocharger 1
105 3 1-5-3 Temperature of engine intake pipe 1
108 3 2-2-1 Air pressure
110 0 1-5-1 Coolant temperature
111 2 4-2-2 Coolant level
111 1 2-3-5 Coolant level
113 2 5-2-4 Check of the alternative OEM control differential switch
156 3 1-1-6 Pressure of injector rail 1

Charts

code
166 2 9-5-1 Engine rated output
167 16 5-9-6 Charging system voltage
168 18 4-4-1 Battery potential / power consumption
168 16 4-4-2 Battery potential / power consumption
174 3 2-6-3 Engine fuel temperature 1
174 4 2-6-5 Engine fuel temperature 1
175 3 2-1-2 Engine oil temperature 1
190 10 1-2-1 Engine speed
191 16 3-4-9 Gearbox output speed
191 18 4-8-9 Gearbox output speed
251 2 3-1-9 Electricity interruption from real-time clock generator
558 2 4-3-1 Accelerator pedal idling speed switch 1
609 2 1-8-4 Engine control module (ECM)
620 18 4-4-4 OEM sensor voltage supply low
620 3 3-8-5 / 2-2-7 DC voltage supply of 5-volt sensor
620 4 1-8-7 DC voltage supply of 5-volt sensor
626 11 3-8-1 / 3-8-2 Starter device 1
627 2 4-3-4 Power loss during ignition
629 12 1-1-1 Engine control module warning: internal hardware fault
629 12 3-4-3 Engine control module warning: internal hardware fault
630 12 3-4-6 Engine control module - software error
630 2 6-4-1 / 3-4-1 Electronic calibration code not compatible
632 4 2-5-4 Control for engine fuel cut-off 1
632 7 2-5-9 Control for engine fuel cut-off 1
633 3 2-7-6 Control command for engine fuel actuator 1
635 5 3-9-4 Actuator circuit for time control 1
639 9 2-8-5 SAE J1939 multiplexing PGN timeout

Charts

code
640 14 5-9-9 Required additional output switched off
647 4 2-4-5 Fan control circuit
647 11 3-8-9 Fan control circuit
651 6 3-1-1 Circuit from injector solenoid drive cylinder 1
702 3 5-2-7 Additional I/O no. 02
703 14 2-1-9-5 Additional I/O no. 03
723 2 7-5-3 Engine speed 2
923 11 7-6-8 Driver for output device
974 3 1-3-3 Remotely controlled accelerator pedal position
974 4 7-6-8 / 1-3-4 Remotely controlled accelerator pedal position
974 19 2-8-8 Remotely controlled accelerator pedal position
1043 3 2-8-3 / 3-8-7 Accelerator pedal position sensor 1
1043 4 2-8-4 / 4-4-3 Accelerator pedal position sensor 1
1043 11 4-9-6 Accelerator pedal position sensor 1
1075 11 2-7-8 Electrical lift pump for fuel supply circuit
1076 13 4-9-3 Trimming circuit for fuel pump calibration
1077 14 3-2-9 Fuel system leaking
1083 3 2-9-3 Additional I/O channel 1
1188 4 4-6-6 Engine turbocharger bypass valve drive position 1
1265 4 2-2-3 Solenoid valve engine oil combustion
1347 4 2-7-1 Circuit of the pressure generator for fuel pump 1
1347 3 2-7-2 Circuit of the pressure generator for fuel pump 1
1347 7 2-7-5 / 2-8-1 Fuel pump element 1
1348 4 2-7-3 High fuel pressure solenoid valve 2
1348 3 2-7-4 High fuel pressure solenoid valve 2
1348 7 2-8-2 / 3-2-8 High fuel pressure solenoid valve 2
1349 3 4-8-3 Engine dosing injector rail 2 pressure

Charts
Calculation examples / formulas

code
1377 2 4-9-7 Engine synchronisation switch
1380 17 2-1-9 Removed engine oil level container
1381 3 5-8-1 Engine fuel pump intake pressure
1383 31 6-1-1 Auxiliary device sensor input 2
1384 31 2-9-9 Switch-off requested by SAE J1939 engine
1387 14 2-9-6 Additional pressure no. 1
1387 11 2-1-9-4 Auxiliary pressure 1
1484 31 2-1-1 Severe fault in at least one module
5.07 Calculation examples / formulas

5.07.01 Water / emulsion
Calculation examples:
Width B = 2.4 m Water addition W = 2 % (0.02)
Depth T = 0.2 m ρW = 1 kg/l
Speed V = 5 m/min Emulsion addition E = 5% (0.05)
Density ρM = 2,200 kg/m3 ρE = 1 kg/l
Emulsion volume in kilogramme per minute [kg/min] ME = B x T x V x ρM x E
ME = 2.4 x 0.2 x 5 [m/min] x 2,200 [kg/m3] x 0.05
ME = 264 [kg/min]
Water volume in kilogramme per minute [kg/min] MW = B x T x V x ρM x W
MW = 2.4 x 0.2 x 5 [m/min] x 2,200 [kg/m3] x 0.02
MW = 105.6 [kg/min]
Fluid volume in litre per minute [l/min] Q = ME : ρE + MW : ρW
Q = 264 [kg/min] : 1 [kg/l] + 105.6 [kg/min] : 1 [kg/l]
Q = 369.6 [l/min]
(Maximum displacement)
Emulsion consumption in litre per hour [l/h] QE = ME : ρE x min/h
QE = 264 [kg/min] : 1 [kg/l] x 60 [min/h]
QE = 15,840 [l/h]
Water consumption in litre per hour [l/h] QW = MW : ρW x min/h
QW = 105.6 [kg/min] : 1 [kg/l] x 60 [min/h]
QW = 6336 [l/h]

Charts
Calculation examples / formulas
5.07.02 Foam bitumen

Calculation examples:
Width B = 2.4 m Addition of bitumen water ZSW = 2% (0.02)
Depth T = 0.2 m ρB = 1 kg/l
Speed V = 5 m/min Bitumen addition ZB = 3% (0.03)
Density ρM = 2,200 kg/m3 ρB = 1 kg/l
Compaction water addition W = 4 % (0,04)
Bitumen volume in kilogramme per minute [kg/min] MB = B x T x V x ρM x ZB
MB = 2.4 x 0.2 x 5 [m/min] x 2,200 [kg/m3] x 0.03
MB = 158.4 [kg/min]
Bitumen volume in litre per minute [l/min] QB = MB : ρB
QB = 158.4 [kg/min] : 1 [kg/l]
QB = 158.4 [l/min]
(Maximum displacement)
Bitumen consumption in litre per hour [l/h] QB = MB : ρB x min/h
QB = 158.4 [kg/min] : 1 [kg/l] x 60 [min/h]
QB = 9504 [l/min]
Bitumen water in kilogramme per minute [kg/min] MSW = MB x ZSW
MSW = 158.4 [kg/min] x 0.02
MSW = 3.17 [kg/min]
Bitumen water in litre per minute [l/min] QSW = MSW : ρSW
QSW = 3.17 [kg/min] : 1 [kg/l]
QSW = 3.17 [l/min]
Bitumen water in litre per hour [l/h] QSW = MSW : ρSW x min/h
QSW = 3.17 [kg/min] : 1 [kg/l] x 60 [min/h]
QSW = 190.2 [l/h]
Compaction water in kilogramme per minute [kg/min] MW = B x T x V x ρM x W
MW = 2.4 x 0.2 x 5 [m/min] x 2,200 [kg/m3] x 0,04
MW = 211,2 [kg/min]
Compaction water in litre per minute [l/min] QW = MW : ρW
QW = 211,2 [kg/min] : 1 [kg/l]
QW = 211.2 [l/min]
Compaction water in litre per hour [l/h] QW = MW : ρW x min/h
QW = 211,2 [kg/min] : 1 [kg/l] x 60 [min/h]
QW = 12672 [l/h]

348 / 370
Installation, assembly and conversion instructions, set-up tasks
6 INSTALLATION, ASSEMBLY AND CONVERSION

INSTRUCTIONS, SET-UP TASKS
6.00 General
6.00.01 General instructions
All activities described in Main Group 6 "INSTALLATION, ASSEMBLY AND
CONVERSION INSTRUCTIONS, SET-UP TASKS" must be completed (depend-
ing on the equipment of the machine) before starting-up the machine and before
on-site operation. Otherwise the machine may be damaged or the results may
be unsatisfactory.
The assembly/removal and set-up of various parts of the machine and items of
equipment are described in the following sections.
Basic requirement:
 The machine is parked on a flat, even surface
 The machine is parked on a firm sub-base
6.01 Programmable logic control (PLC)

6.01.01 Display brightness / date / programme language
Set brightness (display 1) MARGIN

 Select "Display 1 brightness (day)" field with the adjuster.
 Set required brightness in %.
MARGIN

 Select "Display 1 brightness (night)" field with the adjuster.

Set brightness (display 2) MARGIN

 Select "Display 2 brightness (day)" field with the adjuster.
MARGIN

 Select "Display 2 brightness (night)" field with the adjuster.
Keyboard lighting MARGIN

 Select the "keyboard lighting" field with the adjuster.
 Switch keyboard lighting on/off.
Date MARGIN

 Select the "Date" field with the adjuster.
 Set the date.
Time MARGIN

 Select the "Time" field with the adjuster.
 Set the time.
Programme language All screens can be selected in German or other languages (depending on the
programme design), after the electrical power supply has been switched on.
MARGIN

 Select the "Language" field with the adjuster.
 Set the required language.

Diesel engine
6.01.02 IPR code

The IPR code procedure allows enabling of screens with basic electrical
settings (blocked for normal mode), for specific application conditions.
Important parameters can be changed in these screens.
Activation of this feature can only be done by WIRTGEN Customer Service.
Activation is limited to a period of three operational hours.
The operator is prompted to enter a password (IPR code) if a protected screen
is reached when navigating the on-board computer display. This area can be ex-
ited by pressing the HOME key or the ESC key.
Requesting an IPR code
 Reading the IPR code and supplying it to WIRTGEN Service.

 WIRTGEN Service generates a password and communicates it by telephone.
 Enter the password.
 The protected screens are enabled for the duration of 3 hours.
6.02 Diesel engine

6.02.01 Prior to starting the diesel engine
The machine must be lifted completely.
The milling drum must be lifted completely.

Diesel engine
Checking the fuel level
 Check the filling level of the fuel tank and fill up if necessary.
NOTE
It is essential to ensure that the fuel tank contains sufficient fuel in order to pre-
vent emptying of the fuel tank and subsequent suction of air into the drive motor.
In this case the engine must be bled.
Checking the engine oil level
 Pull out oil dipstick.

 The dipstick must indicate a level between MIN and MAX; top up engine oil, if
necessary.

Diesel engine
Checking the coolant level
 Perform visual inspection, if necessary top-up coolant.
Checking the hydraulic oil level
 Visually inspect the sight glass.

 The indication must indicate a level between MIN and MAX, if necessary top-
up hydraulic oil.

Diesel engine
Checking the oil level in the pump splitter gearbox
 Visually inspect the oil dipstick. For this pull out the oil dipstick, clean and
reinsert it lightly - the dipstick must indicate a level between MIN and MAX;
top up gear oil if required.
 Then reinsert the oil dipstick.
Main switch
 Open the cover behind the cabin.

 Set the main switch to "ON" (flag in travel direction forwards).

Diesel engine
MARGIN
EMERGENCY STOP switch

 Turn all EMERGENCY STOP switches in the direction of the arrow.
NOTE
It is to be ensured all EMERGENCY STOP switches are unlocked, otherwise it

will not be possible to start the diesel engine.
MARGIN
Joystick travelling
 Place joystick in the central position, otherwise it will not be possible to start
the diesel engine.
MARGIN
Tool exchange
 Set TOOL EXCHANGE switch to "OFF".
NOTE
It is essential to ensure that the key switch ("tool exchange" control panel on rear
milling drum scraper) is set to "OFF" - else starting of the diesel engine or start-
ing of drives / functions is not possible.
MARGIN
Milling drum drive

 Set the switch to the left; the LED goes out.

Operator's stand

6.03.01 Operator's cabin MARGIN
 Switch on electrical power supply.

 Insert key and place in central position.
MARGIN
 Place steering wheel and operator's seat in working position.

Operator's stand
Move cabin
 Move the cabin into working position.

MARGIN
MARGIN
 Switch off the electrical power supply.

 Insert the key and set to symbol "0".

Operator's stand
6.03.02 Operator's seat unit

The operator seat unit can be adapted to the relevant requirements, de-
pending on the operational mode of the machine.
NOTE
The operator's seat should be moved forward against the stop before the
operator's seat unit can be turned.
Turning the operator's seat unit (max. 90°)
 Fold both armrests to working position, pull the lever to the rear and hold it
there until the seat unit has reached the required position and is engaged.

Operator's stand
Setting up the operator's seat
1 Move the seat.

2 Adjust the seat support angle.
3 Adjust the seat rocker damping.
4 Restrict the spring travel.
5 Move the seat support.
6 Raise / lower seat (with compressed air)
7 Indication of the correct weight setting: green = correct setting / red = incor-
rect setting.
Armrests - right and left
 Loosen the screws on the right and left.

 Adjust the height of the armrests.
 Tighten the screws.

Operator's stand
 Pull the button and hold it.

 Move the armrests to the required position.
 Release the button and let it engage.
Operator's seat
 Put on the lap belt.

Operator's stand
Set the steering console
 Pull the latching lever and move the steering console to the required position.
 Push the lever downwards and lock the steering console.
 To leave the seat, press the pedal down and push the steering console for-
wards.
 After returning to the seat, pull the steering console backwards until it en-
gages in the previously set position.

Operator's stand
Setting the on-board computer
 Release the locking device and move the on-board computer to the required
position.
 Engage the locking device.
6.03.03 Mirrors
 Adjust the rear-view mirrors according to your requirements.

Operator's stand

Setting camera/monitor positions
[1] Camera (outside area left) [2] Camera (milling drum / milling
drum scraper front area)
[3] Camera (milling drum / milling [4] Camera (area behind the ma-
drum scraper rear area) chine / reverse travel)
WARNING
Danger of injury
Camera and monitor systems must not be used as safety devices to detect per-
sons or obstacles.
A system of this kind is only allowed to be used for observing the front and rear
milling drum scrapers (CAM 2+3), the left side of the machine (CAM 1) and/or for
quality control of the working result, or during reverse travel (CAM 4).
During reverse travel (CAM 4), the machine outlines can project beyond the dis-
played lines depending on the situation.
Persons or obstacles could be overlooked. Risk of fatal injury.
 Use an assistant to monitor danger areas.
 Camera and monitor systems must not be used to safeguard the danger
area.

Operator's stand
Adjusting the monitor
 Loosen the locking device.

 Set the monitor so that it can easily be seen by the operator.
 Securing the monitor.
Camera 4
 Camera has a fixed position and does not need to be aligned.

Operator's stand
Aligning camera 3
 Have a second person align the camera so that the rear area of the milling
drum or the milling drum scraper position can easily be seen on the display.
Aligning camera 2
 Have a second person align the camera so that the front area of the milling
drum or the milling drum scraper position can easily be seen on the display.

Milling drum unit
Aligning camera 1
 The camera is equipped with a magnet base, which means it can be moved
to a different position according to the operating conditions.
 Have a second person align the camera so that the required viewing area
(e.g. left machine area) can easily be seen on the display.

6.04.01 Milling drum shell
Draining and filling in milling drum coolant
(for repair work - e.g. dismantling the milling drum gearbox)

Milling drum unit
Drain milling drum coolant
 Remove filler / drain plug.

 Use the milling drum rotation device or the electrical pick extractor to turn the
milling drum until the opening is pointing downwards.
 Collect milling drum coolant in a suitable container.

Milling drum unit
Fill in milling drum coolant
 Use the milling drum rotation device or the electrical pick extractor to turn the
milling drum until the check opening is approx. in the 2 o'clock position.
 Fill the completely emptied milling drum unit with milling drum coolant.
 Close opening.

Dosing unit
6.05 Dosing unit

6.05.01 Foam bitumen consistency
The unit has been fitted with a separate spraying nozzle for taking foam
bitumen samples in order to achieve the correct foam bitumen consis-
tency before starting on-site operation. If required, samples can be taken
by means of pre-selected values by pressing a button and can be collected
in an external container (metal bucket).
MARGIN
Sample extraction before starting on-site operation:

MARGIN
 Place the container for taking samples (metal bucket) underneath the spray-
ing nozzle.
 Open the maintenance flap next to the front access ladder.
 Press the button and hold until the required sample volume has been col-
lected in the bucket.
NOTE
If the foam bitumen consistency does not comply with the specification, the per-
centage bitumen / bitumen water feed must be set again or changed (e.g. bitu-
men parameters or temperature, etc.).

Dosing unit
6.05.02 Water tank / additional water tank

Filling the water tank / ... with the external water pump
additional water tank

 Insert the water hose of an external water supply (with pump) and fill the
tank.
 Subsequently remove the water hose.
 Replace the tank lid.

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INSTRUCTION MANUAL

© Wirtgen GmbH 2012 07WR0001-9999

Document name BAL_07WR_2244971_V02_en

Date of first issue 31.07.2012

Date of amendment 25.02.2014

Copyright © Wirtgen GmbH 2012

2 / 370 BAL_07WR_2244971_V02_en © Wirtgen GmbH 2012

GENERAL INSTRUCTIONS ON THE INSTRUCTION MANUAL

The instruction manual is divided into 6 main groups:

© Wirtgen GmbH 2012 BAL_07WR_2244971_V02_en 3 / 370

© Wirtgen GmbH 2012 BAL_07WR_2244971_V02_en 5 / 370

2.01.04 Fire extinguishers........................................................................... 47

6 / 370 BAL_07WR_2244971_V02_en © Wirtgen GmbH 2012

2.13 Cleaner unit.................................................................... 86

© Wirtgen GmbH 2012 BAL_07WR_2244971_V02_en 7 / 370

3.04.04 Automatic starting/lifting-out function........................................... 145

8 / 370 BAL_07WR_2244971_V02_en © Wirtgen GmbH 2012

4.03.02 Changing the picks.......................................................................228

© Wirtgen GmbH 2012 BAL_07WR_2244971_V02_en 9 / 370

6 Installation, assembly and conversion instructions, set-up

10 / 370 BAL_07WR_2244971_V02_en © Wirtgen GmbH 2012

6.03.04 Camera / monitor system............................................................. 363

© Wirtgen GmbH 2012 BAL_07WR_2244971_V02_en 11 / 370

1.01 Preface / introduction

© Wirtgen GmbH 2012 BAL_07WR_2244971_V02_en 13 / 370

You cannot make claims under the warranty in case of:

1.01.02 Changes / caveats

1.01.03 Packaging / storage

1.01.04 Markers and symbols

14 / 370 BAL_07WR_2244971_V02_en © Wirtgen GmbH 2012

Following it will help:

© Wirtgen GmbH 2012 BAL_07WR_2244971_V02_en 15 / 370

1.01.06 CE declaration of conformity

16 / 370 BAL_07WR_2244971_V02_en © Wirtgen GmbH 2012

The machine is designed:

1.02.02 Incorrect use

1.02.03 Residual risks

© Wirtgen GmbH 2012 BAL_07WR_2244971_V02_en 17 / 370

1.03 Climatic conditions

18 / 370 BAL_07WR_2244971_V02_en © Wirtgen GmbH 2012

High ambient temperature, high altitude

In electronically controlled engines, the fuel quantity is adapted automatically.

1.04 Safety instructions

Materials (metals, plastics)

© Wirtgen GmbH 2012 BAL_07WR_2244971_V02_en 19 / 370

1.04.03 Machine-specific safety instructions

Maximum longitudinal tilt on the machine during milling = 30° (57%).

20 / 370 BAL_07WR_2244971_V02_en © Wirtgen GmbH 2012

First aid - measures for:

Contact with bitumen emulsion

Contact with cement / lime / suspension

© Wirtgen GmbH 2012 BAL_07WR_2244971_V02_en 21 / 370

22 / 370 BAL_07WR_2244971_V02_en © Wirtgen GmbH 2012

© Wirtgen GmbH 2012 BAL_07WR_2244971_V02_en 23 / 370

1.04.04 Danger zones

24 / 370 BAL_07WR_2244971_V02_en © Wirtgen GmbH 2012

1.05 Noise / vibration

The machine emits a noise level of

At the operator position a sound pressure level of

Vibration specifications according to 91/368/EEC:

Total body oscillations

Warning Attention, caution, check

Help, rescue Doors, exits, routes, stations, compartments

Instruction Specific behaviour or activity. (e.g. obligation to