High-quality in-place recycling of asphalt layers

Cold Recycler 3800 CR

Recycling of traffic lanes at full width in a single pass

Damaged bituminous pavement layers are recycled with economic efficiency.

100% reuse: the 3800 CR “Rear Load” transfers mix to a Vögele paver with

high-compaction screed.

It is quite obvious that the 3800 CR is

capable of recycling 3.8 m wide traf-

fic lanes seamlessly in a single pass:

the powerful recycler mixes damaged

asphalt layers with binders to convert

them into high-quality, pre-compact-

ed base layers quickly and with eco-

nomic efficiency while at the same

time minimizing disruptions to traffic.

Different injection systems give the

cold recycler superior flexibility. In ad-

dition, it offers an unparalleled range

of equipment features enabling it to

complete the job at hand in accord-

ance with the specified application or

tender specification.

Flexible concept to ensure optimum machine utilization

In paving screed design, the

3800 CR is capable of using not

only the standard up-cut mode for

recycling but also the down-cut

process developed by Wirtgen.

In conveyor design, the construction

material processed in down-cut

mode is transferred to an asphalt

paver following behind which places

the recycled mix immediately. In this

design, the recycler can additionally

be operated as a high-performance

cold milling machine using the

standard up-cut process.

2 //3

Two cold recycling options using a single machine

Recycling train including the 3800 CR (up-cut / down-cut):

Where specifi ed, cement is pre-spread by a Streumaster binder spreader which is followed by a water tanker and binder tanker truck. The milling and mixing rotor granulates the asphalt layers to a depth of up to 18 cm. The pre-spread cement is mixed in at the same time while water and bitumen emulsion or foamed bitumen are injected into the mixing chamber via injection bars. The recycled material is picked up by the loading conveyor and transferred right into the material hopper of the Vögele asphalt paver which places it true to line and level. Compaction is then effected by Hamm rollers.

Recycling train including the 3800 CR “Rear Load” (down-cut):

Where specifi ed, cement is pre-spread by a Streumaster binder spreader which is followed by a water tanker and binder tanker truck. The milling and mixing rotor granulates the asphalt layers to a depth of up to 15 cm. The pre-spread cement is mixed in at the same time while water and bitumen emulsion or foamed bitumen are injected into the mixing chamber via injection bars. The recycled material is spread across the entire working width by a spreading auger and placed true to line and level by the integrated Vögele paving screed. Compaction is then effected by Hamm rollers.

4 //5

Highlights: Compact recycling train ideally

suited for working in urban

environments.

Short material handling times for

ease of operation and full control

of the work process.

Simple modification allows recy-

cling in up-cut or down-cut mode.

The 3800 CR can also be used

as a cold milling machine (with

conveyor system).

Reduced labour requirements.

Highlights: Optimum material management

thanks to flexible loading concept

enables paving true to line and

level.

State-of-the-art Vögele paving

technology for highest quality

standards.

High compaction thanks to the

paver’s tamper and pressure bar.

The 3800 CR can also be used as

a cold milling machine (in up-cut

mode).

Working direction

Working direction

Perfectly engineered milling and mixing rotor for the tough jobs

The 3.8 m wide, robust milling and

mixing rotor is based on the many

decades of experience Wirtgen

has gained in milling technology.

Whether working in the conven-

tional up-cut mode with the rotor

revolving against the direction of

travel, or in down-cut mode with

the rotor revolving in the direction

of travel: the powerful rotor mixes

the different materials to produce

a homogeneous construction

material. The state-of-the-art

down-cut process enables precise

particle size control when milling

100 % asphalt material, which is

of advantage in particular when

recycling old, highly brittle asphalt

roads. Converting the 3800 CR to

up-cut milling is no problem at all.

The 3800 CR is equipped with

additional safety features when

operated in down-cut mode. In the

event of overloading, they govern

the machine’s advance speed to

prevent the recycler from being

lifted out of the milling cut.

Recycling in or against the direction of travel

6 //7

The milling and mixing rotor works in the recycler’s direc-tion of travel. This process optimizes particle size and prevents the material from breaking into larger chunks.

The milling and mixing rotor works against the recycler’s direction of travel.

Down-cut process

Up-cut process

Innovative injection systems for highly precise binder addition

As binders need to be added in

precise quantities to produce per-

fect mixes and base layers of high

quality, the 3800 CR is equipped

with state-of-the-art injection

systems.

Tanker trucks pushed by the

3800 CR deliver water and bitu-

men emulsion or hot bitumen to

the recycler’s injection systems via

coupled hose connections. Hot

bitumen is foamed prior to injection.

Foamed bitumen is produced by

adding precisely metered quantities

of water and compressed air to hot

bitumen which has a temperature

of 175° C. Production takes place

in the recycler’s injection system.

Foamed bitumen is distinctive for

its economic efficiency and ease of

handling. It is eminently suitable for

mixing with cold and moist con-

struction materials.

The binders are injected into the

mixing chamber via special injec-

tion bars. Microprocessors ensure

injection in precisely metered

quantities across the recycler’s full

working width and in accordance

with the machine’s advance speed

and recycling depth.

A great variety of mixing options

8 //9

All high-tech: electrically

heated bitumen-carrying components, non-contact fl ow meters and

self-cleaning injection nozzles.

The binder quantities to be added are keyed in at the control panel – the system is governed by microprocessors.

Hot bitumen

Expansion chamber with foam nozzle

To further nozzles

Foamed bitumen

Water Air

Foamed bitumen production

State-of-the-art cold recycling – here’s how it works

The heavy-duty milling and mixing ro-

tor – the heart of the 3800 CR – gran-

ulates the existing damaged asphalt

pavement to a depth of up to 15 cm.

The granulated material is then

mixed with injected binding agents

and water in the machine’s mixing

chamber, thus creating a new homo-

geneous mix in an in-situ process.

The mix is deposited between the

rear track units via a material guide

plate system. The spreading auger

spreads the material uniformly across

the full working width, enabling the

paving screed to precisely place and

pre-compact it at a layer thickness of

up to 15 cm.

Paving by means of an integrated paving screed

Material processing with the 3800 CR (up-cut / down-cut)

Working direction

1 Damaged asphalt layer

2 Pre-spread cement 3 Injection bars for water and binding agents 4 Milling and mixing rotor

5 Material guide plate system

6 Spreading auger

7 Paving screed

7

6

5

3

4 2

1

10 //11

The heavy-duty milling and mixing

rotor granulates the existing damaged

asphalt pavement to a depth of up

to 18 cm. The granulated material

is then mixed with injected binding

agents and water in the machine’s

mixing chamber, thus creating a

new homogeneous mix in an in-situ

process. Ejectors on the milling and

mixing rotor then transfer the mix

to the 3800 CR’s primary conveyor.

The slewable and height-adjustable

discharge conveyor forwards the mix

to the asphalt paver’s material hopper

for subsequent precise paving at a

layer thickness of up to 18 cm.

Paving by means of a separate asphalt paver

Material processing with the 3800 CR “Rear Load” (down-cut)

Working direction

1 Damaged asphalt layer

2 Pre-spread cement 3 Injection bars for water and binding agents 4 Milling and mixing rotor

5 Conveyor for material transfer to asphalt paver

5

3

4 2

1

State-of-the-art screed for high-quality paving

The 3800 CR relies on tried-and-

tested Vögele technology to guar-

antee perfect paving of the mix true

to line and level. The continuously

adjustable AB 375 T screed makes

paving easy even in bends or when

having to navigate permanent fix-

tures. A sensor-controlled spreading

auger installed in front of the screed

distributes the mix evenly across the

entire working width. The centrally

divided auger is operated in clock-

wise or counter-clockwise direc-

tion, the conveying speed of both

sections being continuously adjust-

able. The screed’s hydraulic tamper

Paving true to line and level

ensures reliable pre-compaction of

the recycled pavement layer.

The integrated automatic levelling

system ensures paving of the recy-

cled mix precisely to the specified

level. The resulting base layer pro-

vides an ideal base for the subse-

quent construction of a new asphalt

surfacing.

The screed’s hydraulically mova-

ble side plate is yet another useful

feature as it is capable, for example,

of redirecting excess material for

shoulder reinforcement.

Paving around road fixtures is no problem at all thanks to

the hydraulically adjustable screed.

3.8 m wide paving unit with high-compaction Vögele paving

screed and spreading auger.

12 //13

Reliable material loading even under full load

In rear-loading mode, the powerful conveyor transfers the mix to an asphalt paver.

The 3800 CR has been designed

for maximum performance and is

therefore equipped with a powerful

conveyor system offering excep-

tionally high conveying capacities.

The slewing and height-adjustable

discharge conveyor enables huge

amounts of material to be moved

quickly and with maximum flexibility.

When cold recycling in rear-loading

mode, the machine’s discharge con-

veyor forwards the recycled asphalt

mix to the material hopper of an

asphalt paver for immediate placing

and compaction.

Flexibility comes as a standard feature

Excess material is simply removed

from the process and loaded into

trucks via the slewable discharge

conveyor.

A tracked paver from Vögele is the

ideal candidate for completing this

job. It is equipped with a high-com-

paction screed that guarantees

prime, variable quality – as is

customary for the paving of asphalt

base layers. In addition, the hopper

acts as an ideal buffer offering am-

ple storage capacity.

The discharge conveyor fills the paver’s material hopper at adjustable belt speeds.

The 3800 CR as a high-performance milling machine

To ensure full machine utilization,

the 3800 CR can be operated not

only as a recycler but also as an

efficient high-performance milling

machine. An ultra-strong engine and

high conveying capacity make it the

ideal choice for milling jobs involv-

ing extremely high outputs such as

the removal of asphalt pavements

at full depth. High advance rates

and milling depths of up to 35 cm

ensure the quick completion of large

construction projects, such as the

replacement of surface courses on

motorways or airport runways.

Tremendous range of applications

The machine can also be used to

mill off thin pavement layers prior

to recycling in order to retain the

previous level after construction of

a new surface course on top of the

recycled layer.

The variable discharge convey-

or belt speed enables even large

articulated trucks to be loaded to

full capacity. Wide slewing angles

allow trucks to change “on the fly”,

enabling the milling operation to

continue non-stop.

Equipped with a fine milling drum, the 3800 CR is capable of roughening

road surfaces or improving their evenness and skid resistance.

The dual machine concept enables efficient operation as a high-

performance cold milling machine.

14 //15

Ease of operation for effortless milling and recycling

The 3800 CR not only plays a dual

role as a cold recycler and cold

milling machine but is also operat-

ed in opposite directions depend-

ing on the job to be completed.

Flexible positioning of both control

panels allows ease of operation

while offering perfect visibility and

ergonomics at the same time.

The functionally identical control

panels on the left and right can

be adjusted individually in height

and tilt. They can be moved far to

the outside as can the two driver’s

seats, allowing optimal handling

of the machine from either side.

When changing the machine’s

working direction, the control

panels are simply turned about

180° and attached on the opposite

side of the spacious operator’s

platform. In addition, numerous

functions can be operated by the

ground crew via separate control

panels.

The user-friendly LEVEL PRO lev-

elling system is yet another useful

feature. Highly precise results are

guaranteed – whatever the job.

Maximum productivity

Repositioning the control panels – in the machine’s direction of travel – allows optimal handling of the 3800 CR both during recycling in rear-loading mode …

… and when used as a

cold milling machine.

The anti-vibration mounted operator’s platform offers perfect visibility both in upright and seated position.

Impressive manoeuvrability

The height-independent, parallel sliding block guide ensures precise steering angles.

Sometimes even a true giant

becomes incredibly small – in this

case, when turning is called for.

The compact 3800 CR owes its

outstanding manoeuvrability to an

intelligent all-track steering system

which is clearly superior to any

other steering system. The smooth

hydraulic steering system enables

large angles of all four track units

resulting in an extremely small

turning radius of the entire ma-

chine. The selectable differential

lock provides the required traction

at a consistently high level regard-

less of ground conditions. And the

3800 CR has even more to offer in

crab steering mode: it unerringly

approaches the track to be milled

even in extremely restricted space

conditions.

Individually height-adjustable track

units provide high ground clear-

ance, making previously difficult

manoeuvres a routine exercise.

Reversing or loading the recycler

onto a flatbed truck poses no

problem at all.

All-track drive with maximum traction

The hydraulic steering system enables large angles of all four track units.

16 //17

Maintenance – completed in no time at all

The 3800 CR leads by example

when it comes to combining max-

imum productivity with the lowest

possible amount of maintenance.

At the mere push of a button,

hydraulic cylinders open the large

engine cowling. All points of main-

tenance are arranged in a clear

pattern and can be conveniently

accessed. Replacing the hydraulic,

air, fuel, return line and bitumen

filters poses no problem at all. To

simplify maintenance procedures,

lubrication and service points have

been grouped together intelligently.

Improved productivity

Point-attack cutting tools are

replaced quickly and easily using

the hydraulic tool extractor and

automatic rotor turning device.

The extremely hard-wearing HT22

toolholder system is distinctive

for its exceptionally high durability

which pays off in everyday operation

on site by significantly extended

replacement intervals.

Quick cutting tool replacement with the hydraulic tool extractor guarantees ease of maintenance.

Maintenance is made totally easy as the entire machine offers ready access.

P [kW]

[1/min]180017001600150014001300120011001000900 2100

M [Nm]

1000

2200

1200

1400

1800

2000

3000

0

300

50

150

500

1900

1600

2400

100

200

250

350

400

4502800

2600

2000 2200

M [Nm]

[1/min]2100190017001500130011001400

1600

1800

2000

2200

2400

2600

2800

3000

3200

3400

1000 1200 1400 1600 1800 2000 2200900100

150

200

250

300

350

400

450

500

550

600

P [kW]

650

700

3600

3800

High-performance engine technology

To be able to recycle or mill off

complete pavements quickly

and efficiently, the 3800 CR is

equipped with a tried-and-tested

12-cylinder diesel engine. And the

state-of-the-art engine unleashes

tremendous power when it counts:

an intelligent machine management

system controls the advance rate

of the cold milling machine de-

pending on the engine load, which

not only results in fuel savings but

also reduces noise emission lev-

els. A perfectly obvious standard

feature: the engine compartment

is fitted with a highly effective,

all-round sound insulation.

In addition, the mechanical milling

and mixing rotor drive enables

permanently high output rates

while ensuring highly efficient

operation at the same time.

Additional benefits of the smooth

power belt drive in tough every-

day operation on site are low fuel

consumption, high wear resistance

and ease of maintenance. An

automatic belt tensioner ensures

uniform power transmission at all

times.

Engine always runs within the optimal range

Highly efficient

mechanical rotor drive.

In the operating range of the 3800 CR, the engine output remains constant even in case of extreme engine lugging.

Engine power

Torque

Operating range

Transport made easy

The machine is transported on a standard flatbed truck.

The 3800 CR can be easily trans-

ported on a flatbed truck. Heavy-

duty lashing lugs enable the machine

to be securely lashed down for

transport. Sturdy conveyor support

legs are on offer as a separate option.

In addition, the self-propelled

WT 440 mounting carriage en-

sures easy handling of the milling

and mixing rotor unit regardless

of whether installation, removal or

transport is called for. Loaded with

the rotor, the mounting carriage fits

underneath the cold recycler easily,

Easy handling of the milling and mixing rotor unit

offering ideal support during instal-

lation and removal. When used for

transport, the self-propelled WT 440

– loaded with the rotor unit – drives

from the 3800 CR right onto the flat-

bed truck, or from the flatbed truck

right up to the 3800 CR.

The WT 440 mounting carriage is an effective aid for transport, installation and handling of the rotor unit.

18 //19

Technical specifi cation 3800 CR

Dimensions in mm

9,700

Special equipment: Canopy

Special equipment: with spreading auger and paving screed

16,400

5,900

3,200 1,1002,300 **

3,00

0

4,00

0

3,00

0 * 4,

800

2,7001,500

600 ***

4,25

0

2,98

0

2,80

0

1,66

0

1,68

0

3,80

0

R 4,600 with screedR 2,300 without screed

16,900 *

19,200

45°

55°

1,10

0

1,50

0

1,60

0

* = dimensions for low-loader transport** = screed and auger*** = auger

20 //21

* = weight of machine with half-full water tank, half-full fuel tank, driver (75 kg) and on-board tools, excluding optional equipment

Machine weights

Empty weight of machine without filling media 52,010 kg

Operating weight, CE * 55,270 kg

Operating weight, max. 58,350 kg

Transport weights of individual components

Weight of machine without milling drum assembly 32,100 kg

Weight of discharge conveyor 1,800 kg

Weight of milling drum assembly, milling width 3,800 mm 16,600 kg

Weights of filling media

Water tank filling in kg 5,000 kg

Diesel tank filling in kg (0.83 kg / l) 1,160 kg

Optional equipment features increasing / reducing empty weight

Driver and tools

Driver 75 kg

On-board tools 30 kg

Optional additional equipment

Spreading auger and paving screed 4,600 kg

Front weight 3,500 kg

Canopy 280 kg

Cold recycler 3800 CR with front weight, without discharge conveyorDimensions in mm

4009,700

3,00

0

Basic machine Hydraulically opening, soundproof engine cowling Engine cooling system with temperature-governed

fan speed Storage compartments for cutting tool containers Standard painting in Wirtgen white with orange stripes

Milling drum assembly Mechanical cutting drum drive via multiple V-belts with

automatic belt tensioner Milling drum housing of wear-resistant material Hydraulic gradation control beam with conveyor lift

function Hydraulically adjustable scraper blade with manual

locking mechanism Two milling drum speeds Electrically engageable water spray bar in milling drum

assembly Machine equipped for milling in up-cut mode

Milling drum Milling drum, milling width 3.800 mm, HT22 quick-

change toolholder system, tool spacing 15 mm

Loading of milled material Conveyor system with manually or automatically

adjustable conveying speed Hydraulically lifting primary conveyor Material guiding system with hydraulically operated

closing panel to primary conveyor

Cold recycling system Injection system with 1 pump and 1 injection bar

Machine and levelling control Clearly structured main control panel with functional

switches Multi-functional control screen including display of

major machine parameters Engageable, automatic milling power control unit Engageable, automatic traction control

Two exterior control panels for operation by ground staff

Digital height indicator LEVEL PRO automatic levelling system with hydraulic

milling depth sensors at the side plates, left and right Milling depth measurement via sensor package and

display on LEVEL PRO screen

Operator’s platform Anti-vibration mounted, walk-through operator’s

platform Individually adjustable comfort control panels Individually adjustable comfort driver’s seats, left and

right Dual access to operator’s platform Two mirrors at the front, one mirror at the rear of the

machine

Chassis and height adjustment All-track steering system with freely selectable steering

modes Double grouser track pads Inner material guide plates at the rear track units Fourfold full-floating axle for high machine stability Intelligent track speed control with hydraulic all-track

drive Extremely wear-resistant EPS polyurethane track pads

Miscellaneous Lighting package with 6 halogen working lights and

3 halogen flashing beacons Comprehensive toolkit in lockable toolbox Safety package with 6 emergency stop switches European design type certification, GS mark (Geprüfte

Sicherheit = Tested Safety) and CE conformity Standard warranty of 12 months or 1,000 engine

operating hours Machine commissioning by qualified personnel Comprehensive operating manual and machine

documentation

Equipment features of 3800 CR

Standard equipment

Basic machine Special painting in one or several colours Air intake with cyclonic pre-cleaner

Milling drum assembly Drum turning device for cutting tool replacement Hydraulically lifting edge protection plates Machine equipped for milling in down-cut mode Front weight, 3,500 kg, in combination with down-

cut equipment for machine not fitted with discharge conveyor

Pneumatic cutting tool extractor

Loading of milled material Conveyor support legs for transport on a flatbed truck

Cold recycling system Injection system with 2 pumps and 2 injection bars Injection system for foamed bitumen with 2 pumps

and 2 injection bars Injection bar (without pump, for use with WM 1000) Hot-bitumen hose for connection to bitumen tanker,

various lengths Hose for the transfer of water-cement slurry (without

pump)

Paving unit Spreading auger with scraper Variable screed with tamper Hydraulically openable side plates Ultrasonic sensors for screed control on one side,

including digital controller Slope controller for steering the variable screed

Machine and levelling control RAPID SLOPE cross slope sensor Sonic ski sensor for scanning a stringline Multiplex sensors with two additional ultrasonic

sensors including bracket and cable in 3-fold or 7-fold Multiplex system package, left

Wirtgen information and diagnosis system WIDIS 32

Operator’s platform Hydraulically extendable and retractable canopy

Miscellaneous Screen system including display Lighting system including 6 LED working lights

and 3 LED flashing beacons Compressed air system Rear water filling port High-pressure water wash down Electrically operated diesel tank filling pump Hydraulically operated water tank filling pump

Optional equipment

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

Milling drum

Working width 3,800 mm

Milling depth / Recycling depth *1 0 – 350 mm / 0 – 150 mm

Tool spacing 15 mm

Number of tools 294

Drum diameter with tools 1,140 mm

Engine

Manufacturer Caterpillar

Type C27 ATAAC

Cooling water

Number of cylinders 12

Rated power at 2,100 min-1 708 kW / 950 HP / 963 PS

Fuel consumption at rated power 187 l / h

Fuel consumption in field mix 75 l / h

Emission standards no EC regulation / US Tier 2

Electrical system 24 V

Tank capacities

Fuel tank 1,400 l

Hydraulic fluid tank 550 l

Water tank 5,000 l

Driving properties

Operating and travel speed 0 – 84 m / min (0 – 5 km / h)

Theoretical gradeability 90%

Ground clearance 370 mm

Crawler tracksCrawler tracks (L x W x H) 2,200 x 370 x 790 mm

Conveyor system

Belt width of primary conveyor 1,100 mm

Belt width of discharge conveyor 1,100 mm

Theoretical capacity of discharge conveyor 668 m3 / h

Shipping dimensions

Machine without milling drum assembly (L x W x H) 9,700 x 2,800 x 3,000 mm

Machine without milling drum assembly with paving screed (L x W x H) 14,300 x 3,050 x 3,000 mm

Machine with milling drum assembly (L x W x H) 9,700 x 4,400 x 3,000 mm

Milling drum assembly, milling width 3,800 mm (L x W x H) 4,400 x 2,950 x 2,250 mm

Discharge conveyor (L x W x H) 8,700 x 1,700 x 1,300 mm

Front weight (L x W x H) 1,800 x 1,700 x 1,000 mm

Technical specification 3800 CR

Wirtgen GmbHReinhard-Wirtgen-Str. 2 · 53578 Windhagen · Germany

Phone: +49 (0) 26 45 / 131-0 · Fax: +49 (0) 26 45 / 131-392Internet: www.wirtgen.com · E-Mail: info@wirtgen.com

Illustrations and texts are non-binding and may include customized fittings. Subject to technical changes. Performance data depend on operational conditions. No. 2176614 58-11 EN-02/14 © by Wirtgen GmbH 2014. Printed in Germany