Wirtgen WR 240i Recycler

Advanced In-Place Road Recycling Excellence for Sustainable Construction

630 HP Performance • 2.4m Working Width • 400mm Max Depth • German Engineering Excellence

630 Engine Power
(Horsepower)
2.4 Working Width
(Meters)
400 Max Recycling Depth
(Millimeters)
30 Max Working Speed
(m/min)
800+ Units Delivered
Globally

Global Sustainable Road Recycling Technology Leader

German Engineering Excellence: The Wirtgen WR 240i represents the pinnacle of in-place road recycling technology, featuring industry-leading mixing capabilities and precision depth control systems. Engineered for sustainable highway rehabilitation, municipal road reconstruction, and demanding recycling applications, it delivers unmatched environmental benefits and cost efficiency on construction sites worldwide.

Why the Wirtgen WR 240i Defines Modern Road Recycling Excellence

Advanced Recycling System + HVI Performance Analytics

Precision Recycling + Intelligent Monitoring: The WR 240i's advanced in-place recycling system delivers exceptional mixing and stabilization capabilities, enhanced by HVI's comprehensive performance tracking and efficiency optimization.

  • High-performance milling and mixing rotor
  • Variable depth recycling control system
  • HVI tracks recycling performance and material quality
  • Real-time mixing chamber monitoring
  • Automated efficiency benchmarking and reporting
HVI Integration: Monitor recycling performance and predict maintenance needs

Powerful Engine System + Fuel Intelligence

Reliable Power + Efficiency Optimization: High-performance 630 HP diesel engine provides consistent power delivery while HVI's telematics optimize fuel consumption and engine health for recycling operations.

  • 630 HP Caterpillar diesel engine for reliable operation
  • Tier 4 Final emissions compliance technology
  • Real-time fuel consumption tracking via HVI
  • Engine performance diagnostics and alerts
  • Load optimization for recycling cycles
HVI Advantage: Reduce operational costs by up to 22% through intelligent monitoring

Superior Coverage & Precision + Smart Work Monitoring

Optimal Working Width + Performance Tracking: 2.4m working width provides excellent productivity with precise recycling control, enhanced by HVI's comprehensive work cycle analysis.

  • 2.4m working width for maximum productivity
  • Variable recycling depth up to 400mm
  • HVI tracks coverage patterns and recycling progress
  • Automated production rate documentation
  • Productivity analysis and optimization tools
HVI Intelligence: Optimize recycling efficiency with automated analytics

Advanced Control System + Mobile DVIR

Precision Operation + Digital Documentation: Sophisticated LEVEL PRO control systems for precise recycling operations, complemented by HVI's mobile inspection platform for comprehensive equipment documentation.

  • LEVEL PRO automatic grade control
  • Advanced operator interface with touchscreen
  • HVI mobile app for daily equipment inspections
  • GPS-stamped condition documentation
  • Operator performance feedback integration
HVI Mobile: Complete offline inspection capability for construction sites

Versatile Applications + Intelligent Monitoring

Multi-Purpose Capability + Smart Tracking: Wide range of recycling applications with HVI's comprehensive equipment monitoring and performance tracking systems.

  • Highway and municipal road recycling
  • Airport runway and industrial surface rehabilitation
  • HVI application utilization tracking
  • Automated maintenance scheduling
  • Performance optimization by material type
HVI Intelligence: Track equipment performance and optimize utilization

Global Support Network + Smart Parts Management

Worldwide Service + Inventory Optimization: Extensive Wirtgen dealer network combined with HVI's intelligent parts forecasting and inventory management for construction operations.

  • Global Wirtgen dealer and construction support
  • Comprehensive parts availability worldwide
  • HVI automated parts ordering system
  • Predictive inventory management
  • Emergency parts expediting capabilities
HVI Supply Chain: Minimize downtime with intelligent parts management

Complete Technical Specifications

Specification Category WR 240i Performance Notes
Engine Power 630 HP (470 kW) Caterpillar C18 diesel engine
Operating Weight 42,000 kg (92,600 lbs) Standard configuration weight
Working Width 2.4 m (7.9 ft) Effective recycling width
Max Recycling Depth 400 mm (15.7 in) Single pass recycling capability
Working Speed 0-30 m/min Variable speed control
Transport Speed 20 km/h (12.4 mph) Maximum transport speed
Rotor Diameter 2,000 mm (78.7 in) Large mixing rotor
Mixing Tools 240 tools Premium mixing tool configuration
Fuel Tank Capacity 1,300 L (343 gal) Extended operating range
Water Tank Capacity 3,000 L (793 gal) Dust suppression system
Binder Tank Capacity 12,000 L (3,170 gal) Cement/lime storage
Ground Clearance 420 mm (16.5 in) Excellent obstacle clearance
Gradeability 20% Maximum climbing capability
Noise Level < 85 dB(A) Low noise operation
Emissions Standard Tier 4 Final / Stage V Clean emissions compliance

Comprehensive Safety & Protection Systems

The Wirtgen WR 240i incorporates multiple layers of safety features to protect operators and enhance jobsite safety in diverse road recycling environments.

ROPS/FOPS Certified Cab

Roll-Over and Falling Object Protective Structure meets international safety standards. Climate-controlled operator station with excellent visibility and advanced air filtration.

Advanced Warning Systems

Comprehensive safety lighting package including LED work lights, warning beacons, and backup alarms. Visual and audible alerts for critical machine parameters.

Emergency Stop Controls

Multiple emergency stop systems positioned at key locations. Immediate shutdown capability from operator position and ground level for enhanced safety.

Rotor Chamber Safety

Enclosed mixing chamber with safety guards and access controls. Emergency stops along rotor length ensure safe operation during material processing.

Dust Suppression Technology

Advanced water spray system minimizes dust generation. Enclosed mixing chamber and effective ventilation protect operators and environment.

Material Handling Safety

Automated binder delivery system with safety interlocks. Spillage prevention systems and containment measures protect personnel and environment.

Ready to Optimize Your Road Recycling Operations?

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WR 240i Maintenance Excellence with HVI Fleet Management

HVI transforms recycler maintenance into intelligent, predictive fleet management

HVI + Wirtgen Telematics Integration

Seamless Construction Integration: HVI connects directly to your WR 240i's telematics to automatically track operating hours, recycling cycles, mixing performance, and system health for complete fleet visibility.

Real-Time Monitoring: Track engine, hydraulic, and recycling systems continuously
Construction Intelligence: Specialized alerts for road recycling operations
Performance Analytics: Productivity and efficiency reporting

Engine & Power System Management

Caterpillar Engine Optimization: HVI's specialized monitoring ensures your 630 HP engine operates at peak efficiency throughout demanding road recycling operations.

  • Real-time engine parameter monitoring
  • Automated oil analysis scheduling
  • Air filter condition tracking
  • Cooling system health monitoring
  • DEF system management and efficiency tracking
HVI Intelligence: Extend engine life by 20-25% through predictive maintenance

Recycling & Mixing System Excellence

Advanced System Monitoring: Comprehensive tracking of the WR 240i's recycling rotor and mixing systems for maximum uptime and quality performance.

  • Rotor performance monitoring
  • Mixing tool wear analysis
  • Material flow optimization
  • Binder system efficiency tracking
  • Chamber temperature monitoring
HVI Advantage: Prevent costly recycling system failures through continuous monitoring

Mobile Construction Inspection Platform

Operator-Driven Quality: HVI's mobile app guides operators through comprehensive daily inspections specific to the WR 240i's recycling systems.

  • Engine compartment safety inspections
  • Hydraulic leak detection protocols
  • Rotor and mixing tool assessments
  • Binder system functionality checks
  • GPS-stamped photo documentation
HVI Mobile: Works offline on construction sites, syncs when connected

Binder & Material Handling Intelligence

Advanced Component Management: HVI's specialized monitoring maximizes binder system and material handling performance for road recycling applications.

  • Binder delivery system monitoring
  • Material flow efficiency analysis
  • Tank level management
  • Conveyor system optimization
  • Predictive component replacement
HVI Predictive: Extend system life by up to 30% through optimization

Automated Construction Workflows

Intelligent Scheduling: HVI automatically generates maintenance schedules based on actual recycling conditions and equipment health data.

  • Hour-based PM intervals (250/500/1000/2000)
  • Recycling cycle-based maintenance triggers
  • Construction parts ordering and logistics
  • Technician scheduling and dispatch
  • Compliance documentation automation
HVI Automation: Reduce maintenance planning time by 75%

Construction Performance Optimization

Data-Driven Excellence: Transform your WR 240i data into actionable insights for maximum productivity and profitability in road recycling operations.

  • Fuel efficiency benchmarking
  • Recycling production rate analysis
  • Cost per square meter calculations
  • Project productivity tracking
  • Construction ROI analysis and reporting
HVI Analytics: Road recycling customers report 25-32% improvement in productivity

Key Advantages

  • Sustainable Technology: Environmentally friendly in-place recycling
  • German Engineering: Wirtgen's renowned build quality and reliability
  • Cost Effectiveness: Significant material and transport savings
  • High Productivity: 2.4m width with 400mm depth capability
  • Superior Mixing: Excellent material homogenization
  • Global Support: Extensive Wirtgen dealer network worldwide
  • Advanced Automation: LEVEL PRO grade control systems
  • Versatile Applications: Multiple recycling material options
  • Proven Performance: Decades of reliability in demanding applications
  • Environmental Compliance: Tier 4 Final emissions technology

Considerations & Limitations

  • Significant Investment: High initial cost for specialized equipment
  • Transport Requirements: Requires specialized heavy transport equipment
  • Site Limitations: May be too large for confined urban projects
  • Operating Complexity: Requires highly skilled, experienced operators
  • Fuel Consumption: Higher operating costs than smaller machines
  • Material Limitations: Not suitable for all pavement types
  • Maintenance Complexity: Advanced systems need specialized technicians
  • Weather Sensitivity: Moisture content affects mixing quality
  • Setup Requirements: Requires material testing and design
  • Binder Costs: Cement/lime represents significant expense

The WR 240i: Setting New Standards in Road Recycling

From highway rehabilitation to municipal projects, the WR 240i delivers unmatched sustainability and cost efficiency

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How the WR 240i Compares to Competition

Feature Wirtgen WR 240i Caterpillar RM500 Volvo RX8800 Bomag MPH120
Engine Power 630 HP 590 HP 610 HP 575 HP
Working Width 2.4 m 2.2 m 2.3 m 2.0 m
Max Recycling Depth 400 mm 350 mm 380 mm 320 mm
Operating Weight 42,000 kg 41,500 kg 43,200 kg 39,800 kg
Binder Capacity 12,000 L 10,000 L 11,500 L 9,500 L
Max Working Speed 30 m/min 25 m/min 28 m/min 22 m/min
Automation Level LEVEL PRO Plus Grade Control Basic Grade Control Manual Control
Warranty Coverage 2 years/4,000 hours 2 years/3,000 hours 2 years/3,500 hours 2 years/2,500 hours

Maximize Your WR 240i ROI with HVI Fleet Management

Transform how you manage, maintain, and monitor your Wirtgen recycler fleet with construction-grade fleet management technology

HVI Construction Mobile Platform

  • Recycler DVIR: Tailored daily inspection forms for WR 240i systems
  • Engine Bay Inspections: Guided Caterpillar engine component checks
  • Recycling System Monitoring: Comprehensive rotor and mixing assessments
  • Binder System Assessment: Tank and delivery system inspections
  • OSHA Compliance: Construction safety inspection protocols
  • Offline Functionality: Complete inspection capability without connectivity

Wirtgen Telematics Construction Integration

  • Equipment Telematics: Direct integration with Wirtgen's monitoring systems
  • Engine Performance: Continuous monitoring of 630 HP Caterpillar engine
  • Recycling Intelligence: Mixing performance and efficiency monitoring
  • GPS Fleet Tracking: Location monitoring and security features
  • Construction Analytics: Detailed productivity metrics and analysis
  • Diagnostic Alerts: Instant notification of system issues

Predictive Construction Maintenance

  • Smart Scheduling: AI-driven maintenance based on recycling conditions
  • Mixing Tool Management: Predictive tool replacement optimization
  • Engine Health Monitoring: Oil analysis and performance trending
  • Hydraulic Optimization: Filter and component maintenance timing
  • Parts Forecasting: Intelligent inventory management
  • Cost Optimization: Construction maintenance budget control

Digital Construction Management

  • Maintenance History: Complete digital service records
  • Construction Compliance: OSHA and environmental regulatory reporting
  • Project Analytics: Productivity and efficiency tracking
  • Cost Analysis: True cost per square meter calculations
  • Fleet Benchmarking: Cross-equipment performance comparison
  • Construction ROI: Data-driven fleet optimization decisions

Transform Your Road Recycling Operations with HVI

Join over 3,000+ recycling operations worldwide who trust HVI to maximize their recycler ROI

Why HVI is Essential for Your WR 240i Construction Fleet

Road Recycling Expertise

Pre-built maintenance protocols specifically designed for the WR 240i's Caterpillar engine, recycling systems, and sustainable construction components.

Seamless Integration

Direct connection to Wirtgen telematics provides comprehensive monitoring of all recycler systems and construction productivity metrics.

Proven Results

HVI construction customers achieve 25-32% improvement in recycler productivity while maximizing their $1,300,000+ equipment investment.

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Setup in 15 minutes • Works with existing systems • Mobile app included

Legal Disclaimer & Important Notes

Trademark Notice: All brand names, logos, trademarks, and registered trademarks mentioned in this document, including but not limited to "Wirtgen," "WR 240i," "LEVEL PRO," and related marks, are the exclusive property of their respective owners and original equipment manufacturers (OEMs). These trademarks are used for identification purposes only.

Information Source: The specifications, features, safety information, and operational data provided are based on publicly available manufacturer content, industry publications, official Wirtgen documentation, and real-world user reviews as of August 2025. Information is provided for educational and reference purposes only.

Wirtgen Telematics Integration: Integration between Wirtgen telematics and HVI fleet management software requires customers to work with their authorized Wirtgen dealership to enable data sharing. Wirtgen telematics subscription fees apply and are separate from HVI services. Data availability depends on the specific telematics package selected by the customer.

Pricing & Availability: Pricing estimates ($1,200,000-$1,450,000) are based on industry analysis and may vary significantly by region, dealer, configuration, options, and market conditions. Contact authorized Wirtgen dealers for current pricing, availability, and specifications.

Important: Always consult the official Operation and Maintenance Manual and follow manufacturer-specific procedures. Verify all specifications with authorized dealers before making purchase decisions. Operating procedures and safety requirements may vary by region and application.

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