| Machine | Wirtgen W210i (cold milling machine) |
|---|---|
| ECU | Cummins CM2250 |
| Solution | Stage 1 (around +20 %) + DPF off* + EGR off* |
The situation
A cold milling machine is one of the hardest duty cycles in road construction: the engine runs at full load for as long as the drum is in the asphalt, and every interruption stops a whole paving train behind it. On the W210i the Cummins engine under the CM2250 has the reserve for that work. The after-treatment is the weak point – a DPF that regenerates in the middle of a cut and an EGR system that fouls the intake and costs output over time.
The contractor wanted more power at the drum for deeper and faster cuts, and a machine that does not stop for regenerations while the crew is waiting.
What we did
The CM2250 was read and the file developed for this software version. Three things were addressed in one file.
- Stage 1: injection quantity, rail pressure and boost adjusted within the limits of the stock hardware – around 20 % more power with a matching torque curve, so the drum holds its speed under load instead of bogging down. Torque, exhaust temperature and rail pressure are monitored and capped, not simply pushed.
- DPF: regeneration logic disabled, back-pressure model and sensors neutralised – no forced regenerations during a cut.
- EGR: valve closed in software – clean intake, no recirculated soot, stable combustion temperatures.
Checksum corrected and the file written to the ECU.
The result
Around 20 % more power, a noticeably quicker throttle response and no after-treatment stops. With the engine no longer working against back-pressure, the machine does the same cut with less fuel. For the contractor this means a higher milling rate per shift and a paving train that is not held up by the machine in front of it. Files for the CM2250 are developed from the original read of each machine, not from a generic base – the software version decides what the file looks like.
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* Emission-related solutions (DPF, EGR, AdBlue/SCR) are intended for off-road, agricultural, export and motorsport use only, where permitted by local law. The operator is responsible for legal use in their market.
