Efficient milling in the 1-m class
Cold Milling Machine W 100 / W 100 i
Effective cold milling machine for
­asphalt packages and surface courses
Compact, reliable, geared for the future
By designing the state-of-the-art W 100 / W 100 i cold
milling machine, the Wirtgen engineers have succeeded in strengthening the company’s leading position
in the 1-m class. The machine precisely meets the high
requirements in terms of economic efficiency and performance: The reliable, highly versatile cold milling machine
holds its own easily on medium-sized to large milling jobs.
In this way, the W 100 / W 100 i offers its user great benefits
at favourable operating costs. Particular highlights in this
regard are the machine’s modern levelling system, excellent ease of maintenance and generously dimensioned
water and fuel tanks.
The rear loader offers
ease of operation and an
excellent cost-benefit ratio
Rely on the
W 100 / W 100 i for
economic efficiency
The W 100 / W 100 i can optionally be supplied without
canopy and without loading
conveyor
The engine of the W 100 complies with the specifications stipulated by exhaust emission standards EC
Stage 3a / US Tier 3; the engine of the W 100i complies with those stipulated by EC Stage 3b / US Tier 4i.
LEVEL PRO, the automatic levelling system specially
developed for milling operations, optimizes handling
and produces highly accurate milling results of superior quality.
Transport of the milled material from the milling drum
housing is effected quickly and reliably by the powerful
rear loading system.
Exceptionally manoeuvrable wheel units permit fast
travel between construction sites.
2 // 3
Compact rear loader
with large milling width
The 1-m machine can be relied on – whatever the job
The W 100 / W 100 i is the largest rear loader in the
Wirtgen portfolio and can remove complete asphalt packages at milling depths of up to 300 mm in one
single pass. Its large milling width makes it suitable also,
however, for the removal of surface courses on a large
scale. Milling off a 50 mm a
­ sphalt surface course at daily
production rates of up to 5,000 m2 is therefore the ideal
application for this machine. The W 100 / W 100 i perfor-
mance diagram can be used to estimate the actual milling
performance to be expected in each specific case. In this
exercise, an allowance factor accounts for ­parameters or
circumstances having an adverse effect on performance,
such as interruptions by traffic, waiting periods until trucks
arrive, discontinuous milling areas, road fixtures or a
course including many turns and bends.
Efficient pavement
­rehabilitation on
­medium and
large surfaces
Milling depth (cm)
32
28
Hard asphalt
Soft asphalt
24
Most frequent operating area
20
16
12
8
4
Advance
0
rate (m/min)
0 2 4 6 8 1012141618202224
Theoretical area
performance
0
500
1.000
(m2 / h)
Open stretch of motorway
(allowance factor: 0.6)
0
Practical area
performance
(m2 / h)
500
Country road, long haulage
distance of trucks
(allowance factor: 0.5)
0
250
500
Practical area
performance
(m2 / h)
Country road, through traffic
interrupts work
(allowance factor: 0.4)
0 100200300400500
The state-of-the-art engine and direct mechanical milling drum drive guarantee full performance up to
a milling depth of 300 mm.
The W 100 / W 100 i is the ideal candidate for the removal of all types of medium to large road pavements.
Practical area
performance
(m2 / h)
Powerful milling of pavement
­layers at depths of up to 300 mm
Calculation of area performance,
taking account of varying site
­conditions
The generously dimensioned conveyor system ensures
fast and uninterrupted loading of the milled material.
The W 100/W 100i is easily capable of achieving high
daily production rates even in very difficult operating
conditions.
4 // 5
High-tech – yet easy to command
Handling the W 100 / W 100 i is child’s play
The W 100 / W 100 i offers great ease of operation,
enabling highly productive work right from the start.
Clearly arranged controls enable the milling machine to be
handled intuitively while the unambiguous symbols provide
clarity and safety. All levers and switches have been de-
signed with functionality in mind, and have been arranged
in line with functional groups and frequency of operation.
All things considered, the simple operating concept of the
state-of-the-art W 100 / W 100 i enables the operator to
remain fully focused on his job.
Easy operation via the
right-hand armrest
Unmatched ease
of operation
Depth indication via
a wire-rope gauge
Clearly arranged controls and
­unambiguous graphic displays
All controls are arranged within convenient reach and
offer maximum clarity for easy operation.
The control panels are equipped with lockable covers
to protect the machine against unauthorized use.
All major controls have been integrated into the
­right-hand armrest and allow convenient, one-hand
operation.
6 // 7
An ergonomically optimized
­workplace boosts performance
Fully equipped operator’s platform for maximum operator comfort
Anybody who has ever spent several hours operating a milling machine knows that an ergonomically d
­ esigned workplace is of utmost importance. The
W 100 / W 100 i impresses with practical solutions also in
this regard: Both the vibration-damped driver’s seat and
the steering wheel can be ­individually adjusted to suit the
operator’s body size. Whether working in upright or seated
position: The ergonomic ­platform offers ample space and
legroom, and enables the operator to conveniently see the
milling edge at all times.
For no-fatigue,
­intuitive operation
The canopy protects from sun and
rain exposure, and can be adjusted
to the operator’s seating position
All in full view because the
seat can be moved out over
the side of the machine
The adjustable steering wheel
­ upports ergonomic operation
s
both in upright and seated position
The operator’s platform of the W 100 / W 100 i offers
ample space and a good overview of the construction
site.
The comfortable, adjustable driver’s seat can be
moved both in the direction of travel and out over the
right side of the machine.
A perfect view of the milling edge sets new ­standards
in this machine class.
Elastically supported treads minimize the impact of
­machine vibrations on the operator.
8 // 9
LEVEL PRO: the mature
high-precision levelling system
Levelling technology meeting highest demands
The W 100 / W 100 i can optionally be equipped with
the state-of-the-art LEVEL PRO system, a levelling
system that will spark your enthusiasm immediately. An
innovative and highly practical feature is that it permits up
to three sensor signals to be displayed simultaneously.
Another highlight is the ­panel, which has been arranged
within optimum reach of the machine operator and allows
convenient, one-finger operation. The convincing overall
picture is completed by the ­redesigned graphical function
symbols and large, clearly arranged switches.
Wire-rope sensor for
precise milling depth control
High-tech –
easy to handle
Clearly structured control panel
Automatic
ON/OFF
Switchover
button
Set value
Actual value
Controller output
Memory 1
Set values can be pre-programmed individually for
both sides of the machine, stored by pressing the
memory button and then retrieved as and when required.
Different sensors, such as the wire-rope sensor or
slope sensor, can be selected or de-selected during
the milling operation as required.
Settings
Set value
RAISE /
LOWER
Calibration
Cylinder
RAISE /
LOWER
Memory 2
The levelling mode with related sensors can be
­addressed at any time during the milling operation.
The actual levelling controller is located separately
in the electrical cabinet, safely protected against any
damage.
10 // 11
Operating precisely and efficiently
even in tricky situations
Full control from the perfectly
­located operator’s platform
Extremely large steering
angles for tight radii
Flexibility is a valuable asset
Perfect manoeuvrability and easy handling are
needed when milling in narrow bends. That is why
we have ­provided the front wheels of the W 100 / W 100 i
with an exceptionally large steering lock. In addition, the
right-hand rear wheel can be swivelled in front of the mill-
ing drum quickly and conven­iently – a feature that can be
optimized further by means of a hydraulic function. The
practical principle allows flush-to-kerb milling right up to
walls or other obstacles – while guaranteeing a perfect
view of the milling edge at the same time.
Superior ease
in narrow bends
Right-hand rear wheel
in folded-out position
Right-hand rear wheel
in folded-in position
Ample ground clearance at the
wheel for safe operation
The machine offers two different speed options (fast
or slow) for adjustment in height via the rear wheels.
Three milling gears permit different advance speeds
of the machine during the milling operation.
Ample ground clearance at the hydraulic motors of
the rear wheels protects them from damage by, for
­instance, high kerbstones.
The front wheels can be turned about up to nearly
80 degrees.
12 // 13
Broad range of milling drums
offers superior flexibility
Cutting technology – Wirtgen’s core competency
The W 100 / W 100 i is fully geared to meet all challenges in field operation. Both the optimized arrangement of the toolholders on the milling drum and clever
tooling of the drum edges ensure excellent milling power,
a clean milling texture and quiet operation of the machine
at the same time. Centrally arranged ejectors reliably
transport the milled material from the drum housing. As a
special feature, the Flexible Cutter System (Light) permits
the use of milling drums with different tool spacings. This
option increases both the range of applications and the
overall utilization of the machine. In addition, drums with
different tool spacings are installed quickly and with ease.
Cutting tools are replaced
in next to no time
Wide range of
­applications
FCS Light for a multitude
of applications at a milling
width of 1 m
Standard milling drum
Milling width:
1,000 mm
Milling depth:
0 – 300 mm
Tool spacing:
15 mm
FCS milling drum
Milling width:
Milling depth:
Tool spacing:
FCS fine milling drum
Milling width:
1,000 mm
Milling depth:
0 – 100 mm
Tool spacing:
8 mm
FCS micro fine milling drum
Milling width:
1,000 mm
Milling depth:
0 – 30 mm
Tool spacing:
6x2 mm
1,000 mm
0 – 300 mm
15 mm
The milling drum provides good access for the
­replacement of cutting tools, which is carried out
quickly using standard tools.
Optimum arrangement of the tools on the milling drum
guarantees milling patterns that comply with the highest quality requirements.
FCS Light enables milling drums to be exchanged
quickly and easily for applications with different tool
spacings.
Further special milling drums are available on ­request.
14 // 15
Practical functions guarantee
­successful operation
HT11 quick-change toolholder
­system – tools for the pros
Wear markers at 5 mm
­intervals for improved
monitoring
Hydraulically adjustable
drum plate for clean loading
of the milled material
Chip breaking rib for
additional crushing of
milled material
Upper part covers bottom part
completely to minimize deformation of contact surface
Protective
plug prevents
soiling of bolt
head
Optimized shaft angle
geometry for improved
component strength
Large
contact surface
for improved durability
of bottom part
Strong retaining bolt
prevents unwanted
loosening of upper
part
Conical pressure
stud for reliable ­transmission of
­clamping force
Seal to allow simple
and quick insertion/
removal of upper part
For impressive milling results
The W 100 / W 100 i is equipped with many detail
features that save time and offer valuable advantages in field operation. The patented HT11 quick-change
toolholder system, for example, is yet another option to
guarantee profitable operation as it enables the toolholders
to be replaced quickly and easily. The low-wear system
is designed for heavy-duty operation on the construction
site, thus increasing the ­service life of the entire milling
drum and enabling the ­machine user to work much more
economically.
Work accurately
and flush to kerb
… while allowing the
machine to be driven along
­obstacles when raised
Powerful mechanical milling drum
drive with automatic belt tensioner
The hydraulically adjustable
side plates reliably seal the drum
housing when in working position …
The side plates protecting the milling edge can optionally be raised and lowered hydraulically, thus reliably
sealing the drum housing and permitting clean operation.
The drum plate (with optional hydraulic adjustment)
seals the drum chamber towards the front and ensures
clean loading of the milling material.
The hydraulically lifting scraper blade and lockable
side plates permit cutting tools to be replaced quickly
and safely.
Easily accessible storage compartments offer space
for more than 400 cutting tools.
16 // 17
Make the most of each job
with power and high-tech
The folding conveyor is folded
down in just a few swift moves
Powerful loading is assured
with the W 100 / W 100 i
The hydraulically
height-adjustable conveyor can
be smoothly lowered all the way
to the ground for quick removal
Economical removal of milled material
Yet another “outstanding” feature – in more than
just the figurative sense – of the W 100 / W 100 i is
the powerful loading conveyor. It has been provided with
several intelligent and highly practical details to ensure
the fast, smooth removal of the milled material. A low-­
positioned point of m
­ aterial transfer and generously
dimensioned material ­discharge, an appropriately wide
conveyor belt with rugged cleat profile, as well as continuously adjustable belt speed ensure that all is set for high
daily production rates.
Loading material
on the double
Wide loading conveyor with
­brightly lit discharge area
A long conveyor with large slewing
angle offers the flexibility needed
for optimum loading at variable belt
speeds
Generously dimensioned material
discharge for reliable loading
Optimized transfer of the milled material from the
drum chamber to the conveyor guarantees high milling
performance.
Large-volume, clean removal of the milled material is
ensured by the wide loading conveyor.
The loading conveyor has a tremendous conveying
­capacity of 115 m3/h for high daily production rates.
The transport length of the W 100 / W 100 i is reduced
considerably when equipped with the optional folding
conveyor.
18 // 19
W 100 –
high-performance engine technology
1 Exhaust system
2 Air filter
3 Diesel engine
2
3
M [Nm]
P (kW)
M [Nm]
P (kW)
1.000
200
1.000
1
900
180
900
800
800
160
160
700
700
140
140
600
600
120
500
100
500
400
80
300
60
400
80
60
40
200
100
20
40
0
100
0
20
800
900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200 2300 [1/min]
0
800
900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200 2300 [1/min]
Engine output
Torque
Maximum drive power – low emission levels
Thanks to its powerful diesel engine with high torque
increase, the W 100 is fully geared for tough everyday
operation on the job site.
120
100
300
200
0
The engine technology used in the W 100 cold milling
machine complies with the emission standards up to
EC Stage 3a / US Tier 3.
200
180
The water-cooled, low-emission diesel engine
impresses with low consumption rates.
The cold milling machine features effective soundproofing of the engine compartment as well as an
anti-vibration mounted engine station.
W 100 i –
optimizing environmental protection
1 Exhaust gas treatment by means of two-way
catalytic converter and diesel particulate filter
2 Air filter
3 Diesel engine with cooled exhaust
gas recirculation
2
3
M [Nm]
P (kW)
M [Nm]
P (kW)
1.000
900
180
180
900
1
200
200
1.000
800
800
160
160
700
700
140
140
600
600
120
500
100
500
400
80
300
60
400
120
100
80
60
300
200
40
200
100
20
40
0
100
0
20
800
900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200 2300 [1/min]
0
0
800
900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200 2300 [1/min]
Engine output
Torque
The W 100i features state-of-the-art engine technology
for lowest environmental emission levels, complying
with the stringent specifications of exhaust emission
standards EC Stage 3b / US Tier 4i.
To ensure effective exhaust gas purification, the
engine of the W 100i is equipped with a two-way
catalytic converter and diesel particulate filter.
The machine’s advance speed is governed in
accordance with the engine load, enabling the W100i
to always work at the ideal milling speed.
Low noise emission and vibration levels are just as
convincing as the machine’s low diesel consumption
rates.
20 // 21
Save time and money
with simple maintenance
Daily maintenance
made easy
Wide-opening service panels on
both maintenance sides
Practical access to
maintenance points
Ample storage space
for tools or spare parts
Reaching the goal faster with intelligent solutions
The W 100 / W 100 i scores top marks not only in milling but a
­ lso in maintenance. Wide-opening service
panels ­provide perfect access to the points of maintenance and ­inspection. These have been grouped together
and can easily be reached from the ground, enabling
visual inspections to also be carried out quickly and reli-
ably. More time is thus available for the actual task at
hand – rapid completion of the milling job. In addition, the
machine is capable of working for long productive periods
without any stoppages for refilling as large, easily refillable
water and fuel tanks permit extended milling intervals.
Fast transport,
ready for operation quickly
Optimum machine
utilization
The W 100 / W 100 i works
­effectively at all times –
­regardless of weather
conditions or the time of day
Easy loading, easy transport
The retractable canopy is
available as an equipment option
Two headlamps at the front, several flexibly adjustable
halogen spotlights and a warning beacon are part of
the comprehensive lighting package.
The machine’s transport height can be reduced to 2.65
m to enable easy transport.
The folding conveyor design reduces the overall transport length.
Ease of transport and milling operations independent
of darkness or inclement weather ensure optimum
utilization of the machine.
22 // 23
Wirtgen GmbH
Reinhard-Wirtgen-Strasse 2 · 53578 Windhagen · Germany
Phone: +49 (0) 26 45 / 131-0 · Fax: +49 (0) 26 45 / 131-242
Internet: www.wirtgen.com · E-Mail: [email protected]
Illustrations and texts are non-binding and may include customized fittings. Subject to technical changes.
Performance data depend on operational conditions. No. 2176146 09-10 EN-08/11 © by Wirtgen GmbH 2011. Printed in Germany