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

By designing the state-of-the-art W 100 / W 100 i cold

milling machine, the Wirtgen engineers have suc-

ceeded 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 perfor-

mance: 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, excel-

lent ease of maintenance and generously dimensioned

water and fuel tanks.

Compact, reliable, geared for the future

2 // 3

The engine of the W 100 complies with the specifica-

tions stipulated by exhaust emission standards EC

Stage 3a / US Tier 3; the engine of the W 100i com-

plies 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 supe-

rior 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.

Rely on the W 100 / W 100 i for

economic efficiency

The rear loader offers ease of operation and an excellent cost-benefit ratio

The W 100 / W 100 i can op-tionally be supplied without canopy and without loading conveyor

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 as-

phalt 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 asphalt 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.

4 // 5

The state-of-the-art engine and direct mechanical mill-

ing 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 re-

moval of all types of medium to large road pavements.

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.

Efficient pavement rehabilitation on

medium and large surfaces

Powerful milling of pavement layers at depths of up to 300 mm

Calculation of area performance, taking account of varying site conditions

Hard asphalt

Soft asphalt

Most frequent operating area

Country road, long haulage distance of trucks(allowance factor: 0.5)

Country road, through traffic interrupts work(allowance factor: 0.4)

Open stretch of motorway(allowance factor: 0.6)

Practical area performance (m2/h)

Practical area performance (m2/h)

Practical area performance (m2/h)

0 500

0 250 500

0 100 200 300 400 500

Milling depth (cm)32

28

24

20

16

12

8

4

0 0 2 4 6 8 10 12 14 16 18 20 22 24

0 500 1.000

Advance rate (m/min)

Theoretical area performance (m2/h)

High-tech – yet easy to command

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.

Handling the W 100 / W 100 i is child’s play

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All controls are arranged within convenient reach and

offer maximum clarity for easy operation.

All major controls have been integrated into the

right-hand armrest and allow convenient, one-hand

operation.

The control panels are equipped with lockable covers

to protect the machine against unauthorized use.

Unmatched ease of operation

Easy operation via the right-hand armrest

Depth indication via a wire-rope gauge

Clearly arranged controls and unambiguous graphic displays

An ergonomically optimized workplace boosts performance

Anybody who has ever spent several hours oper-

ating a milling machine knows that an ergonomi-

cally designed 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.

Fully equipped operator’s platform for maximum operator comfort

8 // 9

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.

All in full view because the seat can be moved out over the side of the machine

The adjustable steering wheel supports ergonomic operation

both in upright and seated position

For no-fatigue, intuitive operation

The canopy protects from sun and rain exposure, and can be adjusted to the operator’s seating position

LEVEL PRO: the mature high-precision levelling system

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.

Levelling technology meeting highest demands

10 // 11

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 re-

quired.

Different sensors, such as the wire-rope sensor or

slope sensor, can be selected or de-selected during

the milling operation as required.

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.

High-tech – easy to handle

Wire-rope sensor for precise milling depth control

Switchover button

AutomaticON/OFF

Set value

Actual value

Controller output

Memory 1

Settings

Set valueRAISE / LOWER

Calibration

CylinderRAISE / LOWER

Memory 2

Clearly structured control panel

Operating precisely and efficiently even in tricky situations

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 conven iently – 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.

Flexibility is a valuable asset

Full control from the perfectly located operator’s platform

Extremely large steering angles for tight radii

12 // 13

Superior ease in narrow bends

The machine offers two different speed options (fast

or slow) for adjustment in height via the rear wheels.

Ample ground clearance at the hydraulic motors of

the rear wheels protects them from damage by, for

instance, high kerbstones.

Three milling gears permit different advance speeds

of the machine during the milling operation.

The front wheels can be turned about up to nearly

80 degrees.

Ample ground clearance at the wheel for safe operation

Right-hand rear wheel in folded-out position

Right-hand rear wheel in folded-in position

Broad range of milling drums offers superior flexibility

The W 100 / W 100 i is fully geared to meet all chal-

lenges in field operation. Both the optimized arrange-

ment 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 technology – Wirtgen’s core competency

14 // 15

The milling drum provides good access for the

replacement of cutting tools, which is carried out

quickly using standard tools.

FCS Light enables milling drums to be exchanged

quickly and easily for applications with different tool

spacings.

Optimum arrangement of the tools on the milling drum

guarantees milling patterns that comply with the high-

est quality requirements.

Further special milling drums are available on request.

Wide range of applications

FCS Light for a multitude of applications at a milling width of 1 m

Cutting tools are replaced in next to no time

FCS fine milling drumMilling width: 1,000 mmMilling depth: 0 – 100 mmTool spacing: 8 mm

Standard milling drumMilling width: 1,000 mmMilling depth: 0 – 300 mmTool spacing: 15 mm

FCS micro fine milling drumMilling width: 1,000 mmMilling depth: 0 – 30 mmTool spacing: 6x2 mm

FCS milling drumMilling width: 1,000 mmMilling depth: 0 – 300 mmTool spacing: 15 mm

Practical functions guarantee successful operation

The W 100 / W 100 i is equipped with many detail

features that save time and offer valuable advan-

tages 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.

For impressive milling results

Strong retaining bolt prevents unwanted loosening of upper part

Conical pressure stud for reli-able transmission of clamping force

Seal to allow simple and quick insertion/

removal of upper part

Chip breaking rib for additional crushing of

milled material

Optimized shaft angle geometry for improved component strength

Wear markers at 5 mm intervals for improved monitoring

Upper part covers bottom part completely to minimize defor-mation of contact surface

Large contact surface

for improved durability of bottom part

Protective plug prevents soiling of bolt head

Hydraulically adjustable drum plate for clean loading of the milled material

HT11 quick-change toolholder system – tools for the pros

16 // 17

The side plates protecting the milling edge can option-

ally be raised and lowered hydraulically, thus reliably

sealing the drum housing and permitting clean opera-

tion.

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.

Work accurately and flush to kerb

… while allowing the machine to be driven along

obstacles when raised

The hydraulically adjustable side plates reliably seal the drum

housing when in working position …

Powerful mechanical milling drum drive with automatic belt tensioner

Make the most of each job with power and high-tech

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 material transfer and generously

dimensioned material discharge, an appropriately wide

conveyor belt with rugged cleat profile, as well as continu-

ously adjustable belt speed ensure that all is set for high

daily production rates.

Economical removal of milled material

The folding conveyor is folded down in just a few swift moves

The hydraulically height-adjustable conveyor can be smoothly lowered all the way to the ground for quick removal

Powerful loading is assured with the W 100 / W 100 i

18 // 19

Loading material on the double

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.

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

W 100 – high-performance engine technology

Maximum drive power – low emission levels

The engine technology used in the W 100 cold milling

machine complies with the emission standards up to

EC Stage 3a / US Tier 3.

Thanks to its powerful diesel engine with high torque

increase, the W 100 is fully geared for tough everyday

operation on the job site.

The water-cooled, low-emission diesel engine

impresses with low consumption rates.

The cold milling machine features effective sound-

proofi ng of the engine compartment as well as an

anti-vibration mounted engine station.

1 Exhaust system

2 Air filter

3 Diesel engine

1 Exhaust system

2 Air filter

3 Diesel engine

1

2

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P (kW)

[1/min]20001900180017001600150014001300120011001000800 2200

M [Nm]

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[1/min]20001900180017001600150014001300120011001000800 2200

M [Nm]

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Engine outputTorque

20 // 21

The W 100i features state-of-the-art engine technology

for lowest environmental emission levels, complying

with the stringent specifi cations of exhaust emission

standards EC Stage 3b / US Tier 4i.

To ensure effective exhaust gas purifi cation, the

engine of the W 100i is equipped with a two-way

catalytic converter and diesel particulate fi lter.

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.

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

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

1

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P (kW)

[1/min]20001900180017001600150014001300120011001000800 2200

M [Nm]

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[1/min]20001900180017001600150014001300120011001000800 2200

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Engine outputTorque

Save time and money with simple maintenance

The W 100 / W 100 i scores top marks not only in mill-

ing but also in maintenance. Wide-opening service

panels provide perfect access to the points of mainte-

nance 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.

Reaching the goal faster with intelligent solutions

Daily maintenance made easy

Ample storage space for tools or spare parts

Wide-opening service panels on both maintenance sides

Practical access to maintenance points

22 // 23

Fast transport, ready for operation quickly

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 trans-

port length.

Ease of transport and milling operations independent

of darkness or inclement weather ensure optimum

utilization of the machine.

Optimum machine utilization

The W 100 / W 100 i works effectively at all times –

regardless of weather conditions or the time of day

The retractable canopy is available as an equipment option

Easy loading, easy transport

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

Wirtgen GmbHReinhard-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: info@wirtgen.com