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
6 // 7
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
3
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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P (kW)
[1/min]20001900180017001600150014001300120011001000800 2200
M [Nm]
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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: [email protected]