Efficient milling in the 1-m class Cold Milling Machine W 100 / W 100 i

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 asphalt surface course at daily production rates of up to 5,000 m 2 is therefore the ideal application for this machine. The W 100 / W 100 i performance 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.

Milling depth (cm) 32 28 24 20 16 12 8 Hard asphalt Soft asphalt Most frequent operating area Efficient pavement rehabilitation on medium and large surfaces 4 0 0 2 4 6 8 10 12 14 16 18 20 22 24 0 500 1.000 Open stretch of motorway (allowance factor: 0.6) 0 500 Country road, long haulage distance of trucks (allowance factor: 0.5) 0 250 500 Country road, through traffic interrupts work (allowance factor: 0.4) 0 100 200 300 400 500 Advance rate (m/min) Theoretical area performance (m 2 /h) Practical area performance (m 2 /h) Practical area performance (m 2 /h) Practical area performance (m 2 /h) Powerful milling of pavement layers at depths of up to 300 mm Calculation of area performance, taking account of varying site conditions 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. 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 designed 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 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.

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 supports ergonomic operation 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 Settings Switchover button Set value Set value RAISE / LOWER Actual value Controller output Calibration Cylinder RAISE / LOWER Memory 1 Memory 2 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. 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 milling 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.

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: 1,000 mm 0 300 mm 15 mm 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 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 Chip breaking rib for additional crushing of milled material Hydraulically adjustable drum plate for clean loading of the milled material Upper part covers bottom part completely to minimize deformation of contact surface Protective plug prevents soiling of bolt head Strong retaining bolt prevents unwanted loosening of upper part Conical pressure stud for reliable transmission of clamping force Optimized shaft angle geometry for improved component strength Large contact surface for improved durability of bottom part 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 material 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 m 3 /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 1 M [Nm] 1.000 900 800 700 P (kw) 200 180 160 140 600 120 500 400 300 200 100 100 80 60 40 20 0 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 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 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 2 3 Diesel engine with cooled exhaust gas recirculation 3 1 M [Nm] P (kw) 1.000 200 900 180 800 160 700 140 600 120 500 100 400 80 300 60 200 40 100 20 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 also 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 reliably. 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

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 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: info@wirtgen.com