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Introduction to the Wirtgen W2000 Milling Machine
The Wirtgen W2000 is a high-performance cold milling machine designed for large-scale asphalt and concrete removal. With a milling width of up to 2 meters and a robust conveyor system, it’s a staple in road rehabilitation projects worldwide. However, its complex mechanical layout—especially around the drum and conveyor assembly—can present challenges during maintenance, particularly when replacing components like the lower conveyor bearings.
Terminology Clarification
- Cold Milling Machine: A road construction machine that removes pavement layers using a rotating drum equipped with cutting tools.
- Conveyor System: A belt-driven assembly that transports milled material from the drum to a truck or stockpile.
- Bearing Block: A housing that supports and secures a rotating shaft, typically containing a sealed bearing.
- Drum Lift Arm: A hydraulic arm that raises or lowers the milling drum for depth control and transport.
The Bearing Replacement Challenge
One of the more frustrating maintenance tasks on the W2000 involves replacing the bearings at the bottom of the conveyor belt. While three of the four bolts securing the bearing block are accessible, the fourth bolt is notoriously difficult to reach—it sits directly behind the front drum mount on the lift arm assembly. This positioning restricts tool access and visibility, especially when the drum is installed.
Field Techniques for Accessing Hidden Bolts
Experienced technicians have developed several strategies to tackle this issue:
- Raise the drum fully using the hydraulic lift system, then secure it with mechanical locks to prevent movement during work.
- Use a low-profile ratcheting wrench or flex-head socket to reach behind the drum mount.
- Remove adjacent components such as guard plates or hydraulic lines to create temporary access space.
- Fabricate a custom offset wrench or extension tool to reach the bolt without removing the drum.
- In extreme cases, partially dismount the drum assembly to expose the bolt directly.
Recommended Parameters and Tooling
In Utah, a milling crew faced downtime when their W2000’s lower conveyor bearing failed mid-project. The fourth bolt was inaccessible due to the drum mount. Rather than disassembling the drum, the lead technician used a custom-fabricated wrench made from a cut-down socket welded to a flat bar. With patience and precision, they removed the bolt and replaced the bearing in under two hours—saving a full day of disassembly.
Preventive Maintenance Recommendations
To reduce the likelihood of bearing failure and simplify future replacements:
The W2000’s compact design prioritizes milling efficiency and conveyor throughput. Unfortunately, this results in tight packaging around the drum and conveyor interface. Engineers often face trade-offs between serviceability and performance. In newer models like the W210Fi, modular bearing housings and improved access panels have been introduced to address these concerns.
Conclusion: Ingenuity Overcomes Obstruction
Servicing the Wirtgen W2000’s lower conveyor bearings demands more than mechanical skill—it requires creativity, patience, and a deep understanding of the machine’s layout. While the fourth bolt may seem unreachable, field-tested techniques and custom tools can turn a frustrating task into a manageable repair. In the world of road milling, the path to precision often runs through the narrowest spaces.
The Wirtgen W2000 is a high-performance cold milling machine designed for large-scale asphalt and concrete removal. With a milling width of up to 2 meters and a robust conveyor system, it’s a staple in road rehabilitation projects worldwide. However, its complex mechanical layout—especially around the drum and conveyor assembly—can present challenges during maintenance, particularly when replacing components like the lower conveyor bearings.
Terminology Clarification
- Cold Milling Machine: A road construction machine that removes pavement layers using a rotating drum equipped with cutting tools.
- Conveyor System: A belt-driven assembly that transports milled material from the drum to a truck or stockpile.
- Bearing Block: A housing that supports and secures a rotating shaft, typically containing a sealed bearing.
- Drum Lift Arm: A hydraulic arm that raises or lowers the milling drum for depth control and transport.
The Bearing Replacement Challenge
One of the more frustrating maintenance tasks on the W2000 involves replacing the bearings at the bottom of the conveyor belt. While three of the four bolts securing the bearing block are accessible, the fourth bolt is notoriously difficult to reach—it sits directly behind the front drum mount on the lift arm assembly. This positioning restricts tool access and visibility, especially when the drum is installed.
Field Techniques for Accessing Hidden Bolts
Experienced technicians have developed several strategies to tackle this issue:
- Raise the drum fully using the hydraulic lift system, then secure it with mechanical locks to prevent movement during work.
- Use a low-profile ratcheting wrench or flex-head socket to reach behind the drum mount.
- Remove adjacent components such as guard plates or hydraulic lines to create temporary access space.
- Fabricate a custom offset wrench or extension tool to reach the bolt without removing the drum.
- In extreme cases, partially dismount the drum assembly to expose the bolt directly.
Recommended Parameters and Tooling
- Bolt size: Typically M16 or 5/8" hex head
- Torque spec: 120–150 Nm depending on bearing type
- Clearance required: Minimum 60 mm between drum mount and bearing block
- Tool suggestions:
- Flex-head ratchet with 3/8" drive
- Offset box-end wrench
- Magnetic pickup tool for bolt retrieval
- Inspection mirror and LED light for visibility
In Utah, a milling crew faced downtime when their W2000’s lower conveyor bearing failed mid-project. The fourth bolt was inaccessible due to the drum mount. Rather than disassembling the drum, the lead technician used a custom-fabricated wrench made from a cut-down socket welded to a flat bar. With patience and precision, they removed the bolt and replaced the bearing in under two hours—saving a full day of disassembly.
Preventive Maintenance Recommendations
To reduce the likelihood of bearing failure and simplify future replacements:
- Lubricate conveyor bearings every 100 hours with high-temp grease
- Inspect bearing blocks monthly for signs of wear or misalignment
- Replace seals and gaskets during scheduled downtime
- Use anti-seize compound on mounting bolts to ease future removal
- Document bolt torque and access notes for future technicians
The W2000’s compact design prioritizes milling efficiency and conveyor throughput. Unfortunately, this results in tight packaging around the drum and conveyor interface. Engineers often face trade-offs between serviceability and performance. In newer models like the W210Fi, modular bearing housings and improved access panels have been introduced to address these concerns.
Conclusion: Ingenuity Overcomes Obstruction
Servicing the Wirtgen W2000’s lower conveyor bearings demands more than mechanical skill—it requires creativity, patience, and a deep understanding of the machine’s layout. While the fourth bolt may seem unreachable, field-tested techniques and custom tools can turn a frustrating task into a manageable repair. In the world of road milling, the path to precision often runs through the narrowest spaces.
