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The W2000 and Its Role in Road Rehabilitation
The Wirtgen W2000 cold milling machine was introduced in the early 2000s as part of Wirtgen’s push to modernize road surface removal. With a milling width of up to 2 meters and a maximum milling depth of 320 mm, the W2000 was designed for high-production asphalt and concrete removal. It became a staple in highway resurfacing, airport runway rehabilitation, and urban street repair.
Wirtgen, founded in Germany in 1961, pioneered cold milling technology and remains a global leader in surface preparation equipment. The W2000 was one of their most successful models, with thousands sold across Europe, North America, and Asia. Its combination of hydraulic precision, conveyor efficiency, and operator visibility made it a favorite among contractors.
Conveyor Bearing Replacement Challenges
One of the more difficult maintenance tasks on the W2000 involves replacing the bearings at the bottom of the discharge conveyor. These bearings support the rotating shaft that drives the conveyor belt, and over time they wear due to dust, vibration, and thermal cycling.
Accessing the bearing block typically requires removing four bolts. However, one bolt is notoriously difficult to reach—it sits directly behind the front drum mount on the lift arm assembly. This arm raises and lowers the milling drum and is structurally integrated into the frame, making direct access nearly impossible without partial disassembly.
A technician in Utah encountered this issue and found that while three bolts were accessible with standard tools, the fourth was blocked by the drum lift mount. After several attempts, he devised a workaround using a custom-cut wrench and a flexible ratchet extension.
Creative Access Techniques and Tooling
To reach obstructed bolts in tight spaces:
Bearing Selection and Installation Tips
When replacing conveyor bearings:
Preventive Maintenance and Conveyor Longevity
To extend conveyor system life:
Conclusion
The Wirtgen W2000 remains a powerful and precise milling machine, but certain maintenance tasks—like conveyor bearing replacement—require ingenuity and specialized tools. With careful planning, creative access solutions, and preventive care, technicians can keep these machines running smoothly even in the most demanding conditions. In road rehabilitation, uptime is everything—and sometimes, the hardest bolt to reach is the one that teaches the most.
The Wirtgen W2000 cold milling machine was introduced in the early 2000s as part of Wirtgen’s push to modernize road surface removal. With a milling width of up to 2 meters and a maximum milling depth of 320 mm, the W2000 was designed for high-production asphalt and concrete removal. It became a staple in highway resurfacing, airport runway rehabilitation, and urban street repair.
Wirtgen, founded in Germany in 1961, pioneered cold milling technology and remains a global leader in surface preparation equipment. The W2000 was one of their most successful models, with thousands sold across Europe, North America, and Asia. Its combination of hydraulic precision, conveyor efficiency, and operator visibility made it a favorite among contractors.
Conveyor Bearing Replacement Challenges
One of the more difficult maintenance tasks on the W2000 involves replacing the bearings at the bottom of the discharge conveyor. These bearings support the rotating shaft that drives the conveyor belt, and over time they wear due to dust, vibration, and thermal cycling.
Accessing the bearing block typically requires removing four bolts. However, one bolt is notoriously difficult to reach—it sits directly behind the front drum mount on the lift arm assembly. This arm raises and lowers the milling drum and is structurally integrated into the frame, making direct access nearly impossible without partial disassembly.
A technician in Utah encountered this issue and found that while three bolts were accessible with standard tools, the fourth was blocked by the drum lift mount. After several attempts, he devised a workaround using a custom-cut wrench and a flexible ratchet extension.
Creative Access Techniques and Tooling
To reach obstructed bolts in tight spaces:
- Use a low-profile ratcheting box wrench with a cutaway handle
- Employ a flexible socket extension with a universal joint
- Heat and bend a standard wrench to match the required angle
- Remove adjacent components such as guards or hydraulic lines for clearance
- Use a mirror and flashlight to guide tool placement
Bearing Selection and Installation Tips
When replacing conveyor bearings:
- Use sealed, high-load roller bearings rated for dust exposure
- Confirm shaft diameter and housing dimensions before ordering
- Apply anti-seize compound on bolt threads to ease future removal
- Torque bolts to spec using a calibrated wrench
- Grease bearings with high-temperature lithium complex grease
- Inspect shaft for wear or scoring before reassembly
Preventive Maintenance and Conveyor Longevity
To extend conveyor system life:
- Clean belt and rollers daily to remove asphalt buildup
- Check belt tension weekly and adjust as needed
- Inspect bearings for noise or play every 250 hours
- Replace worn scraper blades to prevent belt damage
- Monitor hydraulic motor temperature and flow rate
- Keep spare bearings and bolts in field kits
Conclusion
The Wirtgen W2000 remains a powerful and precise milling machine, but certain maintenance tasks—like conveyor bearing replacement—require ingenuity and specialized tools. With careful planning, creative access solutions, and preventive care, technicians can keep these machines running smoothly even in the most demanding conditions. In road rehabilitation, uptime is everything—and sometimes, the hardest bolt to reach is the one that teaches the most.
