Wirtgen Service

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Over 30 years of experience

Service and repair of Wirtgen machines

Is your recycler losing power during milling, is your cold planer having track drive issues, or is the hydraulics overheating under full load? At WIBAKO, we effectively repair Wirtgen cold planers, recyclers, and soil stabilizers, resolving issues with hydraulic pumps as well as John Deere and Cummins engines. We offer mobile diagnostics directly on the construction site and comprehensive reconditioning of components in our workshop, quickly restoring machines to full operational capability.

When is it time for service?

Symptoms of engine and drive system failure in Wirtgen machines

Ignoring the first signs of wear on the power unit or working system in a cold planer or stabilizer is the quickest path to a costly breakdown of the entire road crew.

Here are key warning signs that indicate a need for diagnostics or an overhaul:

Significant drop in power under load - a situation where a Wirtgen cold planer with a John Deere or Cummins engine drastically loses RPMs after lowering the milling drum into the pavement.

Change in exhaust smoke color and intensity - thick, black smoke from the exhaust usually heralds a failure of the Common Rail injection system or turbocharger, whereas blue smoke indicates burning engine oil.

Starting difficulties and uneven operation - trouble starting the unit (both cold and warm), fluctuating engine speed, and metallic knocking sounds coming from the engine bay.

Excessive crankcase pressure - so-called blow-by (smoke from the breather), indicating wear on piston rings and cylinder liner walls.

Rapid loss of operational fluids - a sudden increase in engine oil consumption or loss of coolant.

 

No more smoking and power drops

Specialized team for internal combustion engines

When the power unit in your Wirtgen loses dynamics or consumes excessive amounts of oil, temporary roadside repairs are not enough. At WIBAKO, we perform advanced, major overhauls of engines used in this brand's machinery – including high-performance John Deere, Cummins, Caterpillar, or Deutz units.

We restore factory technical specifications with the utmost precision. Every engine removed from a cold planer or recycler is disassembled down to the last component, cleaned, and micro-measured. As part of the overhaul, we perform complete machining of the block, crankshaft, and cylinder head, replace repair kits, and precisely recondition fuel injection and valve timing systems. As a result, your Wirtgen's engine gets a second life, guaranteeing stable operation during the toughest road construction tasks.

 

We simulate construction site conditions in our workshop

Professional load testing – engine dynamometer

At WIBAKO, we don't install engines blindly. We have our own stationary engine dynamometer rated up to 500 HP.

Every power unit powering the machines undergoes rigorous load testing that simulates extreme resistance caused by hard asphalt or concrete surfaces. During a controlled cycle, we monitor oil pressure, cooling system temperature, and injection parameters in real time. You receive a fully broken-in, verified engine along with a technical report confirming a return to nominal manufacturer parameters.

 

When to react?

Symptoms of fluid power hydraulic system failure in Wirtgen machines

Failures in the hydraulic system of road construction machinery directly translate to a loss of milling precision and traction loss. Pay attention to the following symptoms:

Reduced feed speed or lack of milling power after warming up - a drastic drop in performance as the hydraulic oil temperature rises indicates a loss of internal tightness in the main pump.

Travel and steering issues (track/wheel steering) - the machine pulls to one side, tracks operate jerkily, or one of the travel hydraulic motors loses power.

Noisy pump operation and cavitation - characteristic whining, "rattling", or foaming oil in the tank, signaling impending seizure of rotating components.

Rapid overheating of hydraulic oil - exceeding safe operating temperatures, which destroys seals throughout the entire system.

Metal shavings in filters - a clear sign of mechanical damage to piston pumps or hydraulic motors.

Our expert team will restore your machine to full performance

Specialized fluid power hydraulics team

Wirtgen machines utilize highly advanced, closed-loop hydraulic systems with high operating pressure. Our dedicated hydraulics team specializes in the reconditioning of multi-flow piston pumps, track hydraulic motors, and control valves.

We recondition drum drive systems, conveyor distributors, and the hydraulics responsible for steering and lifting columns. Instead of replacing entire components with new ones, we replace rotary groups, valve plates, and pistons. After assembly, we restore factory volumetric efficiency and control precision.

 

We minimize downtime

Fast mobile service – Wirtgen repair directly on site

Transporting a multi-ton cold planer or recycler from a construction job site to the workshop incurs massive costs and paralyzes work schedules. That is why our mobile mechanics travel directly to the site of the breakdown.

Fully equipped service vehicles allow for advanced computer and pressure diagnostics directly on the job site. We verify hydraulic test points, check sensors and valve coils, and eliminate actuator faults. In the event of severe mechanical damage, the mobile team safely disassembles the pump, travel motor, or gearbox and delivers it to our service center in Kojszówka.

 

Everything for your Wirtgen in one place

Instant access to parts – WIBAKO's own warehouse

Thanks to a massive inventory of new, used, and reconditioned components, we drastically reduce waiting times for repair. We stock hydraulic pumps, engine repair kits, seals, valves, and drive components for Wirtgen machines right on our shelves. When deploying to the field, our mobile service team takes matching parts along to fix the issue in a single visit.

 

Specialized technical overview of Wirtgen service

Machine Type Example models Most common components subject to reconditioning Scope of service work and testing
Compact / Small Cold Planers W 35 Ri, W 50 Ri, W 100 Fi, W 120 Fi Sauer Danfoss travel pumps, hydraulic motors, conveyor pumps, Deutz / Deutz TCD engines Reconditioning of pump rotary groups, sealing of lifting columns, pressure testing, engine block machining
Large Cold Planers W 150 CFi, W 200 Fi, W 210 Fi, W 220 Fi, W 250 Fi Rexroth multi-section pumps, milling drum gearboxes, Cummins / John Deere engines Major overhauls of engines >400 HP, engine dyno testing (up to 500 HP), pump regulator calibration
Recyclers and Soil Stabilizers WR 200, WR 200i, WR 240, WR 240i, WR 250 Travel hydraulic motors, water/foamed bitumen injection pumps, control valves, Cummins engines Reconditioning of high-torque hydraulic drives, hydraulic dyno testing, valve repair
Slipform Pavers / Finishers SP 15, SP 25, SP 500, SP 94 Track systems, hydraulic pumps powering vibrators, piston motors Sealing, reconditioning of travel drive hydraulic pumps, tuning of proportional valves

Put your machine in the hands of professionals

Wirtgen machine models and types that we service and recondition

We service the full catalog of road construction machinery from manufacturer Wirtgen, regardless of production year and electro-hydraulic system complexity:

Compact cold planers: W 35, W 35 Ri, W 50, W 50 Ri, W 60, W 100, W 100 Fi, W 100 CFi, W 120, W 120 Fi, W 130 CFi.

Large cold planers: W 150, W 150 CFi, W 1900, W 200, W 200 Fi, W 200 Hi, W 210, W 210 Fi, W 220, W 220 Fi, W 250, W 250 Fi.

Recyclers and soil stabilizers (WR series): WR 200, WR 200i, WR 240, WR 240i, WR 250, WR 2500, WR 2500 S.

Shoulder pavers and concrete slipform pavers (SP series): SP 15, SP 15i, SP 25, SP 25i, SP 500, SP 64, SP 94, SP 1500.

Mobile cold recycling mixing plants: KMA 200, KMA 220, ΚΜΑ 220i.

 

Do you provide a warranty on reconditioned hydraulic pumps and overhauled engines?

Yes. We provide a full written warranty on all hydraulic components (pumps, hydraulic motors) reconditioned in our workshop, as well as on internal combustion engines after a major overhaul. Before release, every component undergoes rigorous load testing on our stationary test bench, which is confirmed by an attached technical report.

Do you have spare parts for older Wirtgen models (e.g., the W 2000 or WR 2500 series)?

Yes, we service both the latest Fi series and older generations of Wirtgen machines. Our in-house warehouse stocks a wide selection of new components, aftermarket parts, and factory-rebuilt assemblies available off the shelf, helping to avoid weeks of waiting for imported parts.

Do you provide mobile service for Wirtgen machine breakdowns abroad or on highway construction sites?

Yes, our mobile service teams handle service calls across all of Poland—including infrastructure projects (expressway and highway construction sites, night contracts)—and also carry out field service assignments in neighboring countries upon prior agreement of logistical terms.

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