Maximum performance in large-scale opencast mining

Surface Miner 4200 SM

Cut, crush and load in a single working pass

The 4200 SM surface miner is the ideal choice for the

mining of hard rock or soft rock on a truly grand scale.

Tremendous mining capacity, unmatched economic efficien-

cy and flexible adaptability to most diverse operating condi-

tions and mining regulations count among the outstanding

hallmarks of this high-performance machine. Up to 3,000 tons

per hour of material can be mined in a single operation, with

a single machine and a one-man crew. The four conventional

work steps of drilling, blasting, loading and crushing are

eliminated, as are the unpleasant side effects of dust and

noise. And what’s more: the simple process incurs low

levels of capital expenditure and operating costs, and the

reliable Wirtgen after-sales organisation ensures excellent

availability around the globe.

Reaching new performancedimensions with the 4200 SM

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The 4200 SM surface miner is on offer in two different

model versions – one for the mining of hard rock, and

one for the mining of soft rock.

The diameter of the cutting drum installed in the

4200 SM model for hard rock permits high cutting

performance.

The 4200 SM for soft rock has been designed for a high

conveying capacity – its cutting drum with large diameter

permits the throughput of large material quantities.

Discharge conveyors of different lengths and variable

loading height ensure optimum loading of the trucks on

hand.

Just one machine in operation

Surface mining does away with a whole bundle of time-consuming work processes

High yield rates make the miner aneconomical, cost-effective machine

Wirtgen surface miner

Drilling Blasting Loading Crushing

Mining rock in a single cutting operation

Cutting drum dimensions customized to performance

The cutting drums of the 4200 SM from Wirtgen are

made-to-measure products: they are adapted to the

required grain size, hardness of the material to be mined,

and other customer-specific requirements. Tailoring the de-

sign of the cutting drum – such as the best choice of cutting

tools and their arrangement on the drum – to any given ap-

plication is based on the unique expertise gained in several

decades of experience in the field of cutting technology.

The cutting drum works against the miner’s direction of

travel in an effective way: the favourable angle of penetration

produces a comma-shaped chip which breaks out upwards.

Energy consumption during the mining operation is thus

reduced, vibration levels are kept to a minimum, and the

machine works much more efficiently.

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Using cutting tools of top quality, which are specially

tailored to both the operation and the machine, the

4200 SM achieves top production rates at low tool

wear and tear.

Unlike drilling and blasting, mining by cutting easily

complies with the strict requirements in terms of safety,

vibrations, dust and noise.

In tough opencast mining operation, the miner’s

mechanical cutting drum drive with multiple V-belts is

distinctive for its high efficiency and ease of maintenance.

The fluid coupling installed upstream of the drive system

absorbs vibrations, operates wear-free and requires little

maintenance.

Cutting proves moreeffective than drilling

and blasting

The new HT14 heavy-duty quick-change toolholder system (option)for the quick replacement of toolsand reduced machine downtimes

Each cutting drum is designed in line with the specific

operating conditions it isintended for, using state-of-the-

art 3D CAD technology

Clamping sleevemade of spring

steel for easy toolreplacement

Unique wear plate for easy insertion of tools andoptimum tool protection

Toolholder welded into the prism of thebottom part

High-qualitycarbide

metal for top-quality

cutting results

Heavy-duty design withlarger diameter compared

to the HT6 system

Forged steel part for exceptionally high resistance to wear and tear

Especially tough and wear-resistant, yet easily weldable

Flexibility comes as standard

Optimized loading is of vital importance to ensure the

economical mining of large mineral deposits. Not only

the ample conveying capacity of the 4200 SM’s loading

conveyor leads by example in this regard, however, but also

its outstanding flexibility: a tremendous slewing angle of

180°, height adjustment and continuously adjustable belt

speed ensure the smooth loading of large transport trucks

even in space-restricted conditions. The material is passed

onto the loading conveyor immediately after cutting,

dispensing with laborious and time-consuming loading after

blasting by means of separate loading equipment – one

machine and one operator is all that it takes. It is not only

this part of the operation, however, but the entire process of

mining, crushing and loading that is completed in a smooth

and cost-effective way.

Reliable loading of large quantities of rock

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The primary conveyor transports the material to the dis-

charge conveyor, which is available in two different

lengths to ensure optimum loading of different truck

sizes in opencast mining.

The conveyor drive has tremendous power reserves

to ensure full conveying capacity even when mining

ores of high specific weight.

Loading towards the rear, combined with the counter-

rotating cutting drum, guarantees an excellent material

flow.

The 16-m long discharge conveyor (optional) permits

the powerful loading of all heavy-duty trucks in the 240-t

class.

Economic efficiency,high power

The crusher bar prevents thematerial from breaking into largeslabs, protecting the conveyors

from wear and tear

Slewing angles of up to 90° toboth sides allow perfect adjust-ment to conditions in the deposit

The movable counterweightprovides stability and is easilyretracted when working along

steep sidewalls

Moving into position without losing time

Despite its huge size, the 4200 SM is surprisingly

manoeuvrable and easy to handle. This is due in no

small measure to the surface miner’s all-track steering,

which no other steering system is able to match up to. The

smooth hydraulic steering system enables large angles of all

four crawler track units. In addition, two switchable flow

dividers act as differential lock and ensure uniform traction

even when working on extremely difficult ground. The

system permits three different steering modes: the rear and

front crawler tracks are steered in opposite directions when

moving into position; the front tracks are steered to produce

long, straight cuts; and all four crawler tracks are steered in

the same direction in crab mode to enable the miner to be

repositioned laterally.

Manoeuvrability – a key efficiency driver

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Easy manoeuvring of the 4200 SM increases operator

comfort, enabling the machine operator to remain fully

focused on the actual job.

Effortless turning manoeuvres and modest space

requirements increase productivity by keeping non-

productive times as short as possible.

The four crawler tracks can be adjusted in height sepa-

rately via hydraulic cylinders to allow accurate setting of

the cutting depth and lateral inclination.

The advance rate of the surface miner can be adjusted

continuously from zero to maximum speed.

Quick and easy manoeuvring

The heavy-duty crawler track units are driven separately

by hydraulic motors

Small turning circle throughsteering the front and rear crawlertrack units in opposite directions

Separately height-adjustablecrawler track units

Ergonomic design of operator’s platform increases operator comfort

The productivity of the 4200 SM increases in propor-

tion to the miner operator being able to focus on his

job. We have therefore made sure that he can always feel

well and safe. The cabin is located above the front, left-hand

crawler track unit – far away from the cutting drum and the

engine, soundproof and isolated against vibration. To ensure

perfect visibility during loading and steering, the entire, fully

glazed cabin can be swivelled about 45° to both sides. The

individually adjustable driver’s seat can additionally be

swivelled about 135° to either side. Effortless control of the

entire mining operation is ensured by the clearly structured

control panel and controls integrated in the armrests.

Air-conditioning and heating systems come as standard,

permitting work independent of weather conditions and

complementing the 4200 SM’s comfort package.

No compromises in operator comfort and safety

The standardized FOPS roofeffectively protects the operatorfrom falling objects

The panorama cabin can beswivelled about 45° in all directions

to guarantee optimum visibility

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The comprehensive lighting system with numerous

Xenon spotlights brightly illuminates the entire machine,

the surface ahead of the machine and the discharge

area.

The access ladders and walkways made of anti-skid

grating are illuminated to comply with specific mining

regulations.

Additional, authority-approved safety features include

the FOPS roof, a second emergency exit, fire extinguish-

ers and covers on all rotating parts.

The cabin’s location on the side of the machine oppo-

site the embankment wall is yet another major criterion

for safety at work.

Safety at work comes first

The driver’s seat can be swivelledabout 135° to either side – including

the controls in the armrests

All major control functions and joysticks are convenientlyintegrated in the seat’s armrests

Wide, hydraulically operatedaccess ladders provide safety

and convenient access

Keeping downtimes to a minimum

Machine maintenance is synonymous not only with

costs but also with costly downtimes. The 4200 SM

impresses with low maintenance requirements, prolonged

maintenance intervals and thus extremely short downtimes.

Maintenance is due after every 1,000 hours only. The points

of maintenance are safely accessible via wide, brightly lit ac-

cess ladders and walkways, and are easily reached thanks

to wide-opening service panels. Maintenance procedures

on the clearly arranged points of servicing are completed in

just a few swift moves. It goes without saying that reliable

technical support on site and the supply of spare parts and

wearing parts pose no problem at all: the availability of the

4200 SM on an everyday basis is ensured by around

60 sales and service companies around the globe.

Cut costs with minimum service requirements

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In addition to the prolonged maintenance intervals, extra

big fuel and water tanks ensure extended productive

uptimes.

The low investment costs in just one operator, one

machine, one maintenance crew and spare parts for

one machine pay off quickly.

The optional HT14 quick-change toolholder system

ensures quick tool replacement, low wear and tear, and

therefore high daily production rates.

Convenient access to the cutting drum and quick

positioning by means of the drum turning device

optimize the simple replacement of cutting tools.

Low servicingrequirements

Convenient access to the points of maintenance via

access ladders and walkways

The engine compartment insidethe machine offers ample room tomove for maintenance procedures

Hydraulic cutting tool driver and extractor for quick tool replacement

Complete regular procedures quickly and conveniently

Time-saving features that pay off quickly

It has been our top priority in the design of the 4200 SM

to permit regular procedures during operation to be

carried out quickly and easily. High-quality components and

design optimizations, such as a larger oil sump, enable the

maintenance intervals to be extended from 250 to 1,000

hours. After opening the service panel at the side of the ma-

chine, the readily accessible filling station allows easy supply

with operational materials and consumables. The long travel

range of the front height adjustment permits convenient,

spacious access to the cutting drum for the replacement of

cutting tools. Particularly effective: detachment of the pri-

mary conveyor is simple and does not require any additional

steps, thus preventing long machine downtimes during belt

replacement.

Intelligent detailsoffering soundfinancial benefits

The filling station is reached quicklyand easily from the ground

Replacing belts in the blink of an eye: lower conveyor frame

hydraulically, detach and remove

Discharge conveyor in working position

Primary conveyor in position for detachment

Primary conveyor in working position

2

Position of discharge conveyor fordetachment of primary conveyor

1

2

1

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4200 SM high-end miner: the perfectchoice for large-scale opencast mining

No job is too big for our biggest surface miner! It is the

prime choice for mine operators and customers in

large-scale opencast mining whose goal is to achieve an

annual mining capacity in soft rock of up to 12 million tons

with a single machine. Conventional methods, on the other

hand, require four working steps. The 4200 SM cuts, crush-

es and loads rock with unconfined compressive strengths of

up to around 80 MPa while producing even, stable surfaces

at the same time. The 4.20 m wide cutting drum has a small

diameter for working in hard rock, and a large diameter for

mining soft rock. The giant is driven by a powerful 16-cylin-

der diesel engine, yet impresses also in terms of economic

efficiency on account of its low specific fuel consumption

and automatically engageable power control.

Drum diameter: 1,500 mm Milling depth: 0 - 650 mm

Drum diameter: 1,860 mm Milling depth: 0 - 830 mm

Solid rock

Unconsolidated rock

Fine-grained rock

Coarse-grained rock

3000

2500

2000

1500

1000

500

0

Cut

ting

per

form

ance

(m3 /

h)

UCS (MPa)

10 20 30 40 50 60 70 80

Cutting performance of the Wirtgen 4200 SM surface miner

Illustrations are non-binding and may include customized fittings. Subject to technical changes. Performance data depend on operational conditions. No. 25-14 EN-04/09 © by Wirtgen GmbH 2009. Printed in Germany

Wirtgen GmbHReinhard-Wirtgen-Str. 2 · 53578 Windhagen · Germany

Phone: +49 (0) 26 45 / 131-0 · Fax: +49 (0) 26 45 / 131-242Internet: www.wirtgen.com · E-Mail: info@wirtgen.com