Maximum performance in large-scale opencast mining Surface Miner 4200 SM
Reaching new performance dimensions with the 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 efficiency and flexible adaptability to most diverse operating conditions 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.
High yield rates make the miner an economical, cost-effective machine Just one machine in operation Surface mining does away with a whole bundle of timeconsuming work processes Drilling Blasting Loading Crushing Wirtgen surface miner 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 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. The diameter of the cutting drum installed in the 4200 SM model for hard rock permits high cutting performance. Discharge conveyors of different lengths and variable loading height ensure optimum loading of the trucks on hand. 2// 3
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 design of the cutting drum such as the best choice of cutting tools and their arrangement on the drum to any given application 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.
Forged steel part for exceptionally high resistance to wear and tear Unique wear plate for easy insertion of tools and optimum tool protection High-quality carbide metal for top-quality cutting results Cutting proves more effective than drilling and blasting Toolholder welded into the prism of the bottom part Clamping sleeve made of spring steel for easy tool replacement Especially tough and wear-resistant, yet easily weldable Heavy-duty design with larger diameter compared to the HT6 system Each cutting drum is designed in line with the specific operating conditions it is intended for, using state-of-theart 3D CAD technology The new HT14 heavy-duty quickchange toolholder system (option) for the quick replacement of tools and reduced machine downtimes 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. 4// 5
Reliable loading of large quantities of rock 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.
Economic efficiency, high power The movable counterweight provides stability and is easily retracted when working along steep sidewalls Slewing angles of up to 90 to both sides allow perfect adjustment to conditions in the deposit The crusher bar prevents the material from breaking into large slabs, protecting the conveyors from wear and tear The primary conveyor transports the material to the discharge 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 counterrotating 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. 6// 7
Manoeuvrability a key efficiency driver 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.
Quick and easy manoeuvring Separately height-adjustable crawler track units Small turning circle through steering the front and rear crawler track units in opposite directions The heavy-duty crawler track units are driven separately by hydraulic motors Easy manoeuvring of the 4200 SM increases operator comfort, enabling the machine operator to remain fully focused on the actual job. The four crawler tracks can be adjusted in height separately via hydraulic cylinders to allow accurate setting of the cutting depth and lateral inclination. Effortless turning manoeuvres and modest space requirements increase productivity by keeping nonproductive times as short as possible. The advance rate of the surface miner can be adjusted continuously from zero to maximum speed. 8// 9
No compromises in operator comfort and safety The standardized FOPS roof effectively protects the operator from falling objects The panorama cabin can be swivelled about 45 in all directions to guarantee optimum visibility Ergonomic design of operator s platform increases operator comfort The productivity of the 4200 SM increases in proportion 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.
Safety at work comes first Wide, hydraulically operated access ladders provide safety and convenient access All major control functions and joysticks are conveniently integrated in the seat s armrests The driver s seat can be swivelled about 135 to either side including the controls in the armrests 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 extinguishers and covers on all rotating parts. The cabin s location on the side of the machine opposite the embankment wall is yet another major criterion for safety at work. 10 // 11
Cut costs with minimum service requirements 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 access 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.
Low servicing requirements Hydraulic cutting tool driver and extractor for quick tool replacement The engine compartment inside the machine offers ample room to move for maintenance procedures Convenient access to the points of maintenance via access ladders and walkways In addition to the prolonged maintenance intervals, extra big fuel and water tanks ensure extended productive uptimes. The optional HT14 quick-change toolholder system ensures quick tool replacement, low wear and tear, and therefore high daily production rates. The low investment costs in just one operator, one machine, one maintenance crew and spare parts for one machine pay off quickly. Convenient access to the cutting drum and quick positioning by means of the drum turning device optimize the simple replacement of cutting tools. 12 // 13
Complete regular procedures quickly and conveniently Intelligent details offering sound financial benefits The filling station is reached quickly and easily from the ground Replacing belts in the blink of an eye: lower conveyor frame hydraulically, detach and remove 1 Discharge conveyor in working position 2 Position of discharge conveyor for detachment of primary conveyor 1 Primary conveyor in working position 2 Primary conveyor in position for detachment 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 machine, 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 primary conveyor is simple and does not require any additional steps, thus preventing long machine downtimes during belt replacement.
4200 SM high-end miner: the perfect choice for large-scale opencast mining Cutting performance of the Wirtgen 4200 SM surface miner 3000 2500 Drum diameter: 1,860 mm Milling depth: 0-830 mm Drum diameter: 1,500 mm Milling depth: 0-650 mm Unconsolidated rock Solid rock Fine-grained rock Coarse-grained rock Cutting performance (m 3 /h) 2000 1500 1000 500 0 10 20 30 40 50 60 70 80 UCS (MPa) 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, crushes 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-cylinder diesel engine, yet impresses also in terms of economic efficiency on account of its low specific fuel consumption and automatically engageable power control. 14 // 15
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 GmbH Reinhard-Wirtgen-Str. 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