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Wirtgen Surface Mining

Manual
Edition 2002

This manual outlines the production and operating capabilities of the versatile Wirtgen Surface
Miners. Here we collected a lot of information to help with the selection of an appropriate
Wirtgen Surface Miner meeting your specific requirements for your jobs in hand.
The given data represent an average of our current experience based on a variety of
applications. However, depending on the specific application, given technical data are subject
to change. Since production and consumption data are based on these values, this manual
should be used for preliminary estimates and comparative purposes only.
Due to the fact that applications may vary considerably, especially regarding rock properties
and working conditions, we suggest that you contact a Wirtgen sales subsidiary or a Wirtgen
dealer if you require specific information regarding your project.
Based on detailed material, deposit and site conditions, your local Wirtgen representative, in
co-operation with Wirtgen GmbHs Mining Division, will be pleased to provide you with more
accurate data for your specific project.
Wirtgen shall have no liability for damages, consequential or otherwise, arising from the use of
this manual or any part thereof.

Wirtgen GmbH
Mining Division
Hohner Strasse 2
53578 Windhagen
Germany
Phone: + 49 - 2645 -131- 368
Fax:
+ 49 - 2645 -131- 242
E-Mail: mining@wirtgen.de

CONTENS
Page
1. THE BENEFITS AND APPLICATIONS AT A GLANCE .......................................................... 6
Main applications for Wirtgen Surface Miners .................................................................... 8
Selective Mining .................................................................................................................. 8
Material exploitation and crushing without blasting ............................................................ 9
Precise cutting of trenches, surfaces and slopes ................................................................ 10
Haulroad rehabilitation.......................................................................................................... 11
2. PHYSICAL ROCK PROPERTIES ......................................................................................... 12
3.THE MAIN TECHNICAL DATA ............................................................................................. 13
4. MAJOR DESIGN FEATURES OF WIRTGEN SURFACE MINERS ......................................... 15
5. OPERATION METHODS ...................................................................................................... 18
Harvesting method ............................................................................................................... 18
4

Block operation with ramp cutting ......................................................................................


Ramps .................................................................................................................................
Open cut ..............................................................................................................................
Special operations ...............................................................................................................
Selective mining of inclined seams .....................................................................................
Blending material while cutting on a ramp ..........................................................................
Cutting the bench and floor in a tunnel ...............................................................................
Cutting steep highwall slopes .............................................................................................
Operating conditions ...........................................................................................................
Turning radius ......................................................................................................................
Cutting and travelling on inclinations ..................................................................................
Geometrical factors .............................................................................................................

19
20
21
22
22
23
23
24
25
25
25
26

6. LOADING OPTIONS ............................................................................................................


Direct loading ......................................................................................................................
Front loader .........................................................................................................................
Rear loader ..........................................................................................................................
Smooth loading of trucks with fine material ........................................................................
Truck exchange ...................................................................................................................
Advanced truck exchange....................................................................................................
Considered truck size ..........................................................................................................
Indirect loading.....................................................................................................................
Sidecasting of the material ..................................................................................................
Windrow ...............................................................................................................................

27
28
28
28
29
29
29
30
30
30
31

7. CUTTING TECHNOLOGY ....................................................................................................


Cutting tools ........................................................................................................................
Cutting toolholder ................................................................................................................
Characteristics of different cutting tool types ......................................................................

32
33
34
35

8. TECHNICAL DATA AND DIMENSIONS ................................................................................


Surface Miner 2200 SM ......................................................................................................
Surface Miner 2500 SM ......................................................................................................
Surface Miner 3700 SM ......................................................................................................
Surface Miner 4200 SM ......................................................................................................
Dinting Machine 2600 SM ....................................................................................................

36
36
38
40
42
44

9. PRODUCTION ESTIMATE ..................................................................................................


Surface Miner 2200 SM .......................................................................................................
Surface Miner 2500 SM .......................................................................................................
Surface Miner 3700 SM ......................................................................................................
Surface Miner 4200 SM .......................................................................................................
Comments on the charts .....................................................................................................

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46
47
48
49
50
5

1.

The benefits and applications at a glance

The main advantages of the Wirtgen Surface Miner technology are:


Mining without blasting
Simplified mining technology
Enhanced quality of ROM (Run Off Mine) product by highly selective mining
Stable, clean surfaces and benches

Wirtgen Surface Miners


Possible uses

Uses in the mining sector

Uses in earthmoving
and construction

Selective mining from


thin seams of useful mineral

Production of stable
embankments

Mining rock
without blasting

Production of
defined surfaces

Producing small particle sizes


during the mining process

Production and rehabilitation


of traffic routes

Main features

Main features

High purity of the useful mineral, high


cutting performance, low price per tonne

Production of precise, stable and


defined profiles in rock

The benefits and applications at a glance

Continuous
cutting
Crushed
aggregate

Precise
cutting depth

Direct
loading

Clean, level and


stable surface

Wirtgen Surface Miner cut, crush and load material in one operation with only one machine.

These jobs are no longer required:


Cleaning, levelling and bolder splitting
Drilling

Blasting

Loading

Crushing

Wirtgen Surface Miners

The complex hard rock mining system is replaced by only one machine.

Advantages:
Improved overall availability of the system
Reduced operating cost
Several working steps are realized by only one machine, leading to easier coordination and
process planning during planning, dispatching and maintenance
The benefits and applications at a glance

Main applications for Wirtgen Surface Miners


Selective Mining
One of the most important characteristics of the Wirtgen Surface Miners is their ability to
work highly selective. Thin, disturbed seams, for example, can be mined precisely and
economically.

Is possible when using Wirtgen Surface Miners: Selective mining of thin coal seams.

Mine operators world-wide use the benefits of the Wirtgen Surface Miner technology with its
very precise cutting depth control for the production of high quality ROM material in coal,
phosphate and gypsum mines.
Selective mining with Wirtgen Surface Miners ensures that even thin seams of valuable minerals
and overburden can be mined separately.

Advantages:
Enhanced ROM-quality
Improved exploitation of the deposit
Reduced stripping ratio
Reduced processing after mining required

The benefits and applications at a glance

Material exploitation and crushing without blasting


All over the world, mine operators and construction companies use the advantages of Wirtgen
Surface Miners in numerous mine operations.

Is possible when using Wirtgen Surface Miners: Mining without blasting in the vicinity of buildings, electrical
wires etc.

Drilling and blasting is not necessary


- No vibrations
- No fly rock
Reduced noise and dust development
Production of small particle sizes directly during the mining process
- Cut material can directly be used as gravel
- Primary crushing stage can be omitted
- Gentle loading of trucks due to size of the cut material
- The material can be conveyed without further crushing.
One Wirtgen Surface Miner replaces equipment for drilling, blasting, loading and auxiliary
works i.e. boulder splitting.

Advantages:
Low investment costs in comparison to the range of equipment necessary for conventional
mining
Low operating costs due to less equipment and less personnel
Several working steps are realized by only one machine, leading to easier coordination and
process planning during planning, dispatching and maintenance
Improved exploitation of the deposit
Improved safety

The benefits and applications at a glance

Precise cutting of trenches, surfaces and slopes


Construction companies benefit from technical features of Wirtgen Surface Miners for precise
cutting of:
Trenches
Tunnel floors
Slopes
Surface profiles
in limestone, granite and other medium hard to hard minerals.

Is possible when using Wirtgen Surface Miners: Cutting limestone for a water deposit.

Is possible when using Wirtgen Surface Miners:


Lowering tunnel floors ...

... for modern railway systems with improved capacity.

Advantages:
No blasting required
Cutting of steep and stable surfaces and embankments (better exploitation)
Precise cutting of designed profiles (slopes, surfaces)
Production of small particle sizes directly during the cutting process. The granulometry of the
cut material renders it suitable to be used as gravel.
10

The benefits and applications at a glance

Haulroad rehabilitation
Wirtgen Surface Miners can be used to maintain the surface of existing haulroads in virgin rock
in opencast mines or in underground mines. Wheel ruts, floor heaves because of rock throws,
but also other hard, not rippable spots can be eliminated or smoothened.

Haulroads in an opencast mine

Haulroads in an underground mine

Advantages:
Higher overall travel speed for haulage vehicles due to better road surfaces
Reduced wear and tear of tires, mechanical and structural elements
Less fuel consumption
Improved safety
The benefits and applications at a glance

11

2.

Physical rock properties

The performance, the cutting tool consumption and the economic operation of Wirtgen
Surface Miners is significantly affected by the mechanical properties of the rock to be cut.
The main properties of rock affecting the cutting performance are:
Uniaxial compressive strength [MPa] and tensile strength [MPa]
Abrasivity
Structure of the rock (i.e. number and distance and direction of fractures)
In general, Wirtgen Surface Miners are capable of cutting rock with a hardness of between
10-80 MPa. Under certain circumstances (e.g. highly fractured material) even harder material
can be cut economically.
Please consult Wirtgens Mining Division to determine the cuttability of rock with a Wirtgen
Surface Miner based on the available information concerning the rock and the mine.

soft

hard

very hard

2200 SM

750 t/h

2500 SM

1.550 t/h

220 t/h

65 t/h

3700 SM

2,550 t/h

365 t/h

100 t/h

4200 SM

3,400 t/h

300 t/h

20

475 t/h

40

60

80

MPa

Performance data of Wirtgen Surface Miners for rock with different hardness.

Based on material density (bank) of:


1,3 t/m3 for a compressive strength of approx. 10 MPa
2,5 t/m3 for a compressive strength of 50-80 MPa
The performance data given are guideline values only. Rock with a higher uniaxial compressive
strength than stated can be cut under certain circumstances. The actual performance depends
amongst other factors also on the structure of the rock. Please consult Wirtgens Mining
Division for further information.
12

Physical rock properties

3.

The main technical data


2200 SM
Cutting width:
Cutting depth:
Engine:
Weight:
Cutting drum drive:
Number of tracks:
Track drive system:

2.20 m
0.35 m
811 PS
51.0 t
mechanical
4
hydraulic

2500 SM
Cutting width:
Cutting depth:
Engine:
Weight:
Cutting drum drive:
Number of tracks:
Track drive system:

2.50 m
0.60 m
1,065 PS
103.0 t
mechanical
4
hydraulic

3700 SM
Cutting width:
Cutting depth:
Engine:
Weight:
Cutting drum drive:
Number of tracks:
Track drive system:

The main technical data

3.70 m
0.60 m
1,623 PS
176.0 t
mechanical
4
hydraulic

13

4200 SM
Cutting width:
Cutting depth:
Engine:
Weight:
Cutting drum drive:
Number of tracks:
Track drive system:

4.20 m
0.80 m
1,623 PS
191.4 t
mechanical
4
hydraulic

Dinting Machine 2600


Cutting width:
Cutting depth:
Engine:
Weight:
Number of wheels:
Cutting drum drive:
Wheel drive:

14

2.60 m
0.20 m
326 PS
29.0 t
4
hydraulic
hydraulic

The main technical data

4.

Major design features


Site illumination

Operators cab

Drive unit with


Diesel engine

Boom
counterweight

Slewing ring
Site
illumination

Discharge boom,
slewable and
adjustable in height

Crawler track,
steered and
adjustable in height

Crawler track, adjustable in height


Scraper blade with
primary conveyor
Cutting drum, mechanically driven

Principle design of a Wirtgen Surface Miner.

A range of technical design features ensures that Wirtgen Surface Miners are up for their job.
The Wirtgen Surface Miners are machines made for an efficient, continuous mining operation.
They are equipped with 4-track crawlers with infinitely variable speed. During driving, a
rotating cutting drum, equipped with tungsten carbide bits, cuts the material and crushes it
down to a size suitable for belt conveyors. The cutting drum operates in upward direction.
The cutting tools, mounted to the drum in form of a helix, propel the material towards the
center of the drum. There the material is loaded via the primary belt conveyor to the discharge
belt conveyor.
The main design features are:
Diesel engine
The Wirtgen Surface Miners are all diesel powered. The engines power is transmitted via a
robust belt drive to the drum, ensuring an effective power transmission. Moreover, other
systems (e.g. track and belt drive) are hydraulically driven.

Major design features

15

Central cutting drum with mechanical drive


The cutting drum is located in the center of the machine, between the four crawler tracks. It is
located close to the center of gravity. The entire machine weight and installed power can thus
be converted into cutting force. This allows cutting of harder materials with good results and
ensures at the same time stability of the machine.

Drive concept with central cutting drum

The cutting drum speed can be varied by


interchanging the belt pulleys. The usual
range of drum speeds, which can be realized
with these changings vary from 60 to
100 r.p.m.
The belt pulleys are tensioned automatically
by a hydraulic cylinder. This is an energyeffective, low maintenance system,
minimizing operating and maintenance costs.

Adjustment of drum rotation speed

16

Major design features

Automatic adjustment of cutting depth


The cutting depth is regulated by an automatic levelling system mounted to the machine.
The pre-selected cutting depth is maintained either automatically or can be adjusted manually.
The control system can be connected with:
Cable sensors scanning the distance
to a reference plate sliding on the
surface.
Milling depth
controlled by
scanning the height
(e.g. with a cable
sensor)

Milling depth
controlled via a
slope sensor

Non-contact ultrasonic sensors


measuring the distance to the side
plate or the surface.
Automatic control of transversal
slope: The machine is equipped with
a slope sensor to control transversal
slope of the cutting surface. It can
be used to create defined slopes, for
water drainages for example, on the
cutting surface.

Control unit
3 sensors left

Multiplex sensors working with


three sensors on one or both sides
of the machine, thus levelling uneven
surfaces in longitudinal and
transversal direction.

Slope control

3 sensors right

Laser sensors working with a


transmitter and receiver.

Control unit

In practice operation, a depth tolerance in the range


of 0.5 cm can be achieved.

Major design features

Precise control of cutting depth with a laser.

17

5.

Operating methods

Harvesting mode slice method


In the harvesting mode, the Wirtgen Surface Miner operates on an even field and continuously
cuts the material. The cutting process can thus be continued also during driving a curve with the
machine.
A

8 m

7 m

5 m

6 m

4 m

3 m

2 m

1 m

3
4
5
6
7
8
9
10
11
12
3

5
4

7
6

13

14

15
16
17
18
9
8
7
6
5
4
3

A
Harvesting / slice method (schematic)

The mining area is developed by cutting slice by slice. For each slice the cutting depth only
needs to be set once on the Wirtgen Surface Miner.

Harvesting / slice method: Here the Surface Miner cuts while driving a curve.

18

Operating methods

Block operation with ramp cutting


Wirtgen Surface Miners can be integrated into existing mines and quarries using conventional
drilling and blasting operations in benches. They are able to continue to work on the existing
benches, using the block method.

A
B

A = Block height
B = Block width

Block Method

While cutting the block down to its planned level, the Wirtgen Surface Miner also cuts its
own ramp. After completing the cut of the first block, the next block can be started adjacent
to the first one.
Since turning on narrow benches is difficult and time consuming, two alternative operations
can be recommended:
a.

Turning the machine on an appropriate area outside the ramp (this area can be mined
later together with the bench by means of the Wirtgen Surface Miner).

b.

Reverse the machine after finishing one cut and reposition the Surface Miner at the
adjacent cut.

A Wirtgen Surface Miner (on the right edge of the photo) cutting his own ramp.

Operating methods

19

Ramps
Typical ramps have a gradient of approx. 10-15% in order to allow trucks to traffic them loaded
in upward direction. A Wirtgen Surface Miner is able to cut its own ramp. These ramps can be
made cutting upwards or downwards. In the graphic shown below, cutting a ramp in upward
direction is explained. When cutting in a downward direction, the process is vice-versa. In this
case the cutting depth has to increase from 0 to the maximum cutting depth.

2 m Working width

-0.2

2m

A
-0.4

-0.2

0.2 m

Working direction

B
-0.4
0.11 m
-0.6
-0.6

Example for cutting a ramp (working direction upwards)


1. The Wirtgen Surface Miner cuts the first slice. Once the Miner reaches the red line A it is
gradually decreasing the cutting depth within the next two meters. Therefore less material is being cut. The resulitng ramp has a gradient of 10 %.
2. When the Miner is cutting the second cut, the Miner slowly cuts itself out of the cut until the
red line, once it reaches the green line B. Here the cutting depth shall be zero. At the red line,
the cutting drum should not be able to cut any material because the drum should be above the
cutting surface.
This process will continue slice by slice until the final length of the ramp has been achieved.

20

Operating methods

Operation in an open cut

Operation in an open cut

Depending on the length and the width of the open cut the Wirtgen Surface Miner can be either
turned at the end of each cutting path or driven rearwards to start the next cut on the same side of
the area as the previous one.

2
9

3
10

17

4
11

18
25

5
12

19
26

6
13

20
27

7
14

21
28

8
15

22
29

16
23

30

24
31

32

Cutting sequence of a Wirtgen Surface Miner in an open cut.

Operating methods

21

Special operations
The design (position of the cutting drum in the middle of the machine) and the working
characteristics (continuous cutting, precise cutting depth control, cutting even and stable
surfaces) of a Wirtgen Surface Miner allow to work in various conditions, thus providing technical
solutions for many demanding tasks in mining.
Selective mining of inclined seams
Depending on the degree of inclination of the seams different working methods are possible:

Block 2

Block 1

Slightly inclined seams can be cut in


blocks as shown in the adjacent
drawing.
When cutting at the boundary between
coal and waste, a certain degree of
dilution of the material has to be
considered.

Slightly inclined seams

Cutting very steep seams or pockets of


paymaterial can be mined as shown on
the adjacent drawing.

Steeply inclined multiple seams

22

Operating methods

Blending material while cutting on a ramp

Blending material while cutting on a ramp.

Irregular deposits often require the blending of material in order to maintain quality standards
either for the following process or for the production of market-oriented mineral blends.
Horizontally variations of the deposit can be blended with Wirtgen Surface Miners directly
during cutting. The machine cuts continuously on a ramp, thus mining through all layers and
homogenizing the material. Subsequently the requirements for mixing plants are minimized.

Cutting the bench and floor in a tunnel

Surface Miner lowering the bech of a tunnel ...

... directly loading the cut material onto a train.

Wirtgen Surface Miners can effectively work in congested workspace like tunnels, to cut
benches and floors precisely according to the required profiles in a minimum amount of time.
The cut material fits very good to be used as gravel.
Operating methods

23

Cutting steep highwall slopes


Wirtgen Surface Miners can produce
steep highwall slopes.
Generally, Wirtgen Surface Miner
achieve a slope angle of 60 in normal
operation.
Under certain circumstances even
higher angles have been achieved.
Please consult Wirtgens Mining
Division for specifications.

Cutting steep highwall slopes

Cutting steep highwall slopes

24

Operating methods

Operating conditions
Cutting in edges and curves, turning, turning radius
For sharp turns, the cutting drum has to be lifted in order to acheive a small turning radius.
However, the machine can also turn while the cutting drum is still in operation. As a rule of
thumb the turning, the turning radius is:
12 x cutting width (when cutting harder rock, the cutting depth has to be reduced)
The radii which can be achieved depend amongst other factors on the material to be cut
and the actual depth of the cut. Generally, they can only be determined precisely during the
first operations in a deposit. So it is possible to acheive smaller or larger radii in practice.

Cutting and travelling on inclinations


The following table contains the operation limits for lateral and longitudinal inclinations.
Type of Surface Miner
2200 SM
2500 SM
3700 SM
4200 SM
Dinting machine 2600

*)

Normal operation
Transversal inclination
Longitudinal inclination (*)
8%
8%
8%
8%
5%

20 %
20 %
20 %
20 %

Although these inclinations are possible under normal operating conditions with regard
to stability, the cutting performance of the machine will be reduced when longitudinal inclinations exceed 5. The reduction of cutting performance for even steeper inclinations
depends on the inclination itself and the material to be cut.

Please contact Wirtgens Mining Division for further details.

Operating methods

25

Geometrical factors
Length of working area
The productivity of a Wirtgen Surface Miner depends on the length of the available working
area. Longer cuts will enhance the productivity, because only a smaller amount of time is spent
is in manouvering from one cut to the next. The forward speed (and therefore travel time for a
given cutting length) furthermore depends from a number of factors:
cutting depth
material hardness and structure
type of machine and installed engine power

Effective Production

Therefore, the graph below only can show the general relation between effective production
and cutting field length.

Cutting field length


Cutting field length vs. effective production

In standard applications, the appropriate minimum cutting field length should be in the range
of:
100 m (hard material, low forward speed)
300 m (softer material, high forward speed)

26

Operating methods

6.

Loading options

The Wirtgen Surface Miner range offers the following loading and material handling options:

Loading options

Direct truck
loading

Indirect
loading

front loading

rear loading

2200 SM

2500 SM
3700 SM
4200 SM

sidecast

windrow

Comparison of the different loading methods:


ADVANTAGES
Direct Loading

No re-handling of material required

DISADVANTAGES
Larger working area required for
truck manoeuvering
Production affected by truck
exchange time
Belt wear

Sidecasting

Windrow

Blending of materials in
the mine

Restricted to 3-5 cuts wide on each


side of the mine stockpile

Stockpile of material in the mine

Belt wear

No waiting for trucks,


independent operation

Material has to be re-handled

No waiting for trucks


No belt wear / higher
availability
Higher production rates
than conveyor loading

Material prone to absorb water


when lying on the ground
Large working area required
Material has to be re-handled either
by loader or scraper
Material prone to absorb water
when lying on the ground

Coarser material
Better selectivity on steep
inclined seams

Loading options

27

Direct loading
Direct loading onto trucks
One of the main characteristics of the Wirtgen Surface Miners is their ability to load the cut
material directly onto trucks. Depending on the machine type, Wirtgen Surface Miners are
designed either as front loading or rear loading machines.
Front loading
The 2200 SM is a typical front loader, with the discharge conveyor mounted in front of the machine.
The conveyor can be slewed of the right and the left and the height is adjustable. Depending on
the truck size, these machines load the trucks either from behind (see photo on the left) or from
the side (see photo on the right). The Surface Miners operator has a direct view on the truck.

Front loader loading from behind

Front loader loading from the side

Rear loading
Other models, such as the 2500 SM, 3700 SM and the 4200 SM are rear loaders, with the
discharge conveyor mounted in the rear of the machine. The conveyor can be slewed of the
right and the left and the height is adjustable. The weight of the conveyor is balanced by a
counterweight. To ensure safety when cutting steep benches the counterweight can be lifted.
The Surface Miners operator has direct visual contact to the truck because he may slew his
seat to the right or left hand side.

Rear loader 2600 SM loading from the side


(machine type replaced by the new 2500 SM)

28

Rear loader 4200 SM loading from the side

Loading options

Smooth loading of trucks with fine material


In all cases, the fine gradation of the material cut by a Wirtgen Surface Miner ensures a
smooth, continuous and complete loading of the truck body. The loading characteristics
allow flexibility when choosing a suitable truck size. For example, under certain circumstances
trucks with aluminium truck body and enhanced payload can be used.

Smooth loading of a 27 t truck with aluminium truck body and enhanced payload.

Truck exchange
To enhance productivity and to minimize waiting time for the Wirtgen Surface Miner an
empty truck should be waiting beside the machine just before the presently loaded truck is
completely filled. The normal truck exchange times are between 15-30 seconds, depending
on the type of the Wirtgen Surface Miner and the size of the truck. The exchange times are
also affected by the available area for manoeuvering of the trucks and the drivers experience.

Advanced truck exchange


For Wirtgen Surface Miners with a front loading system the empty truck positions itself
parallel to the presently loaded truck. The loading of the second truck starts by simple swinging
of the conveyor only. Stopping the cutting process is not required. The following sequence
shows a perfect truck exchange while the Surface Miner continuously goes on with cutting.

Truck no. 1 is being loaded, truck no. 2 is positioning.

Loading options

The Surface Miner slews its conveyor to truck no. 2,


truck no. 1 drives to further processing of the material.

29

Recommended truck size


The recommended truck size for a Wirtgen Surface Miner depends on the following factors:
The conveyor booms discharge height determines the maximum loading height of the truck
(see sketches in chapter 8). This is based on the assumption that the Wirtgen Surface Miner
and the truck are on the same (cut) level without any relative inclination.
The cutting performance of the Wirtgen Surface Miner in a given material.
To reach an economic truck loading and transportation cycle the truck size should be selected
such that loading times of 2 to 6 minutes are achieved.

Indirect loading
Sidecasting of the material
Sidecasting the material means that
a stockpile is built by dumping the
material from different cuts via the
conveyor on one pile. Depending on
the slewing angle of the conveyor, up
to 3 to 5 adjacent cuts can be dumped
on top of each other. Due to the height
of the formed stockpile, the material
can easily be reloaded with a front-end
loader.
2200 SM sidecast mode

Advantage:
The cutting operation of the Wirtgen
Surface Miner using sidecasting is
independent from the truck loading operation.

2500 SM sidecast mode

30

Loading options

Windrowing
In windrowing mode the cut material is directly discharged behind the machine without using
a conveyor. Therefore the cutting operation is independent from the truck loading operation,
but the material has to be re-handled with a front-end loader.

Wirtgen Surface Miner windrow operation

Wirtgen Surface Miner windrow operation

Wirtgen Surface Miner windrow operation

Reloading windrow material

For many applications, the higher productivity in the windrow operation in comparison to
direct loading, over-compensates for the additional cost for the re-handling of the material
(e.g. wheel loader). In addition, no belt wear and no operating cost for the conveyor will arise
when working in the windrowing mode.

Loading options

31

7.

Cutting technology

The cutting technology is Wirtgens core competence. We continuously improve our


technology to enhance even further:
Maximum cutting performance
Maximum lifetime of cutting tools
Minimum operating cost
Control of granulometry of cut material

Wirtgen cutting drum 2200 SM

Wirtgen cutting drum 3700 SM

The cutting performance of a Wirtgen Surface Miner is significantly affected by the following
machine parameters:
Type of cutting tool
Type of cutting tool holder
Number of cutting tools on the drum (spacing)
Angle of attack of the tools
Rotation speed of cutting drum
Cutting depth
Advance speed of the machine

Wide tool spacing

32

Narrow tool spacing

Cutting technology

Cutting tools
The selection of the appropriate cutting tool is essential for good cutting performance and
for the lifetime of the cutting tool itself. Wirtgen GmbHs standard delivery range of cutting
tools for mining comprises the tools shown below. Moreover, for special applications,
Wirtgen can provide additional tools, too. Please consult Wirtgens Mining Division for further
information.

W 47 K12

W 47 K13

W 47 K15

12
15

77

77

100

28

24

22

13

W 47 K19
17.5

25

19

40
77

77

30

28.5

Cutting technology

W 47 K25

77

W 47 K17

33

Cutting drum for a Wirtgen Surface Miner 4200 SM.

Cutting toolholders
One of the features of Wirtgen cutting drums is the type of toolholders used. Which type of
toolholders is chosen depends on the application the drum shall be used for. The point attack
tools themselves are fixed in the toolholders, each of them exactly positioned on the drum.
The tools are stuck into a bushing and are fixed by means of a retainer ring so that they keep
their position relatively to the holder, but still are able to rotate during the cutting process. Worn
out tools can be taken away by simple loosening of the retainer ring and fixing a new tool.

Wirtgen toolholder type HT 6 in bushing form, here equipped with a typical mining point attack tool. The tool is
fixed against falling out by means of a retainer ring, but still is able to rotate.

34

Cutting technology

The toolholders are subject to high stress, especially when cutting hard materials, because
irregular rock formations may lead to enormous peak loads on the single toolholders. Here the
heavy duty design of the bushing-type toolholders ensures long lifetime. Special systems take
care of the exact positioning of the toolholders. In consequence worn out toolholders can be
replaced by new ones easily.
Another special feature bases on the fact that only the worn out tools respectively toolholders
have to replaced, not the complete set. This has an extremely positive effect on the costs
arising while working with the Wirtgen Surface Miners.

Characteristics of different cutting tool types

12 mm
25 mm

Small diameter of tungsten carbide:

Large diameter tungsten carbide:

Low lifetime
Good penetration
High cutting performance
Coarse gradation (*)

Long lifetime
Poor penetration
Low cutting performance
Fine gradation (*)

(*)

In general, the gradation of the cut material depends primarily on the material hardness
and structure. Tool spacing, the type of tools on the drum and other machine factors
have only a secondary effect on gradation.

Cutting technology

35

8.

Technical data and dimensions

Wirtgen Surface Miner 2200 SM Technical data


Surface Miner 2200 SM
Cutting width max.
mm
Cutting depth *1
mm
Cutting drum
Spacing
mm
Number of tools
Drum diameter with tools
mm
Drum inclination, max.

Engine
Manufacturer
Type
Cooling
No. of cylinders
Output
kW / HP / PS
Engine speed
min-1
Displacement
cm3
1
Fuel consumption: /1 load
l/h
Fuel consumption: 2/3 load
l/h
Speed / gradeability
Travel speed
m/min (km/h)
Theoretical gradeability
%
Ground clearance
mm
Weights *2
Front axle load, full tanks
daN (kg)
Rear axle load, full tanks
daN (kg)
Own weight
daN (kg)
Operating weight, CE* 3
daN (kg)
Operating weight, full tanks
daN (kg)
Tracks
Front tracks (L x W x H)
mm
Rear tracks (L x W x H)
mm
Tank capacities
Fuel tank
l
Hydraulic fluid tank
l
Water tank
l
Elektrical system
V
Conveyor system
Belt width 1st belt (loading belt)
mm
Belt width 2nd belt (discharge belt)
mm
Theoretical conveying capacity
m3/h
2
Shipping dimensions / Weights*
Dimensions of machine
(L x W x H) mm
Dimensions of discharge conveyor (L x W x H) mm
Upper part of operators cab
(L x W x H) mm
Weight of machine
daN (kg)
Weight of discharge conveyor
daN (kg)
Weight of upper part of operators cab
daN (kg)

2,200
0 350
38
76
1,140
5
Caterpillar
3412E
Water
12
596.5 / 800 / 811
2,100
27,000
150
100
0 84 (0 5)
90
370
25,430
25,350
44,500
47,730
50,780
2.200 x 370 x 790
2.200 x 370 x 790
1,500
450
5,000
24
1,100
1,100
668
9,600 x 2,750 x 3,000
8,600 x 1,600 x 1,200
2,600 x 2,900 x 1,500
41,700
1,800
1,000

* 1 = The maximum milling depth may deviate from the value indicated, due to tolerances and wear.
* 2 = All weights refer to basic machine without any additional equipment.
* 3 = Weight of machine with half-full water tank, half-full fuel tank, driver (75 kg) and tools.

36

Technical data and dimensions

Wirtgen Surface Miner 2200 SM Dimensions


Dimensions in mm

1400

2600

4800

3000 *

3000

9600

1100

3200
5800

16100

55

360

00
25

1680

105

190

1560

2750
2200
2100

45

16800 *

* = Low-loader transportation dimensions

Technical data and dimensions

37

Wirtgen Surface Miner 2500 SM Technical data


Surface Miner 2500 SM
Cutting width, max.
mm
Cutting depth *1
mm
Cutting drum
Number of cutting tools on drum
Cutting drum diameter with tools
mm
Drum inclination max.

Engine
Manufacturer
Type
Cooling
Number of cylinders
Output
kW / HP / PS
Engine speed
min-1
Displacement
cm3
1
Fuel consumption, /1 load
l/h
2
Fuel consumption, /3 load
l/h
Speed/gradeability
Operating speed
m/min
Travel speed
km/h
Theor. gradeability
%
Max. transverse gradient
%
Weights *2
Front axle load, full tanks
daN (kg)
Rear axle load, full tanks
daN (kg)
Own weight
daN (kg)
Operating weight, CE * 3
daN (kg)
Operating weight, full tanks
daN (kg)
Crawler tracks
Front crawlers (L x W x H)
mm
Rear crawlers (L x W x H)
mm
Tank capacities
Fuel tank
l
Hydraulic fluid tank
l
Water tank
l
Electrical system
Control
V
Lighting
V
Conveyor system
Width of primary belt (Loading belt)
mm
Width of secondary belt (Discharge belt)
mm
Theoretical discharge belt capacity
m3/h
Shipping weights / Weights *2
1st module
(L x W x H)
mm
2nd module
(L x W x H)
mm
Weight 1st module
daN (kg)
Weight 2nd module
daN (kg)

2,500
0 600
Depends on application
1,400
4
Cummins
QST 30
Water
12
783 / 1,050 / 1,065
2,100
30,500
191.5
127.6
0 25
0 3.9
20
8
39,200
63,800
98,000
100,500
103,000
2,920 x 400 x 970
2,920 x 400 x 970
2,400
500
2,800
24
24
1,400
1,400
1,100
12,800 x 3,470 x 3,300
15,700 x 2,750 x 3,400
76,600
21,400

* 1 = The maximum cutting depth may deviate from the value indicated, due to tolerances and wear.
* 2 = All weights refer to basic machine without additional equipment.
* 3 = Weight of machine with half-full water tank, half-full fuel tank, driver (75 kg) and tools.

38

Technical data and dimensions

Wirtgen Surface Miner 2500 SM Dimensions


Dimensions in mm

113
00

4935

4300 7500

22700

5195

970

2920
3545

39

1840
3470

400

1900

90

R8
50
0

8740

Technical data and dimensions

39

Wirtgen Surface Miner 3700 SM Technical data


Surface Miner 3700 SM
Cutting drum

Cutting width max.

mm

3,700

Cutting depth *

mm

0 600

Cutting drum diameter with tools

mm

1,400

Number of cutting tools on drum

Depending on machine application

Engine
Make

Cummins

Type

KTA 50

Cooling

Water

No. of cylinders

16

Output

kW/HP/PS

1,194 / 1,600 / 1,623

Fuel consumption: / load

l/h

284

Fuel consumption: 2/3 load

l/h

189

1 1

Speed /gradeability
Operating speed

m/min

0 20

Travel speed

km/h

0 2.5

Gradeability

20

Max. transverse gradient

Weights / loads * 2
Front axle load

daN (kg)

59,000

Rear axle load

daN (kg)

98,000

Own weight

daN (kg)

157,000

Operating weight, full tanks

daN (kg)

176,000

Crawler tracks
Front crawlers (L x W x H)

mm

3,880 x 500 x 1,200

Rear crawlers (L x W x H)

mm

3,880 x 500 x 1,200

Tank capacities
Fuel tank

2,900

Hydraulic fluid tank

800

Water tank

15,000

Control

24

Lighting

220

Electrical system

Spotlights

10 x 400 W each

Conveyor system
Width of primary belt

mm

1,800

Length of primary belt

mm

7,000

Width of discharge belt

mm

1,800

Length of discharge belt

mm

12,000

m /h

2,400

Theoretical discharge belt capacity

* 1 = The maximum cutting depth may deviate from the value indicated, due to tolerances and wear.
* 2 = All weights refer to basic machine without additional equipment.

40

Technical data and dimensions

Wirtgen Surface Miner 3700 SM Dimensions

8200

min. 4300 / max. 7000

Dimensions in mm

3550

5375
8925
25330

90

2470

2240

5000

500

0
25
16

3832

45

90
0
50

Technical data and dimensions

41

Wirtgen Surface Miner 4200 SM Technical data


Surface Miner 4200 SM
Cutting drum
Cutting width max.

mm

4.200

Cutting depth* 1

mm

0 800

Cutting drum diameter with tools

mm

1.860

Number of cutting tools on drum

Depending on machine application

Engine
Make

Cummins

Type

KTA 50

Cooling

Water

Number of cylinders
Output

16
kW/HP/PS

1.194 / 1.600 / 1.623

Fuel consumption, /1 load

l/h

284

Fuel consumption, 2/3 load

l/h

189

Speed / Gradeability
Operating speed

m/min

0 20

Travel speed

km/h

0 2,5

Gradeability

20

Max. transverse gradient

Weights * 2
Front axle load, full tanks

daN (kg)

73.600

Rear axle load, full tanks

daN (kg)

117.800

Own weight

daN (kg)

172.400

Operating weight, full tanks

daN (kg)

191.400

Crawler tracks
Front crawlers (L x W x H)

mm

3.880 x 500 x 1.200

Rear crawlers (L x W x H)

mm

3.880 x 700 x 1.200

Tank capacities
Fuel tank

2.900

Hydraulic fluid tank

800

Water tank

15.000

Control

24

Lighting

220

Electrical system

Spotlights

10 400 W

Conveyor system
Width of primary belt

mm

1.800

Length of primary belt

mm

7.000

Width of discharge belt

mm

1.800

Length of discharge belt

mm

15.000

m /h

2.400

Theoretical discharge belt capacity

* 1 = The maximum cutting depth may deviate from the value indicated, due to tolerances and wear.
* 2 = All weights refer to basic machine without any additional equipment.

42

Technical data and dimensions

Wirtgen Surface Miner 4200 SM Dimensions

8200

min. 5070 / max. 8500

Dimensions in mm

3550

5375
8925
28000

90

2500

2240

5500

700

0
25
16

3832

45

90
0
50

Technical data and dimensions

43

Wirtgen Dinting Machine 2600 Technical data


Dinting Machine 2600
Cutting width max.

mm

2,600

Cutting depth *

mm

0 200

Spacing

mm

15

Number of tools

mm

855

Cutting drum

Drum diameter with tools


Drum inclination, max.

212

Engine
Manufacturer

Deutz

Type

BF 12 L 413 FW

Cooling

Air

No. of cylinders

12

Output

kW/HP/PS

240 / 321/ 326

Engine speed

min-1

2,300

Displacement

cm3

19,144

Fuel consumption: /1 load

l/h

71.2

Fuel consumption: / load

l/h

51.7

2 3

Speed / gradeability
Working gear (1st gear)
Travel gear (2nd gear)

m/min

0 36

km/h

0 20

Theor. gradeability (1st gear)

35

Theor. gradeability (2nd gear)

12

Ground clearance

Weights / loads*

Front axle load

daN (kg)

15,000

Rear axle load

daN (kg)

13,000

Own weight

daN (kg)

28,000

Operating weight, full tanks

daN (kg)

29,000

Tyre size, front

mm

1,200

Tyre size, rear

mm

1,200

Tyres

Tank capacities
Fuel tank

1,000

Hydraulic fluid tank

435

Elektrical system

24

Shipping dimensions
Machine (L x W x H)

mm

8,790 x 3,000 x 1,700

* 1 = The maximum milling depth may deviate from the value indicated, due to tolerances and wear.
* 2 = All weights refer to basic machine without any additional equipment.

44

Technical data and dimensions

Wirtgen Dinting Machine 2600 Dimensions


Dimensions in mm

8790
8550
120

1700

120

750

3950

1850

2000

Technical data and dimensions

3000

2700

5800

45

9.

Production estimate

Production range (cutting performance) of the Wirtgen Surface Miner 2200 SM


700
Windrowing max.
Conveyor
loading max.
Conveyor
loading min.

600

Cutting performance (bm3/h)

500

400

300

200

100

10

Note:

46

20

30

40

50

60

70

80

90 100 110 120

UCS (MPa)

Material with a hardness >50 MPa can only be cut only under certain
conditions.
Production estimate

Production range (cutting performance) of the Wirtgen Surface Miner 2500 SM


1400
Conveyor
loading max.
Conveyor
loading min.

1200

Cutting performance (bm3/h)

1000

800

600

400

200

10

Note:

20

30

40

50

60

70

80

90 100 110 120

UCS (MPa)

Material with a hardness >80 MPa can only be cut under certain
conditions.

Production estimate

47

Production range (cutting performance) of the Wirtgen Surface Miner 3700 SM


2000
Conveyor
loading max.

1800

Conveyor
loading min.

1600

Cutting performance (bm3/h)

1400

1200

1000

800

600

400

200

10

Note:

48

20

30

40

50

60

70

80

90 100 110 120

UCS (MPa)

Material with a hardness >80 MPa can only be cut under certain
conditions.
Production estimate

Production range (cutting performance) of the Wirtgen Surface Miner 4200 SM


3000
Conveyor
loading max.
Conveyor
loading min.

2500

Cutting performance (bm3/h)

2000

1500

1000

500

10

Note:

20

30

40

50

60

70

80

90 100 110 120

UCS (MPa)

Material with a hardness > 60 MPa can only be cut under certain
conditions.

Production estimate

49

Comments to the charts


The figures in the production charts are based on cutting performance without downtimes for
manoeuvering the machine etc. They are based on 100 % efficiency (e.g. sufficient number of
trucks).
Drums with a tool spacing of 35-50 mm are considered for materials with a compressive
strength (UCS) of 25-80 MPa. Materials with UCS values > 80 MPa are only to be cut under
certain circumstances (fractured material).
For materials with a UCS < 25 MPa, cutting drums with 90 mm tool spacing are considered.
The maximum curves represent operation under ideal conditions only. The assumptions are:
weathered rock, horizontally laminated or heavily fractured rock (fractures in different
directions with max. 5 cm distance).
The minimum curve represents cutting performance in solid rock or benches with only little
amount of fractures (distance of fractures 0.5-1 m).
For the 2200 SM (front loading machine), the cutting performance depends on the loading
method (conveyor or windrow method). Please see section loading methods.
Because of the large variety of possible influences the charts can only be used for preliminary
estimates and forecasts.
More detailed estimates have to be based on specific information such as rock properties,
deposit and site information. Please consult Wirtgens Mining Division for further information.
Wirtgen GmbH shall have no liability for damages, consequential or otherwise, arising from
the use of the production analysis or any part of thereof.

50

Production estimate

Phone: + 49 (0) 26 45 / 131- 0


Fax:
+ 49 (0) 26 45 / 131- 242
Internet: www.wirtgen.com

Illustrations are without obligation. Subject to technical changes. Performance data depend on operational conditions. No. 25-12 EN- 09/01 by Wirtgen GmbH 2001 Printed in Germany

Wirtgen GmbH Hohner Strasse 2


53578 Windhagen Germany