Instruction Manual BG 36: Keep For Future Use!

Instruction Manual
BG 36
BV1058505.wmf
Keep for future use!

BAUER Maschinen GmbH
P.O. Box No. 12 60 D-86522 Schrobenhausen, Germany
Telephone +49 8252 97-0 Fax +49 8252 97-1359
PREFACE
US
UK
BG
If you are not familiar with the language used in this operating manual you
must not operate the equipment. If you cannot read this operating manual or
understand its contents, you must contact the customer service department of
BAUER Maschinen GmbH and order a manual in a language you understand.
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CZ
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DE
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BG 36 / 2009
II
FR
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veuillez contacter le service aprs -vente de BAUER Maschinen GmbH et
commandez u manuel d'utilisation rdig dans une langue comprhensibles
pour vous.
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III
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eng Betribsuleedung an enger Sprooch di Dir verstitt.
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lietoanas instrukciju, kas ir iespiesta jums saprotam valod.
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IV
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idioma que entenda.
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sizden geri alnmayacaktr. Bu gibi bir durumda, BAUER Maschienen GmbH
ile temasa gein ve sizin anlayabileceiniz dilde bir kullanm klavuzu sipari
edin.
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VI
This Instruction Manual is written for use by operating and maintenance personnel.
Before the first use of this equipment PLEASE
First, take your time and read the "Instruction Manual" and the
enclosed booklet entitled "Safety Information".
These two documents shall always be kept at the equipment to be accessible for review
at any time.
The "Instruction Manual" gives you a detailed description of the equipment, guidelines
for transport and initial start-up as well as comprehensive instructions for the operation
of the equipment, trouble shooting tips and information related to maintenance.
Technical data, weights and measurements are accurate as of the day this Instruction
Manual is printed. Due to the continuous technical advancements made, there may be
minor deviations between the technical data, weights and measurements contained in
the Instruction Manual and the equipment as actually built and delivered. These minor
deviations are, however, inconsequential and do not change in any material way nor do
they invalidate the contents of this Instruction Manual.
The equipment as delivered to you may have options that might not be pictured in the
photographs or described in the text contained in this Instruction Manual exactly as they
appear on your equipment. This is due to the individualization of the equipment based
on the wishes and orders of the individual customers and no claims of any kind shall be
based on such deviations.
The equipment shall only be used for the authorized purposes listed in the Instruction
Manual. The manufacturer shall have no liability whatsoever for the improper or unauthorized use of the equipment, operator errors or mistakes or improper respectively insufficient maintenance.
The enclosed booklet entitled "Safety Information" contains the directions and related
information for the safe use of the equipment. The "Safety Information" must be followed at all times.
Also, pay attention to and follow all the instructions contained in the attached documents (Appendix ___) of the component manufacturers.
BG 36 / 2009
VII
The "Instruction Manual" was written and published by

BAUER Maschinen GmbH Postfach 12 60 D-86522 Schrobenhausen, Germany
Copyright 2009, BAUER Maschinen GmbH
The information contained in this manual and/or any of its parts, sub-parts or chapters,
is the intellectual property of BAUER Maschinen GmbH and is protected by domestic
and international copyright and other intellectual property laws.
The information contained herein is provided for the operation, service, maintenance
and troubleshooting of the equipment described herein.
Any duplication, reproduction, translation, micro filming, storage in electronic or magnetic form, processing as electronically or magnetically stored media, copying or dissemination of these materials and/or the information contained herein, or any part
thereof, except for the internal use of BAUER Maschinen GmbH or its authorized external suppliers, consultants or agents, without the prior written consent of BAUER
Maschinen GmbH is hereby strictly prohibited.
All rights and remedies are hereby expressly reserved.
Violators will be prosecuted.
BAUER Maschinen GmbH shall have no liability whatsoever arising from or connected
in any way to the so prohibited use of the information contained herein by any person or
entity, wherever located.
BAUER Maschinen GmbH reserves the right to change, delete or otherwise alter or
modify any information contained herein, or the equipment itself, at any time and for any
reason, with or without notice.
BG 36 / 2009
VIII
TABLE OF CONTENTS
PREFACE ......................................................................................................................................................I
TABLE OF CONTENTS.............................................................................................................................. IX
ABOUT THE MANUAL.............................................................................................................................. XV
NAMEPLATES......................................................................................................................................... XVII
AFTER SALES SERVICE....................................................................................................................... XVIII
WARRANTY TERMS................................................................................................................................ XIX
WARRANTY CLAIM..................................................................................................................................XXI
PERSONALANFORDERUNG / STAFF REQUEST ................................................................................XXII
1
1.1
1.2
1.2.1
1.2.1.1
1.2.1.2
1.2.2
1.2.2.1
1.2.2.2
DESCRIPTION .......................................................................................................................1 - 1
INTENDED AND AUTHORIZED USE .................................................................................. 1 - 1
COMPONENTS..................................................................................................................... 1 - 4
Basic Rig / Kelly Equipment ...................................................................................................1 - 4
Components Overview ...........................................................................................................1 - 4
Components Description ........................................................................................................1 - 5
CFA Equipment *....................................................................................................................1 - 7
Components Overview *.........................................................................................................1 - 7
Components Description * .....................................................................................................1 - 8
2
2.1
2.2
2.3
2.4
2.4.1
2.4.2
2.4.3
2.4.4
2.4.5
2.4.6
2.5
2.5.1
2.5.2
2.5.2.1
2.5.2.2
2.6
SAFETY .................................................................................................................................2 - 1
GENERAL SAFETY REQUIREMENTS ................................................................................ 2 - 1
EQUIPMENT SAFETY .......................................................................................................... 2 - 1
MAJOR HAZARDS................................................................................................................ 2 - 1
SAFETY DEVICES................................................................................................................ 2 - 2
Emergency Stop .....................................................................................................................2 - 2
Pilot Control Safety Stick........................................................................................................2 - 2
Fire Extinguisher ....................................................................................................................2 - 3
Medical Box ............................................................................................................................2 - 3
Emergency Exit ......................................................................................................................2 - 3
Limit Switches.........................................................................................................................2 - 4
STABILITY............................................................................................................................. 2 - 5
Stability Guidelines.................................................................................................................2 - 5
Stability for BG 36 # 2089 - Kelly BK 40/470/4/68 .................................................................2 - 6
Load Capacity Chart...............................................................................................................2 - 6
Weights / Gravities - Drilling Distance 4.65 m........................................................................2 - 7
PERMISSIBLE WIND SPEED............................................................................................... 2 - 8
3
3.1
3.1.1
3.2
TECHNICAL DATA................................................................................................................3 - 1
DIMENSIONS........................................................................................................................ 3 - 1
Kelly Equipment BK 40/470/4/68............................................................................................3 - 1
EQUIPMENT SPECIFICATIONS .......................................................................................... 3 - 2
BG 36 / 2009
IX
3.3
3.3.1
3.4
3.4.1
3.5
3.5.1
3.5.2
3.5.3
3.6
3.7
3.8
ROTARY DRIVE SPECIFICATIONS .................................................................................... 3 - 4

Rotary Drive, Shiftable ...........................................................................................................3 - 4
DRILLING SPECIFICATIONS............................................................................................... 3 - 5
Kelly Equipment BK 40/470/4/68............................................................................................3 - 5
ROPE SPECIFICATIONS ..................................................................................................... 3 - 6
Main Rope ..............................................................................................................................3 - 6
Auxiliary Rope ........................................................................................................................3 - 7
Crowd Ropes..........................................................................................................................3 - 8
NOISE EMISSION................................................................................................................. 3 - 9
TEMPERATURE CONDITIONS ........................................................................................... 3 - 9
EXPOSURE TO VIBRATIONS.............................................................................................. 3 - 9
4
4.1
4.2
4.3
4.4
4.5
CONTROLS AND INDICATORS...........................................................................................4 - 1

OPERATOR'S CAB............................................................................................................... 4 - 1
BASE MACHINE CONTROL CONSOLE.............................................................................. 4 - 2
CONTROL PANEL 1 ............................................................................................................. 4 - 3
CONTROL PANEL 2 ............................................................................................................. 4 - 4
B-TRONIC SYSTEM ............................................................................................................. 4 - 5
5
5.1.
5.2
5.3
5.3.1
5.3.2
5.3.2.1
5.3.2.2
5.4
5.4.1
5.4.2
5.4.2.1
5.5
5.5.1
5.5.2
5.5.3
5.6
5.6.1
5.6.2
5.6.3
5.6.4
5.7
5.7.1
5.7.2
5.8
5.8.1
5.8.1.1
5.8.1.2
5.8.2
5.8.2.1
5.8.2.2
5.8.2.3
5.8.2.4
OPERATION ..........................................................................................................................5 - 1
TO TRAVEL AND STEER..................................................................................................... 5 - 1
UPPER CARRIAGE SWING ................................................................................................. 5 - 2
MAST REPOSITIONING....................................................................................................... 5 - 3
Mast auto reset to vertical ......................................................................................................5 - 4
Mast Repositioning by Manual Control ..................................................................................5 - 5
To Adjust the Mast Inclination ................................................................................................5 - 5
To Adjust the Drill Distance ....................................................................................................5 - 5
TRAVELLING WITH THE RIG .............................................................................................. 5 - 6
Travelling over Level Ground .................................................................................................5 - 6
Travelling Up and Down Slopes.............................................................................................5 - 7
With Raised Mast and Without Drilling Equipment ................................................................5 - 7
ROTARY DRIVE CONTROL................................................................................................. 5 - 8
With Kelly Equipment (Rotary Drive Shiftable).......................................................................5 - 8
With CFA Equipment..............................................................................................................5 - 9
Torque Limiting with Key-operated Switch...........................................................................5 - 10
WINCH CONTROL.............................................................................................................. 5 - 11
Lifting / Lowering ..................................................................................................................5 - 11
To Operate with Freewheel ..................................................................................................5 - 13
To Operate with "Slack Rope Switch-Off" ............................................................................5 - 14
To Operate with "Slack Rope Switch-Off" ............................................................................5 - 15
DEPTH MEASURING CONTROL....................................................................................... 5 - 16
To Interrupt Depth Measuring ..............................................................................................5 - 16
To Reset Depth Measuring ..................................................................................................5 - 16
CROWD CONTROL............................................................................................................ 5 - 17
Basic Functions ....................................................................................................................5 - 17
Moving the Crowd Sledge Down / Up ..................................................................................5 - 17
Switching on the Fast Crowd ...............................................................................................5 - 18
Special Functions .................................................................................................................5 - 19
Which Crowd Functions for Which Drilling Methods? ..........................................................5 - 19
Crowd Pressure Adjustment ................................................................................................5 - 20
Crowd Speed Adjustment.....................................................................................................5 - 21
Pulling by Crowd + Reeved Main Rope ...............................................................................5 - 22
BG 36 / 2009
5.8.2.5
5.8.2.6
5.8.2.7
5.8.2.8
5.8.3
5.9
5.10
5.10.1
5.10.2
5.10.3
Operating the Kelly Drilling Assistant ...................................................................................5 - 23

Operating the CFA Drilling Assistant * .................................................................................5 - 25
Operating the FDP * .............................................................................................................5 - 28
Pulling Assistant Operation ..................................................................................................5 - 32
To Use the Main Winch in Combination with Crowd............................................................5 - 36
CENTRAL LUBRICATION CONTROL................................................................................ 5 - 37
EMERGENCY CONTROL................................................................................................... 5 - 38
Emergency Control of Processors .......................................................................................5 - 38
Pump Emergency Control ....................................................................................................5 - 39
Emergency Control of Diesel Engine Speed........................................................................5 - 39
6
6.1
6.1.1
6.1.2
6.1.3
6.1.3.1
6.1.3.2
6.1.3.3
6.1.4
6.1.4.1
6.1.4.2
6.1.4.3
6.2
6.2.1
6.2.2
START-UP / SHUT-DOWN....................................................................................................6 - 1
START-UP............................................................................................................................. 6 - 1
Initial Start-Up.........................................................................................................................6 - 1
Visual Inspection Before Starting ...........................................................................................6 - 1
Daily Start-Up .........................................................................................................................6 - 2
Starting the Equipment...........................................................................................................6 - 2
Starting the Control System ...................................................................................................6 - 2
Selecting the Work Application ..............................................................................................6 - 3
Safety Tests Before Starting Work.........................................................................................6 - 4
Checking the Emergency STOP ............................................................................................6 - 4
Checking the Pilot Control Safety Stick..................................................................................6 - 4
Checking the Limit Switches ..................................................................................................6 - 5
SHUT-DOWN ........................................................................................................................ 6 - 6
Daily Shut-Down.....................................................................................................................6 - 6
Shutting Down for a Longer Period ........................................................................................6 - 6
7
7.1
7.2
7.3
7.4
7.5
7.6
7.6.1
7.6.2
7.6.3
7.6.4
7.6.5
7.6.5.1
7.6.5.2
7.6.6
7.6.7
7.6.8
7.7
7.7.1
7.7.1.1
7.7.1.2
7.7.1.3
7.7.1.4
7.7.2
7.7.2.1
7.7.2.2
7.7.2.3
RIGGING / DE-RIGGING .......................................................................................................7 - 1

GUIDELINES FOR RIGGING AND DE-RIGGING................................................................ 7 - 1
WAX REMOVAL.................................................................................................................... 7 - 2
EXTENDING THE CRAWLERS .......................................................................................... 7 - 3
MOVING THE MAIN WINCH TO ITS WORKING POSITION............................................... 7 - 5
MOUNTING THE COUNTERWEIGHT ................................................................................. 7 - 6
ASSEMBLING THE MAST.................................................................................................... 7 - 8
Mounting the Trestle...............................................................................................................7 - 8
Assembling the Mast Sections ...............................................................................................7 - 9
Mounting the Masthead........................................................................................................7 - 11
Adjusting the Masthead to the Drilling Procedure................................................................7 - 12
Installing the Ropes..............................................................................................................7 - 13
Installing the Main and Auxiliary Rope .................................................................................7 - 13
Installing the Upper Crowd Rope .........................................................................................7 - 14
Mounting Crowd Stroke Limiters ..........................................................................................7 - 15
Raising the Mast...................................................................................................................7 - 16
Raising the Mast with 3.0 m Mast Extension .......................................................................7 - 17
ASSEMBLY OF WORK ATTACHMENTS........................................................................... 7 - 18
Attaching Kelly Equipment ...................................................................................................7 - 18
Installing the Rope Swivel ....................................................................................................7 - 18
Mounting the Rotary Drive....................................................................................................7 - 19
Mounting the Kelly Auger Cleaner * .....................................................................................7 - 21
Installing the Kelly Bars ........................................................................................................7 - 22
Assembly of CFA Equipment * .............................................................................................7 - 24
Retrieving the Main Rope.....................................................................................................7 - 25
Mounting the Wedge (Only for CFA V) * ..............................................................................7 - 26
Reeving the Main Rope for the Drilling Procedure "CFA with Main Winch" * ......................7 - 27
BG 36 / 2009
XI
7.7.2.4
7.7.2.5
7.7.2.6
7.7.2.7
7.7.2.8
7.7.2.9
7.7.2.10
7.7.2.11
7.7.2.12
7.7.2.13
7.7.2.14
7.7.2.15
7.8
7.8.1
7.8.1.1
7.8.2
7.8.2.1
7.8.2.2
7.8.2.3
7.8.2.4
7.8.2.5
7.8.2.6
7.8.2.7
7.8.2.8
7.8.2.9
7.8.3
7.9
7.9.1
7.9.2
7.9.3
7.9.3.1
7.9.4
7.9.5
7.9.6
7.9.7
7.10
7.11
Mounting Crossbeam to Rotary Drive for "CFA with Main Winch" * ....................................7 - 28
Mounting Concreting Kelly (Version I)..................................................................................7 - 29
Mounting Concreting Kelly (Version II).................................................................................7 - 30
Mounting Concreting Head (Version I).................................................................................7 - 30
Mounting Concreting Head (Version II)................................................................................7 - 31
Mounting Torque Support (Version I)...................................................................................7 - 31
Mounting Torque Support* (Version II) ................................................................................7 - 32
Mounting Holding Bracket for Concrete Hose......................................................................7 - 33
Connecting Concrete Pressure Gauge ................................................................................7 - 33
Mounting the CFA Auger * ...................................................................................................7 - 34
Mounting the CFA Auger Cleaner *......................................................................................7 - 37
Mounting Auger Guidance * .................................................................................................7 - 38
DISASSEMBLY OF WORK ATTACHMENTS..................................................................... 7 - 39
Disassembly of Kelly Equipment..........................................................................................7 - 39
Removing the Kelly ..............................................................................................................7 - 39
Removing the CFA Equipment * ..........................................................................................7 - 39
Removing the CFA Auger Cleaner * ....................................................................................7 - 40
Removing the Auger Guidance *..........................................................................................7 - 40
Removing Torque Support *.................................................................................................7 - 41
Removing Concreting Kelly (Version II) ...............................................................................7 - 41
Removing Concreting Kelly (Version I) ................................................................................7 - 42
Removing the Concreting Head (Version II) ........................................................................7 - 42
Removing the Concreting Head (Version I) .........................................................................7 - 43
Removing CFA Auger * ........................................................................................................7 - 44
Removing the Wedge (Only for CFA V) *.............................................................................7 - 46
Removing the Rotary Drive ..................................................................................................7 - 47
DISASSEMBLING THE MAST............................................................................................ 7 - 48
Lowering the Mast ................................................................................................................7 - 48
Lowering the Mast with 3.0 m Mast Extension.....................................................................7 - 49
Removing the Ropes............................................................................................................7 - 50
Removing the Main and Auxiliary Rope ...............................................................................7 - 50
Removing the Upper Crowd Rope .......................................................................................7 - 51
Disassembling the Mast .......................................................................................................7 - 52
Mounting Transport Supports on the Masthead...................................................................7 - 53
Lowering the Trestle.............................................................................................................7 - 54
REMOVING THE COUNTERWEIGHT ............................................................................... 7 - 55
RETRACTING THE CRAWLERS ....................................................................................... 7 - 57
8
8.1
8.2
8.3
8.4
8.5
8.6
TRANSPORT .........................................................................................................................8 - 1
SAFETY GUIDELINES FOR TRANSPORT.......................................................................... 8 - 1
TRANSPORT MEASURES ................................................................................................... 8 - 2
DRIVING ON / OFF A LOWLOADER ................................................................................... 8 - 3
LIFTING POINTS .................................................................................................................. 8 - 4
TYING DOWN ....................................................................................................................... 8 - 5
TRANSPORT DATA.............................................................................................................. 8 - 6
9
9.1
9.2
9.3
9.3.1
9.3.2
9.3.3
9.3.4
MAINTENANCE.....................................................................................................................9 - 1
SAFETY GUIDELINES FOR MAINTENANCE...................................................................... 9 - 1
MAINTENANCE INTERVALS ............................................................................................... 9 - 1
MAINTENANCE PLAN.......................................................................................................... 9 - 2
Entire Equipment....................................................................................................................9 - 2
Attachments............................................................................................................................9 - 3
Equipment ..............................................................................................................................9 - 6
Upper Carriage.......................................................................................................................9 - 7
BG 36 / 2009
XII
9.3.5
9.3.6
9.4
9.5
9.6
9.6.1
9.6.2
9.6.3
9.6.3.1
9.7
9.7.1
9.7.2
9.8
9.8.1
9.8.2
9.8.3
9.8.4
9.8.4.1
9.8.4.2
9.9
9.9.1
9.9.2
9.9.2.1
9.9.2.2
9.9.3
9.9.4
9.9.5
9.9.6
9.9.6.1
9.9.6.2
9.9.7
9.9.8
9.9.9
9.10
9.10.1
9.10.2
9.10.2.1
9.10.2.2
9.10.3
9.10.4
9.10.4.1
9.10.4.2
9.10.5
9.10.5.1
9.10.5.2
9.11
9.12
9.12.1
9.12.2
9.13
9.14
9.14.1
Undercarriage.........................................................................................................................9 - 9
Optional Equipment..............................................................................................................9 - 10
LUBRICATION PLAN.......................................................................................................... 9 - 11
MAINTENANCE DURING LONGER PERIODS OF STANDSTILL .................................... 9 - 12
HYDRAULIC SYSTEM........................................................................................................ 9 - 13
Hose Assemblies..................................................................................................................9 - 13
Hydraulic Cylinders ..............................................................................................................9 - 14
Changing Filters ...................................................................................................................9 - 15
Replacing Line Filters...........................................................................................................9 - 15
WINCHES............................................................................................................................ 9 - 16
Checking the Gear Oil Level ................................................................................................9 - 16
Changing the Gear Oil..........................................................................................................9 - 17
WIRE ROPE ACCESSORIES............................................................................................. 9 - 18
Rope Swivel..........................................................................................................................9 - 18
Rope Hold-down Rollers ......................................................................................................9 - 19
Rope Fasteners, Thimbles and Sockets ..............................................................................9 - 19
Rope Sheaves ......................................................................................................................9 - 20
Greasing Rope Sheaves ......................................................................................................9 - 20
Checking Rope Sheaves......................................................................................................9 - 21
ROTARY DRIVE ................................................................................................................. 9 - 22
Visual Inspection ..................................................................................................................9 - 22
Checking the Oil Level .........................................................................................................9 - 23
Main Gear.............................................................................................................................9 - 23
Planetary Gears ...................................................................................................................9 - 24
Changing the Oil...................................................................................................................9 - 25
Checking the Oil ...................................................................................................................9 - 28
Hollow Shaft Mounting Bolts ................................................................................................9 - 29
Kelly Driver / Guide Flange ..................................................................................................9 - 30
Checking the Mounting Bolts ...............................................................................................9 - 30
Checking Driver Strips for Wear...........................................................................................9 - 31
Cardan Joint .........................................................................................................................9 - 32
Crowd Sledge Wear Strips ...................................................................................................9 - 32
Greasing the Shaft Seal Ring...............................................................................................9 - 33
CRAWLER TRACK ASSEMBLIES ..................................................................................... 9 - 34
Visual Inspection ..................................................................................................................9 - 34
Crawler Tracks .....................................................................................................................9 - 35
Checking the Chain Tension ................................................................................................9 - 35
Adjusting the Track Tension.................................................................................................9 - 36
Checking the Mounting Bolts ...............................................................................................9 - 38
Travel Gear...........................................................................................................................9 - 39
Checking the Oil Level .........................................................................................................9 - 39
Changing the Oil...................................................................................................................9 - 39
Checking and Adjusting the Clearance of the Cross beams ...............................................9 - 40
Play at Cross-Beam Centres................................................................................................9 - 40
Play at Crossbeam Ends......................................................................................................9 - 41
CENTRAL LUBRICATION SYSTEM .................................................................................. 9 - 42
MAINTENANCE OF THE SWING MECHANISM ............................................................... 9 - 42
External Swing Mechanism Teeth........................................................................................9 - 42
Slewing Ring Mounting Bolts................................................................................................9 - 42
BOLTED CONNECTIONS .................................................................................................. 9 - 43
ELECTRIC SYSTEM........................................................................................................... 9 - 44
Replacing Dust Filter on Switch Cabinet..............................................................................9 - 44
BG 36 / 2009
XIII
10
10.1
10.1.1
10.1.2
10.1.3
10.1.3.1
10.1.3.2
10.1.3.3
10.1.3.4
10.1.3.5
10.1.3.6
10.1.3.7
10.1.3.8
10.1.3.9
10.1.3.10
10.1.3.11
10.1.3.12
10.2
10.2.1
10.3
10.3.1
10.3.2
10.4
LUBRICANTS / TABLES.....................................................................................................10 - 1
LUBRICANTS...................................................................................................................... 10 - 1
General.................................................................................................................................10 - 1
Lubricant Table.....................................................................................................................10 - 2
Lubricant Guide ....................................................................................................................10 - 4
List of Approved Gear Oils, Petroleum - CLP ......................................................................10 - 4
List of Approved Gear Oils, Petroleum API.......................................................................10 - 5
List of Approved Gear Oils, Petroleum ATF......................................................................10 - 6
List of Approved Gear Oils, Synthetic CLP PG .................................................................10 - 7
List of Approved Gear Oils, Synthetic CLP HC .................................................................10 - 8
List of Approved Hydraulic Oils, Petroleum HVLP(D) .......................................................10 - 9
List of Approved Hydraulic Oils, Fixed HEES - Unsaturated Esters ...............................10 - 10
List of Approved Hydraulic Oils, Fixed HEES - Saturated Ester .....................................10 - 11
List of Approved Engine Oils API CI-4 ............................................................................10 - 12
List of Approved Engine Oils, Synthetic API CF .............................................................10 - 13
List of Approved Engine Oils, Petroleum API CH-4 ........................................................10 - 14
List of Approved Greases, Petroleum KP2N...................................................................10 - 15
OPERATING FLUID.......................................................................................................... 10 - 16
Cooling Fluid.......................................................................................................................10 - 16
BOLT TORQUE VALUES ................................................................................................. 10 - 17
Bolts with Coarse-Pitch Metric Thread...............................................................................10 - 17
Bolts with Fine-Pitch Metric Thread ...................................................................................10 - 18
CONVERSION TABLE...................................................................................................... 10 - 19
* not used in this version
BG 36 / 2009
XIV
ABOUT THE MANUAL

This Manual is made for
Equipment model:
Construction number:
Construction year:
Date of 1st operation:
BG 36
2089
2009
.. / .. / ....
Certification:
THIS MANUAL WAS PUBLISHED IN

07 / 2009
THE CHAPTERS OF THIS MANUAL

1
2
3
4
5
6
7
8
9
10
DESCRIPTION
SAFETY
TECHNICAL DATA
CONTROLS AND INDICATORS
OPERATION
START-UP / SHUT-DOWN
RIGGING / DERIGGING
TRANSPORT
MAINTENANCE
LUBRICANTS / TABLES
APPENDICES
G:\...\2089_BG36_en_0000499012
BG 36 / 2009
XV
SYMBOLS USED IN THIS MANUAL

DANGER!
"Danger!" is used to identify an immediate hazard that can result in
serious injury or loss of life if the instructions in the manual are ignored or not correctly followed.
WARNING!
"Warning!" is used to identify a potential hazard that can result in serious injury or loss of life if the instructions given in the manual are
ignored or not correctly followed.
CAUTION
NOTE
BG 36 / 2009
"Caution" is used to identify a hazard that can result in moderate injury and / or damage to the equipment if the instructions given in the
manual are ignored or not correctly followed.
"Note" is used to highlight an operation, assembly or maintenance

procedure. In general, observance of the information here will facilitate
the work.
XVI
NAMEPLATES
Nameplates on the equipment
Assembly
Total equipment
Location
Nameplate
Beside cab door
Bauer Maschinen GmbH

D - 86522 Schrobenhausen Made in Germany
Gertetyp
type
nchste Prfung
91011
2001
345
1
12 2
Baujahr
year of manufacture
678
Sachkundigenprfung
expert test
CE - Zeichen
CE sign
Trgergert
base carrier
Bau - Nr.
serial No
Inv. - Nr.
Inv. No
Rckzugkraft
pulling force
kN
max. Druck
max. pressure
bar
Gesamtgewicht
total weight
kg
Motorleistung
engine power
kW
Vorschubkraft
pushing power
Betriebsdruck
working pressure
Arbeitspannung
working voltage
Frequenz
frequency
kN
bar
V
Hz
B0000551.wmf
BG 36 / 2009
XVII
AFTER SALES SERVICE
How to reach the Service Centre
Phone
+49 8252 97-2586
Fax
+49 8252 97-2587
Whenever you consult the Service Centre, please give the following information so that your inquiry can be dealt with more quickly:
NOTE
Equipment description
- Name of model:
- Construction number:
- Number of operating hours:
Description of damage
- Date (DD.MM.YY):
- Cause of damage (if identifiable):
- Course of events leading to damage:
For possible check-backs
- Name of person to contact, phone / fax:
Description of site
- Name of site:
- Address (post code, town, street):
- Route description for a mechanic (as necessary)
BG 36 / 2009
XVIII
WARRANTY TERMS
If a warranty agreement was concluded with the client, the following terms shall apply to warranty procedures:
Warranty period:
The contractual agreement is principally decisive for the warranty

period; if no agreement on the warranty period was concluded, the
warranty shall be valid for 12 months from the time of commissioning.
Commencement:
The warranty officially comes into effect when the equipment is put
into initial operation at the Client's, a process which must be recorded in the "Commissioning Certificate" and verified by the signatures of both the Client and a representative of BAUER. In any
event, the warranty shall come into effect no later than 1 week
after delivery.
Warranty terms
and conditions:
- Original BAUER spare parts must be used throughout the warranty period.
- Components and operating systems must not be dismantled or
repaired at any time during the warranty period without proper
authorisation.
- Any faults must be notified to BAUER in writing on the appropriate "Warranty Claim" form within 24 hours of their occurrence.
- The Client or Operator of the BAUER equipment agrees to carry
out all services throughout the warranty period within the specified service intervals in full compliance with the Instruction Manual.
- Any work (servicing, repairs, etc.) carried out on the equipment
must be recorded in the Maintenance and Repair Log provided
for this purpose with each item of equipment.
Warranty exclusions:
- Improper use or operation (misuse) of the equipment.

- Failure to adequately maintain or service the equipment leading
to breakdowns and damage.
- Repairs which have been carried out improperly.
- Unauthorised modifications or alterations to the equipment.
- Forceful physical damage.
- Damage resulting from incorrect or improper operation.
- All normal wear and tear.
Note:
Wear and tear parts include drilling tools, kelly bars, ropes etc.
If a buyer can prove that the damage was caused by a manufacturing defect, the claim shall be dealt with on a warranty basis.
BG 36 / 2009
XIX
A) Liabilities and Responsibilities of BAUER

BAUER will supply spare parts required for carrying out repairs to BAUER equipment
under warranty to the Client.
Spare parts will be delivered c.i.f. (cost, insurance, freight) to the Client.
If necessary, BAUER will also provide personnel for carrying our repairs under warranty.
Any defective parts replaced under warranty shall become the property of
BAUER.
BAUER shall determine whether defective parts are to be returned to their factory at Schrobenhausen, Germany. Transport costs for redeliveries will be paid
by BAUER Maschinen GmbH (after sales service).
NOTE
Redeliveries / deadlines
Concerning requested redeliveries, the following deadlines are valid from the date of arrival of the new parts on the jobsite in the assignment country until arrival of the damaged parts in Schrobenhausen.
Redeliveries via air freight: 4 weeks
Redeliveries via sea freight: 4 months
If the damaged parts, which are redelivered via sea freight, are not redelivered in time
due to the jobsite situation, the after sales service department has to be informed correspondingly, at the latest 6 weeks before expiry of the deadline.
Concerning redeliveries via air freight, an extension of the deadline is principally not
possible.
In case requested redeliveries are not returned within the agreed time period, the corresponding open amounts according to the sales invoice have to be paid by the respective
customer.
B) Liabilities and Responsibilities of the Client
Any customs duties payable in the country of destination for a consignment of spare
parts supplied under warranty shall be carried by the Client.
Local transport to a final destination (construction site) in connection with a warranty
claim shall also be the responsibility of the client.
Full and meticulous compliance with all operating instructions and observance of proper
operating procedures for all equipment.
Full compliance with the specified and necessary service schedule.
Entering and maintaining full and comprehensive records in the Maintenance and Repair
Log.
BG 36 / 2009
XX
To:

After Sales Service Department
P.O. Box 12 60
86522 Schrobenhausen, Germany
Phone
+49 8252 97-2586
Fax
+49 8252 97-2587
From (Customer, Agent):

Phone:
Fax:
Total number of pages of claim:
WARRANTY CLAIM
1. Product specifications
Equipment:
Constr.
year:
Constr. no.:
Operating hours:
Current location of the equipment, postal address:

Date of commissioning:
Date of damage:
2. Description of damage
Please describe damaged parts and state their material number:
Description
Construction no.
Material no.
Note (symptoms/malfunctions, causes, position of damaged parts):
3. Delivery of new parts and repair

Replacement of damaged parts from customer's own stock?
Replacement of damaged parts by ordering from after sales service?
Shipment (by courier, air or sea freight):
Delivery address:
Information for a proforma invoice:
Replacement work by customer, agent?
Yes
No
Estimated additional costs:
Estimated working time (hrs):
Date
Name of claimant
(please print)
Signature
Company
4. For internal use only (to be filled in by BAUER)

Subject to warranty?
If yes, give order number:
Yes
No
If no, give reasons:
Further reports:
Further actions:
Return of damaged parts by:
Estimated working time (hrs):
(Signed by authorized BAUER employee)
To:

After Sales Service Department
P.O. Box 12 60
86522 Schrobenhausen, Germany
Phone +49 8252 97-2586
Fax
+49 8252 97-2587
E-Mail: KVT@bauer.de
PERSONALANFORDERUNG / STAFF REQUEST

Von Firma / Company:
Besteller / Ordered by:
Phone:
Fax:
Bestell-Nr. / Order no.:
E-Mail:
Ausrstung /
Attachment:
Gert /
Equipment:
Bestell-Nr. /
Order no.:
Betriebsstd. /
Working hours:
Standort des Gerts / Location of machine:
Ansprechpartner Baustelle /
Contact person on site:
Baustellentelefon /
Site phone no.:
Zielflughafen / Airport of destination:

Datum des gewnschten Einsatzes / Date of requested assignment:
Gewnschtes Personal / Requested staff:
Mechaniker
mechanic
Elektriker
electrician
Einweiser
operator
Voraussichtliche Dauer / Estimated duration:

Auszufhrende Arbeiten / Work to be carried out:
Besonderheiten / Special requirements:
Ersatzteile / Spare parts:
Kommunikation auf der Baustelle /Communication on site:

deutsch/German
Datum / Date:
englisch/English
Landessprache/Language of country
Unterschrift / Signature:
BAUER Maschinen GmbH 86529 Schrobenhausen, Germany Tel. +49 (0) 82 52/97-0
DESCRIPTION
DESCRIPTION
1.1
INTENDED AND AUTHORIZED USE
The equipment shall only be used for the following operations:

Operation
Abbreviation
Authorized use?
Drilling with Kelly equipment
Kelly
yes
Drilling with Continuous Flight Auger equipment
CFA
no
Drilling with Front of Wall equipment
FOW
no
Drilling with Dual Rotary Drive equipment
DKS
no
Drilling with Triple Auger equipment
MIP
no
Vibrating with Vibrator equipment
no
Drilling with High Pressure Injection equipment
HPI
no
Drilling with Full Displacement equipment
FDP
no
Drilling with Soil Stabilization equipment
CSV
no
Authorized use means use in strict compliance with and strict adherence to all directives, mandates, precautions and prohibitions contained in this Instruction Manual as
well as in all additional manuals and documents supplied herewith.
Everything contained in the Instruction Manual refers to and applies only to the equipment as first delivered to the original purchaser including all original attachments and
factory installed options as of the day of delivery.
Any modification of the equipment or its attachments or factory installed options made
after delivery might render the equipment unsafe and therefore invalidates this Instruction Manual. The equipment shall not be used after any such modifications are
made unless such use after modification has been approved in writing by BAUER
Maschinen GmbH as set forth below.
The manufacturer disclaims any liability of any kind arising from or connected with the
so prohibited and unauthorized use of the equipment in any way unless such use
after modification has been approved in writing by BAUER Maschinen GmbH.
BG 36 / 2009
1-1
DESCRIPTION
After modification of the equipment, the original attachments or factory installed options
as of the day of delivery, the equipment is not authorized for any use whatsoever and
wherever unless or until an authorization is first given by BAUER Maschinen GmbH in
writing. To obtain such an authorization a Change Request as shown below must be
submitted to BAUER Maschinen GmbH.
The authorization to use the equipment after any modification of the equipment, the
original attachments or factory installed options can only be given by BAUER
Maschinen GmbH after submission and review of a properly completed Change Request. No other person, entity or organization, including but not limited any government
entity located anywhere, shall have the right to give such an authorization. Neither any
agents, distributors, importers, dealers or subsidiaries of BAUER Maschinen GmbH
shall have the right to or are able to give such a valid authorization. Only the corporate
headquarters of BAUER Maschinen GmbH can issue a valid authorization after submission of a properly completed Change Request.
The equipment described in this Instruction Manual is only intended for and therefore
shall only be used in the country for which it was ordered by the original purchaser. All
contractual agreements between the manufacturer and the original purchaser with respect to the requirements and restrictions of use and operation of the equipment in a
country other than the one the equipment was ordered for are binding on any and all
subsequent purchasers.
Any use of the equipment in any country other than the country for which it was ordered
by the original purchaser is unauthorized use and strictly prohibited unless the prior written authorization of BAUER Maschinen GmbH has been requested and received.
Any use of the equipment in the United States of America is only allowed if the
equiment was first ordered for and delivered for use within the United States of America
or if the equipment has been expressly approved and authorized in writing for use within
the United States of America by BAUER Maschinen GmbH.
Any use of the equipment other than the use authorized and described in this Instruction
Manual shall constitute unauthorized and strictly prohibited use and is hereby expressly
forbidden. The same applies if the equipment is used as a crane, for leveling purposes
or for the transport of people. These uses are expressly unauthorized and hereby
strictly prohibited.
The manufacturer shall not be liable for any injuries or damages of any kind which are
caused by, directly or indirectly, or are in any way, shape or form connected to, or arising from any unauthorized use described herein or any use that is not expressly authorized in this Instruction Manual.
BG 36 / 2009
1-2
DESCRIPTION
An/
To:

Abteilung Kundendienst
Postfach 12 60
D-86522 Schrobenhausen
Tel.
+49 8252 97-2586
Fax
+49 8252 97-2587
E-Mail kvt@bauer.de
Von (Eigentmer, Betreiber)/From (owner, user):

Tel::
E-Mail:
Fax:
Gesamtseitenzahl dieses Antrages/Total number of pages of this request:
nderungsantrag / Change request

fr/for
Gert/Equipment
Ausrstung/Attachment
Anbauteil/factory installed option
1. Grunddaten/Equipment specifications
Gert/Anlage
Equipment/
Baunummer/
Plant:
Serial number:
Aktueller Standort des Gertes/der Anlage mit Anschrift/
Current location of the equipment/plant with complete address:
Datum der Kommissionierung/Date of commissioning (first use):
Baujahr/
Year of
manufacture:
Betriebsstunden/
Operating
hours:
Anbauteile (original)/Factory installed options (OEM):

Bezeichnung/Description
Materialnummer/Material number
Baunummer/Serial number
Ausrstung (original)/Attachment (OEM):

Bezeichnung/Designation
Materialnummer/Material number
Baunummer/Serial number
2. nderungsdaten/Change data fr/for

Gert/Equipment
Ausrstung/Attachment
Anbauteil/Factory installed option
nderungsbeschreibung/Description of changes
ggf. Angebotsnr. BAUER/BAUER offer no. (if applicable)
910.818.1+2BMA
05/2009 bjm
Es wird hiermit ausdrcklich erklrt und besttigt, dass sich das Gert zum aktuellen Zeitpunkt im Originalzustand (Auslieferungzustand) befindet und ausschlielich mit BAUER-Originalkomponenten bestckt ist.
Das Gert befindet sich in einem technisch einwandfreien Zustand./
It is herewith explicitly declared and confirmed that the equipment is presently in its original condition
(as delivered) and contains only genuine original BAUER OEM components.
The equipment is in a technically flawless condition.
Eigentmer bittet um technische berprfung des Gertes./
The owner requests a technical inspection of the equipment.
Name/Name
Unterschrift/Signature
Datum/Date
3. BAUER-intern (wird von BAUER ausgefllt) / For BAUER internal use (to be filled in by BAUER)
Antrag erhalten am/Request received on:
Antrag weitergeleitet an/
VT
Name:
Datum/Date:
Request forwarded to:
EK
Name:
Datum/Date:
PM
Name:
Datum/Date:
andere/other
Name:
Datum/Date:
Name KVT-Mitarbeiter/Name of KVT employee:
BG 36 / 2009
1-3
DESCRIPTION
1.2
COMPONENTS
1.2.1
Basic Rig / Kelly Equipment
1.2.1.1 Components Overview

Basic rig
1 Boom
2 Boom cylinders
3 Swing mechanism
4 Travel gear
5 Counterweight
6 Main winch
7 Main rope
8 Auxiliary winch
9 Auxiliary rope
10 Wedge
11 Masthead tilting cylinder*
12 Kinematic triangle*
13 Mast (upper mast section / lower mast
section / mast extension)
14 Mast prop *
15 Mast pivot
16 Masthead
18 Mast extension (lower) *
19 Backstay cylinders
20 Upper carriage
21 Rope swivel
22 Clamp cylinder, crowd rope *
23 Supporting boom *
24 Supporting trestle
25 Undercarriage
26 Crowd sledge
27 Crowd ropes (upper / lower)*
28 Thrust rod *
29 Crowd winch*
30 Crowd cylinder
Kelly equipment
40
41
42
43
44
45
46
Drilling tool
Rotary drive
Casing drive adapter
Shock absorber
Cardan joint
Kelly drivers
Kelly bar
16
21
10
30
46
13
26
43
45
41
44
42
19
13
9
40
8
24
20
15
14
2
1
25
5
3
4
BM17195004.wmf
*) not supplied with this version
BG 36 / 2009
1-4
DESCRIPTION
1.2.1.2 Components Description

Basic-rig components description table
Component
Description / function
Swing mechanism
Is a movable link from the machine to the mast pivot.

Are moveable connections between the boom and the
machine. They allow the adjustment of the drilling distance.
Enables rotation of the upper carriage to both sides.
Travel gear
For driving the two crawlers forward and in reverse.
Counterweight
Gives the equipment stability.
Main winch with main rope
Used as a hoist for the kelly bar.
Auxiliary winch with auxiliary rope
Used for rigging operations and load handling.
Wedge
Allows the distance from mast to bore to be changed.
Kinematic triangle (H)
Enables parallel repositioning of the mast.
Mast (upper section / lower section)
Provides guidance for the crowd sledge.
Mast prop
Supports the rig during withdrawal of the drilling tool.
Mast pivot
Is a swivel link between the mast and the boom.
Masthead
Houses sheaves which guide ropes over the mast.
Mast extension (intermediate)
Enables use of longer drilling tools.
Mast extension (lower)
Upper carriage
Allows the crowd sledge to be positioned further down.

Support the mast and allow its inclination to be adjusted.
Allow the mast to be lowered.
Houses the engine, hydraulic system and controls.
Rope swivel
Prevents rope twist.
Crowd rope tensioning cylinder (S)
Stresses the crowd ropes.
Supporting boom (H)
Enables parallel repositioning of the mast.
Supporting trestle (V)
Thrust rod (Z)
Is a mount for the backstay cylinders.

Carries the upper carriage and enables onsite travelling
with the equipment, from one spot to the next.
Runs up and down the mast while carrying the drilling
tool.
Transfer the power from the crowd winch to the crowd
sledge.
Is a distance keeper for the crowd cylinder.
Crowd winch (S)
Generates the crowd forces.
Crowd cylinder (Z)
Generates the crowd forces.
Boom
Boom cylinders
Backstay cylinders
Undercarriage
Crowd sledge
Crowd ropes (upper / lower) (S)
Z) For rig fitted with cylinder crowd

S) For rig fitted with rope crowd
BG 36 / 2009
V) For mast lowering to the front

H) For mast lowering to the rear
1-5
DESCRIPTION
Kelly equipment components description table

Component
Description / function
Drilling tool
Erodes and conveys soil.
Rotary drive
Generates rotary movement and torque for the drilling

tool and/or casing tube.
Its main gear is driven by planetary gears which take
power from hydraulic motors.
Casing drive adapter
Serves as a connector between the cardan joint and

the casing tube and transfers the torque.
Shock absorber
Absorbs shocks from the kelly bar.
Cardan joint
Transfers torque from rotary drive to casing drive

adapter and prevents torsional stress.
Kelly driver
Transfers torque from rotary drive to kelly bar.
Kelly bar (Kelly)
Consists of telescopic tubes the total length of which

determines the achievable drilling depth of the bore. It
transfers torque from the rotary drive to the drilling
tool.
BG 36 / 2009
1-6
DESCRIPTION
1.2.2
CFA Equipment *
1.2.2.1 Components Overview *

1 Concreting kelly extension
2 Concreting swivel head

3 Auger cleaner
4 Rope crossbeam
5 Continuous flight auger (CFA)
BK537503.wmf
* does not exist in this version
BG 36 / 2009
1-7
DESCRIPTION
1.2.2.2 Components Description *

Table CFA equipment components description
Component
Concreting kelly extension
Description / Function
Transmits torque from rotary drive to drilling tool
and conveys slurry from the concreting head into
the CFA auger.
Allows increasing the drilled depth by as much as
the length of the concreting kelly extension.
Concreting swivel head

Auger cleaner
Rope crossbeam
Guides slurry into the rotating concreting kelly.

Is fitted with a concrete pressure gauge.
Wipes off soil from the auger flight during withdrawal and serves as a guidance of the auger.
Is pinned to the rotary drive and has a rope sheave
to reeve the main rope, the end of which is anchored to the masthead.
Serves for use of the main winch force to sustain
the crowd system in pulling the auger.
CFA auger
Is a hollow stem with a continuous flight auger

which cuts and transports soil and through which
the bore may be filled with slurry during the withdrawal.
* does not exist in this version
BG 36 / 2009
1-8
SAFETY
SAFETY
2.1
GENERAL SAFETY REQUIREMENTS
It is fundamental that the national accident prevention codes be observed where this
equipment is used.
In addition, the "Safety Information" book supplied with this equipment must be read
and understood. It contains general safety requirements and such that have been
compiled by the manufacturer especially for this type of equipment.
Also, the safety messages given in the manual of the equipment must be followed.
2.2
EQUIPMENT SAFETY
The safety built into this equipment is state-of-the-art and complies with all valid EC requirements.
Equipped safety devices guarantee the highest possible safety standard.
2.3
MAJOR HAZARDS
- In drilling operations, the equipment operates with rotating tools. Being pulled in by
such a tool could lead to severe or even mortal injuries.
- In vibrator applications, the equipment operates with high-frequency oscillating tools.
Getting knocked down by a component thereof is mortal.
- The stability of the equipment must not be compromised. Exceeding the rig's capacity or operating with faulty limit switches can make the equipment fall violently causing severe personal injury or even loss of life.
- Never remove equipped safety devices nor render them out of order.
- Be observant of oil spills from the hydraulic system. Oil spraying with high pressure
from a leak in the hydraulic system can cause severe burns and poisoning.
- The cooling system gets very hot from operation. Coming into contact with components containing coolant can cause burns.
- Engine, gear and hydraulic oils get very hot during operation. Touching a component
containing such oil can cause burns.
- Be sure the equipment is properly shut down before you begin a maintenance, repair
or cleaning job on it. Set all controls to Off, stop the engine and interrupt the power
supply by setting the battery main switch to Off position.
- To prevent abuse and unauthorised starting of the equipment, shut it down, remove
the ignition key and lock the cab whenever you leave the equipment unattended.
BG 36 / 2009
2-1
SAFETY
2.4
SAFETY DEVICES
2.4.1
Emergency Stop
In an emergency !!
Press the Emergency STOP button (1) !!
All equipment functions will promptly come to
a stop.
Emergency Stop
NOT-AUS
To re-start, pull the depressed Emergency

STOP button.
B0000795.wmf
2.4.2
Pilot Control Safety Stick
With the safety stick (1), the operator must

shut off the pilot control before leaving the
driver's seat. With the stick in the "Off" position, all hydraulic functions are blocked.
Pilot control On: stick moved to position (1.1)
Pilot control Off: stick moved to position (1.2)
1.1
1.2
B0000796.wmf
BG 36 / 2009
2-2
SAFETY
2.4.3
Fire Extinguisher
Machines with an engine power of < 200 kW

are equipped with one fire extinguisher / machines with an engine power of > 200 kW
are equipped with two fire extinguishers.
Their location in or on the machine is identified with a decal (see fig.).
Personnel must recapitulate the instructions
given on fire extinguishers from time to time
to be familiar with their use.
2.4.4
B0000506.wmf
Medical Box
A First Aid medical box is found in the

operators cab. Its location is identified
with a decal (see fig.).
B0000562.wmf
2.4.5
Emergency Exit
Whenever the normal exit from the cab is

blocked, the operator can use the emergency hammer (see fig.) to smash a window.
The hammer is found in the upper corner
behind the operators seat.
GAALM055.wmf
BG 36 / 2009
2-3
SAFETY
2.4.6
Limit Switches
Table of limit switches

Name
ES 2
ES 2.1*
Function
Limits mast inclination to left.
Initial situation:
- ES 2 is faulty
Switches off engine when max. permissible mast inclination to left is obtained.
ES 3
Enables the rigging mode when boom

cylinders are fully extended.
ES 4
Limits mast inclination to right.
ES 4.1*
ES 10*
Initial situation:
- ES 4 is faulty
HS 1
HS 2
ES 16
ES 15
Switches off engine when max. permissible mast inclination to right is obtained.
Initial situation:
- boom cylinders fully extended
- inclinometer is faulty.
Limits mast inclination forward or backward for drilling operations.
ES 15*
ES 16*
Switches off the "Crowd up" function.

(Only in kelly mode.)
Stops the main winch lifting any further
before the load hits the masthead. (Only
with kelly guidance.)
HS 1
Stops the main winch lifting any further

before the load hits the masthead.
HS 2
Stops the auxiliary winch lifting any further before load hits the masthead.
ES 2
ES 4
ES 10
ES 3
BM781503.wmf
*) Not supplied in this version
NOTE
BG 36 / 2009
When switch ES 2.1 or ES 4.1 is activated, the engine can be restarted

by holding the by-pass button depressed while turning the ignition on.
2-4
SAFETY
2.5
STABILITY
2.5.1
Stability Guidelines
Rig capacity charts are calculated in compliance with the European standard
DIN EN 791 (issue 1995).
WARNING!
Tipping hazard!
The conditions listed in the following must be observed to guarantee the
stability of the rig.
Conditions for operation:
The angles and loads for main rope, auxiliary rope, and crowd specified in the load
capacity charts are maximum values and may not be exceeded for safety reasons.
Specified loads do not apply in combination with one another and on an altered
equipment setup.
If equipment with a higher weight or centre of gravity is added (e.g. conversion from
kelly to CFA equipment), the stability must be re-calculated.
Machine on firm, horizontal and even surface. Observe national standards and guidelines regarding soil and working platform conditions.
Upper carriage at a standstill during crowd and main rope load.
Swing upper carriage slowly with auxiliary rope load.
No diagonal pull.
NOTE
The pulling and pushing forces of the winches / crowd cylinder and the
current centre of gravity (position of the work attachments) are factors
which have an additional influence on the rigs stability.
The loads given in the load capacity charts take into consideration the
most adverse position of the components.
Conditions for on-site travelling:

Machine on firm, horizontal and even surface. Observe national standards and guidelines regarding soil and working platform conditions.
Upper carriage in line with undercarriage.
Equipment and moveable loads must be kept as close to the ground as possible.
Mast 3 to the back.
No abrupt movements.
BG 36 / 2009
2-5
SAFETY
2.5.2 Stability for BG 36 # 2089 - Kelly BK 40/470/4/68

2.5.2.1 Load Capacity Chart
Valid only for
Conditions for operation
1.90 t
Mast extension 3.0 m
15.30 t
Kelly BK 40/470/4/68
28.30 t
Counterweight
2.10 t
Casing drive adapter 1630
2.85
t
Drilling bucket 1500 mm
Crowd sledge stroke limiter mounted (max. stroke: 10250 mm)
Max permissible load / max ground pressure**
B00005001.wmf
B00005003.wmf
B00005002.wmf
Max. drilling distance*:

4.65 m
Min. drilling distance*:

m
Auxiliary
rope
10.0 t
630 kPa
Main rope
30.0 t
580 kPa
Crowd
40.0 t
820 kPa
Auxiliary
rope
Main rope
Crowd
= 5
= 5
= 0
= 75
= 5
= 2
= 4
= 75
= 5
= 2
= 4
= 75
8.0 t
1140 kPa
30.0 t
850 kPa
40.0 t
1300 kPa
Auxiliary
rope
= 5
= 5
= 0
1.0 t
750 kPa
Main rope
= 5
= 2
= 4
26.0 t
780 kPa
Crowd
= 5
= 2
= 4
21.0 t
790 kPa
= 3
4 / 450 kPa
Max. travel gradability / max. ground pressure
*) Drilling distance = centre distance from machine to drilling tool

**) Max. value of ground pressure as calculated in conformance with DIN EN 791 (1995 issue)
BG 36 / 2009
2-6
SAFETY
2.5.2.2 Weights / Gravities - Drilling Distance 4.65 m

Valid only for
Drilling distance*
4.65 m
Weight
[kN]
Xres
[m]
Zres
[m]
Completely equipped drilling rig
1316.90
0.69
6.09
Undercarriage with connections to CO
242.00
0.14
0.65
Upper carriage with BAUER attachments,

with crowd sledge
with counterweights
without work equipment,
without undercarriage,
without rotary drive
792.90
-0.52
5.40
78.00
4.40
12.77
21.00
153.00
28.50
1.50
4.65
4.65
4.65
4.65
11.00
14.50
3.70
23.99
Component
B0000919.wmf
B0000920.wmf
B0000921.wmf
Rotary drive KDK 367 S

with kelly driver
Casing drive adapter 1650
Kelly BK 40/470/4/68
Drilling bucket 1500
Swivel
B0000922.wmf
A
S
B
4.60
3.77
0.80
Length of crawler tread

Track gauge, extended
Width of track pads
Dimension
[m]
Undercarriage
B0000929.wmf
*) Drilling distance = centre distance from machine to drilling tool
BG 36 / 2009
2-7
SAFETY
2.6
PERMISSIBLE WIND SPEED
The place to measure the wind speed is at the masthead:

Max. permissible wind speed for equipment operation
m/s
20
km/h
72
miles/h
45
Beaufort
8
ktn
39
Barrier effect
250 (N/m)
WARNING!
Tipping hazard!
Shut down the equipment before the value is exceeded.
Remove attached drilling tool(s) and suspended load.

Lower movable components as close to the ground as possible.
Adjust the upper carriage in line with the undercarriage and interlock them.
Set the mast into the minimum working range.
Extend the mast prop, if equipped.
Table of wind forces and speeds

Wind force
Beaufort
English
Wind speed
Wind effects
m/s
km/h
0 - 0.2
less than 1 Smoke rises straight in the air, sea is calm-glassy
calm
light air
0.3 - 1.5
1-5
Smoke drifts but vanes remain still, sea is rippled
light breeze
1.6 - 3.3
6 - 11
gentle breeze
3.4 - 5.4
12 - 19
moderate
breeze
5.5 - 7.9
20 - 28
Wind can be felt on your face, leaves rustle, sea

has wavelets
Leaves and thin twigs move, pennants stretch,
wave crests begin to break
Dust and paper lift, twigs and branchlets sway,
waves are growing in length, scattered white-caps
fresh breeze
8 - 10.7
29 - 38
strong breeze
10.8 - 13.8
39 - 49
near gale
13.9 - 17.1
50 - 61
gale
17.2 - 20.7
62 - 74
strong gale
20.8 - 24
75 - 88
BG 36 / 2009
Small trees begin to sway, waves are white-capped

all over the sea
Sturdy branches move, wires sing, umbrellas are
hard to handle, sea is rough, crests break
Whole trees swaying, working towards the wind is
difficult, sea is very rough, foam on crests
Branches break off, walking outdoor is extremely
difficult, waves are high, spray from crests
Minor damage to buildings (roof tiles and chimney
hoods are ripped off); on the sea, waves are very
high and the visibility is obstructed by spray
2-8
TECHNICAL DATA
TECHNICAL DATA
3.1
DIMENSIONS
3.1.1
Kelly Equipment BK 40/470/4/68
3000
1650
9500
2140
1683
26869
27232
20250
10000
665
Dimensions in [mm]
10250
1300
3500
1877
800
1150
2934
1920
1500
56
4600
5675
4288 (4650)
R 4800
BM20885000.wmf
BG 36 / 2009
3-1
TECHNICAL DATA
3.2
EQUIPMENT SPECIFICATIONS
Base machine
Upper carriage
Type
Serial number
BS 80 B
80.6.1049
Engine
Type
Serial number
Output
Speed
CAT C 15
JRE 10262
354 kW
1850 rpm
Undercarriage
Type
Serial number
Width over crawlers
Length of crawlers
Width of track pads
UW 110 C
1407
3.400 - 4.600 mm
5.675 mm
800 mm
Max. mast inclination

During operation without work equipment
forward
backward
to left
to right
5
19
5
5
During operation with work equipment

See load capacity chart
Drilling distance
See load capacity chart
Operating weight
With:
Kelly equipment BK 40/470/4/68
BG 36 / 2009
132.00 t
3-2
TECHNICAL DATA
Main winch
Type
Serial number
Pulling force (1st layer)
Rope diameter
Rope length
Rope speed
("lifting" with a load of 20 kN)
4.31 1000299
188
300 kN
36 mm
105 m
80 m/min
Auxiliary winch
Type
Serial number
Pulling force (1st layer)
Rope diameter
Rope length
Rope speed
("lifting" with a load of 10 kN)
4.22 1000328
920
100 kN
20 mm
70 m
55 m/min
Crowd winch
Type
Serial number
Max. stroke of crowd sledge
Max. pushing force at crowd sledge
Max. pulling force at crowd sledge
Rope diameter
Rope length upper / lower
Crowd speed:
"Fast crowd up"
"Fast crowd down"
"Slow crowd up"
"Slow crowd down"
BG 36 / 2009
77 WH 103/12
66453
10250 mm
330 kN
310 kN
28 mm
80 m / 75 m
26.0 m/min
26.0 m/min
6.5 m/min
6.5 m/min
3-3
TECHNICAL DATA
3.3
ROTARY DRIVE SPECIFICATIONS
3.3.1
Rotary Drive, Shiftable
Pth = 300 kW
Qth = 2 x 320 l/min
1st gear
2nd gear
300
400
368
350
250
Drehmoment / Torque M [kNm]
306
300
250
200
150
208
200
150
110
100
110
100
50
50
0
0
88
10
15
20
23
25
Drehzahl n [1/min] / Speed n [rpm]
11 12
10
15
20
23
25
BM658500.wmf
BM658502.wmf
Efficiency not considered

1st gear (reduced torque)
200
177
160
147
120
80
53
40
0
0
10
16 17
20
30
40
48
50
BM658501.wmf
BG 36 / 2009
3-4
TECHNICAL DATA
3.4
DRILLING SPECIFICATIONS
3.4.1
Kelly Equipment BK 40/470/4/68

L1
Dimensions [mm]
L1
L2
L3
A max. (with swivel)
A max. (without swivel)
Hd
Bore diameter [mm]

uncased
cased
L2
Casing tube length

without CO
with CO
L3
25104
14129
3879
20325
21225
10306
2300
2000
Hw 1.0 m
Hw 1.5 m
Hd
Hw
Drilling depth / Kelly data
Kelly type
B
BK 40/470/4/68
A [m]
20.25
B [m]
70.79
B1 [m]
70.48
Hw [m]
2.65
Kelly
locked
with
without
CO
CO
T [m]
T [m]
Kelly
unlocked
without
with
CO
CO
T [m]
T [m]
68.80
69.11
67.30
67.61
Weight
[t]
15.30
W
BM638504.wmf
BG 36 / 2009
Note:
Information on drilling depths are based on minimum operating radius of the mast.
At maximum operating radius, the drilling depth increases by 0.43 m.
A:
A max.:
B / B1:
T:
Hw:
Hd:
L1:
L2:
L3:
W:
CO:
Length of retracted kelly

Max lifted length of kelly
Length of extended kelly unbolted / bolted
Max. possible drilling depth
Maximum height to drilling tool
Maximum height to casing drive adapter
Highest possible position of kelly lifting eye
Highest possible position of kelly driver upper edge
Lowest possible position of kelly driver upper edge
Length of drilling tool: 2.20 m
BAUER Casing Oscillator
3-5
TECHNICAL DATA
3.5
ROPE SPECIFICATIONS
3.5.1
Main Rope
WARNING!
Accident risk!
Ropes breaking can cause serious accidents.
Ropes installed in hoist winches must have a minimum breaking load
which is at least three times the winch pull force.
The ropes' safety factors must comply with the standards required for the equipment
and must be observed.
Technical data:
Finished length
Diameter
105 m
36.00 mm
Characteristics:
Lay and direction
Rotation characteristics
Rope end characteristics
BG 36 / 2009
Lang lay, right (zZ)

non-rotating
pointed - thimble
3-6
TECHNICAL DATA
3.5.2
Auxiliary Rope
WARNING!
Accident risk!
Technical data:
Finished length
Diameter
60 m
20.00 mm
Characteristics:
Lay and direction
BG 36 / 2009
regular lay, right (sZ)

non-rotating
pointed - thimble
3-7
TECHNICAL DATA
3.5.3
Crowd Ropes
WARNING!
Accident risk!
Technical data:
Finished length (upper/lower)
Diameter
80 m / 75 m
28.00 mm
Characteristics:
Lay and direction
BG 36 / 2009
regular lay, right (sZ)

non rotation resistant
pointed - pointed
3-8
TECHNICAL DATA
3.6
NOISE EMISSION
Measurements made in accordance with DIN EN 791:

1. Inside Cab (door closed)
Sound-pressure level in cab
LpA =
78.0 dB(A)
2. Outside
Average sound-pressure level
Sound-power level
3.7
LPA = 81.0 dB(A)

LWA = 111.6 dB(A)
TEMPERATURE CONDITIONS
The drilling equipment can be used at temperatures ranging from -20 C to +40 C
(-4 F to +104 F).
For use in temperatures outside the specified range, the manufacturer must be consulted.
3.8
EXPOSURE TO VIBRATIONS
The operators exposure to vibration acceleration during operation with this equipment
is less than 0.5 m/s2.
BG 36 / 2009
3-9
4.1
OPERATOR'S CAB
1.5
1.3
1.1
2.1
21
20
Emergency Stop
NOT-AUS
4
2
10.7
10.5
10.1
10.4
10.10
2
1
10.3
10.9
16
10
11
10
10.2
10.6
10.8
10
9
10
23
14
24
25
29
30
10
13
15.2
15.6
15.8
2.2
2.3
15.4
15.10
15.3
15.9
1.2
1.4
1.6
15.7
15.5
15.1
19
18
17/17.1
5
22
4
26
27
28
6
7
8/8.1
9/9.1
00000000
12
BM1098504.wmf
1.1
1.2
2.1
2.2
3
4
5
6
7
8
9
10.1
10.2
10.3
10.4
10.5
Left crawler travel forward

Left crawler travel reverse
Right crawler travel forward
Right crawler travel reverse
Freewheel release
Freewheel mode ON / OFF
Indicator: Freewheel released
Crowd fast mode ON
Horn ON
In Kelly mode: To dump spoil
Rotary drive fast mode ON / OFF
Crowd down
Crowd up
Rotary drive rotate right (cw)
Rotary drive rotate left (ccw)
In Rigging mode:
Right backstay cylinder extend
10.6 In Rigging mode:
Right backstay cylinder retract
11 Engine speed adjustment
12 Engine ignition ON / OFF
13 Heater control
14 In Kelly mode:
Crowd pressure adjustment
15.1 Winch 1 / 2 down
15.2 Winch 1 / 2 up
BG 36 / 2009
15.3 Uppercarriage swing left

15.4 Uppercarriage swing right
Left backstay cylinder extend
Left backstay cylinder retract
16 Emergency STOP
17 Auger cleaner
18 Swing brake unlock
19 Swing brake lock
20 Freewheel release
21 Pilot control ON / OFF
22 Main rope retract force adjustment
23 Not used
24 Crowd speed adjustment *
25 Central lubrication ON / Flashing code
Warning: Central lubrication system fault
26 Not used
27 Not used
28 Sideward inclination end limiter by-pass:
push and hold button, and restart engine
by ignition key
29 Indicator: Crowd sledge - Lube trouble
30 Central lubrication system ON / OFF
*
not used in this version
4-1
13 14 15 16 17
18 19 20 21 22
2
1
BG 36 / 2009
9 10 11 12
n
min
10
45
46
56
39
40
41
42
43
44
16
17
18
19
20
21
22
23
24
25
28
29
30
31
35
36
37
Indicator: freewheel released

Adjust rope retract force, winch 1
Freewheel on/off
Monitor diagnostic system
Displays battery voltage
Displays diesel tank fill level
Displays coolant temperature
Displays engine oil pressure
Displays hydraulic oil temperature
Displays engine speed
Displays operating hours
Displays time
Indicator: swing brake locked
Warning: air filter contaminated
Warning:
return-flow filter for hydraulic oil contaminated
Warning: pilot control filter contaminated
Not used
Warning: coolant temperature too high
Warning: coolant level too low
Indicator: valve on hydraulic tank closed
Warning: hydraulic oil level too low
Not used
Right control lever
Headlights on / off
Rear lights on / off
Adjust wiper interval
Front windscreen wiper on / off
Roof windscreen wiper on / off
Air conditioning system on / off
Automatic speed reset On / Off
Load limit regulation manual / automatic
Warning: engine diagnostics
Red indicator= engine OFF!
Yellow indicator = error code
Electric socket
Fan on / off
Engine speed adjustment
Ignition on / off
Operating hours counter
By-pass of sideward-angle limit
switches to start the engine
Not used
Not used
Serive socket of engine
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
BASE MACHINE CONTROL CONSOLE
4.2
46 45 44
29 30
24 25
23
28 41
59 35
31
36
37
40
00000000
43 39
42
56
B0000992.wmf
4-2
4.3
CONTROL PANEL 1
Mast prop cylinder

retract
extend
Winch
rigging
Rigging
Mast
reset
Derigging
Boom
extend
Backstay cylinder
extend
extend
Extendable
crawlers
Backstay
cylinders
Boom
retract
Backstay cylinder
retract
retract
Main
AT
Winch
Aux
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
B0000924.wmf
1 Preselection of rotary-drive big torque

and high speed
2 Preselection of rotary-drive big torque
and reduced speed
3 Preselection of rotary-drive medium torque
and high speed
4 Preselection of rotary-drive small torque
and maximum speed
5 Not used
6 Not used
7 Mast prop retract
8 Mast prop extend
9 In rigging mode: select the winch
10 Select rigging mode
11 Select de-rigging mode
12 In drilling mode:
extend boom
extend left backstay cylinder
BG 36 / 2009
extend right backstay cylinder
15 Extendable crawlers select
16 Not used
17 Set mast automatically vertical
18 Not used
19 In rigging mode:
Indicator: Backstay cylinders selected
retract boom
retract left backstay cylinder
retract right backstay cylinder
23 Select winch 1 (main winch)
24 Select winch 2 (auxiliary winch)
* Not used in this version
4-3
4.4
CONTROL PANEL 2
Drill
automatic
Pull
automatic
Depth
interrupt
Rope tensioner
tension
release
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
B0000917.wmf
1 - 4 Not used
5 In kelly / CFA mode:
Drill assistant ON / OFF
6 Pull assistant ON / OFF *
7 Depth measuring interrupt
8 - 22 Not used
23 Crowd rope tension
24 Crowd rope slacken
* Not used in this version
BG 36 / 2009
4-4
4.5
B-TRONIC SYSTEM
For further details please refer to the supplementary documentation on the B-Tronic
System.
BG 36 / 2009
4-5
OPERATION
OPERATION
5.1.
TO TRAVEL AND STEER
CAUTION
Risk of shortening the service life of crawler components due to incorrect loading!
The main direction of travel should always be - as shown - following the
direction of the arrow (2); the front idlers (1) facing forward and the
travelling drive (3) at the back.
When working, the front idlers (1) should also face the drilling spot.
1
CA00005000.wmf
B0000552.wmf
CAUTION
Risk of damaging the crawler components!

The machine's installed crawlers are designed for standard operations
with drilling loads.
This equipment should not travel over longer distances!
Suitable and designated means of transport must be used to reposition
the machine!
NOTE
BG 36 / 2009
5-1
OPERATION
5.2
UPPER CARRIAGE SWING
Swing brake
The swing brake serves to arrest the upper carriage against rotation during operation.
CAUTION
Risk of damaging components!

The swing brake may be applied only when the upper carriage has
come to a stop.
WARNING!
Risk of getting crushed or hit!
Before swinging the upper carriage, check the danger zone is free. The
rear-view mirror (and tail camera if equipped) must be clean at all times.
Swing brake lock (close):

Press button (19);
indicator light (30) comes on.
Swing brake unlock (open):
Press button (18);
indicator light (30) goes out.
30
19
18
15.3
15.4
B0000798.wmf
Swing control
Upper carriage swing to left:
Release swing brake.
Move control lever (15) to left (15.3) from centre.
Upper carriage swing to right:
Move control lever (15) to right (15.4) from centre.
Letting the lever return to centre makes the swing slowly come to a stop in hydraulic
way.
A quicker stop can be implemented by carefully moving the lever in the opposite direction.
BG 36 / 2009
5-2
OPERATION
5.3
MAST REPOSITIONING
CAUTION
CAUTION
CAUTION
BG 36 / 2009
Risk of causing damage to components!

The mast must be parallel to the drilling axis at all times!
During drilling mode and especially during casing oscillator applications it is important to watch the inclination of the mast on the operators screen. Should the inclination change due to the forces, the mast
must be repositioned to the original inclination.
Risk of components getting damaged and the rope breaking !
On machines where the winches are housed in the upper carriage, the
ropes must be sufficiently slackened before the mast is repositioned.
Otherwise, the ropes may be subjected to excessive stress.
Risk of components getting damaged and the rope breaking !
On equipment fitted with an overload protection for the main rope, various functions will shut off when the rope is overloaded and a message
will appear on the operator's screen.
When this is the case: unlock the Kelly (if locked) and spool out rope
from the main winch.
Immediately replace any damaged components of the overload protection.
5-3
OPERATION
5.3.1
Mast auto reset to vertical

CAUTION
Press button
Neither the mast prop nor components of the drilling equipment may be
in touch with the ground when the "Mast Auto Reset" is actuated.
AT
and hold on.
The mast sets to vertical position.

Releasing the button too soon stops the action.
The mast will first set to vertical position in the X axis and then, after a
pause, in the Y axis.
NOTE
BG 36 / 2009
5-4
OPERATION
5.3.2
Mast Repositioning by Manual Control
5.3.2.1 To Adjust the Mast Inclination

In Drilling Mode
The rigging modes
lected:
and
Extend left backstay cylinder by
Extend right backstay cylinder by
Retract left backstay cylinder by
Retract right backstay cylinder by
are not se-
In Rigging Mode
Rigging mode
or
and backstay cylinders
are selected:
Lowering the mast:
Move left / right control lever forward
B0000504.wmf
Raising the mast:

Move left / right control lever back
5.3.2.2 To Adjust the Drill Distance
Increasing machines distance to the bore:
Extend boom cylinders by
Decreasing machines distance to the bore:
Retract boom cylinders by
NOTE
To adjust the mast parallel (see fig.), the mast

inclination must be readjusted.
B0000505.wmf
BG 36 / 2009
5-5
OPERATION
5.4
TRAVELLING WITH THE RIG
5.4.1
Travelling over Level Ground
Risk of accident due to drivers obstructed round-view from the cab.

The driver of the rig must be assisted by a signalman during travel.
CAUTION
Provide an obstacle free travel path.
Adjust the uppercarriage in line with the crawlers and apply the swing brake.
Lower work attachments and movable loads as close to the ground as possible.
Set the mast in position of minimum working range.
Set the mast vertical.
Travel on firm and level surfaces only.
Avoid making abrupt movements.
BG 36 / 2009
5-6
OPERATION
5.4.2
Travelling Up and Down Slopes
5.4.2.1 With Raised Mast and Without Drilling Equipment
Tipping hazard!
Observe all instructions found in sect. "Travelling over level ground"!
CAUTION
Tipping hazard!
It is prohibited to travel up/down gradients of more than 15 and also to
traverse gradients!
CAUTION
On slopes the backstay cylinders are extended so that the mast is upright.
When travelling uphill
The mast should be facing the uphill side.
When travelling downhill

The mast should be facing the uphill side.
CAUTION
It is forbidden to travel downhill with the mast facing forwards.
BG 36 / 2009
B0000906.wmf
5-7
OPERATION
5.5
ROTARY DRIVE CONTROL
5.5.1
With Kelly Equipment (Rotary Drive Shiftable)

8
9
31
32
33
10
34
B0000895.wmf
Function
Control
To select high torque (1st gear)

with high speed:
with reduced speed:
(with rotary drive out of motion)

Press button (31)
Press button (32)
and to shift between high and reduced speed:
Press button (9)
To select reduced torque (1st gear):
Press button (33)
To select low torque (2nd gear)

with max speed:
(with rotary drive out of motion only)

Press button (34)
To accelerate or decelerate rotation:
Move control lever (10) away from or back to centre
To rotate counter-clockwise:
To rotate clockwise:
Move control lever (10) to right

Move control lever (10) to left
CAUTION
Risk of damaging the kelly!

Only dump spoil when the kelly is
unlocked.
To dump spoil (abrupt stopping clockwise rotation):
BG 36 / 2009
Move control lever (10) to left and press button (8)
5-8
OPERATION
5.5.2
With CFA Equipment

8
9
31
32
33
10
34
B0000895.wmf
Function
Control
To select high torque (1st gear)

with high speed:
with reduced speed:

Press button (31)
Press button (32)
and to shift between high and reduced speed:
Press button (9)
To select reduced torque (1st gear):
Press button (33)
To select low torque (2nd gear)

with max speed:

Press button (34)
To accelerate or decelerate rotation:
Move control lever (10) away from or back to centre
To rotate counter-clockwise:
To rotate clockwise:
Move control lever (10) to right

Move control lever (10) to left
BG 36 / 2009
5-9
OPERATION
5.5.3
Torque Limiting with Key-operated Switch
CAUTION
Risk of damaging the kelly bar!

If the kelly bar used is not capable of transmitting the full torque of the
rotary drive, the torque must be reduced!
The torque reduction is an overload protection for drill string components (kelly bars, joints of
auger sections and FDP pipe joints) not capable of transmitting the full torque of the rotary
drive.
To switch the torque reduction on:
Turn the key-operated switch (1) in the wiring

cabinet to position "I".
B0000904.wmf
Enabled control functions:
In kelly mode:
For tubing the full torque may be enabled for the casing drive adapter even in
the case that the torque limiting is switched on.
Precondition: The load on the main rope is at least 1 tonne.
min.
1 to
To activate the full torque for the casing drive adapter:

Press button (8). Light (1) blinks.
Spool in at least one metre of main rope,

i. e. so that the kelly is hanging freely
suspended on the main rope.
Light (1) is lit up.
The full torque will be deactivated again
as soon as the main rope is spooled out.
B0000903.wmf
min.
1m
B0000910.wmf
BG 36 / 2009
5 - 10
OPERATION
5.6
WINCH CONTROL
5.6.1
Lifting / Lowering
WARNING!
Danger of getting squashed, entangled, drawn-in and scrubbed!
Never put a hand in the winch moving area.
Never reach between winch and rope.
Never seize a rope in motion.
WARNING!
Hitting hazard, squashing hazard!
Hook up the auxiliary rope on the holding arm.
Do not tension hooked-up rope when people are in the danger zone.
CAUTION
CAUTION
BG 36 / 2009
Risk of damaging the winches!

When unspooling rope from winches, the operator must ensure that
three wraps of rope remain on the drums, for safety reasons.
Risk of damaging the rig!

Hoist limiters are out of function during rigging operations so that the
winches must be controlled with great care.
5 - 11
OPERATION
In drilling mode
In rigging mode
Set all rigging controls to off.
Lamp in buttons
will not light up.
and
Select "winch rigging" mode:
Lamp in button
will light up.
Winch selection:
Press button
for main winch or
press button
for auxiliary winch.
Operating the selected winch:
BO000702.wmf
BG 36 / 2009
5 - 12
OPERATION
5.6.2
To Operate with Freewheel
The freewheel function enables the main winch to automatically follow the drilling progress and prevents the drilling tool getting stuck in soft soil formations.
4
Preconditions for release of freewheel function:

Load on rope is maximum: 2.0 tonnes
9
10
2
6
8
9
10
Freewheel activation:
Turn the key-operated switch (1) to the "Freewheel
mode On" position.
Press foot switch (4) all the way down and hold.
Briefly press button (3).
5
7
1
Freewheel is released! Indicator (5) is lit.
0 0 000 0 00
BV737510.wmf
The rope will first automatically tension (by up to approx. 500 kg) ensuring tipped swivel raises to upright. This avoids damage to the rope.
NOTE
Freewheel speed setting:
BV737427.jpg
BV737501.wmf
Using the handwheel (see fig.), set the freewheel speed such that the operating
pressure at the rotary drive does not exceed 270 bar during the drilling process. This
prevents the drilling tool getting stuck.
Handwheel setting
0
10
Freewheel speed
Max
0
If the handwheel is set to max., the winch will stop and the indicator (5) will go out. In
this case, turning the handwheel back slightly will make the freewheel release again.
Freewheel deactivation:
Release the foot switch or
lift / lower by the winch control lever.
Turn the key-operated switch (1) back to the "Freewheel mode Off" position.
BG 36 / 2009
5 - 13
OPERATION
5.6.3
To Operate with "Slack Rope Switch-Off"
The "switch-off" here is a function that enables power-controlled and slack-free unspooling of rope from the main winch.
To activate the Slack rope switch-off:
10
Retraction force [t]
Potentiometer setting
Turn potentiometer (7) to right past the

switch-point.
Set potentiometer (7) to the desired rope retraction force (= the value at which the winch
is to stop unspooling rope).
5
1
7
2
Emergency Stop
NOT-AUS
5
1
0
3
2
9
10
2.0
10
10
00 0 00 00 0
Bj637501.wmf
Power-controlled unspooling of rope:

Push left control lever forward, until load lands on solid surface.
If slack rope creates, the main winch will stop and the following message appears on
the screen:
Main winch slack rope switch-off
NOTE
From now on, activation of the "Freewheel" function of the main winch
(see separate sect.) can be used to continue the automatic slack-free
unspooling of rope.
To deactivate the Slack rope switch-off:
Turn potentiometer (7) to left up to stop.
BG 36 / 2009
5 - 14
OPERATION
5.6.4
To Operate with "Slack Rope Switch-Off"
The "switch-off" here is a function that enables power-controlled and slack-free unspooling of rope from the main winch.
To activate the Slack rope switch-off:
7
4
Freewheeling
winch 1 activ
Slack rope
limiter
6
8
9
10
Lift / lower
Freewheel
7
Turn potentiometer (7) to right past the

switch-point.
Set potentiometer (7) to the desired rope retraction force (= the value at which the winch
is to stop unspooling rope).
1
5
2
6
Slack rope
limiter
Retraction force [to]
Potentiometer setting
10
Slack rope
limiter
5
10
Slack rope
limiter
5
Slack rope
limiter
6
8
9
10
2.0
10
10
BM514501.wmf
Power-controlled unspooling of rope:

Push left control lever forward, until load lands on solid surface.
If slack rope creates, the main winch will stop and the following message appears on
the screen:
Main winch slack rope switch-off
NOTE
From now on, activation of the "Freewheel" function of the main winch
(see separate sect.) can be used to continue the automatic slack-free
unspooling of rope.
To deactivate the Slack rope switch-off:
Turn potentiometer (7) to left up to stop.
BG 36 / 2009
5 - 15
OPERATION
5.7
DEPTH MEASURING CONTROL
5.7.1
To Interrupt Depth Measuring
In CFA mode, depth measuring must be interrupted every time the drill string is extended with a new section.
Press button
to interrupt depth measuring.
Press the button again to restart the depth measuring.
5.7.2
To Reset Depth Measuring
Place drilling tool in desired position.

Press
Reset
button to reset the depth indicator to "0".
The depth measuring may be reset to zero at any time.

NOTE
*) Not used in this version.
BG 36 / 2009
5 - 16
OPERATION
5.8
CROWD CONTROL
Do not use the boom cylinders to boost the crowd system or the crowd
system will be overloaded and the drilling axis displaced.
Do not use the fast crowd for drilling down or the drilling equipment will
be damaged.
CAUTION
WARNING!
Crushing hazard !
Do not reach into the moving area of the crowd sledge.
5.8.1
Basic Functions
5.8.1.1 Moving the Crowd Sledge Down / Up

Control
10
p
5
7
9
To move the crowd sledge down. Push the control lever (10) forward.
Function
10
3
2
10
The speed changes with the

amount of lever (10) movement.
To control the crowd speed.
v
8
Pull the control lever (10) back.
To move the crowd sledge up.
BM000502.wmf

CAUTION
When extending or retracting the kelly,

reduce the crowd speed in the area of the locking
recesses (1).
BM000503.wmf
BG 36 / 2009
5 - 17
OPERATION
5.8.1.2 Switching on the Fast Crowd

Application for: all drilling methods.
Do not switch on "fast crowd":
when the kelly is locked,

for locking the kelly,
while retracting and extending the kelly,
during drilling operation.
CAUTION
Switch on the "fast crowd" only in the idle stroke.
10
p
5
10
v
2
7
8
9
10
Press the button (6) and hold

down.
Move the control lever (10).
To switch "fast crowd" on.
Control
Function
BM000504.wmf
If you switch-on "fast crowd", it will not respond if the "drilling assistant" or "pulling assistant" and "crowd + main winch" are switched on.
NOTE
BG 36 / 2009
5 - 18
OPERATION
5.8.2
Special Functions
5.8.2.1 Which Crowd Functions for Which Drilling Methods?

Drilling
method
Kelly
CFA
Crowd
Function
CFA
with
MW
FDP
FDP
with
MW
TRD
TRD
BTM
SMW
CSM
FOW
ROB
RSV
Manually controlled functions

Adjustment
of crowd
pressure
Setting
crowd
speed
Pulling by
crowd +
main rope
Assistants
Drilling assistant with
kelly
CFA*

FDP *
Pulling assistant*
*) Only for B-Tronic
BG 36 / 2009
5 - 19
OPERATION
5.8.2.2
Crowd Pressure Adjustment
Application for: all drilling methods.

Function:
crowd pressure reduction
Practice:
The driver can adjust the crowd pressure exactly without permanent fine adjustment at the control lever and maintain it at a constant level.
10
14.1
1
0
3
9
10
v
4
10
10
p
4
p
min.
max.
BM000505.wmf
BM000506.wmf
Control
Adjust the potentiometer (14.1).
BG 36 / 2009
Indicator
Black piston in the display shows the adjusted
value in %
(only displayed in the Kelly drilling method)
5 - 20
OPERATION
5.8.2.3
Crowd Speed Adjustment
Applicable to drilling methods:

Kelly
CFA
CFA
with
MW
FDP
FDP
with
MW
TRD
TRD
BTM
SMW
CSM
FOW
ROB
Function:
Reduce crowd speed
Practice:
The driver can adjust the crowd speed without permanent fine adjustment
at the control lever and maintain it at a constant level.
10
14.2
3
2
1
0
3
2
1
10
v
4
10
9
10
min.
p
4
max.
v
4
RSV
BM000507.wmf
BM000508.wmf
Control
Adjust the potentiometer (14.2).
Indicator
1 (grey)*
= optimal speed
2 (white)
= actual speed
3 (red)*
= deviation from the optimal

speed
4 (green)* = optimal range
* * Indicators 1, 3 and 4 are computed by the program in dependence on the

equipment specific presets entered in the Drilling Assistant menu.
NOTE
BG 36 / 2009
The indicators 1, 3 and 4 are not displayed in the FDP drilling method.
5 - 21
OPERATION
5.8.2.4
Pulling by Crowd + Reeved Main Rope
Applicable to drilling methods:
Kelly
Practice:
CFA
CFA
with
MW
FDP
FDP
with
MW
TRD
TRD
BTM
SMW
CSM
FOW
ROB
RSV
The operator uses both the crowd winch and the main winch for pulling the drill
string.
15
10
p
5
10
v
2
9
10
BM000509.wmf
Control
Pull both control levers (10) and (15) simultaneously back from centre.
Indicator
-
Only possible with extended mast prop.

NOTE
BG 36 / 2009
5 - 22
OPERATION
5.8.2.5
Operating the Kelly Drilling Assistant
Program sustained function applicable to drilling methods:

Kelly
CFA
CFA
with
MW
FDP
FDP
with
MW
TRD
TRD
SMW
BTM
CSM
FOW
ROB
RSV
Aim:
Optimally torque-oriented crowd pressure on the drilling tool.
Function:
The crowd pressure is controlled by the program in accordance with the pressure
at the rotary drive.
Practice:
After initial drilling, the operator switches the function on leaving the control of the
crowd pressure to the program.
How to control
Depth
interrupt
Press button
(5) on the control panel.
The lamp (5) on the control panel lights up.
Concrete valve
open
Air valve
close
open
Auger to casing adjustment
close
Rope tensioner
retract
extend
Winch
Mud-hopper
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
BM1097522.wmf
10
Push the control lever (10) forward and turn

the rotary drive.
p
p
5
v
4
10
10
10
NOTE
The potentiometer setting

(14.1) influences the crowd
pressure.
14.1
BM000510.wmf
Displays on the screen:

V
= crowd pressure in bars and %
KDK = rotary drive pressure (torque) in bars
and %
BM000511.wmf
BG 36 / 2009
5 - 23
OPERATION
Example:
The program regulates the crowd

pressure in dependence on the
pressure at the rotary drive (KDK).
BM000512.wmf
Rotary drive pressure = 275 bar Crowd pressure "V" = 50 %
Whenever the pressure at the rotary

drive gets too high, the program
regulates the crowd pressure down
to 0.
BM000511.wmf
The drilling tool can cut itself free.
The crowd pressure rises again.
BM000513.wmf
BG 36 / 2009
5 - 24
OPERATION
5.8.2.6
Operating the CFA Drilling Assistant *

Kelly
CFA
CFA
with
FDP
MW
FDP
with
MW
TRD
TRD
BTM
SMW
CSM
FOW
ROB
RSV
Aim:
To achieve optimal filling of the drill auger in avoidance of a "corkscrew" effect.
Function:
The drilling down speed is regulated by the program in dependence on the rotation speed of the rotary drive.
Practice:
After initial drilling and presetting, the operator switches the function on leaving
the regulation of the crowd speed to the program.
How to control
Enter the required presets for the Drilling Assistant
(see sect. "Presetting for the Drilling Assistant in
CFA").
Depth
interrupt
Concrete valve
open
close
Air valve
open
close
Rope tensioner
retract
extend
Winch
Mud-hopper
Press button
(5) on control panel 2.
Lamp (5) on the control panel blinks.
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
BM1097522.wmf
BG 36 / 2009
5 - 25
OPERATION
Maximum "penetration rate" (in mm/revolution):

10
Push the control lever (10) forward to max. and turn

the rotary drive.
8.1
p
5
10
v
3
10
Shortly press button (8.1) on the control lever
BM000514.wmf
The lamp
10
(5) on the control panel lights up.

p
Use the lever (10) to only rotate the rotary drive.
10
v
2
10
BM000515.wmf
The program drills down at maximal consistent

penetration rate.
The yellow line denoting the "Penetration rate" (1)

runs along the red nominal line.
BM000516.wmf
Using the Assistant at lower "Penetration rate" (in mm per revolution):

10
Push the control lever (10) forward and turn the

rotary drive.
p
5
10
v
3
10
When the optimal crowd speed has been reached,

shortly press button (8.1) on the control lever.
The attained crowd speed is stored.
BM000514.wmf
10
(5) on the control panel lights up.

p
5
10
Use the lever (10) to only rotate the rotary drive.
The lamp
8.1
v
2
9
10
BM000515.wmf
The program drills down at maximal consistent

penetration rate.
The yellow line denoting the "Penetration rate" (1)

runs parallel to the red nominal line.
BM000517.wmf
BG 36 / 2009
5 - 26
OPERATION
To deactivate the Drilling Assistant in CFA:

p
5
10
v
2
9
10
Shortly press button (8.1) again

Lamp (5) on the control panel flashes.
8.1
10
Depth
interrupt
or
Concrete valve
Let the control lever (10) return to neutral.
open
close
Air valve
open
or
close
Rope tensioner
retract
extend
Winch
Mud-hopper
Switch off by pressing button

panel 2.
(5) on control
BM000518.wmf
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
BM1097522.wmf
The lamp (5) on the control panel goes out.

Presetting for the Drilling Assistant in CFA
Switch on drilling.
Select Crowd assistant.
Open the CFA drilling assistant adjustment
menu.
BM000519.wmf
Enter the required values by
The program calculates the "penetration rate" in

[mm/U].
BM000520.wmf
The calculated maximum penetration rate is

represented on the operating screen as a red line
(1) and provides orientation for an optimal crowd
speed.
BM000521.wmf
BG 36 / 2009
5 - 27
OPERATION
5.8.2.7
Operating the FDP *

Kelly
CFA
CFA
with
FDP
MW
FDP
with
MW
TRD
TRD
SMW
BTM
CSM
FOW
ROB
RSV
Aim:
To ensure that a certain min rpm is maintained by the rotary drive as drilling
progresses.
Moreover, it offers assessment of the strength (penetration resistance) of the
soil enabling the length of the pile to be adapted correspondingly.
Function:
Whenever the rotation speed drops below a min rpm, the program will throttle
the crowd speed.
Practice:
After initial drilling and presetting, the operator switches the function on
leaving the regulation of the crowd speed to the program.
How to control
Enter the required presets for the Drilling
Assistant (see sect. "Presetting for the Drilling
Assistant in FDP").
Depth
interrupt
Concrete valve
open
close
Air valve
open
Press button (5)

on control panel 2.
close
Rope tensioner
retract
extend
Winch
Mud-hopper
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
BM1097522.wmf
Mast prop cylinder

retract
extend
The function (2)
on control panel 1 is
selected (meaning "reduced rotation speed").
Winch
rigging
Rigging
Mast
reset
Derigging
Boom
extend
Backstay cylinder
extend
extend
Backstay
cylinders
Boom
retract
Backstay cylinder
retract
retract
AT
9
17
Extendable crawlers
retract / extend
Main
Winch
Aux
10
11
12
13
14
15
16
18
19
20
21
22
23
24
B0000896.wmf
Continuation
BG 36 / 2009
5 - 28
OPERATION

14.2
v
max. min.
10
4
2
10
p
4
10
speed and the rotation speed. However,

the program will throttle the crowd speed
when the rotation speed drops below the
min rpm.
8.1
10
The operator controls both the crowd
BM000522.wmf
The crowd speed is influenced by

the potentiometer setting (14.2).
NOTE
Shortly press button (8.1) on the control
lever
8.1
10
p
5
10
v
2
The lamp
10
(5) on the control panel 2
lights up.
BM000523.wmf
The crowd speed attained by the amount

of lever (10) movement is stored.
Use the lever (10) to only rotate the rotary
drive.
The program keeps the crowd speed

consistent, however will throttle the crowd
speed when the rotation speed drops
below the min rpm.
BM000524.wmf
To deactivate the Drilling Assistant in FDP:
8.1
10
p
Shortly press button (8.1) again.

Lamp (5) on the control panel flashes. The stored crowd
speed is deleted.
10
v
2
9
10
BM000518.wmf
Depth
interrupt
or
Concrete valve
open
close
Air valve
open
or
close
Rope tensioner
retract
extend
Winch
Mud-hopper
Turn off button
Lamp (5) on the control panel goes out.
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
BM1097522.wmf
BG 36 / 2009
5 - 29
OPERATION
To Assess the Strength (Penetration Resistance) of the Soil

1
Borderline to bearing layer as determined

from the subsoil investigation
Estimated length of piles
ye l l o w
grey
red
green
Layer of insufficient bearing capacity

Layer of sufficient bearing capacity
Zone of insufficient bearing capacity as not
detected by the subsoil investigation
Pile lengths adapted to the prevailing
bearing capacity of the subsoil
BM000525.wmf
The lower the penetration resistance (strength of

the soil), the further left the yellow curve.
After arrival in the bearing layer, the yellow curve

will run across the red line over several metres.
Parallel thereto , the curve of the torque in Ma
must keep close to 100 % M.
BM000526.wmf
BM000527.wmf
BG 36 / 2009
5 - 30
OPERATION
Presetting for the Drilling Assistant in FDP
Switch on drilling .
Select Crowd assistant .
Open the
FDP drilling assistant adjustment.
BM000528.wmf
Enter the required values with
For "Nominal value penetration

resistance",
enter from experience : 8000
BM000529.wmf
In the diagram on the operating screen the

entered value of "Nominal value penetration resistance" appears as a red line (1).
BM000530.wmf
For "Min. rpm"

enter as recommended: 8
or
switch the reduced rotation speed function on by button
idling, read the rpm off the operating screen.
Enter: n -1
BG 36 / 2009
, rotate with the rotary drive
5 - 31
OPERATION
5.8.2.8
Pulling Assistant Operation

Kelly
CFA
CFA
with
FDP
MW
FDP
with
MW
TRD
TRD
SMW
BTM
CSM
FOW
ROB
Aim:
To produce a homogenous pile of an optimal quantity of concrete.
Function:
The program regulates the pulling speed in dependence on the concrete

quantity and concrete pressure.
Practice:
The operator switches the Pulling Assistant on leaving the regulation of the
pulling speed to the program.
RSV
How to control
Enter the required presets for the Pulling
Assistant (see sect. "Presetting for the Pulling
Assistant").
Depth
interrupt
Concrete valve
open
Press button (6)
close
Air valve
open
on control panel 2.
close
Rope tensioner
retract
extend
Winch
Mud-hopper
9
17
10
11
12
13
14
15
16
18
19
20
21
22
23
24
BM1097522.wmf
Mast prop cylinder

retract
extend
The function (2)
on control panel 1 is
selected (meaning "reduced rotation speed").
Winch
rigging
Rigging
Mast
reset
Derigging
Boom
extend
Backstay cylinder
extend
extend
Backstay
cylinders
Boom
retract
Backstay cylinder
retract
retract
AT
Extendable crawlers
retract / extend
Main
Winch
Aux
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
B0000896.wmf
Continuation
BG 36 / 2009
5 - 32
OPERATION
Continuation
8.1
10

p
6
10
9
10
v
7
The lamp
Shortly press button (8.1) on the control

lever
(6) on control panel 2
BM000531.wmf
glows.
The program regulates the pulling speed

in dependence on the concrete quantity
and concrete pressure.
BM000532.wmf
Switching the concrete pump off:

When the pile has been built-up to the blue line (1), the
concrete pump can be switched off, since the quantity of
concrete contained in the pipe is sufficient for the rest of
the pile.
The blue line appears in the diagram if, in the
" Crowd assistant " menu,
the " Concreting pipe quantity " has been entered.
BM000533.wmf
To deactivate the Pulling Assistant:
8.1
10
p
Shortly press button (8.1) again.

10
v
10
BM000518.wmf
Depth
interrupt
or
Concrete valve
or
open
close
Air valve
open
close
Rope tensioner
retract
extend
Winch
Mud-hopper
Turn off button
Lamp (6) on the control panel goes out.
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
BM1097522.wmf
BG 36 / 2009
5 - 33
OPERATION
Presetting for the Pulling Assistant
Switch on to concrete.
Select Crowd assistant.
Select Pulling assistant adjustment.
BM000534.wmf
Enter the required values with
For "Set piston stroke" enter in litres the

quantity delivered by one stroke of the
concrete pump.
For "Pile diameter" in mm enter in millimetres
the diameter of the pile to be produced.
For "Concreting pipe quantity", enter the
capacity of the concreting pipe in litres
BM000535.wmf
The program calculates the consumption from

the pile diameter.
The "Rated increased consumption" (+%,
see red area in fig. right) depends on the
prevailing soil conditions.
+%
BM000536.wmf
BG 36 / 2009
5 - 34
OPERATION
" No. of strokes per depth interval "

This value influences the diagram (the yellow bars) on
the display and helps the operator to control the pullup where the Pulling Assistant is not used.
The two examples right show 2 and 4 pump strokes
respectively per depth interval until the nominal
quantity (red line) is obtained. Causes the differing
heights of the bars.
NOTE
The fewer the number of strokes

entered the quicker can the operator
observe whether the pull-up speed is
correct.
BM000537.wmf
Entry: 2 strokes
BM000538.wmf
Entry: 4 strokes
"Pull process threshold value"

enter in bars the minimum value of the concrete
pressure pstart for start of pulling.
Not until this value has been obtained, will the
red line (1) appear in the diagram.
BM000530.wmf
start
BM000539.wmf
For "Depth at circumfusion"

enter in meters the depth (s) at which the concrete
pressure will collapse (p = 0 bar).
p= 0 bar
The pulling assistant will use the entered value to

determine from where on the concrete pressure is
no more to be considered and the Pulling Assistant
be regulated by the concrete quantity alone.
BM000540.wmf
BG 36 / 2009
5 - 35
OPERATION
For "Min pressure at pulling assistant" enter in

bars the minimum concrete pressure (pmin) that must
be maintained for the Pulling Assistant.
Whenever the pressure drops below the entered
value, the pulling procedure will stop until the
concrete pressure has built-up again.
min
If the concrete pressure is not to be

considered at all in the production of
the pile, just enter "0" here.
NOTE
BM000541.wmf
5.8.3
To Use the Main Winch in Combination with Crowd
CAUTION
Danger of damaging the slewing ring and undercarriage by overloading!

Pulling the main winch combined with pulling by the crowd system is
permissible only under observance of the following instructions.
Pulling by the main winch together with the crowd system is allowed only
in case of recovery and
where the rig is equipped with a mast prop which is fully extended and
where the attached tool string has the appropriate provisions (e. g. a defined stop for
the kelly on the casing drive adapter, in kelly applications)
NOTE
BG 36 / 2009
Equipment fitted with a mast prop may have an automatic control feature which stops the main switch from pulling during crowd as soon as a
certain value of the combined forces is exceeded.
If there is no such automatic control feature, the operator himself is responsible for not endangering the capacities of the rig when forces sum
up.
5 - 36
OPERATION
5.9
CENTRAL LUBRICATION CONTROL
The central lubrication system automatically lubricates all of the lubrication points connected to
it at intervals. Both the length of the lubrications and the length of the pauses are preadjustable. The red push-button can be used to trigger lubrication at any time.
The interval is interrupted by switching off the ignition. The time is saved. After switching the
ignition on again the interval will be resumed.
Not all the places to be lubricated are covered by the central lubrication system.
These lubrication points can be found in the lubrication plan.
NOTE
NOTE
It is also possible to lubricate with a grease gun through a free nipple located on
the distributor block on the crowd sledge.
During automatic lubrication, it is recommended that the crowd sledge be run up
and down the mast 2 - 3 times in order to distribute the grease from the runners to
the rails.
Flashing codes:
1
System on
on
off
on
off
Lubrication on
on
off
on
off
Low lubricant level
on
off
on
off
High lubricant pressure
on
off
on
off
Control failure
Permanent lubrication
on
off
on
off
Sledge lubrication failure
on
off
1.5 sec.
1.5 sec.
1 sec. 1 sec.
on
off
on
off
0.5 sec. / 0.5 sec.
1 sec.
1 sec.
To avoid failures in the central lubrication system, switch OFF the central lubrication system during the rigging procedure (switch in the cab).
NOTE
A manufacturer's documentation on the Central Lubrication System is supplied in
the Appendices of this manual.
NOTE
BG 36 / 2009
5 - 37
OPERATION
5.10
EMERGENCY CONTROL
The most important equipment functions can be operated with the emergency control
should the standard controller break down.
WARNING!
Rig damage and tipping hazard!
The emergency control does not enable functions to be carried out sensitively.
Do not use an emergency control other than in an emergency, to help
move the equipment out of a hazardous situation.
5.10.1 Emergency Control of Processors

Shut down the equipment and stop the
engine.
In the control cabinet, unplug processors
B1.2 and B1.3 (pull safety lever down
(1) and remove plug (2)).
Turn the key-operated switch (3) into
"On" position.
Start up the equipment. Now the essential functions may be controlled by the
control levers.
When the emergency operation is completed, shut down the equipment and
stop the engine.
Repair the defect.
Turn the key-operated switch into "Off"
position.
Plug in the processors again.
Start up the equipment.
2.
B 1.2
1.
2.
B 1.3
1.
B0000764.wmf
BG 36 / 2009
5 - 38
OPERATION
5.10.2 Pump Emergency Control

If equipment movements will not function due to insufficient supply with oil from the hydraulic pumps.
Check the load limit regulator is working

properly (see the operating manual for
the base machine).
Shut down the equipment and stop the

engine.
In the engine compartment (behind the

wiring cabinet), remove the cotter pins
from the valves (1) and push the two
valve levers down.
BS 80 uses two valves.
BS 100 uses three valves.
BV993501.jpg
Start up the equipment.
5.10.3 Emergency Control of Diesel Engine Speed

If the engine speed cannot be adjusted by the controls in the cab:
Check the load limit regulator is working

properly (see the operating manual for
the base machine).
Adjust the speed of the engine by the

rotary switch (2) located in the engine
compartment.
BV993500.jpg
BG 36 / 2009
5 - 39
6.1
START-UP
6.1.1
Initial Start-Up
The initial start-up of the equipment concerns both the manufacturer and the future
user, the customer. In general, the job required here will be carried out jointly in a training held at the manufacturer's or in a briefing on the construction site.
Even before the first rigging operations are begun, the operator of the equipment must
be familiar with all the control elements and their capabilities.
6.1.2
Visual Inspection Before Starting
A visual inspection and thorough check are required before putting the equipment into
operation:
Inspect the entire equipment for loose connections and missing pins or bolts.
Check all components for wear.
Check all electric lines for damage.
Look for leaks and fluid spills.
Check that all contained oils and fluids have the proper level.
BG 36 / 2009
6-1
6.1.3
Daily Start-Up
6.1.3.1 Starting the Equipment
CAUTION
Risk of damaging the equipment!

Observe instructions in the manual of the base machine !
Set the battery main switch to "On" position.
Set all controls to "0" position.
Pull the Emergency STOP button.
Start the engine by turning the ignition key.
CAUTION
CAUTION
Risk of damaging the engine!

Allow cold engine to warm up at idle speed for approx. 10 minutes!
Risk of damaging the control!

When starting with the aid of an external power source, first switch off
main fuse F1 (BAUER part)!
Move the safety stick of the pilot control to "On" position.
6.1.3.2 Starting the Control System
CAUTION
Damage to the computer program!

The following points must always be observed when starting the computer.
Non-compliance can damage the software such that correct and safe
operation of the equipment can no longer be guaranteed or could even
lead to a total breakdown of the equipment.
Do not touch the screen while the computer is starting up.

Only touch the screen when either "Mode Selection" or "Operating Screen" appears
on the screen.
If the computer start-up is interrupted or stopped by an error, reset the computer by
disconnecting the operating voltage.
BG 36 / 2009
6-2
6.1.3.3 Selecting the Work Application

After booting up the computer, the "Select mode" menu appears.
The driver can select a work application here.
With equipment designed for one work application only, the operating
screen of the respective work application will appear right away when
the computer has started up.
NOTE
Colours used in the display mean:
green
white
grey
selected
available
not available
The operator now has 10 seconds to select a new work application:
Touch the desired field

Field
Application
Kelly
Drilling with kelly equipment
CFA
Drilling with Continuous Flight Auger equipment
FOW
Drilling with Front-Of-Wall equipment
TRD
Drilling with Twin-Rotary-Drives equipment
MIP
Drilling with Mixed-In-Place (triple auger) equipment

Drilling with continuous-flight-auger equipment sustained
by main winch pull
Drilling with High Pressure Injection equipment
CFA with main winch

HPI
Touch the "End" field.

The operating screen of the new application comes on display.
NOTE
BG 36 / 2009
If no other application is selected within 10 sec., the screen will automatically change over to the operating screen of the selected application.
6-3
6.1.4
Safety Tests Before Starting Work

WARNING!
Severe accident hazard!
Faulty safety devices are dangerous.
All equipped safety devices must be tested prior to starting work, and any
faults found must be repaired by skilled personnel.
The equipment may be put to work only when all safety devices are in
proper working order.
Initial situation:
- Diesel engine is running.
6.1.4.1 Checking the Emergency STOP
Press the EMERGENCY STOP button.

All control elements must be out of function and the diesel engine come to a stop.
6.1.4.2 Checking the Pilot Control Safety Stick
Move the safety stick of the pilot control to "Off" position.

All hydraulic functions must be blocked. The diesel engine remains on.
BG 36 / 2009
6-4
6.1.4.3 Checking the Limit Switches

Initial situation: Drilling mode selected
- Hoist Limiters (HS 1 and HS 2)
Select a main winch.

Spool in rope and slowly lift attached load (approx. 100 kg) by the winch until the
load block hits the contactor weight.
The winch must come to an immediate stop.
Repeat the procedure with the other winch.
- Boom cylinder limit switch (ES 3)
Extend boom cylinders half way.

Selection of rigging modes must not be enabled.
Extend boom cylinder completely.
Selection of rigging modes must be enabled.
- Mast sideward angle limit switches (ES 2 and ES 4)

WARNING!
Crushing hazard !
Do not actuate limit switches with your bare hands!
Only actuate them by touching with an object (piece of wood e.g.) held
in your hand.
Hold left limit switch depressed and extend right backstay cylinder.
The right backstay must not extend.
Hold right limit switch depressed and extend left backstay cylinder.
Left backstay cylinder must not extend.
- Mast forward / backward angle limit switch (ES 10, optional)

Precondition: inclinometer is faulty
Extend boom cylinder completely.

Retract or extend both backstay cylinders.
Drilling mode is blocked when a certain mast angle forward or backward is exceeded.
BG 36 / 2009
6-5
6.2
SHUT-DOWN
6.2.1
Daily Shut-Down
Park the machine on firm level ground.
Set the mast to upright.
Lower attached work equipment and suspended load as close to the ground as possible.
Adjust the upper carriage in line with the undercarriage.
Set all controls to "0" position.
Move the safety stick of the pilot control to "Off" position.
Stop the engine.
CAUTION

If the engine has been operating under heavy load, it must run idle for
about 5 minutes before stopping to allow the coolant and oil temperature to drop and stabilise.
Before leaving, remove the ignition key and lock the operator's cab.
Set the battery main switch to "Off" position.
6.2.2
Shutting Down for a Longer Period
Fuel tank
Before longer periods of standstill, fill up fuel tank completely with fuel for protection
against corrosion.
BG 36 / 2009
6-6
RIGGING / DE-RIGGING
7.1
GUIDELINES FOR RIGGING AND DE-RIGGING
Have assembly job carried out by skilled personnel only.

Carry out rigging and de-rigging operations in the "Kelly mode" exclusively.
CAUTION

The operator must be familiar with all the control elements and their
capabilities before he starts rigging operations.
WARNING!
Danger of falling down!
Personnel carrying out assembly on the mast or on the uppercarriage
must wear the prescribed fall protection equipment.
Provide an unobstructed and level area for the assembly.
Before assembling, check all parts for possible damage resulting from the transport.
Before start of assembly, inspect the equipment for a film of protecting wax. All such
wax must be removed (see sect. Wax Removal).
For lifting and loading, use only the lifting slings forming part of the basic outfit.
Attach lifting slings only to provided lifting eyes.
CAUTION
Rig tipping hazard!

During rigging operations, the uppercarriage must be in line with the
undercarriage and be interlocked with the same.
Select Rigging mode:

To rig up:
Press button
To de-rig:
Press button
BG 36 / 2009
7-1
7.2
WAX REMOVAL
Prior to putting into service, remove all protecting wax with a hot water jet, at a temperature of 90 95C (approx. 200 F).
NOTE
Alternatively, the equipment can be washed down with a cold water detergent.
The treatment must be repeated until all the wax has been totally removed.
CAUTION
BG 36 / 2009
- Detergents used must not be harmful to seals etc.

Check detergents for their areas of application prior to use.
- Clean the exposed piston rods of the cylinder with hydraulic oil only.
7-2
7.3
EXTENDING THE CRAWLERS

Rig tipping hazard!
CAUTION
The crawlers must be extended as soon as the machine has been

unloaded from the transporting vehicle and before rigging operations are
begun.
WARNING!
Squashing hazard, shearing hazard and drawing-in hazard!
The machine must be out of motion during work on the undercarriage. A
reliable communication between person at undercarriage and operator
in cab must be provided at all times.
The danger zone must be cleared before crawlers are extended.
BG 36 / 2009
7-3
First extend the left crawler!
NOTE
The picture shows the left crawler:

The front idler (1) is at the front,
the drive (2) is at the back.
The crossbeams of the left crawler
are larger than the crossbeams of
the right crawler.
BOHSL038.ti
From the outside and using a lever, lift up

pawl (4) found midway on track carrier of left
crawler (see arrow, fig. above).
3
BN814504.wmf
Lubricate the lubricating nipples of the

crossbeams (5) front and back.
Press button
on the control panel to
release the hydraulic system, and activate
telescoping with the relative control levers:
1
2
3
4
Right front telescoping cylinder

Right rear telescoping cylinder
Left rear telescoping cylinder
Left front telescoping cylinder
Lever pulled up cylinder retracts

Lever pushed down cylinder extends
BN814406.jpg
Remove pins from inclined tubes behind crossbeams, insert into bores (pos. 3 in central
picture) and secure.
Repeat the procedure with the right crawler.
BG 36 / 2009
7-4
7.4
MOVING THE MAIN WINCH TO ITS WORKING POSITION
Attach lifting slings to lifting eyes (1).

Injury hazard!
CAUTION
Danger of getting crushed between the upper carriage and

the main winch!
Exercise increased caution in
the danger zone.
Lift the winch and tilt it forwards.
BN954752.jpg
Secure the winch by inserting four pins (2).

Remove lifting slings.
Connect electric lines.
Connect hydraulic lines.
Risk of causing damage!
Connect the leak-oil line first.
CAUTION
BN954751.jpg
Winch connections equipped with idlers:

45A/45B
46A/45B
1
10
47
33
132
P
Working connections
Return movement
Leaking oil
Supply
Engine trigger X
Winch control
Idler connection X
Central lubrication
Additional connections for free fall:

132
Not in use
P
Free-fall control
K
Free-fall brake
S
Free-fall winch lubrication
BG 36 / 2009
BM10414000.jpg
7-5
7.5
MOUNTING THE COUNTERWEIGHT

WARNING!
Tipping hazard!
The machine must be fitted with the appropriate counterweight before
rigging operations are begun.
The counterweight(s) must remain unchanged and installed as long as
the machine is rigged.
WARNING!
No person must stand on or under a counterweight while it is being
mounted.
Persons working on the upper carriage must wear a fall protection belt
secured to the upper carriage (red painted loop).
CAUTION

Counterweights consisting of several parts are to be transported in upright position.
To mount counterweight:
Mount the counterweights individually
at all times!
Use sling devices with a minimum
stand length of 1.6 m.
Attach suitable sling devices to the
lifting equipment and to the lifting points
(9) of the counterweight (10) (5.0 t).
Hoist counterweight (10) onto machine
using lifting equipment.
Lightly tension sling devices.
Mount counterweight (10) on the upper
carriage with both pins (4). Tighten with
torque of 1500 Nm.
B00005000.jpg
BG 36 / 2009
7-6

of the additional counterweight (11)
(5.0 t).
Hoist additional counterweight (11)
onto machine using lifting equipment.
Mount additional counterweight (11)
on the upper carriage with pins (4).
Tighten with torque of 1500 Nm.
Hoist counterweight (2) onto machine
using lifting equipment.
B00005000.jpg
Mount counterweight (2) on the upper carriage with both pins (4). Tighten with torque
of 1500 Nm.
Secure counterweights (10, 11 and 2) to the rear panel of the machine with the hex
head bolt (3) provided. Tighten with torque of 1500 Nm.
Turn bolt head until the bolt head surfaces are parallel to the cut-out.
Move lock plate (8) over the bolt head.
Fasten hex head bolt (5) to the bolt (3) with washers (6, 7).
Tighten hex head bolt (5) using 40 Nm force.
BG 36 / 2009
7-7
7.6
ASSEMBLING THE MAST
7.6.1
Mounting the Trestle
Select backstay cylinder operation by pressing button
Using the control levers, retract backstay cylinders and slightly raise the mast.
CAUTION

With the supporting trestle folded to the front, the mast may be raised
by max. 20.
Mount transport supports (4).
Using the control levers, extend backstay cylinders and put down the mast on the
ground.
Underpin the transport supports with timber if the ground is soft.

NOTE
Unlock upper carriage from undercarriage.
Extend backstay cylinders (1) by control levers, until supporting trestle (2) can be
mounted to machine with pin (3).
Install the pin and secure it.
Retract backstay cylinders and raise the mast enough to enable the transport supports (4) to be removed from the lower mast section.
2 3
4
BM339512.wmf
BG 36 / 2009
7-8
7.6.2
Assembling the Mast Sections
Place the mast sections on a firm and level surface to front of the lower mast section.
Clean flange faces and locating pins and check for damage.
CAUTION
With the machine, travel up to the mast sections.
WARNING!
Risk of crushing, shearing and hitting!
Avoid getting limbs in between the mast sections.
Minor backstay cylinder movements can lead to major movements of the
mast sections.
During the assembly operations, the operator must keep the person
working at the mast in view at all times.
During operation with the backstay cylinders, adjust the lower mast section (3) to the
next mast section (1) until holes for assembly pins (2) are in line.
1
B0000567.wmf
Install the pin and secure it.

Retract backstay cylinders to raise the lower mast section until flange faces meet.
Take care the locating pins are properly in place!
CAUTION
BG 36 / 2009
7-9
Bolt the mast section (6) to the lower mast section (5) in the manner shown here.
6
Bolt tightening torque value Ma [Nm]:

1900
1
2
3
4
5
6
Hex head bolt

Washer
Hex nut
Lock nut
Lower mast section
Upper mast section
1 2
23 4
B0000999.wmf
Remove transport supports.

Make hydraulic connections between the mast sections.
Make electric connections between the
mast sections.
To do so, remove plug (1) of electric cable from transport socket (2) and plug it
to the next mast section.
Check on the ladder that fall protection
rail (3) transfer points are in line. Readjust at the ladder mounting points (4) as
necessary.
WARNING!
Danger of falling!
The lanyard can slip out of
its rail.
Precisely adjust transfer
points.
BG 36 / 2009
BM400462.jpg
7 - 10
7.6.3
Mounting the Masthead
Rig the masthead with a crane.

Unscrew the bolts from the
transport support and remove
it.
Lower the masthead onto the
upper mast section
BM20885001.wmf
Join the masthead to the upper mast section with

four bolts:
tightening torque Ma [Nm]:1850
1
2
3
4
5
6
7
Hex head bolt

Washer
Tension bush
Hex nut
Lock nut
Upper mast section
Masthead
BG 36 / 2009
1 2
24 5
B0000568.wmf
7 - 11
7.6.4
Adjusting the Masthead to the Drilling Procedure
For various drilling procedures, a wedge is inserted between the upper section of the mast and
the masthead.
This is to adjust the drilling axis or to take the masthead out of the collision zone. It must be
ensured here that the right wedge for the procedure is installed (see table).
Dismantle the transport support (1).
Insert wedge (2) and fasten to the masthead and

mast using four screws (3).
3
4
2
a
BM20885002.wmf
Bolt tightening torque value Ma [Nm]: 1850

1
2
3
4
5
Detail 3:
Bolt
Washer
Tension bush
Nut
Lock nut
12
24 5
BM1097515.wmf
Other measures:
Depending on the attached equipment, the nose (4) on the masthead may have to be
mounted or dismounted.
Depending on the attached equipment, the auxiliary rope may have to be dismounted from
the masthead, because it is not guaranteed that the hoist limit switch is working (see table).
Drilling procedure
Kelly
Angle of -wedge (2)
Drilling distance
Auxiliary rope
permitted
1,550 mm
Yes
Yes
9.3
1,300 mm
Kelly
* Drilling with a longer, height-adjustable concreting kelly
BG 36 / 2009
7 - 12
7.6.5
Installing the Ropes
7.6.5.1 Installing the Main and Auxiliary Rope

The main (4) and the auxiliary (3) rope must be installed while the mast is down.
Select the "winch rigging" mode with button

Remove rope guard pins (1) from the masthead.
1
2
for the main winch or button
for the
Select the winch: Press button
auxiliary winch.
With the left control lever, unwind a sufficient length of rope from the selected winch.
Pass ropes over guide sheaves (5) and unwind until rope ends are at contactor
weights (6).
Thread ropes through contactor weights (6) of hoist limit switches (7).
Reinstall the rope guard pins and secure (1).
Unwind until rope ends are at resting on the machine.

Check contactor weights are properly attached.
CAUTION
1 5
5 1
6
BM091514.wmf
BG 36 / 2009
7 - 13
7.6.5.2 Installing the Upper Crowd Rope
Extend the rope tensioning cylinder (1) with button

.
Remove the crowd sledge stoppers from the transport position (2) and install them in
bores on the upper mast section (3).
7
5
1
5 3
6
2
7 3
2
BFASE192.wmf
Remove crowd rope from transport deposit.

Move crowd sledge down to lowermost point.
Pass the end of the rope behind the guide sheave (4), up and around the upper left
guide sheave (5), down to the guide sheave on the sledge (6), counter-clockwise
back up to the sheave (7) on the upper end of the mast to the rope tension cylinder
(1).
Anchor rope end with wedge to rope tension cylinder (1).
WARNING!
Serious injury hazard!
3 wraps of upper crowd rope and 3 wraps of lower crowd rope must be
installed on the drum of the crowd winch for safety reasons.
to tension the crowd ropes.

Press
Run the crowd sledge up and down several times.
Move crowd sledge down to lowermost point.
Press
BG 36 / 2009
to re-tension the crowd ropes.
7 - 14
7.6.6
Mounting Crowd Stroke Limiters
WARNING!
Rig tipping hazard !
For reasons of stability, the crowd sledge fitted with kelly equipment
must not be free to move to the upper mast end.
8
BK587503.wmf
Remove the two sledge travel stoppers from their position (3) on the upper mast end
and reinstall hem into bores (8) located further down the mast.
BG 36 / 2009
7 - 15
7.6.7
Raising the Mast

WARNING!
Avoid getting limbs in between the mast sections.
mast sections.
Completely extend the boom cylinders.
CAUTION
Danger of being injured by falling objects!

All loose objects must have been removed from the mast.
Select backstay cylinder operation and uniformly and synchronously pull both control
levers back to retract the backstay cylinders. The mast is now raised.
CAUTION
BG 36 / 2009
Tipping hazard!
Do not allow the mast to drift aside. The backstay cylinders must be
retracted in a uniform manner and without interruptions.
7 - 16
7.6.8
Raising the Mast with 3.0 m Mast Extension
CAUTION
Danger of being injured by falling objects!

All loose objects must have been removed from the mast.
Select the "rigging" mode with button
Attach lifting slings (of approx. 5 m length) to the

blue lifting eyes on the mast extension.
The use of an assist crane must be approved in
the B-Tronic.
Slowly raise the mast synchronously with the
crane and backstay cylinders.
Once the mast has been raised, remove the
transport supports from the floor.
BM400445.jpg
CAUTION
BG 36 / 2009
Risk of damaging the backstay cylinders

To avoid damaging the backstay cylinders due to overloading, the mast
must be set up with a crane and the backstay cylinders must be adjusted precisely.
7 - 17
7.7
ASSEMBLY OF WORK ATTACHMENTS

WARNING!
Risk of crushing, shearing and getting entangled!
Minor movements by the backstay cylinders can create sudden and
uncontrolled major movements of attached components during their
assembly. Work attachment components are extremely heavy.
The operator must keep the person performing the assembly in view
throughout the whole procedure.
7.7.1
Attaching Kelly Equipment
7.7.1.1 Installing the Rope Swivel
CAUTION

The kelly bar must be suspended by a rope swivel at all times.
Use only the genuine BAUER Maschinen GmbH rope swivel.
The rope swivel must be designed for the max. lifting force of the winch
used.
Mount the rope swivel as shown in the figure below.
CAUTION

Mount the rope swivel in the right position. The lube nipple must face
up.
After mounting, grease the rope swivel and test whether it rotates freely.
1
6
1
2
3
4
5
6
Main rope
Pin
Lube nipple
Hex head bolt
Lock washer
Washer
5
2
4
B0000572.wmf
BG 36 / 2009
7 - 18
7.7.1.2 Mounting the Rotary Drive

Set the mast to the upright position.
Move crowd sledge to lowermost point.
Attach lifting slings to lifting eyes (5), lift and put
down the rotary drive to front of the mast.
1
1 2
Suspend the slings to the rig's main rope (3) (or to

the hoist rope of a crane, if not equipped) and lift
until rotary drive can be pinned to the crowd sledge.
Thread the rotary drive onto the sledge, mount with
pins (1 and 2), and secure the pins.
NOTE
On rotary drive fitted with an auxiliary

lifting lug, the rig's auxiliary rope (4)
may be used additionally to help align
the rotary drive.
4
5

Stop the engine.
B0000700.wmf
BG 36 / 2009
7 - 19
Connect hydraulic lines:

Connect the leak-oil line first.
CAUTION
Connection
no.
Name
1/T
3/A1
4/B1
5/A2
6/B2
9/SPL
12/P
41/Auto
Leak-oil from KDK

KDK 1ST AXIS TO RIGHT
KDK 1st axis to left
KDK 2nd axis to right
KDK 2nd axis to left
Feed oil line to KDK
Pilot oil supply to KDK
Automatic casing drive adapter "open" (40 bar cyl.
retract/oil supply 12/P)
Automatic casing drive adapter "closed" (100 bar cyl.
extend / oil supply 58)
Auger-to-casing "extend" (100 bar)
Auger-to-casing "retract" (150 bar high torque
of one TRD drive - 200 bar low torque of the other))
FOW locking "extend" (100 bar)
FOW locking "retract" (150 - 200 bar)
TRD concrete valve "extend" (100 bar)
TRD concrete valve "retract" (100 - 200 bar)
TRD ejection slot "open" (100 bar)
TRD ejection slot "close" (100 bar)
Air intake "open" (100 bar) / Auger cleaner control
Air intake "close" (100 bar) / Auger cleaner control
42/Auto
58/Relat.
59/Relat.
60/Verrieg.
62/Verrieg.
114/Betons.
115/Betons.
116/Ausw.
117/Ausw.
151/Lufts.
152/Lufts.
151 114
116
152
62 115
59 117
A:
"A"
1
9
4
6
12
3 58
60
42
41
BK651519.wmf
Hydraulic lines and connections have matching identifications.

NOTE
Connect cable from crowd sledge to rotary drive (1).
BM639420.jpg
BG 36 / 2009
7 - 20
7.7.1.3 Mounting the Kelly Auger Cleaner *
Place the kelly auger cleaner (3) under

the mast.
Move the rotary drive down.
Attach the chains (2) of the kelly auger
cleaner with shackles (1) to the crowd
sledge below.
Remove the lower sledge end stoppers
(4).
Raise the rotary drive and thread the
kelly auger cleaner sledge from below
into the slide rails on the mast.
Reinstall the sledge end stoppers.
1
2
3
4
BM086545.wmf
1
2
3
4
5
Connect the hydraulic hoses to the bulkhead plate.

Extend kelly auger cleaner
Retract kelly auger cleaner
CFA auger cleaner: feed line (P)
CFA auger cleaner: return line (R)
CFA auger cleaner: leak-oil (T)
5
BM086530.wmf
BG 36 / 2009
7 - 21
7.7.1.4 Installing the Kelly Bars

To mount the kelly bar, the mast must be in upright position and be
fitted with the rotary drive.
NOTE
Lay the kelly bar down lengthwise at front of the machine, in the centreline of the
machine.
The kelly eye must face the machine.
NOTE
Mount the rope swivel to the kelly eye in accordance with fig. below.
1
2
3
4
5
6
7
8
Main rope
Rope swivel
Pin
Kelly bar
Lock washer
Hex head bolt
Washer
Lube nipple
8
7
6
5
4
B0000621.wmf
Lower the rotary drive to lowest point.

Tilt the mast forward by 2 3.
By the main winch, lift the kelly bar as shown
to right and at the same time travel with the
machine towards the kelly bar.
B0000622.wmf

Keep the main rope vertical at all times.
CAUTION
BG 36 / 2009
7 - 22
Lift kelly bar until its square stub is approx. 20 cm above the rotary drive.
Risk of damaging the rotary drive!
Avoid collision with the rotary drive!
CAUTION
Set mast to upright again.

Allow the kelly bar to stop swinging and then insert it into the rotary drive.
Slightly rotating the rotary drive can prove helpful when inserting the
kelly bar.
NOTE
Insert the kelly bar through the rotary drive.

Mount drilling tool to kelly with two pins.
CAUTION
BG 36 / 2009

At all times, use TWO pins to mount the drilling tool, and do not forget
to secure the pins.
7 - 23
7.7.2
Assembly of CFA Equipment *

A lifting platform authorised for lifting people is required when installing
the CFA equipment.
NOTE
The following information is valid for drilling procedures in which the
main rope is used to support the crowd system.
NOTE
NOTE
In main winches with free-fall function:

switch over the key switch in the wiring cabinet to position 1 "Automatic
free-fall, CFA with main winch".
Following drilling in the "CFA with main winch" mode, turn the key
switch in the control cabinet back to position 0.
Rigging mode
CAUTION

In the rigging mode, activating the backstay cylinder, boom cylinder,
crowd and the relative shift can lead to very high pulling forces being
generated on the main rope. This can damage the components. During
rigging, the main winch must always be spooled out by the manual control of the winch.
Drilling mode
When changing to drilling mode the following message appears on the screen:
"Confirm automatic free fall / free wheel with the "Winch 1" button!"
Press the "Winch 1" button for at least 1 second to confirm the function.
In drilling mode, automatic free-fall / freewheeling is activated if the following functions are executed:
- backstay cylinder extension (only if the main winch is in the base machine) or
- boom cylinder extension (only if the main winch is in the base machine) or
- crowd down or
- extend relative shift
BG 36 / 2009
7 - 24
7.7.2.1 Retrieving the Main Rope
NOTE
In all CFA methods (except for the "CFA with Main Winch" mode), the
rig's main rope must be retrieved from the masthead. When drilling with
CFA, the Drilling mode function of the main winch is deactivated. The
main winch can be used only in the rigging mode.
Remove the rope swivel from the main rope.

Retrieve main rope from masthead and rewind to first rope guide sheave.
Risk of damaging the main rope and mast components!
CAUTION
With the rope end rewound to the first rope guide sheave, the resting
main rope must be slack
BG 36 / 2009
7 - 25
7.7.2.2 Mounting the Wedge (Only for CFA V) *
NOTE
To prevent a collision between the kelly extension and the masthead, a

wedge must be mounted when a kelly extension is used between the
masthead and the upper mast section.
Unscrew the bolts on the masthead (2).

Tilt the masthead with the lifting equipment (in H equipment, with the masthead tilting cylinder.
Insert the CFA wedge (1) with the lifting device and screw it to the upper mast section (3).
Tilt the masthead and screw the wedge to the masthead.
WARNING!
Crushing hazard !
When tilting the masthead, the danger zone must be free of people.
3
B0000815.wmf
BG 36 / 2009
7 - 26
7.7.2.3 Reeving the Main Rope for the Drilling Procedure "CFA with Main Winch" *
Initial situation:
Mast in lowered.
To reeve the rope
Pass main rope around rope sheave on
crossbeam (3).
Close the rope guard pins!
NOTE
Crossbeam with rope guide

sheave (3) cannot be mounted
with pins (4) to rotary drive until
the mast has been raised.
4
BM779505.wmf
Remove bolts from the hole (1).

Anchor main rope end thimble with pin in bore
(2) on masthead.
Unwind rope from the main winch and raise
the mast to upright while pulling the crossbeam towards the base machine to avoid a
collision.
BM779419.jpg
BG 36 / 2009
7 - 27
7.7.2.4 Mounting Crossbeam to Rotary Drive for "CFA with Main Winch" *
Initial situation:
Mast in upright position.
The main rope (1) is installed on sheave (3) on crossbeam
and anchored to bore (2) on masthead before mast is
raised.
Mounting the crossbeam
Mount crossbeam to rotary drive with pins (4) and secure.
Tension the main rope.
NOTE
For ease of presentation, the fig. shows the

rotary drive on the upper mast end. The
mounting itself, however, takes place with the
rotary drive positioned at the lower mast end.
1
2
3
4
BM639521.wmf
BG 36 / 2009
7 - 28
7.7.2.5 Mounting Concreting Kelly (Version I)
Attach lifting slings to eyes (7) on concreting kelly.
Using lifting equipment, lift concreting

kelly in place above rotary drive.
Lower concreting kelly through rotary

drive until groove (1) is in reach below
the drive.
Place ring and split ring flange into
groove (1) and screw tight.
Elevate rotary drive to upper end of
concreting kelly (fig. on right).
Connect torque support and concreting

head with pins (2).
Connect electric cable to concrete pressure gauge (3). The cable comes
stowed in the torque support.
Lower the rotary drive and lock it to the

concreting kelly.
2
3
7
7
4
BM473516.wmf
BG 36 / 2009
7 - 29
7.7.2.6 Mounting Concreting Kelly (Version II)
1
2
3
4
5
Concreting kelly
Cardan joint
Eye
Pin
Retaining ring
With the main rope, insert concreting

kelly (1) from below into rotary drive.
Mount concreting kelly (3) to cardan

joint with the two free pins (4).
2
4
5
Tighten the retaining rings (5).

3
BM639417.wmf
7.7.2.7 Mounting Concreting Head (Version I)

1 Concreting head
Clean flange faces.

Install O-ring.
Connect both parts with bolts and lock
washers provided.
2
BM086521.wmf
BG 36 / 2009
7 - 30
7.7.2.8 Mounting Concreting Head (Version II)

1 Concreting head
2 Concreting kelly
Clean flange faces.

Install O-ring.
Place concreting head on concreting
kelly
Install bolts and lock washers and
screw tight.
1
2
BM639519.wmf
7.7.2.9 Mounting Torque Support (Version I)

Using lifting equipment, lift torque support (1) from above into rotary drive.
Install pins (2) and secure.
2
B0000814.wmf
BG 36 / 2009
7 - 31
7.7.2.10 Mounting Torque Support* (Version II)
CAUTION
Risk of damaging the concreting head and drive components !

The concreting head must be prevented from rotating with the drive.
Depending on the manufacturer's specifications, either a torque support
or a concrete conduit with a holding bracket must be installed to arrest
the concreting head!
Mount torque support (4) with pins (3) to concreting head.
3 4
B0000821.wmf
BG 36 / 2009
7 - 32
7.7.2.11 Mounting Holding Bracket for Concrete Hose
CAUTION
Risk of damaging the concreting head and drive components !

The concreting head must be prevented from rotating with the drive.
Depending on the manufacturer's specifications, either a torque support or a concrete conduit with a holding bracket must be installed to
arrest the concreting head!
1 Flange on rotary drive

2 Holding bracket for concrete hose
Remove cover plate from flange on

rotary drive.
Bolt down concrete hose bracket.
Mount concrete conduit.
B0000817.wmf
7.7.2.12 Connecting Concrete Pressure Gauge
Connect cable from concrete pressure gauge to electric junction box on

rotary drive.
1 Connection to concrete pressure

gauge of CFA
2 Connection to crowd sledge
3 Connection to concrete pressure
gauge of CFA-V
BG 36 / 2009
2
1
2
3
B0000835.wmf
7 - 33
7.7.2.13 Mounting the CFA Auger *

To suspend the CFA auger
Adjust upper carriage in line with undercarriage.

Place the auger to front of the machine, in the machine's direction of
travel.
Attach lifting slings from the auger (2)
to the cardan joint (1 for CFA-V), or to
the lifting eyes on the concreting kelly
itself for CFA (2).
1
2
BM086515.wmf
WARNING!
Use genuine lifting slings of sufficient capacity supplied by BAUER
Maschinen GmbH only.
BG 36 / 2009
7 - 34
To raise CFA auger
BE021516.wmf
Slowly and uniformly elevate the rotary drive and at the same time carefully travel up
towards the auger.
WARNING!
Tipping hazard!
The crawlers must keep in line with the auger.
Carry out the movements with care.
BG 36 / 2009
7 - 35
To mount CFA auger to concreting kelly

3
3
2
2
2
5
2
BM086524.wmf
Version 1
600 mm
Version 2
750/880 mm
Slightly lift the auger off the ground and then put it down again.
Adjust the rotary drive into a central position above the auger.
Clean the male end fitting of auger (1) and check the O-rings (2) are properly in
place.
Lower the rotary drive and let the female fitting (3) of the concreting kelly settle on
the male end fitting of the auger, down to stop.
Push chains (4) or wedges (7) into the opening (5) on the female.
Install the cover plate (6) such that the locating block on the plate separates the
chains or wedges from one another.
Screw the cover down.
Remove lifting slings from the cardan joint and the auger.
BG 36 / 2009
7 - 36
7.7.2.14 Mounting the CFA Auger Cleaner *
Lower drill string into initial bore.
Remove pilot bit from auger.
Remove the sledge end stoppers from

mast.
By lifting equipment, lift and thread

auger cleaner from below onto slide rails
on mast and pull upward.
Reinstall sledge stoppers on mast.
By auxiliary rope, pull auger cleaner up.
Reinstall pilot bit on auger.
BM086516.wmf
Switch off the engine and connect the hydraulic hoses.

The bulkhead plate for reconnecting the hydraulic hoses for the auger cleaners
is located to the right on the lower mast section.
View from below:
1
2
3
4
5
Kelly auger cleaner / lower tube guide

Kelly auger cleaner / lower tube guide
CFA auger cleaner, leak-oil
CFA auger cleaner
CFA auger cleaner
5
BM086530.wmf
BG 36 / 2009
7 - 37
7.7.2.15 Mounting Auger Guidance *
CAUTION
Risk of damaging drill auger, rotary drive and mast components by drill
auger swinging when drilling is started !
At all times, use an auger guidance or an auger cleaner when drilling
with CFA.
By lifting equipment, lift auger guidance

(1) in place at lower mast end.
Install pins (2 + 3) and secure.

1
B0000832.wmf
Connect hydraulic lines to the main bulkhead plate on the

upper carriage:
63
64
Close
Open
64
63
BM1097511.wmf
BG 36 / 2009
7 - 38
7.8
DISASSEMBLY OF WORK ATTACHMENTS

WARNING!
Risk of crushing, shearing and getting entangled!
Minor movements by the backstay cylinders can create sudden and
uncontrolled major movements of attached components during their
disassembly. Work attachment components are extremely heavy.
The operator must keep in view the person performing the disassembly
throughout the whole procedure.
7.8.1
7.8.1.1
Disassembly of Kelly Equipment

Removing the Kelly

Remove drilling tool.
Unlock the kelly bar and move the rotary drive to the lowermost position.
Lift kelly bar until square stub is approx. 20 cm above rotary drive.
Tilt the mast forward by 2 3.
Lower kelly bar until kelly rests with square stub on ground.
Go on lowering the kelly bar and at the same time travel in reverse with the machine.
Remove the kelly bar from the main rope.
7.8.2
Removing the CFA Equipment *

A lifting platform authorised for lifting people is required when disassembling the CFA equipment.
NOTE
BG 36 / 2009
7 - 39
7.8.2.1 Removing the CFA Auger Cleaner *
Lower drill string into initial bore.
Remove pilot bit from auger.
Stop engine and uncouple hydraulic

hoses.
Using lifting equipment, lift the auger

cleaner.
Remove the lower sledge stoppers.
Lower auger cleaner and unthread from

slide rails on mast.
Reinstall sledge stoppers on mast.
Reinstall pilot bit on auger.
BM086516.wmf
7.8.2.2 Removing the Auger Guidance *
Sling auger guide (1) to lifting equipment.
Remove pins (2 + 3).
Lift off auger guide.
B0000832.wmf
BG 36 / 2009
7 - 40
7.8.2.3 Removing Torque Support *

Using lifting equipment (1), secure the
torque support.
Remove pins (2).
Using lifting equipment, lift off the
torque support.
2
B0000814.wmf
7.8.2.4 Removing Concreting Kelly (Version II)
1
2
3
4
5
Concreting kelly
Cardan joint
Eye
Pin
Retaining ring
Using lifting equipment (1), secure the

concreting kelly.
2
4
5
Unscrew pin retaining rings (5).

Remove the two pins (4) from cardan
joint.
1
3
Lower the main rope and lay the kelly

on the ground.
B0000824.wmf
BG 36 / 2009
7 - 41
7.8.2.5 Removing Concreting Kelly (Version I)
Attach lifting slings to eyes (7) on concreting kelly.
Elevate rotary drive to upper end of

concreting kelly (fig. on right).
Unplug the electric cable from the

concrete pressure gauge (3).
Remove pins (2) between the torque

support and the concreting head.
Remove ring and split ring flange from

groove (1).
Using lifting equipment, lift concreting

kelly from the rotary drive.
6
2
3
7
7
4
BM473516.wmf
7.8.2.6 Removing the Concreting Head (Version II)

1 Concreting head
2 Concreting kelly
1
2
Uncouple the concrete conduit.

Remove concrete hose holding bracket.
Remove torque support.
Unplug cable from concrete pressuregauge.
Remove the concreting head.
BM639519.wmf
BG 36 / 2009
7 - 42
7.8.2.7 Removing the Concreting Head (Version I)

1 Concreting head
Loosen the screws and remove the

concreting head.
BM086521.wmf
BG 36 / 2009
7 - 43
7.8.2.8 Removing CFA Auger *

To suspend the CFA auger
Adjust upper carriage in line with undercarriage.
Set the CFA auger down in front of the
equipment.
Attach lifting slings from the auger (2) to
the cardan joint (1 for CFA-V), or to the
lifting eyes on the concreting kelly itself
for CFA (2).
Remove chains or wedges from the
concreting kelly coupling.
1
2
B0000822.wmf
WARNING!
Use genuine lifting slings of sufficient capacity supplied by BAUER
Maschinen GmbH only.
BG 36 / 2009
7 - 44
To lower CFA auger
B0000823.wmf
Slowly and uniformly lower the rotary drive and at the same time carefully travel in
reverse away from the auger.
CAUTION
BG 36 / 2009
Tipping hazard!
The crawlers must keep in line with the auger.
Carry out the movements with care.
7 - 45
7.8.2.9 Removing the Wedge (Only for CFA V) *

Unscrew bolts (2) from masthead and wedge.
Tilt the masthead with the lifting equipment (in H equipment, with the masthead tilting
cylinder.
By lifting equipment, secure the CFA wedge (1) and unscrew bolts from wedge and
upper mast section (3).
Remove the wedge.
Tilt back masthead and screw down to upper mast section.
WARNING!
Crushing hazard !
The danger zone must be free of people during the tilting of the masthead.
3
B0000815.wmf
BG 36 / 2009
7 - 46
7.8.3
Removing the Rotary Drive

Move crowd sledge to lowermost point.
Stop the engine.
Disconnect electric lines.
Disconnect hydraulic lines.
151 114
116
115 114 152 62 115
59 117
A:

Disconnect the leak-oil line (T) last.
CAUTION
"A"
1
9
4
6
12
3 58
60
(42)
41
BV1058509.wmf
Attach lifting slings to lifting eyes (5).

Suspend the lifting slings to the rig's main rope (3)
(or to the hoist rope of an assist crane, if not
equipped), and slightly pre-stress the rope.
Remove pin retainers and pull the pins out (1 and
2).
NOTE
On rotary drive fitted with an auxiliary

lifting lug, the rig's auxiliary rope (4)
may be used additionally to help align
the rotary drive.
1 2
Lift off and put the rotary drive down on ground.
4
5
B0000700.wmf
BG 36 / 2009
7 - 47
7.9
DISASSEMBLING THE MAST
7.9.1
Lowering the Mast
Adjust the upper carriage in line with the undercarriage, with the mast being located
on the same side as the crawler front idlers.
CAUTION
There is a risk that the mast could collide with the undercarriage and
any parts attached to it.
The upper carriage must be in the correct position.
Unwind the main and auxiliary rope, and place the ropes on the ground beside the
machine.
Completely extend the boom cylinders.
Select the "de-rigging" mode.
Select backstay cylinder operation and uniformly and synchronously push both control levers forward to extend the backstay cylinders.
The mast is lowered.
CAUTION
BG 36 / 2009
Tipping hazard!
Take care not to let the mast drift aside during the lowering. The backstay cylinders must be extended uniformly and without interruptions.
7 - 48
7.9.2
Lowering the Mast with 3.0 m Mast Extension
Attach lifting slings (of approx. 5 m length) to the green

lifting eyes on the mast extension.
Select the "de-rigging" mode with button
Lower the mast to approx. 5

Slowly lower the mast synchronously with the crane and
backstay cylinders.
Risk of damaging the backstay cylinders!

To avoid damaging the backstay cylinders
due to overloading, the mast must be set
up with a crane and the backstay cylinders
must be adjusted precisely.
CAUTION
BM400445.jpg
5000
BK620503.wmf
From an inclination of approx. 45 (Fig. 2), the crane must actively support the mast.
Otherwise there is a risk that the mast is lowered uncontrollably.
Before setting the mast (fig. 3) onto the ground, mount the transport supports.
BG 36 / 2009
7 - 49
7.9.3
Removing the Ropes
7.9.3.1
Removing the Main and Auxiliary Rope
The main (4) and the auxiliary (3) rope must be retrieved while the mast is down.
Remove rope guard pins (1) from the masthead.
Select the winch: Press button

auxiliary winch.
Carefully wind in the rope with the left control lever.
Unthread the ropes from the contactor weights of the hoist limit switches.
Wind in both rope ends to the intermediate guide block (2).
Remove the rope guard pins (1) from the masthead.
for the main winch or button
for the
1
BM526513.wmf
BG 36 / 2009
7 - 50
7.9.4
Removing the Upper Crowd Rope

The rope can only be removed when the mast is lying down.
NOTE
14 15 13
8/9
10 4
3 12
Y
8
"X"
6 2
9
9
11
"Y"
6 2
10
16
4 16
3 12
BK587507.wmf
Move the crowd sledge to its transport position.

Remove the end stoppers from the upper mast section and reinstall them at (16) to
secure the crowd sledge.
Completely extend the rope tensioning cylinder (7).
Remove the rope clip (14).
At the rope tensioning cylinder, remove the pin from the rope end socket (15).
Knock the wedge out (13) to relieve the rope, and pull the rope out of the socket.
Remove the entire rope.
Coil the rope loosely and fix it to the lower end of the mast.
BG 36 / 2009
7 - 51
7.9.5
Disassembling the Mast

WARNING!
mast sections.
Mount transport supports to upper mast section.

Undo hydraulic and electric connections between the mast sections.
Unscrew bolts from mast connecting flanges, and stow the bolts for later use.
Lower the mast until the masthead and rear mast supports rest on the ground.
Remove pin retainers from the rear side of the mast, and pull the pins out.
Drive the machine in reverse and disengage the upper mast section from the lower
mast section.
CAUTION
BG 36 / 2009
Risk of corrosion!
Corrosion-protect the flange faces with grease if the storage or transport
of the rig is expected to take long.
7 - 52
7.9.6
Mounting Transport Supports on the Masthead
Remove the bolts between the

upper mast section and the
masthead.
Rig the masthead with a crane

and lift it.
Insert the transport support and

fix it in place with two bolts on
the upper mast section and two
on the mast head:
1
2
3
4
5
BM20885001.wmf
Hex head bolt

Washer
Tension bush
Hex nut
Lock nut
1 2
24 5
B0000568.wmf
BG 36 / 2009
7 - 53
7.9.7
Lowering the Trestle
Mount the transport support (4).

Lower the lower mast section until the transport support rests on the ground.
Pull pins (2) out of supporting trestle.
Prevent the pins dropping down.
CAUTION
Retract backstay cylinders until the supporting trestle rests on the bearing point (3).
1
2
3
BM639515.wmf
BG 36 / 2009
7 - 54
7.10
REMOVING THE COUNTERWEIGHT

WARNING!
Risk of getting crushed or hit!
No person must stand on or under a counterweight while it is being dismounted.
Avoid getting limbs in between machine and counterweights.
Before releasing or removing safety components, secure the counterweights to prevent them from tipping or falling down.
Persons working on the upper carriage must wear a fall protection belt
secured to the upper carriage.
CAUTION

Counterweights consisting of several parts are to be transported in upright position.
During their intermediate storage, the counterweights must be secured
against tipping.
To remove counterweight:
Remove the counterweights individually
at all times!
Before removing the counterweights,
check that the pins (4) are securely in
place!
Use sling devices with a minimum stand
length of 1.6 m.
Unscrew hex head bolt (5). Remove bolt
(5) and safety material (6, 7 and 8).
Unscrew hex head bolt (3) and pull out.
Unscrew pins (4) of counterweight (2)
and remove them.
Lower counterweight (2) safely using
lifting equipment and secure against
tipping.
BG 36 / 2009
B00005000.jpg
7 - 55
Attach suitable sling devices to the lifting equipment and to the lifting points of
the additional counterweight (11; optional) (5.0 t).
Unscrew pins (4) of additional counterweight (11) and remove them.
Lower additional counterweight (11)
safely using lifting equipment and secure against tipping.
Attach suitable sling devices to the lifting equipment and to the lifting points
Unscrew pins (4) of counterweight (10)
and remove them.
Lower counterweight (10) safely using
lifting equipment and secure against
tipping.
BG 36 / 2009
B00005000.jpg
7 - 56
7.11
RETRACTING THE CRAWLERS

WARNING!
Crushing hazard, shearing hazard and drawing-in hazard!
The machine must be stationary during work on the undercarriage.
A reliable communication between the person(s) working at the undercarriage and the operator in the cab must be provided at all times.
The danger zone must be cleared before the crawlers are retracted.
Begin with the right crawler!
NOTE
The picture shows the left

crawler:
The idler (1) is at the front,
the drive (2) is at the back.
The crossbeams of the right
crawler are smaller than the
crossbeams of the left crawler.
BOHSL038.tif
Remove the pins (3) and stow them

away in inclined tubes behind the
crossbeams.
3
BN814504.wmf
BG 36 / 2009
7 - 57
Lubricate the lubricating nipples of the

crossbeams (5) front and back.
Press button
on the control panel
to release the hydraulic system, and activate telescoping with the relative control levers:
1
2
3
4
Right front telescoping cylinder

Right rear telescoping cylinder
Left rear telescoping cylinder
Left front telescoping cylinder
Lever pulled up cylinder retracts

Lever pushed down cylinder extends
BN814406.jpg
Retract the crawler until the pawl (4; central picture) snaps to fix the track carrier in
place.
Repeat the procedure with the left crawler.
BG 36 / 2009
7 - 58
TRANSPORT
TRANSPORT
8.1
SAFETY GUIDELINES FOR TRANSPORT
Only use hoisting equipment and lifting slings that have sufficient bearing capacity.
WARNING!
Attach lifting slings only to the provided and identified lifting points. Lifting points on the machine are painted GREEN and have a hook symbol.
In addition, numbers tell the weight picked up at the respective points.
CAUTION
The hoist rope must be vertical at all times, to prevent swinging. If the
load begins to swing, set it down immediately and readjust until the rope
is vertical again.
Arrest and secure movable parts of the equipment.
Put accessories to be stored safely away so they will not be an obstacle to traffic on
the roads or on a construction site and will not be interfered with by accident or
abuse.
Additionally cover up and secure sharp edges, projecting points and cutting blades.
The driver of the transporting vehicle is responsible for checking each time before he
starts to drive that all the equipment, the machine and accessories, are restrained
from movement and properly tied down to the deck of the vehicle.
The hauler in charge is responsible for the transport of the equipment, the machine
and accessories.
The hauler should be informed of the transport dimensions, the weights and the
route.
A road permit must be obtained.
BG 36 / 2009
8-1
TRANSPORT
8.2
TRANSPORT MEASURES
MACHINE
The machine must be in the transport position before it may be driven onto a
low-loader or lifted by a crane:
The machine is in its transport position, if
all of the attachments have been removed from the mast.
the mast has been lowered.
the upper mast section is removed.
the lower mast section is removed (if necessary).
the upper carriage is in line with the crawlers and locked to the undercarriage.
the crawlers are retracted.
the beam extensions (if so equipped) have been removed.
counterweights have been removed (if necessary).
After loading:
Underpin the lower mast section with transport supports and secure.
Move the safety stick of the pilot control to the "Off" position.
Stop the engine and remove the ignition key.
Lock the operator's cab and remove the key.
Put the battery main switch to the "off" position.
Tie the machine safely down to the deck of the transporting vehicle.
EQUIPMENT
The rotary drive must be in an upright position during transport.
BG 36 / 2009
8-2
TRANSPORT
8.3
DRIVING ON / OFF A LOWLOADER
Aufrsten
Abrsten
6.
8. 8.
5.
9. 9.
10.
10.
7.
7.
4.
2.
00 00 00 00
1.
0
I
3.
11.
I
7.
!!!
0
x.4
a
m
9.
10.
8.
10 A
B0000968.wmf
1
2
3
4
5
6
Set battery main switch to "ON"

Release emergency STOP button
Start engine
Adjust engine speed
Set pilot control stick to "ON"
Select rigging mode
CAUTION
BG 36 / 2009
7 Slightly raise the lower mast section using the right

and left control lever
8 Travel forward by pushing both levers forward
9 Travel in reverse by pulling both levers back
10 Lower the lower mast section with the right and left
control lever
11 Set battery main switch to "OFF"

With the supporting trestle still folded to the front, the lower mast section must not be raised by more than 40.
8-3
TRANSPORT
8.4
LIFTING POINTS
BM638505.wmf
CAUTION
BG 36 / 2009

Do not lift the machine when the supporting trestle is still folded to the
front.
8-4
TRANSPORT
8.5
TYING DOWN
WARNING!
Tie-downs must be attached to the provided intended points only.
The chains used for tie-downs have sufficient load-bearing capacity.
Tying points
On blue undercarriages, the points provided for tying down are painted YELLOW.
On yellow undercarriages, the points provided for tying down are painted BLUE.
In addition, tying points bear a hook symbol and tell the max. tension to be applied.
To tie down
Tie the equipment down to the transporting vehicle in a professional manner and in
compliance with the national directives. The transport company is always responsible
for professionally tying down the equipment.
Example of tying-down points
CI439400.jpg
BG 36 / 2009
8-5
TRANSPORT
8.6
TRANSPORT DATA
Dimensions in [mm]
800
1400
3250
3000
3240
700
1550
2400
200
12300
1700
4600
5675
200
4400
210
210
1500
1500
1500
12350
235
800
3400 - 4600
1500
600
1150
3500
3500
2500
13120
575
BN19915001.wmf
Weights
Component
Weight in [t]
Machine
Machine with lower mast section and with counterweights
95.40
Machine with lower mast section and without counterweights
68.20
Lower mast section with basic sledge without backstay cylinders
17.70
Counterweights
Main winch with main rope
5.00 + 5.00 + 5.00 + 10.30

5.30
Equipment
Rotary drive KDK 367 S
Kelly BK 40/470/4/68
7.80
15.30
Casing drive adapter 1650 mm
2.10
Drilling tool 1500 mm
2.85
BG 36 / 2009
8-6
MAINTENANCE
MAINTENANCE
9.1
SAFETY GUIDELINES FOR MAINTENANCE
Have maintenance carried out by the after sales service only or by skilled personnel
authorized by the after sales service.
Only use genuine BAUER Maschinen GmbH spare parts.
Observe the "Safety Information" leaflet supplied with the equipment.
Carry out maintenance at the prescribed intervals.
Also observe the other manufacturers' service instructions for components of the
equipment.
9.2
MAINTENANCE INTERVALS
The maintenance for this equipment is organized into the following intervals:
Every
10 hours of operation or daily
Every
50 hours of operation or weekly
Every 250 hours of operation or monthly

Every 500 hours of operation or every three months
Every 1000 hours of operation or yearly
Every 2000 hours of operation or yearly
Every 3000 hours of operation or every two years.
Normally the intervals are cumulative, meaning that when the 1000 hours maintenance
is due, the 10, 50, 250 and 500 hours services will also have to be carried out again.
If the equipment is used under extremely wet and dusty conditions, it may be necessary
to service more often.
CAUTION
BG 36 / 2009
Loss of the equipment warranty!

Maintenance carried out on the equipment must be entered into the
"Maintenance and Repair Log" supplied
In case of a warranty claim, BAUER shall have the right to consult the
log.
9-1
MAINTENANCE
9.3
MAINTENANCE PLAN
9.3.1
Entire Equipment
Entire equipment table

Item
Prescribed interval
Service
10 h
daily
50 h
250 h 500 hrs/ 1000 h
weekly monthly every
yearly
3 months
2000 h
yearly
3000 hrs
every
2 years
Note
Entire equipment
Visual inspection
- Missing or damaged parts
- Missing or loose
pinned/bolted/screwed connections
- Missing or damaged
safety equipment, such as
fire extinguishers,
medical box,
warning signs
- Leaks
Check for proper function of:
- Controls and indicators
- Safety devices such as
emergency STOP,
pilot control safety stick,
limit switches,
hoist limiters
- Free-fall function (optional)
Work platforms
- Check for missing or loose
bolt / screw connections
- Check the locks can move easily
and are working properly
Inspection by competent engineer
X
X
X
X
X
X
X
X
X
X
* only during running-in period
BG 36 / 2009
9-2
MAINTENANCE
9.3.2
Attachments
Attachment table
Item
Prescribed interval
Service
10 h
daily
50 h
250 h 500 hrs/ 1000 h
yearly
3 months
2000 h
yearly
3000 hrs
every
2 years
Note
Masthead
X*
- Check that the connecting bolts

and screws for the mast, if provided, are firmly screwed in;
tighten screws
- Replace connecting screws for
the mast, if provided
10000 hrs
Mast
Mast
- Lubricate guide rails
- Check that the connecting bolts
and connecting screws between
the mast components, if provided,
are firmly screwed in;
tighten screws
- Replace connecting bolts between
the mast components, if provided
Mast prop (optional)
- Ensure that bolt safety mechanism
and bolts are screwed in tightly
- Lubricate pivot mount
Mast ladder (optional)
- Check that the mounting bolts are
firm
- Check transition between the
parts of the mast ladder
- Check fall protection equipment
for proper functioning
X
X*
5000 hrs
X
X
X
X
X
Mast pivot
- Lubricate mast pivot
- Lubricate mounting bolts
- Check flange bolts are firmly
screwed in, tighten bolts
- Replace flange bolts
X
X
X*
10000 hrs
BG 36 / 2009
9-3
MAINTENANCE
Attachment table
Item
Prescribed interval
Service
10 h
daily
50 h
250 h 500 hrs/ 1000 h
yearly
3 months
2000 h
yearly
3000 hrs
every
2 years
Note
Winches
- Check oil level
Main winch
Auxiliary winch
X
X
- Change oil
Main winch
Auxiliary winch
Crowd winch
- Lubricate counter bearings
Main winch
Auxiliary winch
X*
X*
X*
X
X
X
X
X
- Ensure that mounting bolts of the

winch trestles are firm, tighten bolts
- Replace mounting bolts of the
winch trestles
X*
10000 hrs
Cylinders
- Clean piston rods
- Check tightness of cylinder
- Lubricate joints
X
X
X
Bearings and bearing pins

- Lubricate all bearings and bearing
pins that are equipped with lube
nipples
BG 36 / 2009
9-4
MAINTENANCE
Attachment table
Item
Prescribed interval
Service
10 h
daily
50 h
250 h 500 hrs/ 1000 h
yearly
3 months
2000 h
yearly
3000 hrs
every
2 years
Note
Wire rope and accessories

Ropes, rope fasteners,
thimbles and sleeves
- Inspect for wear and damage
Rope swivel
- Lubricate
- Check if bolts are secure
- Check slew function
Rope hold-down rollers
- Check parallel position to cable
drum
Rope sheaves
- Inspect for wear, damage,
and if bearing gap is exceeded
- Check sheaves are free to rotate
- Check groove radii for deviation
and edge formation
- Put grease in lube nipples,
where fitted:
- Rope sheaves with friction bearing
- Rope sheaves with roller bearings
Rope roller brackets
- Ensure that mounting bolts of the
turning blocks are firm, tighten
bolts
- Replace mounting bolts of the
turning blocks
X
X
X
X
X
X
X
X
X
X
X
X*
10000 hrs
BG 36 / 2009
9-5
MAINTENANCE
9.3.3
Equipment
Equipment table
Item
Prescribed interval
Service
10 h
daily
50 h
250 h 500 hrs/ 1000 h
yearly
3 months
2000 h
yearly
3000 hrs
every
2 years
Note
Rotary drive
Rotary drive
- Clean
- Check leakage
- Check magnetic bars for adhesion
of metal parts
- Check oil level
Main gear
Planetary gears
- Change oil
Main gear
Planetary gears
- Take oil sample and check oil
- Check if hollow shaft mounting
bolts are securely fastened
- Check switch pressure
- Change filter
Line filter
Oil pre-cleaner
- Lubricate oil seal
X
X
X
X
X
X
X*
X*
X
X*
X
X
X
X*
X*
Nominal value:
35-40 bar
X
X
Kelly driver / guide flange / shock absorber

- Check springs, shock absorbers
and buffer rings for damage
Check that the mounting bolts are
firm
- Check driver strips for wear
X
X
X
Cardan joint
- Check rubber buffers for damage
X
X
Crowd sledge
- Check wear strips for wear
Kelly bar
X*
Drilling tool
- Clean and check for wear and
damage
CFA/FOW/TRD equipment
- Lubricate concreting head
BG 36 / 2009
9-6
MAINTENANCE
9.3.4
Upper Carriage
Upper carriage table

Item
Prescribed interval
Service
10 h
daily
50 h
250 h 500 hrs/ 1000 h
yearly
3 months
Engine
Observe separate engine manual!!
Cooling system
Observe separate engine manual!!
2000 h
yearly
3000 hrs
every
2 years
X*
Note
Pump distributor gear

- Check oil level
- Change oil
X
X*
Hydraulic system
Hydraulic tank
- Check oil level
- Change oil
- Take oil sample and check oil
Hose assemblies
- Have them inspected for damage
by an expert
Filter replacement
- Pilot control filters
- Return-flow filters
- Leak-oil filters
- Secondary filters
- Free-fall filters
- Rotary drive filters
- Tank breather filter
Pressure accumulators
- Check preload pressure
Oil cooler
- Clean
- Check for damage
X
X
X
X*
X*
X*
X*
X*
X*
X*
X
X
X
X
X
X
X
Or if
contamination
is indicated
X
X
Swing mechanism
- Grease external slewing ring
teeth
- Lubricate slewing ring and rotor
bearing
- Tighten up screws
X
X*
X
X*
BG 36 / 2009
9-7
MAINTENANCE
Upper carriage table

Item
Prescribed interval
Service
10 h
daily
50 h
250 h 500 hrs/ 1000 h
yearly
3 months
2000 h
yearly
3000 hrs
every
2 years
Note
Counterweight
- Check all fastening elements are
applied and firm
Electrical system
Batteries
- Check electrolyte level
- Check cable connections
Fuses
- Check fuses
Filters
- Replace air filter on wiring cabinet
X
X
X
X
BG 36 / 2009
9-8
MAINTENANCE
9.3.5
Undercarriage
Item
Prescribed interval
Service
Crawler track assemblies

Visual inspection
- Missing or damaged parts
- Check the mounting bolts of the
crawler drive wheels, castors and
travel gear to ensure they are
firm.
Tighten if necessary.
Travel gear
- Check oil level
- Change oil
Crawler tracks
- Check chain tension
- Check that the mounting bolts
for the crawler track plates are
firm
Telescoping guidance
- Clean and grease
- Adjust the play of the crawler
cross-beams
10 h
daily
50 h
250 h 500 hrs/ 1000 h
yearly
3 months
2000 h
yearly
3000 hrs/
2 years
Note
X
X
X
X*
X*
X
X
BG 36 / 2009
9-9
MAINTENANCE
9.3.6
Optional Equipment
Optional equipment table

Item
Prescribed interval
Service
10 h
daily
50 h
250 h 500 hrs/ 1000 h
yearly
3 months
2000 h
yearly
3000 hrs
every
2 years
Note
Air conditioning
- Operate the air conditioning system
- Clean the air filter *
- Clean condenser
Compressor*
-
2 - 3 weeks
X
X
Observe separate compressor manual!!
Clean cooling ribs

Clean suction air filter
Replace suction air filter
Clean lubricating oil filter
Replace lubricating oil filter
Change oil
Check air service unit
Drain condensate on compressor,
air-service unit, 70 l pressure accumulator
X
X
X
X
X
X
X*
X
X
after every
use
Oxidation-type catalytic converter

X
- Measure the counter pressure of

the exhausts treated by the CRT
system
Generator*
- Check the oil level

- Replace the air filter
- Check ISO meter
Before each
use
X
Before each
use
Before each
use
BG 36 / 2009
9 - 10
MAINTENANCE
9.4
LUBRICATION PLAN
The machine is equipped with a central lubrication system. However, not all lubrication
points are supplied by this system. Some must be manually lubricated and these points
are marked in the table in bold print.
1 1000h
1.1 1000h
10h 18
1000h 21
22 250h
250h 17
23 1000h
250h 15
2 10h
10h 25
3 10h
10h 14
50h 13
50h 12
50h 11
50h 10
10h 9
50h 8
50h 6
250h 7
4 50h
50h 20
5 50h
1000h 19
10h 29
50h 26
28 50h
26 50h
BV1058506.wmf
Every 10 operating hours:
2
3
9
14
18
29
25
4
5
6
8
10
11
12
13
20
26
28
Mast wear strips

Rope sheaves
Mast prop joint
Rope sheave
Rope swivel
Gear ring (outside)
Shaft seal ring, rotary drive
- Concreting head*, not shown

- Auger cleaner* (guide rollers: 4 nipples,
reamer: 1 nipple, bearing: 4 nipples) not shown
- Kelly guidance bearing* not shown
Backstay cylinder joints

Boom cylinder joints
Boom pins
Mast pivot pins
Mast pivot joints
Boom cylinder joints
Mast prop
Auxiliary winch bearing
Crowd winch bearing
Crawler guides
Slewing ring bearing
7
15
17
22
1
1.1
19
21
23
Supporting trestle pin

Crowd cylinder joint *
Crowd cylinder joint *
Rope tensioning cylinder joints
Masthead rope sheaves in kelly mode

Not supplied in this version
Crowd rope sheave
Crowd rope sheaves
Crowd rope sheaves
BG 36 / 2009
9 - 11
MAINTENANCE
9.5
MAINTENANCE DURING LONGER PERIODS OF STANDSTILL
Engine
Every 2 to 3 weeks, start the diesel engine and let it run in the medium rpm range for
about 1 hour.
CAUTION
If it is not possible to start the engine during the standstill, preservation

measures must be taken. Please refer to the diesel engine operating
manual.
Air conditioning
Every 2 to 3 weeks, turn the air conditioning on (if fitted) for a short time.
Slewing ring
Preserve the slewing ring teeth.
From time to time during the standstill, remove dust and inspect the surface of teeth,
slewing ring and drive pinion for the onset of corrosion; clean and grease as required.
Undercarriage telescoping guidance
Preserve telescopic guides with grease.
Rotary drive
In case of standstill periods of longer than 3 months, the gears must be completely
filled with oil. When the machine is put into operation again the oil must be changed.
Use a cover to protect the housing from rain water.
Cylinders
Exposed piston rods should be retracted as far as possible and preserved (clean
with hydraulic oil before putting into operation again).
BG 36 / 2009
9 - 12
MAINTENANCE
9.6
HYDRAULIC SYSTEM
WARNING!
Injury hazard from hydraulic oil spray!
Hydraulic systems must be depressurized before any maintenance or
repair is performed. This applies to pressure tanks in particular.
CAUTION
9.6.1
Risk of fire from hydraulic oil spray!

Hydraulic systems must be depressurized before any maintenance or
repair is performed. This applies to pressure tanks in particular.
Hose Assemblies
Inspection
Hose assemblies must be inspected at least once a year by a competent person. A
hose assembly on which one or several of the following criteria are found must be replaced with a new one:
Damage in the outer layer down to the core of the hose (e.g. abrasions, cuts or fissures).
The outer layer of the hose is brittle (cracks in the tubing).
The hose is no longer its natural shape, both with and without pressure and while it is
bent (e.g. layers separating, bubbles forming) (See also DIN 20066 Part 4).
Leaks.
Damage or deformation of hose end fittings (tightness impaired); minor damage to
the surface does not require replacement.
Hose slips out of end fitting.
Corrosion on the end fitting, impairing the function and stability.
The hose is not assembled in compliance with instructions.
The storage and service life are exceeded.
BG 36 / 2009
9 - 13
MAINTENANCE
Storage and service life

Hoses and hose assemblies must be stored in a cool, dry and dust-free environment.
Avoid exposure to direct sunlight or UV radiation.
Storage and service life:
Storage time
Service life
(including storage time)
Hose
2 years
Hose assembly
2 years
6 years
Re-use
Generally, hoses that have been in service as part of a hose assembly ought not to be
re-used in a new hose assembly as they will no longer meet the requirements.
9.6.2
Hydraulic Cylinders
Every 10 operating hours or daily, and every time before starting up again after a
longer period of rest, clean all cylinders and check them for tightness.
Risk of causing damage to the piston rods!
CAUTION
CAUTION
Do not clean cylinder piston rods with a water jet, sharp tool, caustic lye
or an abrasive.

Immediately repair or replace cylinders that are not tight.
Every 50 operating hours or once a week, grease the cylinder lugs (holes for pins).
On cylinders that are kept extended during rest:

Risk of corrosion damage in corrosion-supporting environments!
The tasks specified below must be carried out without fail.
CAUTION
Once or twice a week, rub down piston rods with hydraulic oil, or repeatedly retract
and extend the rods.
Before a longer standstill, preserve piston rods with an acid-free grease.
BG 36 / 2009
9 - 14
MAINTENANCE
9.6.3
Changing Filters
9.6.3.1 Replacing Line Filters

The elements of the line filters must be replaced after the first 250 operating hours or
one month. Subsequent replacements of the line filter cartridges are due every
1000 operating hours or whenever contamination is indicated (optional; by a warning
lamp or by an error message).
WARNING!
Serious injury hazard!
Before beginning to replace a filter element, de-pressurise the hydraulic
system and allow it to cool down.
NOTE
When the hydraulic oil is still cold, the contamination indicator may light
up briefly.
Detail "A"
Line filter:
1
2
3
Freewheel filter
Rotary drive filter
Pilot control filter
"A"
3
BU17345006.wmf
The leak oil filter and the return-line filter are located in the hydraulic tank and can be
accessed from the top of the tank. Observe instructions in the manual of the base machine!
Place a suitable container underneath
the filter housing and unscrew the bottom (3).
Remove filter element (2) from top (1) of
housing, and dispose of with hazardous
waste.
Clean the top and bottom of the housing.
Install a new filter cartridge in the top of
the housing.
Screw on the bottom on top and tighten.
BG 36 / 2009
1
2
3
B0000623.wmf
9 - 15
MAINTENANCE
9.7
WINCHES
9.7.1
Checking the Gear Oil Level
All equipped winches must be checked for proper level of gear oil every 50 operating
hours or weekly, and whenever the equipment is started up again after a longer standstill.
CAUTION
Danger of oil spray!

Check the oil level only when the winch is off.
Winches with dipstick
Position the winch such that the tube (2) is upright.

Unscrew and remove the oil dipstick (1).
Dry the dipstick with a clean and lint-free cloth.
Reinsert the stick completely.
Pull the stick out again and read it:
If the oil has sunk to the MIN mark, top up with
new oil and check again. The MAX mark must
not be exceeded.
Clean sealing surfaces, check seal for wear and
damage, replace as required.
Reinsert the dipstick and screw it down tight.
1
max.
min.
2
3
B0000574.wmf
Winches with sight glass

The oil level can be checked in any winch position.
If the oil level has reached the lower limit

("min." = 20 mm below the winch centre line), add
oil through one of the screw plugs (2), then recheck the oil level. The upper limit (max = centre
of the winds) must not be exceeded.
Reinsert the screw plug and screw it down tight.
max.
min.
20 mm
1
B0000846.wmf
BG 36 / 2009
9 - 16
MAINTENANCE
9.7.2
Changing the Gear Oil
The gear oil must be changed after the first 250 operating hours or after one month.
Subsequent gear oil changes are due every 1000 operating hours or once a year.
CAUTION
Danger of oil spray!

Change oil only when the winch is off.
Winches with dipstick
Position the winch such that the tube (2) is upright.

Unscrew and remove the oil dipstick (1).
Remove the drain screw (3) and drain the gearbox.
At low outdoor temperatures, flush the empty
gearbox with a warmed-up part of the new oil.
Reinsert the drain screw.
Refill with new oil.
Check the oil level.
Reinsert the dipstick (1) and screw it down tight.
1
max.
min.
2
3
B0000574.wmf
Winches with sight glass

The gear oil can be changed in almost any winch
position.
Unscrew one of the screw plugs (2).
Unscrew one of the screw plugs (1) and drain the
gear oil.
At low outdoor temperatures, flush the empty
gearbox with a warmed-up part of the new oil.
Reinsert the screw plug (1).
Refill with new oil.
Check the oil level.
Screw in the screw plug (2) and tighten.
BG 36 / 2009
max.
min.
20 mm
1
B0000846.wmf
9 - 17
MAINTENANCE
9.8
WIRE ROPE ACCESSORIES
9.8.1
Rope Swivel
Every 10 operating hours or daily:
Apply grease to nipple (2) until grease exits from

the housing.
Test the swivel rotates freely.
1
2
Conduct the test by hand, without load suspended

from the swivel.
If the swivel will not rotate properly after it has been
greased, repair or replace it with a new one.
Check tie bolts (1 and 3) are firmly in place.

Retighten them as required. Replace the tie bolts with
new ones if they are torn or have excessive play.
CAUTION
BG 36 / 2009
3
BO000576.wmf
Immediately inspect the swivel for any damage if the kelly bar is accidentally dropped.
9 - 18
MAINTENANCE
9.8.2
Rope Hold-down Rollers
Every 50 operating hours or weekly:

Check rope hold-down rollers for wear and
proper function.
Check the roller is parallel to the drum of the
winch.
Check the roller mounting bolts are properly in
place and firm.
Adjust at tension screws until all springs are
equal. Do not tension worn-out springs too
much but replace them with new ones.
B0000509.wmf
Re-align protecting bars that are bent, or replace them with new ones.
If there is excessive play, replace the roller centre pin, bushings and spacers respectively with new ones.
If grooves have been created in a roller, reface the roller (by turning it on a lathe), or
replace it with a new one.
Mind that a refaced roller will have a diminished diameter so that the respective tension will have to be pre-tensioned correspondingly.
9.8.3
Rope Fasteners, Thimbles and Sockets

Check whether the wire rope is firmly in place in the fitting.
With poured rope fittings, inspect for broken wires and corrosion directly where the
rope exits the fitting.
With swaged-on rope fittings, inspect for broken wires next to the fitting, cracks in the
material and firm seizure of the rope.
CAUTION
BG 36 / 2009
Danger of rope breaking!

If a defect is found on a rope fitting, cut off the rope end and re-fit it.
9 - 19
MAINTENANCE
9.8.4
Rope Sheaves
CAUTION
Danger of rope breaking!

Sluggish or seized rope sheaves subject the rope to excessive wear and
abrasion and make the load distribute unevenly on the rope structure.
Repair or replace sluggish or seized rope sheaves, if greasing will not do.
9.8.4.1 Greasing Rope Sheaves

Rope sheave type
Prescribed interval
Maintenance instructions
Rope sheaves with

friction bearings
10 operating hours or
daily
BM659821.jpg
Rope sheaves with roller

bearings
1000 operating hours/

yearly
CAUTION
Risk of damaging
the bearing seal!
Grease while rope
sheave is rotating.
Press grease in
slowly to prevent
squeezing out
bearing seal.
BM659822.jpg
Rope sheaves greased

by the central lubrication
system
Automatic
BM659823.jpg
BG 36 / 2009
9 - 20
MAINTENANCE
9.8.4.2 Checking Rope Sheaves

Service
Prescribed interval
Check the rope sheaves

are free to rotate.

monthly
Check sheave centre

pins have the proper
bearing play and are
properly in place.

monthly
Check for burrs and

edges on the sheaves
and that the grooves in
the sheaves still comply
with the diameter of the
rope used.

yearly
BG 36 / 2009
Maintenance instructions
Re-machine the groove, or replace

the sheave with a new one, of the
groove no longer complies.
9 - 21
MAINTENANCE
9.9
ROTARY DRIVE
9.9.1
Visual Inspection

Clean the rotary drive with a water jet.
Examine all components for damage
and wear.
The following must be specifically
checked in rotary drives with shock
absorbers:
-
Buffer ring (1)

Spring-loaded ring (2)
Compression springs (3)
Shock absorbers (4)
1
2
3
4
Check the rotary drive for leaks.

B0000577.wmf

Immediately replace damaged components with new ones.
CAUTION
BG 36 / 2009
9 - 22
MAINTENANCE
9.9.2
Checking the Oil Level
9.9.2.1 Main Gear

The oil level in the main gear must be checked every 10 operating hours or once a day.
Set the rotary drive to the upright position.
Check oil level at gear standstill.
The oil must reach to middle of the sight glass (see Fig.).
CAUTION

Make sure the oil level is correct at all times.
The oil must reach slightly more than half way up the glass.
B0000624.wmf
CAUTION
CAUTION
BG 36 / 2009

If the oil is cloudy, water has got in and the oil must be changed immediately. Drain and thoroughly flush the drive repeatedly with the new oil
before refilling.

An oil level which is too high in the main gear is an indication of a defect
in the planetary gears. Shut down the rotary drive and repair.
9 - 23
MAINTENANCE
9.9.2.2 Planetary Gears

The oil level in the planetary gears must be checked every 10 operating hours or once a
day.
Set the rotary drive to the upright position.
Check oil level at gear standstill.
The oil must reach to middle of the sight glass (see Fig.).
Risk of damaging the planetary gears!

Make sure the oil level is correct at all times.
CAUTION
B0000625.wmf
CAUTION
BG 36 / 2009
Risk of damaging the planetary gears!

If the oil is cloudy, water has got in and the oil must be changed immediately. Drain and thoroughly flush the drive repeatedly with the new oil
before refilling.
9 - 24
MAINTENANCE
9.9.3
Changing the Oil
Change the oil for the first time after 250 operating hours. Then change oil after every
1000 operating hours or once a year.
Try to change the oil when it is at operating temperature.
NOTE
To drain the main gear:
Stop the rotary drive.
Position the rotary drive such that the
drain valve (1) is at its lowest position.
Unscrew filler screws (2).
Have a collecting container ready.
Screw the drain hose onto the drain
valve (1). The valve opens by itself and
the oil flows out.
Ansicht "A"
View "A"
2
Ansicht "B"
View "B"
Ansicht "A"
View "A"
1
Ansicht "B"
View "B"
B0000578.wmf
To drain the planetary gears:

Position the rotary drive vertically.
Have a collecting container ready.
Screw a drain hose onto the drain valves
(1). The valves open by themselves and
the oil flows out.
K0000507.wmf
Scalding hazard!
Hot gear oil can cause severe injury!
CAUTION
BG 36 / 2009
9 - 25
MAINTENANCE
Inspect the magnets on the magnetic sticks for gear abrasives and clean the screws
(see also the section "Oil Sampling").
NOTE
Check the mounting bolts of the hollow shaft (see the section "Checking
Hollow Shaft Mounting Bolts").
If the outside temperature is low at the time of the oil change, warm up (to approx.
50C / 122F) a part of the new oil and rinse the gear housing with this oil before refilling.
Benzol (benzene) or flushing oils may also be used here for rinsing.
NOTE
CAUTION

Do NOT use petrol (gasoline), petroleum or diesel oil for rinsing here.
Allow the rinsing fluid to drain off completely.
To replace the line filter:

Line filter:
1 Rotary drive
1
KX000502.wmf
Place a suitable container underneath the

filter housing and unscrew the bottom (3).
Remove filter element (2) from top (1) of
housing, and dispose of with hazardous
waste.
Clean the top and bottom of the housing.
Install a new filter cartridge in the top of the
housing.
Screw on the bottom on top and tighten.
1
2
3
B0000623.wmf
BG 36 / 2009
9 - 26
MAINTENANCE
Cleaning the oil precleaner:

2 Pump suction strainer
2
KX000516.wmf
NOTE
KAP841410.jpg
To clean the strainer, the main gear must be empty of oil, or an oil collecting container must be held at the ready.
Disconnect the hydraulic hose used (2) and unscrew the strainer.
Clean and reinstall the strainer.
Reinstall the hydraulic hose.
To refill the main and planetary gears:
Remove the drain hose and close the drain valves.

Refill the main gear with the quantity of oil specified for the main gear.
Screw in the filler screws.
Start the engine and run the rotary drive at medium speed for approx. 2 minutes to fill
up the planetary gears.
CAUTION

The rotary drive must not be operated at maximum capacity until the
planetary gears have been filled with oil.

Refill the main gear with the quantity of oil specified for the planetary gears.
Screw in the filler screws and tighten.
Let the rotary drive rotate for a short while and stop it again.
Let the oil settle.
Check for proper oil level at the main gear; top up with more oil as necessary.
BG 36 / 2009
9 - 27
MAINTENANCE
9.9.4
Checking the Oil
Every 250 hours of operation or monthly:

Inspect the oil for dark or black colouring.
If the colour of the sampled oil is dark or black, the operating temperature of the oil
has been above 100C (212F). This results in an accelerated ageing of the oil, and
in reduced lubricity. The oil change must be carried out at shorter intervals.
Inspect the oil for water and dirt.
If the oil is found to be contaminated or water has got in, the seal rings must be
checked and replaced as necessary.
Inspect the oil for solid particles (abrasives).
The maximum permissible amount of foreign particles in the total oil fill of one gearbox must not exceed 0.15%. Lots of foreign matter may only consist of small abrasion (up to max. 5 m) (examination of foreign matters according to DIN 51592).
With coarse-grained abrasion (above 5 m) the gear must be dismounted - regardless of the quantity of the abrasion.
BG 36 / 2009
9 - 28
MAINTENANCE
9.9.5
Hollow Shaft Mounting Bolts
The mounting bolts of the hollow shaft must be checked every time the oil of the rotary
drive is changed.
Unscrew and remove access plugs (1).
Visually check if mounting bolts (2) are firm.
CAUTION

Do not re-tension these bolts unless
necessary, or the Loctite seal of the bolts
will break making the bolts loosen during
operation. Check visually only. Do not
put fingers into the bores.
1
Turn the rotary drive to allow all of the
screws to be checked.
Ansicht von unten:

View from below:
NOTE
1
Unscrew mounting bolts found to be loose, clean
them and apply Loctite to threads, reinstall and tension the bolts with the specified torque (see below).
1
BHVSF177.wmf
Bolt torque value MA [Nm]

Hollow shaft mounting (2)
Hex head bolts
BG 36 / 2009
See Spare Parts List
9 - 29
MAINTENANCE
9.9.6
Kelly Driver / Guide Flange
9.9.6.1 Checking the Mounting Bolts

Check mounting bolts of the kelly driver and guide flange for proper place and firm fitting
every 50 operating hours or weekly.
Visually check if mounting bolts (1; 2) are firm.
CAUTION

Do not re-tension these bolts unless necessary, or the Loctite seal of the bolts will
break making the bolts loosen during operation. Check visually only.
Unscrew mounting bolts found to be loose, clean

them and apply Loctite to threads, reinstall and tension the bolts with the specified torque (see below).
1
2
B0000579.wmf
Bolt torque value

Ma [Nm]
Kelly driver mounting (1)
Hex socket head bolts
Guide flange mounting (2)

Hex head bolts
Set screws with nut

To replace the kelly driver and/or guide flange:

Clean contacting surfaces of the hollow shaft and the kelly driver / guide flange free
of grease. Apply Loctite 0586 Type AVX on the cleaned surfaces.
Apply Loctite to threads of the mounting bolts, and screw the bolts down with the
specified torque in a diagonal manner.
BG 36 / 2009
9 - 30
MAINTENANCE
9.9.6.2 Checking Driver Strips for Wear

If the wear (x )> 8 mm, reinstall kelly tappet bands (5) by turning 180 or replace
completely.
Replace bushings (4) and screws (3) with heavy wear as well.
When fitting a new driver strip, the play (y) should not exceed 0.5 mm.
NOTE
Bolt torque value
Ma [Nm]
Kelly driver strips mounting
Hex socket head bolts
Hex socket head bolts with nuts
A-A

1
2
3
4
5
x
KAP770504.wmf
BG 36 / 2009
9 - 31
MAINTENANCE
9.9.7
Cardan Joint
Check whether suspension pins (see arrow)

are properly in place and firm.
Check rubber buffers for damage.
K0000501.wmf
9.9.8
Crowd Sledge Wear Strips

Replace wear strips (1) with a remaining thickness of (X) < 16 mm.
"A"
B-B
5
X
"A"
1
2
3
4
B0000582.wmf
Unscrew bolts (2) and remove the tension plates (3).

Pull out the wear strip (1) and install a new wear strip.
Reinstall the tension plates and screw tight.
BG 36 / 2009
9 - 32
MAINTENANCE
9.9.9
Greasing the Shaft Seal Ring
Clean the rotary drive.

Apply grease to lube nipples (1 or 2) and
rotate the drive in between, from time to
time.
Repeat the procedure until grease exits
steadily along the whole circumference
(arrow).
1
2
4
4
K0000515.wmf

CAUTION
Insufficient greasing can allow solid matters to enter into the gears and
cause damage.
CAUTION

Brownish coloured gear oil or a heavily contaminated filter (3 or 4) can
be an indicator of solid matter brought in from the outside.
Shut down the rotary drive and contact the After Sales Service.
BG 36 / 2009
9 - 33
MAINTENANCE
9.10
CRAWLER TRACK ASSEMBLIES

WARNING!
Crushing hazard, shearing hazard and drawing-in hazard!
The machine must be stationary during work on the undercarriage.
A reliable communication between the person(s) working at the undercarriage and the operator in the cab must be provided at all times.
9.10.1 Visual Inspection

With the upper carriage positioned crosswise, thoroughly clean crawlers until they are
free of mud and dirt.
Walk-around and inspect for wear, damage and loss of oil, especially on following
components:
Track pads (1)

Track links (2)
Carrier rollers (3)
Front idlers (4)
Track guide (5)
Tread rollers (6)
Crawler drive wheels (7)
Travel gear (8)
1 2
B0000676.wmf
The crawler guides should be greased to protect them from corrosion.

NOTE
BG 36 / 2009
9 - 34
MAINTENANCE
9.10.2 Crawler Tracks

9.10.2.1 Checking the Chain Tension
Check the chain tension every 10 operating hours or daily.
Thoroughly clean each crawler, track
and rollers.
Travel forward a short distance with the
machine and then park it.
Measure the sag over a length of 1 1.5 m (see fig.).
The distance between the measuring
rod and crawler chain (see fig.) should
be roughly 2 - 3 cm in the centre
If this is not the case, increase/reduce
the tension in the crawler chain.
1 - 1,5 m
2-3 cm
1 - 1,5 m
2-3 cm
1 - 1,5 m
2-3 cm
B0000680.wmf
BG 36 / 2009
9 - 35
MAINTENANCE
9.10.2.2 Adjusting the Track Tension

To tighten the track
Remove cover plate (5) and clean the grease nipple (2).
2
5
1 3 4
B0000725.wmf
Put a high-pressure grease gun to the grease nipple.

Work the grease gun until the proper track tension is obtained.
Check the chain tension again after a short travel forward and backward, and top up
with more grease as necessary.
Reinstall the cover plate.
BG 36 / 2009
9 - 36
MAINTENANCE
To loosen the track
2
5
1 3 4
B0000725.wmf
Remove the cover plate.

Unscrew the safety valve (1) by approx. 3 turns (SW 41) until excess grease escapes
at the marked spot (4).
WARNING!
Risk of injury from pressurised grease!
Unscrew the safety valve with great care only.
Retighten the safety valve when the proper chain tension is obtained.
Check the chain tension again after a short distance forward and backward.
Clean the nipple and surroundings so they are free of grease.
Reinstall the cover plate.
WARNING!
Risk of injury due to pretensioned spring element (compressible silicone
oil at 1500 to 2000 bar)!
If the spring elements are defective, replace them completely with new
ones. Do not attempt to repair, for safety reasons.
BG 36 / 2009
9 - 37
MAINTENANCE
9.10.3 Checking the Mounting Bolts

Visually check if the mounting bolts are firmly in place.
Retighten loose bolts.
5
6
BK587502.wmf
BM564683.jpg
BK587440.jpg
Bolt torque value

Ma [Nm]
Maintenance interval
in operating hours
141070
50
Carrier rollers (2)
560
250
Track guide (3)
560
250
Tread rollers (4)
720
250
Crossbeam (5)
---
250
Crawler drive wheels (6)
1600
250
Travel gear (7)
1100
250
---
250
755 (M24)
After the first 250

and then every 2000
Bolted connection
Track pads (1)
Telescopic cylinder mounting

Slewing ring (8)
BG 36 / 2009
9 - 38
MAINTENANCE
9.10.4
Travel Gear
9.10.4.1
Checking the Oil Level
Check the oil level every 250 operating hours or monthly.
Drive the machine until the drain plug (2) is positioned at the bottom.
Unscrew inspection/filler screw (1) together with

seal (if equipped).
The oil must reach the lower edge of the filling
opening, if necessary top up oil.
Clean inspection/filler screw and sealing surfaces

on housing. Replace with new seals as necessary.
Reinstall the inspection/filler screw with a new

seal and screw tight.
3
2
B0000514.wmf
9.10.4.2
Changing the Oil
The gear oil must be changed after the first 250 operating hours or after one month.
Subsequent oil changes are due every 1000 operating hours or once a year at least.
Move machine until oil drain plug (2) on crawler
drive wheel is at its lowest position.
Unscrew the inspection/filler screw (1) together
with seal (if equipped).
Place an oil collecting container underneath the
drain.
Remove the drain plug (2) and drain the oil.
Clean screw and plug and sealing surfaces on
housing.
Reinstall drain plug with new seal and screw
tight.
Refill with new oil to the proper level.
Reinstall the inspection/filler screw with a new
seal and screw tight.
BG 36 / 2009
3
2
B0000514.wmf
9 - 39
MAINTENANCE
9.10.5
Checking and Adjusting the Clearance of the Cross beams
The play at the two crawler cross-beams must be checked after the first 250 operating
hours and subsequently every 1000 operating hours.
Starting position:
Both crawler cross-beams are extended. The pins are installed.
9.10.5.1 Play at Cross-Beam Centres
1
2
3
4
3
s1
Detail X:
s2
Bolts
Cover with pressure pin
Distance plates
Small pressure pins
Z
BM779511.wmf
To check the play:

Remove the cover with pressure pin (2). Measure the length of the pin (s2).
Measure the depth of the bore (s1).
s1 s2 = x = clearance
Permissible play x: 0 mm 0.5 mm.
To adjust the play:
Remove the respective distance plate (3).
Secure the pins again with the bolts (1). Ma: 540 Nm
BG 36 / 2009
9 - 40
MAINTENANCE
9.10.5.2 Play at Crossbeam Ends

X
Detail Y:
Y
1 Wedge
2 Bolts
3 Distance plates
1
2
1
2
3
Bm779512.wmf
To measure the space:

Measure the space Y between the wedge (1) and the crossbeam with an inside
calliper.
Permissible space Y: 0.5 mm 0.1 mm
To adjust the space:
Loosen the bolts (2).
Loosen the wedge (1).
If the wedge will not loosen, tension
the extraction bolt (4).
Remove the respective plate (3) in
compliance with the table below:
BM564690.jpg
Thickness of the distance plate in mm
Altered space at wedge in mm
0.5
1.0
2.0
3.0
0.09
0.18
0.35
0.53
Retighten the bolts (2). Ma: 960 Nm.

Adjust space Z with the same procedure as Y.
BG 36 / 2009
9 - 41
MAINTENANCE
9.11
CENTRAL LUBRICATION SYSTEM
The grease receptacle contains 2 kg of normal commercial grease of class NGLI-Kl. 2

and must be topped up with a grease gun (if possible pneumatically) every 50 operating
hours or weekly.
For further details on the central lubrication system, see the enclosed documentation.
Greases containing solids such as graphite or copper pastes may not
be used.
To prevent the grease becoming contaminated and leading to clogging, the grease must be pressed onto the container via the grease
nipples (do not unscrew the lid).
The grease should be topped up until max. 2 cm below the upper
edge as otherwise the ventilation system will be smeared with grease.
NOTE
9.12
MAINTENANCE OF THE SWING MECHANISM
9.12.1 External Swing Mechanism Teeth
Spray the swing mechanism teeth daily with gear wheel spray.
The surface of the teeth should be inspected for dust and rust following longer
standstills: the surface condition of the slewing ring and of the pinion gear should
also be checked. Open the gear ring cover if necessary.
9.12.2 Slewing Ring Mounting Bolts
Check that the slewing ring mounting bolts are securely in place and tighten if necessary, after 250 operating hours during the running-in period, and later every
2000 operating hours.
BG 36 / 2009
9 - 42
MAINTENANCE
9.13
BOLTED CONNECTIONS
After the first 250 operating hours, retighten all the bolted connections described
here.
Generally apply the prescribed torque on these bolts to tighten them
("torque pretensioning method").
NOTE
Bolted connections of mast sections
After every 5000 hours of ordinary operation, replace all of the elements used in the
bolted connections.
WARNING!
Replace the elements of bolted connections which have been openedup more than 25 times or which are corroded, fissured, deformed or
have damaged threads.
Bolted connections of mast pivot, winch trestles, roller brackets and masthead
After every 10000 hours of ordinary operation, replace all of the elements used in
the bolted connections.
WARNING!
Replace the elements of bolted connections every time components are
mounted or reassembled and whenever the connections have been excessively stressed from rig tipping or improper handling.
BG 36 / 2009
9 - 43
MAINTENANCE
9.14
ELECTRIC SYSTEM
9.14.1 Replacing Dust Filter on Switch Cabinet
Every 250 operating hours or monthly,

replace the filter element in the air intake
to the switch cabinet.
BN1100413.jpg
BN1100412.jpg
BG 36 / 2009
9 - 44
LUBRICANTS / TABLES
10
LUBRICANTS / TABLES
10.1
LUBRICANTS
10.1.1 General
Observe instructions given in the supplied "Safety Information" book on this subject.
Use only oils and greases prescribed or suitable for the application in question.
Before changing to another kind of lubricant, check it is compatible with the previous
one used.
The lubricants used must be fresh.
CAUTION
NOTE
BG 36 / 2009

A damage resulting from non-observance of lubricant instructions in this
manual will not be covered by the equipment warranty.
The lubricants listed in the lubricant tables of this manual are suitable
for ambient temperatures from -20C to +40C (-4F to +104F). Information on applications below -20C and above +40C can be ordered from the BAUER customer service.
10 - 1
LUBRICANTS / TABLES
10.1.2 Lubricant Table

The following table lists the lubricants with which the equipment is filled when leaving
the factory.
NOTE
Quantities given in the table serve as a guide only. Decisive are the
specifications found on the nameplates of the respective parts and the
actual fill level found when checking.
Alternative lubricants are listed on the following pages.
Initial lubricant fill table

Application
Specification Viscosity grade
Qty.
[ litres ]
Producer
Name of product
VG 220
ARAL
Aral ATF 22
Pump distributor gear
ISO VG 220
BP
Enersyn EP-XF 220
8.5
Travel gear
ISO VG 220
BP
Enersyn EP-XF 220
2 x 20.0
Main winch
ISO VG 220
BP
Enersyn EP-XF 220
20.0
Crowd winch
ISO VG 220
BP
Enersyn EP-XF 220
15.0
Auxiliary winch
ISO VG 220
BP
Enersyn EP-XF 220
3.0
Gear oil,
petroleum
CLP
Gear oil,
petroleum
API
Gear oil,
petroleum
ATF
Rotary drive,
main gear
BG 36 / 2009
100.0
CLP PG
Gear oil,
synthetic
Gear
synthetic
*At 40 :
38 mm2/s
at 100 :
7.1 mm2/s
oil,
CLP HC
10 - 2
LUBRICANTS / TABLES
ISO viscosity
grade
/ descripSpecification
tion
Qty.
[ litres ]
Producer
Name of
product
ISO VG 46
ARAL
VITAM VF 46
660.0
ISO VG 46
ARAL
VITAM VF 46
2x
23.0
SAE 15W-40
ARAL
Aral Plus Tuboral

SAE 15W-40
32.0
Roller bearing /
friction bearing
ARAL
Aralub HLP 2
If
required
Central lubrication
system
ARAL
Aralub HLP 2
If
required
Application
Hydraulic oil,
petroleum
Hydraulic oil
HVLPD
Rotary drive,
planetary gears
Hydraulic fluid
organic
HEES
unsaturated
esters
Hydraulic fluid
organic
HEES
saturated
esters
Petroleum
engine oils
API CF-4
Engine oil
Petroleum
engine oils
API CH-4
Petroleum
greases
KP2N-20
NLGIclass 2
Multi-purpose
grease on lithium
soap base
BG 36 / 2009
10 - 3
LUBRICANTS / TABLES
10.1.3
Lubricant Guide
10.1.3.1
List of Approved Gear Oils, Petroleum - CLP
Application
Specification
DIN 51517/
DIN 51502
Gear oil,
petroleum
CLP
Viscosity grade
ISO-VG / DIN 51519 at 40C in mm2/s
Producer
VG 100
VG 150
VG 220
ARAL
ARAL
Degol BG 100
ARAL
Degol BG 150
ARAL
Degol BG 220
SHELL
SHELL Omala 100
SHELL Omala 150
SHELL Omala 220
BP
BP Energol
GR-XP 100
BP Energol
GR-XP 150
BP Energol
GR-XP 220
MOBIL
Mobilgear 627
Mobilgear 629
Mobilgear 630
AVIA
Avilub RSX 100
Avilub RSX 150
Avilub RSX 220
CASTROL
Alpha SP 100
Alpha SP 150
Alpha SP 220
CHEVRON
NL Gear
Compound 100
NL Gear
Compound 150
NL Gear
Compound 220
ESSO
Spartan EP 100
Spartan EP 150
Spartan EP 220
FINA
Giran 150
Giran 220
GULF
EP Lubricant
HD 150
EP Lubricant
HD 220
TEXACO
Meropa 150
Meropa 220
TOTAL
Carter EP 150
Carter EP 220
Description
KLBER
Unimoly Oil 100
Unimoly Oil 150
Unimoly Oil 220
ELF
Reductelf SP 100
Reductelf SP 150
Reductelf SP 220
Renep
Compound 106
FUCHS
AGIP
Blasia 100
Blasia 150
Blasia 220
DEA
Falcon 100
Falcon 150
Falcon 220
PANOLIN
BG 36 / 2009
Mecano ISO 220
10 - 4
LUBRICANTS / TABLES
10.1.3.2
List of Approved Gear Oils, Petroleum API
Application
Specification
DIN 51502
Gear oil,
petroleum
API GL-5 /
MIL-L-2105 B
Viscosity grade
SAE / DIN 51511
Producer
SAE 90
SAE 85W-90
Description
ARAL
Gear oil HYP 90
SHELL
Shell Spirax MB 90
BP
Energear Hypo 90
MOBIL
Mobilube HD-A 90
AVIA
AVIA
HYPOID 90 EP
CASTROL
Castrol EPX 90
CHEVRON
ESSO
ESSO GEAR OIL

GX-D 90
FINA
GULF
Gear oil HYP

SAE 85W-90
Energear
Hypo 85W-90
Mobilube
HD 85W-90
RPM Universal
Gear Lubricants
SAE 80W-90
ESSO GEAR OIL
GX-D 85W-90
FINA PONTONIC
MP 85W-90
Gulf Multi-Purpose
Gear Lubricant
SAE 90
TEXACO
TOTAL
KLBER
ELF
FUCHS
AGIP
DEA
PANOLIN
BG 36 / 2009
Fuchs Titan Gear

Hypoid 90
TRANSELF
TYP B SAE 90
Fuchs Titan Gear
8090 MC
Agip Rotra MP
Daegear EP-B
SAE 85W90
Panolin Super Duty Panolin Super Duty
SAE 80W-90
SAE 90
10 - 5
LUBRICANTS / TABLES
10.1.3.3
List of Approved Gear Oils, Petroleum ATF
Application
Specification
DIN 51502
Gear oil,
petroleum
Dexron II D
Viscosity grade
Producer
Description
*At 40 C:
38 mm2/s
at 100 C:
7.1 mm2/s
ARAL
ATF 22
SHELL
Donax TA
BP
Autran DX II
MOBIL
ATF 220
AVIA
AVIAFLUID
ATF 86
CASTROL
CHEVRON
ESSO
FINA
Finamatic II D
GULF
TEXACO
Texamatic
TOTAL
Totalfluid ATX
KLBER
ELF
FUCHS
AGIP
DEA
PANOLIN
BG 36 / 2009
10 - 6
LUBRICANTS / TABLES
10.1.3.4
List of Approved Gear Oils, Synthetic CLP PG
Application
Specification
DIN 51517/
DIN 51502
Gear oil,
synthetic
CLP PG
Viscosity grade
Producer
VG 100
VG 150
VG 220
Description
ARAL
ARAL Degol
GS 150
ARAL Degol
GS 220
SHELL
SHELL Tivela WA
SHELL Tivela WB
BP
BP Enersym
SG-XP 150
BP Enersym
SG-XP 220
MOBIL
Mobil Glygoyle 22
Mobil Glygoyle 30
AVIA
Avilub VSG 150
Avilub VSG 220
CASTROL
CHEVRON
Circulation oil
220
ESSO
FINA
GULF
TEXACO
TOTAL
KLBER
Klbersynth
GH 4-150
Klbersynth
GH 4-220
ELF
Syntherma P 270
FUCHS
Renodiol PGP 220
AGIP
DEA
PANOLIN
BG 36 / 2009
10 - 7
LUBRICANTS / TABLES
10.1.3.5
List of Approved Gear Oils, Synthetic CLP HC
Table of gear oils, synthetic CLP HC

Application
Specification
DIN 51517
Gear oil,
synthetic
CLP HC
Viscosity grade
Producer
VG 100
VG 150
VG 220
Description
ARAL
AVIA
ARAL Degol
PAS 100
AVIA Synthogear
EP 100
ARAL Degol
PAS 150
AVIA Synthogear
EP 150
BP Enersyn
EP-XF 150
ARAL Degol
PAS 220
AVIA Synthogear
EP 220
BP Enersyn
EP-XF 220
Tribol 1710 / 100
Tribol 1710 / 150
Tribol 1710 / 220
BP
CASTROL
DEA
Intor HCLP 150
ESSO
FUCHS
Renolin Unisyn
CLP 100
KLBER
MOBIL
Renolin Unisyn
CLP 150
Klbersynth
EG 4-150
Mobilgear
SHC XMP 150
OPTIMOL
SHELL OMALA
HD 150
Pinnacle
EP 150
SHELL
TEXACO
TOTAL
TRIBOL
BG 36 / 2009
Intor HCLP 220

Spartan Synthetic
EP 220
Renolin Unisyn
CLP 220
Klbersynth
EG 4-220
Mobilgear
SHC XMP 220
Optigear Synth
A 220
SHELL Omala
HD 220
Pinnacle
EP 220
Carter EP/HAT 150 Carter EP/HAT 220

Tribol 1710 / 100
Tribol 1710 / 150
Tribol 1710 / 220
10 - 8
LUBRICANTS / TABLES
10.1.3.6
List of Approved Hydraulic Oils, Petroleum HVLP(D)
List of hydraulic oils, petroleum HVLP(D)

Application
Specification
DIN 51524/
DIN 51502
Hydraulic oil,
petroleum
HVLP(D)
Viscosity grade
Producer
VG 32
VG 46
VG 68
Description
AGIP
Agip Arnica 32
ARAL
ARAL Vitam HF 32 ARAL Vitam VF 46
ARAL Vitam VF 68
AVIA
Avia Fluid HVI 32 /

Avia Arctic 32
Avia Fluid HVI 46 /

Avia Arctic 46
Avia Fluid HVI 68 /

Avia Arctic 68
BP
BP Bartran V 32
BP Bartran V 46
BP Bartran HV 68
CASTROL
Hyspin AWH-M 32
Hyspin AWH-M 46
Hyspin AWH-M 68
CHEVRON
Mechanism LPS 32 Mechanism LPS 46 Mechanism LPS 68
DEA
Astron Z HLP 32
Astron Z HLP 46
Astron Z HLP 68
ELF
Hydrelf DS 32
Hydrelf DS 46
Hydrelf DS 68
ESSO
Univis N 32
Univis N 46
Univis N 68
FINA
Hydran HV 32
Hydran HV 46
Hydran HV 68
FUCHS
Renolin MR 32 MC Renolin MR 1025 MC Renolin MR 68 MC
MOBIL
Mobil DTE 13 M
Mobil DTE 15 M
Mobil DTE 16 M
Q8
Q8 Handel 32
Q8 Handel 46
Q8 Handel 68
SHELL
SHELL
Tellus Oil T32
SHELL
TELLUS OIL TD46
SHELL
TELLUS OIL T68
TEXACO
Rando HD-Z 32
Rando HD-Z 46
Rando HD-Z 68
TOTAL
Equivis ZS 32
Equivis ZS 46
Equivis ZS 68
BG 36 / 2009
Agip Arnica 46
Agip Arnica 68
10 - 9
LUBRICANTS / TABLES
10.1.3.7
List of Approved Hydraulic Oils, Fixed HEES - Unsaturated Esters
Application
Specification
Hydraulic fluid
organic
HEES
Viscosity grade
Producer
VG 46
VG 68
Description
ARAL
SHELL
Aral Vitam EHF 46

SHELL
NATURELLE
HF-E 46
BP
MOBIL
Mobil
EAL Syndraulik 46
AVIA
CASTROL
CHEVRON
ESSO
FINA
Univis
HEES 46
FINA BIOHYDRAN
TMP 46
GULF
TEXACO
TOTAL
TOTAL
Biohydran TMP 46
KLBER
ELF
FUCHS
Plantohyd
S 46
AGIP
Agip ARNICA S46
DEA
PANOLIN
CAUTION
BG 36 / 2009

Oils from different producers must not be mixed with one another.
10 - 10
LUBRICANTS / TABLES
10.1.3.8
List of Approved Hydraulic Oils, Fixed HEES - Saturated Ester
Application
Specification
Hydraulic fluid
organic
HEES
Viscosity grade
Producer
VG 46
VG 68
Description
ARAL
SHELL
BP
Biohyd SE-S 46
MOBIL
AVIA
Avia
Syntofluid N 46
CASTROL
CHEVRON
ESSO
FINA
GULF
TEXACO
TOTAL
TOTAL
Biohydran SE 46
KLBER
ELF
FUCHS
Plantosyn
46 HVI
AGIP
DEA
Econa E 46
PANOLIN
HLP Synth 46
CAUTION
BG 36 / 2009

Oils from different producers must not be mixed with one another.
10 - 11
LUBRICANTS / TABLES
10.1.3.9
List of Approved Engine Oils API CI-4
Application
Specification
DIN 51502
Engine oil
API CI-4
Viscosity grade
SAE / DIN 51511
Producer
SAE 5W-40
SAE 10W-40
SAE 15W-40
Description
AGIP
ARAL
AVIA
Aral Plus Turboral

SAE 15W-40
Avia Multi HDC Plus
SAE 15W-40
BP
CASTROL
CHEVRON
Chevron Delo 400

Multigrade SAE 15W-40
DEA
ELF
ESSO
FINA
FUCHS
GULF
Fina Universal Plus XL

SAE 15W-40
Titan Truck Plus
SAE 15W-40
Gulf Super Duty Select
SAE 15W-40
KLBER
MOBIL
Mobil Delvac MX 15W-40
PANOLIN
Q8
SHELL
Q8 T 750 SAE 15W-40

Shell Rimula Super
15W-40
TEXACO
TOTAL
BG 36 / 2009
10 - 12
LUBRICANTS / TABLES
10.1.3.10 List of Approved Engine Oils, Synthetic API CF

Table Engine oils, synthetic API CF
Application
Specification
DIN 51502
Synthetic engine oils
API CF /
MIL-L-2104 C/D
Viscosity grade
SAE / DIN 51511
Producer
SAE 5W-40
SAE 10W-40
SAE 15W-40
Product
ARAL
SHELL
BP
MOBIL
Aral Extra Turboral

SAE 10W-40
MYRINA
TX SAE 10W-40
Vanellus HAT
ESSO
Mobil Delvac 1310

AVIA TURBO
SYNTH HAT-E
10W-40
Castrol RX Super
15W-40
Chevron RPM
Heavy Duty
Motor oil
SAE 10W-40
Essolube XTS 301
FINA
Fina Kappa FE
AVIA
CASTROL
CHEVRON
GULF
TEXACO
TOTAL
KLBER
ELF
FUCHS
AGIP
DEA
PANOLIN
BG 36 / 2009
ELF ECOMAX
FE PLUS 10W-40
Titan Unic 1040
MC
Agip Sigma
Super TFE
Premium XL
SAE 10W-40
PANOLIN
UNIVERSAL SFE
LC
SAE 10W-40
10 - 13
LUBRICANTS / TABLES
10.1.3.11 List of Approved Engine Oils, Petroleum API CH-4
Application
Specification
DIN 51502
Petroleum
engine oils
API CH-4
Viscosity grade
SAE / DIN 51511
Producer
SAE 5W-40
SAE 10W-40
SAE 15W-40
Description
ARAL
SHELL
BP
MOBIL
AVIA
CASTROL
CHEVRON
ESSO
FINA
GULF
TEXACO
TOTAL
KLBER
ELF
FUCHS
AGIP
DEA
PANOLIN
BG 36 / 2009
Aral Plus Turboral

SAE 15W-40
Rimula Super
SAE 15W-40
Vanellus C3 Extra
Delvac MX
15W-40
Multi HDC Plus
15W-40
Tection
15W-40
Delo 400
SAE 15W-40
Essolube XT 401
Kappa Extra Plus
15W-40
-Ursa Super LA
15W-40
Rubia Tir 6400
15W-40
-Performance
Trophy DK
15W-40
Titan Universal HD
SAE 15W-40
Blitum T
15W-40
Cronos Super TDL
SAE 15W-40
Dyna-Plex 21C
SAE 15W-40
10 - 14
LUBRICANTS / TABLES
10.1.3.12 List of Approved Greases, Petroleum KP2N
Application
Specification
DIN 51502
Petroleum
greases
KP2N-20
Description
Producer
Description
Multipurpose
grease
on
lithium soap base
ARAL
Aralub HLP 2
SHELL
Retinax EP 2
Energrease
LS-EP 2
Mobilux EP 2
BP
MOBIL
AVIA
CASTROL
CHEVRON
ESSO
Beacon EP 2
FINA
Marson EPL 2A
GULF
TEXACO
TOTAL
KLBER
ELF
Epexa 2
FUCHS
Renolit MP
AGIP
Agip GR MUEP 2
DEA
Glissando EP 2
PANOLIN
EP Grease 2
BG 36 / 2009
10 - 15
LUBRICANTS / TABLES
10.2
OPERATING FLUID
10.2.1 Cooling Fluid

Adding Coolant and Checking the Radiator
Risk of damage to the cooling system and the engine caused by silting
or gelling of the coolant!
CAUTION
BG 36 / 2009
Use only CAT ELCTM (Caterpillar Extended Life Coolant).

Do not mix different coolants.
Do not add any additives.
Observe the supplementary documentation provided by the coolant
manufacturer.
10 - 16
LUBRICANTS / TABLES
10.3
BOLT TORQUE VALUES
CAUTION
Bolt torque values given in the following tables are valid only for slightly
oiled bolted connections and where the Spare Parts List does not prescribe other torque values.
10.3.1 Bolts with Coarse-Pitch Metric Thread

Strength class as per DIN/ISO 898
8.8
Coarse-pitch
metric thread
M4
M5
M6
M8
M 10
M 12
M 14
M 16
M 18
M 20
M 22
M 24
M 27
M 30
M 33
M 36
BG 36 / 2009
10.9
12.9
Bolt torque values MA [Nm]

2.8
5.5
9.5
23
46
79
125
195
280
390
530
670
1000
1350
1850
2350
4.1
8.1
14
34
68
117
185
280
390
560
750
960
1400
1900
2600
3300
4.8
9.5
16.5
40
79
135
215
330
460
650
880
1120
1650
2250
3000
3900
10 - 17
LUBRICANTS / TABLES
10.3.2 Bolts with Fine-Pitch Metric Thread

Strength classes as per DIN/ISO 898
8.8
Fine-pitch
metric thread
M 8x1
M 10x1
M 10x1.25
M 12x1.25
M 12x1.5
M 14x1.5
M 16x1.5
M 18x1.5
M 20x1.5
M 22x1.5
M 24x2
M 27x2
M 30x2
M 33x2
M 36x3
BG 36 / 2009
10.9
12.9
Bolt torque values MA [Nm]

24.5
52
49
87
83
135
205
310
430
580
730
1070
1490
2000
2500
36
76
72
125
122
200
300
440
620
820
1040
1500
2120
2800
3500
43
89
84
150
145
235
360
520
720
960
1220
1800
2480
3300
4100
10 - 18
LUBRICANTS / TABLES
10.4
CONVERSION TABLE
Measures for power
N
dyn
105
1
9.81105
9.81108
981
1
10-5
9.81
9.81103
9.8110-3
kp
Mp
1.0210-4
1.0210-9
10-3
0.102
1.0210-4
1
103
10-3
102
1.0210-2
103
106
1
1
10-6
Measures for energy and operating efficiency

J
1
10-7
9.81
3.60106
4187
1.610-19
erg
107
1
9.8110-7
3.601013
4.191010
1.610-12
kpm
0.102
1.0210-8
1
3.67105
427
1.6310-20
kWh
kcal
2.7810-7
2.7810-14
2.7210-6
2.3910-4
2.3910-11
2.3410-3
1
1.1610-3
4.4510-26
860
1
3.8310-23
ev
6.241018
6.241011
6.121019
2.251025
2.611022
1
Measures for output

W
1
103
981
735.5
4187
1.16
kW
10-3
1
9.8110-3
0.7355
4.19
1.610-3
kpm/s
0.102
102
1
75
427
0.119
PS
1.3610-3
1.36
1.3310-2
1
5.69
1.5810-3
kcal/s
2.3910-4
0.239
2.3410-3
0.1757
1
2.7810-4
kcal/h
0.86
860
8.43
632
3600
1
Measures for pressure

at
atm
1
1.033
1.02
1.0210-5
1.3610-3
0.968
1
0.987
9.8710-6
1.3210-3
0.070
0.0680
bar
0.981
1.0133
1
10-5
1.3310-3
0.0689
N/m2
98100
101330
105
1
133
0.145
Torr
736
760
750
7510-4
1
51.72
Psi
14.22
14.69
14.5
14.510-5
19.2810-3
1
Measures for length

in
ft
yd
1
12
36
0.03937
39.37
39370
0.08333
1
3
328110-6
0.02778
0.3333
1
109410-6
3.281
3281
1.094
1094
BG 36 / 2009
mm
25.4
304.8
914.4
1
1000
106
m
0.0254
0.3048
0.9144
0.001
1
1000
km
10-6
0.001
1
10 - 19

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Bu kullanm klavuzunda kullanlan dili anlayamadnz taktirde, cihaz / sistem

+49 8252 97-2586

+49 8252 97-2586

+49 8252 97-2586

The "Instruction Manual" was written and published by

ROTARY DRIVE SPECIFICATIONS .................................................................................... 3 - 4

CONTROLS AND INDICATORS...........................................................................................4 - 1

Operating the Kelly Drilling Assistant ...................................................................................5 - 23

RIGGING / DE-RIGGING .......................................................................................................7 - 1

* not used in this version

ABOUT THE MANUAL

THIS MANUAL WAS PUBLISHED IN

THE CHAPTERS OF THIS MANUAL

SYMBOLS USED IN THIS MANUAL

"Note" is used to highlight an operation, assembly or maintenance

Beside cab door

Bauer Maschinen GmbH

AFTER SALES SERVICE

How to reach the Service Centre

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+49 8252 97-2587

The contractual agreement is principally decisive for the warranty