Professional Documents
Culture Documents
Bauer BG20H
Bauer BG20H
BG 20H
BI647510.wmf
This manual has been made for operators and maintenance personnel.
They must be kept with the equipment and be accessible at all times!
In the Instruction Manual you will find a detailed description of the equipment, guide-
lines for transporting and putting into operation, comprehensive instructions for operat-
ing and troubleshooting and information on service and maintenance.
Technical data, dimensions and weights relate to the date of print of the manual. They
may differ slightly to those on your version of equipment, although only in some details
so that the factual information of the manual is still relevant and pertinent.
Any deviations from texts, drawings or photographs will be due to options with which
your equipment is fitted, and can consequently not form grounds for complaint.
The equipment shall be used only for the purposes specified in this manual.
As you will understand, the manufacturer of the equipment cannot be held responsible
for any damage caused by misuse, abuse or neglect.
The Safety Information Book supplied with this equipment comprises instructions and
regulations for the safe handling of this type of equipment and must be observed by all
means.
Also to be observed are the documents for components found in the appendices of this
manual and also all other documents supplied with the equipment.
© Publisher’s copyright:
No part of this manual may be reproduced or translated or made available to third
parties without the express permission from the publisher.
BG 20H/2005 I
TABLE OF CONTENTS
INTRODUCTION............................................................................................................................................I
TABLE OF CONTENTS................................................................................................................................II
NAMEPLATES ............................................................................................................................................ IX
1 DESCRIPTION .......................................................................................................................1 - 1
1.1 EQUIPMENT APPLICATIONS ...............................................................................................1 - 1
1.2 COMPONENTS......................................................................................................................1 - 2
1.2.1 Basic Rig / Kelly Equipment....................................................................................................1 - 2
1.2.1.1 Components Overview ...........................................................................................................1 - 2
1.2.1.2 Components Description ........................................................................................................1 - 3
2 SAFETY..................................................................................................................................2 - 1
2.1 GENERAL SAFETY REQUIREMENTS .................................................................................2 - 1
2.2 EQUIPMENT SAFETY ...........................................................................................................2 - 1
2.3 MAJOR HAZARDS.................................................................................................................2 - 1
2.4 SAFETY DEVICES .................................................................................................................2 - 2
2.4.1 Emergency Stop .....................................................................................................................2 - 2
2.4.2 Pilot Control Safety Stick ........................................................................................................2 - 2
2.4.3 Fire Extinguisher.....................................................................................................................2 - 2
2.4.4 Medical Box ............................................................................................................................2 - 3
2.4.5 Emergency Exit.......................................................................................................................2 - 3
2.4.6 Limit switches .........................................................................................................................2 - 4
2.5 STABILITY..............................................................................................................................2 - 5
2.5.1 Guidelines for Stability ............................................................................................................2 - 5
2.5.2 Load Capacity Chart with Kelly Equipment.............................................................................2 - 6
2.6 PERMISSIBLE WIND SPEED................................................................................................2 - 7
3 TECHNICAL SPECIFICATIONS............................................................................................3 - 1
3.1 DIMENSIONS .........................................................................................................................3 - 1
3.1.1 Kelly Equipment BK 18/368/4/50 ............................................................................................3 - 1
3.2 EQUIPMENT SPECIFICATIONS ...........................................................................................3 - 2
BG 20H/2005 II
3.3 ROTARY DRIVE SPECIFICATIONS......................................................................................3 - 4
3.3.1 Rotary Drive, Shiftable............................................................................................................3 - 4
3.4 DRILLING SPECIFICATIONS ................................................................................................3 - 5
3.4.1 Kelly equipment ......................................................................................................................3 - 5
3.5 ROPE SPECIFICATIONS ......................................................................................................3 - 6
3.5.1 Main Rope ..............................................................................................................................3 - 6
3.5.2 Auxiliary Rope.........................................................................................................................3 - 7
3.6 NOISE EMISSION ..................................................................................................................3 - 8
3.7 TEMPERATURE CONDITIONS.............................................................................................3 - 8
3.8 EXPOSURE TO VIBRATION .................................................................................................3 - 8
5 OPERATION ..........................................................................................................................5 - 1
5.1 TRAVEL..................................................................................................................................5 - 1
5.1.1 To Travel and Steer................................................................................................................5 - 1
5.2 UPPERCARRIAGE SWING ...................................................................................................5 - 2
5.2.1 Swing Brake............................................................................................................................5 - 2
5.2.2 Swing Control .........................................................................................................................5 - 2
5.3 MAST REPOSITIONING ........................................................................................................5 - 3
5.3.1 Mast Auto Reset to Vertical ....................................................................................................5 - 3
5.3.2 Mast Repositioning by Manual Control ...................................................................................5 - 4
5.3.2.1 To Adjust the Mast Inclination ................................................................................................5 - 4
5.3.2.2 To Adjust the Drill Distance ....................................................................................................5 - 5
5.4 MAST PROP CONTROL (OPTIONAL) ..................................................................................5 - 6
5.5 TRAVELLING WITH THE RIG ...............................................................................................5 - 6
5.5.1 Travelling over Level Ground..................................................................................................5 - 6
5.5.2 Travelling Up and Down Slopes .............................................................................................5 - 7
5.5.2.1 With Raised Mast without Drilling Equipment.........................................................................5 - 7
5.5.2.2 With Lowered Mast.................................................................................................................5 - 7
5.5.3 Lowering and Raising the Mast with Kelly equipment ............................................................5 - 8
5.5.3.1 Lowering the Mast - with Kelly ................................................................................................5 - 8
5.5.3.2 Raising the Mast - with Kelly...................................................................................................5 - 9
5.6 ROTARY DRIVE CONTROL ................................................................................................5 - 10
5.6.1 Kelly Application....................................................................................................................5 - 10
5.7 WINCH CONTROL...............................................................................................................5 - 12
5.7.1 Lifting / Lowering...................................................................................................................5 - 12
5.7.2 To Operate with Free-Fall.....................................................................................................5 - 13
5.8 DEPTH MEASURING CONTROL ........................................................................................5 - 14
5.8.1 To Reset the Depth Measuring.............................................................................................5 - 14
BG 20H/2005 III
5.9 CROWD CONTROL.............................................................................................................5 - 15
5.9.1 Manual Control of the Crowd ................................................................................................5 - 15
5.9.2 To Use the Main Winch in Combination with Crowd ............................................................5 - 16
BG 20H/2005 IV
8 TRANSPORT .........................................................................................................................8 - 1
8.1 SAFETY GUIDELINES FOR TRANSPORT ...........................................................................8 - 1
8.2 MEASURES TO TAKE FOR TRANSPORT ...........................................................................8 - 2
8.3 DRIVING ON / OFF A LOWLOADER ....................................................................................8 - 3
8.4 LIFTING POINTS ...................................................................................................................8 - 4
8.5 TRANSPORT DATA...............................................................................................................8 - 5
8.6 TYING DOWN ........................................................................................................................8 - 7
9 MAINTENANCE .....................................................................................................................9 - 1
9.1 SAFETY GUIDELINES FOR MAINTENANCE .......................................................................9 - 1
9.2 MAINTENANCE INTERVALS ................................................................................................9 - 1
9.3 MAINTENANCE PLAN ...........................................................................................................9 - 2
9.3.1 Entire Equipment ....................................................................................................................9 - 2
9.3.2 Components ...........................................................................................................................9 - 3
9.3.3 Work Equipment.....................................................................................................................9 - 6
9.3.4 Uppercarriage.........................................................................................................................9 - 7
9.3.5 Undercarriage.........................................................................................................................9 - 8
9.3.6 Optional Equipment ................................................................................................................9 - 9
9.4 MAINTENANCE DURING LONGER PERIODS OF STANDSTILL......................................9 - 10
9.5 LUBRICATION PLAN ...........................................................................................................9 - 11
9.6 HYDRAULIC SYSTEM .........................................................................................................9 - 12
9.6.1 Hose Assemblies..................................................................................................................9 - 12
9.6.2 Hydraulic Cylinders ...............................................................................................................9 - 13
9.6.3 Filter Replacement ...............................................................................................................9 - 14
9.6.3.1 Replacing the Line Filters .....................................................................................................9 - 14
9.7 WINCHES.............................................................................................................................9 - 15
9.7.1 Checking the Oil Level..........................................................................................................9 - 15
9.7.2 Changing Gear Oil ................................................................................................................9 - 16
9.8 WIRE ROPE ACCESSORIES ..............................................................................................9 - 17
9.8.1 Rope Swivel..........................................................................................................................9 - 17
9.8.2 Rope Hold-Down Rollers ......................................................................................................9 - 17
9.8.3 Rope Fasteners, Thimbles and Sockets ..............................................................................9 - 18
9.8.4 Rope Sheaves ......................................................................................................................9 - 19
9.8.4.2 Greasing Rope Sheaves ......................................................................................................9 - 19
9.8.4.2 Checking Rope Sheaves ......................................................................................................9 - 20
9.9 ROTARY DRIVE...................................................................................................................9 - 21
9.9.1 Routine Inspection ................................................................................................................9 - 21
9.9.2 Checking the Oil Level..........................................................................................................9 - 22
9.9.2.1 Main Gear .............................................................................................................................9 - 22
9.9.3 Changing the Oil ...................................................................................................................9 - 23
9.9.4 Oil Sampling .........................................................................................................................9 - 26
9.9.5 Hollow Shaft Mounting Bolts.................................................................................................9 - 27
BG 20H/2005 V
9.9.6 Kelly Driver and Guide Flange..............................................................................................9 - 28
9.9.6.1 Checking the Mounting Bolts................................................................................................9 - 28
9.9.6.2 Checking Driver Strips for Wear...........................................................................................9 - 29
9.9.7 Cardan Joint .........................................................................................................................9 - 30
9.9.8 Sledge Sliding Strips.............................................................................................................9 - 30
9.10 CRAWLER TRACK ASSEMBLIES.......................................................................................9 - 31
9.10.1 Routine Inspection ................................................................................................................9 - 31
9.10.2 Crawler Tracks .....................................................................................................................9 - 32
9.10.2.1 To Check the Track Tension ................................................................................................9 - 32
9.10.2.2 Adjusting Crawler Track Tension .........................................................................................9 - 32
9.10.3 Checking Mounting Bolts ......................................................................................................9 - 34
9.10.4 Crawler Drive Gears .............................................................................................................9 - 35
9.10.4.1 Checking the Oil Level..........................................................................................................9 - 35
9.10.4.2 Changing the Oil ...................................................................................................................9 - 35
9.11 CENTRAL LUBRICATION SYSTEM (OPTIONAL) ..............................................................9 - 36
9.12 BOLTED CONNECTIONS....................................................................................................9 - 37
BG 20H/2005 VI
ABOUT THE MANUAL
Certification: CE
10.2005
1 DESCRIPTION
2 SAFETY
3 TECHNICAL SPECIFICATIONS
4 CONTROLS AND INDICATORS
5 OPERATION
6 START-UP / SHUT-DOWN
7 RIGGING / DERIGGING
8 TRANSPORT
9 MAINTENANCE
10 LUBRICANTS / TABLES
11 EXTRA EQUIPMENT (OPTIONAL)
APPENDICES
G:\...\0000394886_en_BG20H_718
BG 20H/2005 VII
SYMBOLS USED IN THIS MANUAL
DANGER!
WARNING!
BG 20H/2005 VIII
NAMEPLATES
Gerätetyp Trägergerät
type base carrier
nächste Prüfung Baujahr Bau - Nr. Inv. - Nr.
year of manufacture serial No Inv. No
Rückzugkraft Vorschubkraft
1 kN kN
12 2 pulling force pushing power
91011
345
2001 max. Druck Betriebsdruck
max. pressure
bar working pressure
bar
678
Gesamtgewicht Arbeitspannung
total weight
kg working voltage
V
Sachkundigenprüfung CE - Zeichen Motorleistung Frequenz
expert test CE sign engine power
kW frequency
Hz
B0000551.wmf
BG 20H/2005 IX
AFTER SALES SERVICE
Whenever you consult the Service Centre, please give the following in-
formation so 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:
Description of site
- Name of site:
- Address (post code, town, street):
- Route description for a mechanic (as necessary):
BG 20H/2005 X
WARRANTY TERMS
The warranty terms listed in the following apply to all equipment sold by the BAUER
company.
Þ Commencement: - The warranty comes officially into effect when the equip-
ment is put to the 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.
Þ Warranty terms - Original BAUER spare parts must be used throughout the
and conditions: warranty period.
- Components and operating systems must not be dis-
mantled 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 after
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 In-
struction Manual.
- Any work (servicing, repairs etc.) carried out on the equip-
ment must be recorded in the Maintenance and Repair Log
provided for this purpose with each item of equipment.
BG 20H/2005 XI
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 re-
NOTE deliveries will be paid by BAUER Maschinen GmbH (after sales
service).
- 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.
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 in-
formed 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.
BG 20H/2005 XII
To: BAUER Maschinen GmbH
After Sales Service Department
P.O. Box 12 60
86522 Schrobenhausen, Germany
Phone Germany + 82 52/97-25 86
Fax Germany + 82 52/97-25 87
Phone: Fax:
WARRANTY CLAIM
1. Product specifications
Equipment: Constr. no.: Constr. year: 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
Name of damaged part Material no. Construction no.
1 DESCRIPTION
The equipment is designed and intended for the following applications only:
Observance of the instruction manual and all the documents supplied with the equip-
ment is also considered part of the intended application.
Using the equipment in another or a further application than those stated here is not
permitted and will be considered misuse.
Hence it is strictly forbidden to use the equipment as a liftcrane or for grading jobs or as
a personal hoist.
The manufacturer does not assume any responsibility for damages resulting from mis-
use of the equipment.
BG 20H/2005 1-1
DESCRIPTION
1.2 COMPONENTS
1.2.1 Basic Rig / Kelly Equipment
Basic Rig 16
7
1 Boom 9
2 Boom cylinders
3 Swing mechanism
11
4 Crawler drives 21
5 Counterweight 31
33
6 Main winch
7 Main rope 32
8 Auxiliary winch
9 Auxiliary rope
10 Wedge*
11 Masthead tilting cylinder 13
12 Kinematic triangle
13 Mast (upper section / lower section)
46
14 Mast prop*
15 Mast pivot
16 Masthead
17 Mast extension (intermediate)* 30
18 Mast extension (lower)*
19 Backstay cylinders
20 Uppercarriage
21 Rope swivel 43/45
22 Crowd rope tensioning cylinder* 26
23 Supporting boom 41
24 Supporting trestle* 44 19
25 Undercarriage
15
26 Crowd sledge 42
12
27 Crowd ropes (upper / lower)*
28 Thrust rod*
29 Crowd winch* 2
8
30 Crowd cylinder 23
31 Mast extension (upper) 6
1 20
32 Mast extension tilting cylinder
33 Kelly guidance
Kelly equipment 40 5
40 Drilling tool 3
41 Rotary drive 25 4
42 Casing drive adapter
43 Shock absorber BI647511.wmf
44 Cardan joint
45 Kelly drivers
46 Kelly bar
*) does not exist with this version
BG 20H/2005 1-2
DESCRIPTION
BG 20H/2005 1-3
DESCRIPTION
BG 20H/2005 1-4
SAFETY
2 SAFETY
· 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.
The safety built into this equipment is state-of-the-art and complies with all EC requirements.
Equipped safety devices guarantee highest possible safety standard.
- In drilling applications, the equipment operates with rotating tools. Being caught by a
rotating part is mortal.
- 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 endangered. Exceeding the rig's capacity
or operating with faulty end-limiters can make the equipment fall violently causing
severe personal injury or even loss of life.
- Never remove equipped safety devices or render them out of order.
- Be observant of oil spills from the hydraulic system. If there is a spill, find the cause
and repair it. 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 in touch with components
containing coolant can cause burns.
- Engine, gear and hydraulic oils get very hot from operation. Touching a component
containing such an oil can cause burns.
- Be sure the equipment is properly shut down before you begin a maintenance, re-
pair or cleaning job on it: Set all controls to Off, stop the engine and set 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 20H/2005 2-1
SAFETY
In an emergency !!
Press the Emergency STOP button (1) !!
All equipment functions will promptly come
to a stop. 1 Emergency Stop
NOT-AUS
1.1
With the safety stick (1), the operator must
shut off the pilot control before leaving the 1.2
driver's seat. With the stick in the "Off"
position, all hydraulic functions are
blocked.
B0000796.wmf
BG 20H/2005 2-2
SAFETY
B0000562.wmf
BG582504.wmf
BG 20H/2005 2-3
SAFETY
Name Function
BG 20H/2005 2-4
SAFETY
2.5 STABILITY
2.5.1 Guidelines for Stability
Rig capacity charts are calculated in compliance with the European standard EN 791.
WARNING!
Pulling and pushing forces of the winches / crowd cylinder and the pre-
sent centre of gravity (position of the work attachments) are factors
which have additional influence on the rig’s stability.
NOTE The loads given in the capacity charts take into consideration the most
adverse position of the components.
BG 20H/2005 2-5
SAFETY
Kelly BK 18/368/4/50
Valid only for Mast extension 1.2 m 0.50 to
Kelly BK 18/368/4/50 7.50 to
Casing drive adapter Æ 1180 mm 1.20 to
Drilling tool Æ 1060 mm 1.30 to
Conditions for operation Crowd sledge stroke limiter mounted (max. stroke: 5600 mm)
B0000689.wmf Max permissible load [tonnes]
B0000691.wmf
B0000690.wmf Min drill distance*: m Max drill distance*: 3.80 m
Auxiliary
5.5
rope
Main
17.0
rope
Crowd 26.0
"= ° " = 5°
Auxiliary $= ° $ = 5°
5.5
rope (= ° ( = 0°
*= ° * = 90°
"= ° " = 5°
Main $= ° $ = 5°
17.0
rope (= ° ( = 15°
*= ° * = 90°
"= ° " = 5°
$= ° $ = 5°
Crowd 26.0
(= ° ( = 15°
*= ° * = 90°
"= ° " = 5°
Auxiliary
$= ° $ = 5° 5.5
rope
(= ° ( = 0°
"= ° " = 5°
Main
$= ° $ = 5° 17.0
rope
(= ° ( = 15°
"= ° " = 5°
Crowd $= ° $ = 5° 26.0
(= ° ( = 15°
BG 20H/2005 2-6
SAFETY
WARNING!
BG 20H/2005 2-7
TECHNICAL SPECIFICATIONS
3 TECHNICAL SPECIFICATIONS
3.1 DIMENSIONS
3.1.1 Kelly Equipment BK 18/368/4/50
Dimensions in [mm]
20998
18814
1200
18162
17611
15554
15900
9012
7574
5212
5600
900
2773
1974
1714
949
1225
0
4440
5360
3338 - 3794 R 3450
BI647512.wmf
BG 20H/2005 3-1
TECHNICAL SPECIFICATIONS
Base Machine
Uppercarriage
Type Hyundai R 305LC-7
Engine
Type Cummius 6CT8.3C
Output 190 kW
Speed 1900 rpm
Undercarriage
Type UW 65
Serial number --
Width over crawlers 3200 - 4400 mm
Length of crawlers 5358 mm
Width of track pads 700 mm
Mast Inclination
forward 5°
backward 15°
to left 5°
to right 5°
Operating Range
Working Weight
With:
BG 20H/2005 3-2
TECHNICAL SPECIFICATIONS
Main Winch
Type 66 WF 12/0
Serial number --
st
Pulling force (1 layer) 170 kN
Rope diameter 26 mm
Rope length 80 m
Rope speed 55 m/min
("lifting" with 10 kN load)
Auxiliary Winch
Crowd Cylinder
BG 20H/2005 3-3
TECHNICAL SPECIFICATIONS
Pth = 210 kW
Qth = 2 x 210 l/min
1st gear 1st gear with reduced torque
i = 132.94 i = 132.94
210 160
203
150
180
125
120
150
120
80
90
55
60
40
30
0 0
7 9 23 27 12 23 27
0 10 20 30 0 10 20 30
Drehzahl n [1/min] / Speed n [rpm] Drehzahl n [1/min] / Speed n [rpm]
BS647500.wmf BS647501.wmf
2nd gear
i = 60.8
Motor regulates 120
Pump regulates
K0000506.wmf 93
90
Drehmoment / Torque M [kNm]
77
30
29
25
0
16 58
0 10 20 30 40 50 60
Drehzahl n [1/min] / Speed n [rpm]
BS647502.wmf
BG 20H/2005 3-4
TECHNICAL SPECIFICATIONS
L1 Dimensions [mm]
L1 18163
L2 9012
L3 3412
A max. 14661
A Hd -
L2
Bore diameter [mm]
uncased 1500
cased 1200
Casing length
without CO Hw – 1.0 m
L3
Hd with CO Hw – 2.0 m
Hw
Notice: Drilling depth specifications are based on min. operating radius of mast.
With max. operating radius the drilling depth increases by 0.456 m.
BG 20H/2005 3-5
TECHNICAL SPECIFICATIONS
Ready-made length 80 m
Nominal diameter 26 mm
Permissible deviation +4%
Weight per meter 3.12 kg/m
Nominal wire strength 1960 N/mm2
Fill factor 0.653
Spinning loss factor 0.770
Nominal aggregate breaking load 680.20 kN
Minimum breaking load 519.50 kN
Diameter of outer wires 1.30 mm
Total metal cross section 347.00 mm2
Total number of wires 245
Number of load-bearing wires
(outer strands) 112
BG 20H/2005 3-6
TECHNICAL SPECIFICATIONS
Ready-made length 50 m
Nominal diameter 15 mm
Permissible deviation +4%
Weight per meter 1.072 kg/m
Nominal wire strength 1960.00 N/mm2
Fill factor 0.67
Spinning loss factor 0.75
Nominal aggregate breaking load 235.00 kN
Minimum breaking load 176.00 kN
Diameter of outer wires 0.80 mm
Total metal cross section 120.00 mm²
Total number of wires 189
Number of load-bearing wires
(outer strands) 105
BG 20H/2005 3-7
TECHNICAL SPECIFICATIONS
1. Inside Cab
2. Outside
The equipment can be used in outdoor temperatures ranging from -20° to +40° C
(– 4 to +104 F).
For use at temperatures outside the specified range the manufacturer must be con-
sulted.
The operator’s exposure to vibration acceleration during operation with this equipment
is less than 0.5 m/s².
BG 20H/2005 3-8
CONTROLS AND INDICATORS
4.1 CAB
1.1 2.1 3
11
5.7
9.5 13 12 5.5
9.1 5.1
10 4
1.2 2.2
9.3 9.4 5.3 5.4
9.2 5.2
9.6 5.6
5.8
8
7
6
BS756500.wmf
1.1 Left crawler travel forward 5.7 Rigging mode + Boom cylinders se-
1.2 Left crawler travel reverse lected: Boom cylinders retract
2.1 Right crawler travel forward 5.8 Rigging mode + Boom cylinders se-
2.2 Right crawler travel reverse lected: Boom cylinders extend
3 Free-fall / Freewheel release 6 Indication: Free-fall / Freewheel released
4 Horn On 7 Free-fall / Freewheel mode On / Off
5.1 Crowd down 8 Emergency STOP
5.2 Crowd up 9.1 Winch 1/2 down
5.3 In Kelly / CFA mode: 9.2 Winch 1/2 up
Rotary drive rotate right 9.3 Uppercarriage swing to left
5.4 In Kelly / CFA mode: 9.4 Uppercarriage swing to right
Rotary drive rotate left 9.5 Rigging mode + Backstay cylinders
5.5 Rigging mode + Backstay cylinders selected: Left backstay cylinder extend
selected: Right backstay cylinder extend 9.6 Rigging mode + Backstay cylinders
5.6 Rigging mode + Backstay cylinders selected: Left backstay cylinder retract
selected: Right backstay cylinder retract 10 Free-fall / Freewheel release
11 Pilot control On / Off
12 Crowd fast mode On
13 Not used
BG 20H/2005 4-1
CONTROLS AND INDICATORS
1 2 3 4 5 6 7 15 16 17 18 19 20 21
8 9 10 11 12 13 14 22 23 24 25 26 27 28
BI647503.wmf
BG 20H/2005 4-2
CONTROLS AND INDICATORS
1 2 3 4 5 6 7 8
-0.0 1 0.0 t
2 0.0 t
0.0
0.0 bar
Depth: +0.00m 0
-
7 8 9
+
. 4 5 6
Depth 1
D=0 AT Depth 2
Cal 0 1 2 3
14 13 12 11 10 9
BI054502.wmf
BG 20H/2005 4-3
OPERATION
5 OPERATION
5.1 TRAVEL
5.1.1 To Travel and Steer
B0000552.wmf
BG 20H/2005 5-1
OPERATION
The swing brake serves to arrest the uppercarriage against rotation during operation.
BI647504.wmf
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 opposed direc-
tion.
BG 20H/2005 5-2
OPERATION
AT
· Press button and hold on.
The mast will first set to vertical position in the X axis and then, after a
pause, in the Y axis.
NOTE
BG 20H/2005 5-3
OPERATION
- In Drilling Mode
The rigging mode switch (1) on the control panel is not
selected:
· Extend left backstay cylinder by button (6) on the control
panel.
· Extend right backstay cylinder by button (7) on the control
panel.
· Retract left backstay cylinder by button (13) on the control
panel.
· Retract right backstay cylinder by button (14) on the con-
trol panel.
- In Rigging Mode
Rigging mode switch (1) on the control panel is selected:
· Select backstay cylinder operation by switch (3) on the
control panel.
B0000570.wmf
Lowering the mast:
· Move left / right control lever back
1 2 3 4 5 6 7 15 16 17 18 19 20 21
8 9 10 11 12 13 14 22 23 24 25 26 27 28
BI647503.wmf
BG 20H/2005 5-4
OPERATION
- In Drilling Mode
The rigging mode switch (1) on the control panel is not
selected.
Increasing the machine’s distance to the bore:
· Retract boom cylinders.
- In Rigging Mode
Rigging mode switch (1) on the control panel is selected.
· Select boom cylinder operation.
1 2 3 4 5 6 7 15 16 17 18 19 20 21
8 9 10 11 12 13 14 22 23 24 25 26 27 28
BI647503.wmf
BG 20H/2005 5-5
OPERATION
The mast prop must be fully extended when strong forces result from the extraction of
the tool.
1 2 3 4 5 6 7 15 16 17 18 19 20 21
8 9 10 11 12 13 14 22 23 24 25 26 27 28
BS756501.wmf
BG 20H/2005 5-6
OPERATION
Tipping hazard!
Observe all instructions found in sect. "Travelling over level ground"!
CAUTION
Tipping hazard!
Max. permissible gradient is 6°.
Travel straight to the grade only. Never zigzag or traverse!
CAUTION
Tipping hazard!
Observe all instructions found in sect. "Travelling over level ground"!
CAUTION
Tipping hazard!
Max. permissible gradient is 15°.
Travel straight to the grade only. Never zigzag or traverse!
CAUTION
B0000536.wmf
BG 20H/2005 5-7
OPERATION
BG440504.wmf
BG440505.wmf
· Unspool sufficient length of rope
6
from main-/auxiliary winch to allow
the mast lay down on the uppercar-
riage. 1m
BG 20H/2005 5-8
OPERATION
Initial situation:
BG440507.wmf
BG440509.wmf
· Extend backstay cylinders (4) com-
pletely.
BG440510.wmf
BG 20H/2005 5-9
OPERATION
11
5.7
15 16 17 18 19 20 21 9.5 13 12 5.5
9.1 5.1
10 4
1.2 2.2
9.3 9.4 5.3 5.4
22 23 24 25 26 27 28 9.2 5.2
9.6 5.6
5.8
8
7
6
BI647506.wmf BS756500.wmf
The operator's manual control of the rotary drive is the right four-way lever. Selection
and indication of the modes in which the rotary drive can be operated are as follows.
Pushing the buttons (15), (16) or (17) on Shifting to "Fast" speed makes rotary
the control panel shifts the torque mode drive rotate with max. revolutions under
between low, middle and high - the lamp no load. The higher the load and required
of the chosen button glows. torque the lower the speed - down to min.
speed at max. torque.
Shifting to "Slow" speed puts rotary drive
instantly into "High" torque, and lamp (23)
stops glowing.
BG 20H/2005 5 - 10
OPERATION
Shifting the torques is allowed only when the rotary drive isn’t in motion
and the drilling tool not in touch with the borehole bottom!
CAUTION
Only kelly bars capable of transmitting the "High" torque of the rotary drive may be used
in the High torque mode. Know the max. permissible torque of your kelly before you
begin or your kelly could get damaged.
When the kelly bars used are not designed for the torque of the rotary drive, the key-
operated switch (1) in the control cabinet must be turned to position of "High Torque
OFF" to prevent damage to the kelly.
High Torque
OFF ON
1
BS628500.wmf
With the key-operated switch (1) set to "OFF" in the control cabinet,
the 1st gear of high torque is automatically blocked. And button (17)
NOTE on the control panel is out of function.
BG 20H/2005 5 - 11
OPERATION
The rigging mode switch (1) on the control The rigging mode switch (1) on the control
panel is not selected: panel is selected:
Winch selection:
· Set switch (2) on the control panel for Main winch or for Auxiliary winch.
B0000702.wmf
BG 20H/2005 5 - 12
OPERATION
1.1 2.1 3
Mode selection:
· Select mode with the key- 11
operated switch (7): 9.5 13
5.7
12 5.5
9.1 5.1
10 4
Free-fall mode "On": 9.3 9.4
1.2 2.2
5.3 5.4
"Free-fall" activation:
· Set key-operated switch (7) to position of Free-fall mode "On".
· Press button (10) and hold on.
· At the same time, press pedal (3) all the way down and then slowly let it go.
Þ free-fall is on !
Indicator light (6) glows. Button (10) can be released.
· Regulate the free-fall speed with pedal (3): The more the pedal is pressed the lower
the speed of the fee-fall.
"Free-fall" deactivation:
· Shortly pull left control lever back.
· Set key-operated switch (7) to position of Free-fall mode "Off".
BG 20H/2005 5 - 13
OPERATION
T=0
· Press button , to reset the depth indicator to "0".
NOTE
BG 20H/2005 5 - 14
OPERATION
11
5.7
9.5 13 12 5.5
9.1 5.1
10 4
1.2 2.2
9.3 9.4 5.3 5.4
9.2 5.2
9.6 5.6
5.8
8
7
6
BS756500.wmf
BG 20H/2005 5 - 15
OPERATION
Pulling by the main winch together with the crowd system is allowed only
BG 20H/2005 5 - 16
START-UP / SHUT-DOWN
6 START-UP / SHUT-DOWN
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 train-
ing 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.
A visual inspection and thorough check is required before putting the equipment into
operation:
· Inspect the entire equipment for loose connections and missing pins or bolts.
· Check all components for wear.
· Look for leaks and fluid spills.
· Check all contained oils and fluids have the proper level.
BG 20H/2005 6-1
START-UP / SHUT-DOWN
WARNING!
Initial situation:
- Diesel engine is running
All control elements must be out of function and the diesel engine comes to a stop.
All hydraulic functions must be blocked. The diesel engine remains on.
BG 20H/2005 6-2
START-UP / SHUT-DOWN
WARNING!
· Hold left end limiter depressed and extend right backstay cylinder.
® Right backstay cylinder must not extend.
· Hold right end limiter depressed and extend left backstay cylinder.
® Left backstay cylinder must not extend.
BG 20H/2005 6-3
START-UP / SHUT-DOWN
6.2 SHUT-DOWN
6.2.1 Daily Shut-Down
· Lower attached work equipment, tools and suspended load as close to the ground
as possible.
· Before leaving, remove the ignition key and lock the cab.
BG 20H/2005 6-4
RIGGING / DERIGGING
7 RIGGING / DERIGGING
WARNING!
Danger of falling down!
Personnel carrying out assembly on the mast or on the uppercarriage
must wear the prescribed fall protection equipment.
BG 20H/2005 7-1
RIGGING / DERIGGING
For safe raising and lowering of the mast, a dialog program showing all the steps to be
carried out has been installed.
For more information, please refer to special manual for "Monitor Unit"
or "B-Tronic" found in the Appendices of this manual.
NOTE
· Prior to putting into service, remove all protecting wax with a hot water jet, at a tem-
perature of 90 - 95° C (approx. 200° F).
Alternatively, the equipment can be washed down with a cold water de-
tergent.
NOTE The treatment must be repeated until all the equipment is totally free of
wax.
BG 20H/2005 7-2
RIGGING / DERIGGING
Tipping hazard!
The crawlers must be extended as soon as the machine has been un-
loaded from the transporting vehicle and before rigging operations are
CAUTION begun.
BG 20H/2005 7-3
RIGGING / DERIGGING
DANGER !
Serious injury hazard!
DO NOT stay in the folding area of mast components.
Keep away from the danger zone!
Bi647410.jpg
Bi647411.jpg
Bi647412.jpg
Bolted connection: 7 6
1 Hex head bolt
2 Washer
3 Tension bush
4 Hex nut
5 Locknut
6 Mast
7 Upper mast extension 1 2 3 24 5
B0000568.wmf
Bolt torque value in Ma [Nm]:1850
BG 20H/2005 7-4
RIGGING / DERIGGING
BJ095518.wmf
BG 20H/2005 7-5
RIGGING / DERIGGING
Initial situation:
- Transported shape
BE399500.wmf
2 1
· Raise mast by approx. 1 m,
tension ropes, raise mast-
head (1).
1m
· Position rotary drive (2) in 3
line of kinematic triangle.
BG440512.wmf
BG440513.wmf
Without supporting 5
clamps it is not al-
lowed to drill. Sup- 6
porting clamps pre-
CAUTION vent improper drilling
position.
BG440514.wmf
BG 20H/2005 7-6
RIGGING / DERIGGING
2 2
B0000754.wmf
BG 20H/2005 7-7
RIGGING / DERIGGING
1 Main rope 1
2 Pin
3 Lube nipple 6
4 Hex head bolt
5
5 Lock washer
6 Washer 2
B0000572.wmf
BG 20H/2005 7-8
RIGGING / DERIGGING
4/B1 42 41
1/T 3/A1 12/P
Hydraulic lines and connections wear
matching identifications.
NOTE
B0000808.wmf
BG 20H/2005 7-9
RIGGING / DERIGGING
2 3
Initial situation:
1
– The kelly is removed.
– Arms (2) for holding the guidance (1)
are mounted with pins (3). B0000708.wmf
5
B0000711.wmf
6
Mounting the kelly guidance:
4
· Mount to the kelly bar (5) an extension
(4) for the rope swivel.
· Mount the kelly guidance (2) with bolts
2
(7) to the kelly bar. 7
BG 20H/2005 7 - 10
RIGGING / DERIGGING
1 Main rope
2 Mounting pin
3 Lube nipple 3
4 Swivel extension
5 Hex socket tie bolt 7
6 Lock washer 6
2
7 Washer 5
B0000710.wmf
DANGER!
Serious injury hazard by revolving kelly guidance !
Danger of causing damage to components !
Drill with care and without people in the danger zone.
3 2 8
· Run the rotary drive down to the lowest
point.
· Remove the pins (3).
· Swivel the arms (2) towards the mast
(8) by 180°.
· Reinstall the pins (3) and secure them.
3 2
B0000709.wmf
BG 20H/2005 7 - 11
RIGGING / DERIGGING
To mount the kelly, the mast must be in upright position and be fitted
with the rotary drive.
NOTE
· Lay the kelly bar down lengthwise to front of the machine, in the centerline of the
machine.
NOTE
1
· Mount rope swivel to eye on kelly, in accor-
dance with fig. below.
1 Main rope 2
2 Rope swivel 8
3 Pin 7 3
4 Kelly
5 Lock washer 6
6 Hex head bolt 5
7 Washer
8 Lube nipple 4
B0000621.wmf
B0000622.wmf
BG 20H/2005 7 - 12
RIGGING / DERIGGING
· Lift kelly until its square stub is approx. 20 cm above the rotary drive.
· Allow the kelly to stop swinging and then insert it into the rotary drive.
Slight rotation with the rotary drive can be helpful when inserting the
kelly.
NOTE
BG 20H/2005 7 - 13
RIGGING / DERIGGING
CAUTION
B0000700.wmf
BG 20H/2005 7 - 14
RIGGING / DERIGGING
2 2
B0000755.wmf
BG 20H/2005 7 - 15
RIGGING / DERIGGING
BG440516.wmf
BG 20H/2005 7 - 16
RIGGING / DERIGGING
BJ095523.wmf
BG 20H/2005 7 - 17
RIGGING / DERIGGING
DANGER !
Serious injury hazard!
DO NOT stay in the folding area of mast components.
Keep away from the danger zone!
Bi647412.jpg
Bi647413.jpg
Bi647414.jpg
Bi647410.jpg
BG 20H/2005 7 - 18
RIGGING / DERIGGING
BG 20H/2005 7 - 19
TRANSPORT
8 TRANSPORT
· Only use hoisting equipment and lifting slings that have sufficient capacity.
WARNING!
BG 20H/2005 8-1
TRANSPORT
Before loading
The machine must be put into the following shape before it may be driven onto a low-
loader or be lifted by a crane:
- all attachments (except the rotary drive) have been removed from the mast,
- the mast is resting on the mast support,
- the uppercarriage is in line with the crawlers and locked to the undercarriage,
- the crawlers are retracted,
- the beam extensions (if so equipped) have been removed,
- the rotary drive is positioned at the lower mast end,
- the masthead is tilted down.
After loading
BG 20H/2005 8-2
TRANSPORT
7.
1 2 3 4 5 6 7
8 9 10 11 12 13 14
10. 10.
ENGINE SPEED
12.
6. 11. 11.
3.
9.
4.
5.
2.
9
1.
12 9
12
10 1m
11
? ? 10 A
?
Bi718500.wmf
BG 20H/2005 8-3
TRANSPORT
In case of lifting the rig with a crane, the counterweight has to be taken
off before.
NOTE
BI647514.wmf
BG 20H/2005 8-4
TRANSPORT
Version 1
16030
3450
2930
1225
1000
1400
3257
700
3200 - 4400
BI647515.wmf
Weights
Equipment
Rotary drive (1400 x 1200 x 2100 mm) 4.0
Casing drive adapter (1100 x 2000 mm) 1.2
Kelly bar BK 18/368/4/50 (600 x 12500 mm) 7.5
Drilling tool 1.0
BG 20H/2005 8-5
TRANSPORT
Version 2
16070
3640
1680
1225
600
6054 5360 4656
1225
3257
700
3200 - 4400
BI647513.wmf
Version 3
16300
3640
3600
1225
600
700
3200 - 4400
BI647516.wmf
BG 20H/2005 8-6
TRANSPORT
WARNING!
Serious accident hazard!
Tie-downs must be attached to the provided intended points only.
The chains used for tie-downs must have sufficient 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 wear a hook symbol and tell the max. tension to be applied.
To tie down
● Tie the equipment down to the transporting vehicle in the professional manner and in
compliance with national directives.
Principally, the haulier in charge is responsible for tying down correctly.
CI439400.jpg
BG 20H/2005 8-7
MAINTENANCE
9 MAINTENANCE
Normally the intervals are cumulative, meaning that when the 1000 hours maintenance
is due also the 10, 50, 250 and 500 hours services will 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.
BG 20H/2005 9-1
MAINTENANCE
Entire equipment
Visually check for:
- Missing or damaged parts X
- Missing or loose pinned / bolted / X
screwed connections
- Missing or damaged safety X
equipment such as
fire extinguishers,
medical box,
warning signs
- Leaks X
Check the functioning of:
- Controls and indicators X
- Safety devices like the X
emergency Stop,
pilot control safety stick,
end limiters,
hoist limiters
- Free-fall (optional) X
Thorough inspection by an expert X
BG 20H/2005 9-2
MAINTENANCE
9.3.2 Components
Masthead
- Check head-to-mast mounting X*
pins and bolts are firm; re-tension
the bolts
- Replace the head-to-mast 10000 hrs
mounting bolts with new ones
(if equipped)
Mast
Mast
- Grease the slide rails X
- Check mast assembly pins and X*
bolts are firm; re-tension the bolts
- Replace the mast assembly bolts 5000 hrs
with new ones (if equipped)
Mast prop (optional)
- Check hinge pin and pin retainer X
are firm
- Grease piston lug X
Mast ladder (optional)
- Check mounting bolts are firm X
- Check transits between ladder X
sections are flush
- Check fall protection equipment X
for proper functioning
Mast pivot
- Grease the pivot assembly X
- Grease the pivot pin X
- Check the mounting bolts are firm; X*
re-tension them
- Replace the mounting bolts with 10000 hrs
new ones
BG 20H/2005 9-3
MAINTENANCE
Winches
- Check oil level in
main winch X
auxiliary winch X
- Change oil in
main winch X* X
auxiliary winch X* X
BG 20H/2005 9-4
MAINTENANCE
BG 20H/2005 9-5
MAINTENANCE
Rotary drive
Rotary drive
- Clean X
- Check for wear and damage X
- Check for leaks X
- Check magnetic sticks for metal X
particles
- Check oil level in
main gear X
- Change oil in
main gear X* X
planetary gears X* X
- Take oil sample and check it X
- Check mounting bolts of the X* X
hollow shaft are firm
- Check response pressure X Nominal value:
35-40 bar
- Lubricate rotary shaft seal X
Kelly driver / Guide flange / Shock absorber
- Check for damage on springs, X
buffer ring and absorbers
- Check mounting bolts are firm X
- Check wear on driver strips X
Cardan joint
- Check rubber buffers for damage X
- Check suspension pins are X
properly in place and firm
Crowd sledge
- Check wear on sliding strips X
Kelly bar
- Check for wear and damage X* X
Drilling tool
- Clean it and check for wear and X
damage
CFA/FOW/TRD-Equipment
- Lubricate concreting head X
BG 20H/2005 9-6
MAINTENANCE
9.3.4 Uppercarriage
BG 20H/2005 9-7
MAINTENANCE
Counterweights
- Check they are properly in place X
and firm and all the fixating ele-
ments are applied
Electric system
Batteries
- Check electrolyte level X
- Check cable connections X
Fuses
- Check the fuses X
Filter
- Change breather filter(s) on X
switch cabinet
9.3.5 Undercarriage
BG 20H/2005 9-8
MAINTENANCE
BG 20H/2005 9-9
MAINTENANCE
Engine
· Every 2 to 3 weeks, start the diesel engine and let it run in the medium r.p.m. range
for about 1 hour.
Air conditioning
· Every 2 to 3 weeks, turn the air conditioning on (if equipped) for a short while.
Slewing ring
BG 20H/2005 9 - 10
MAINTENANCE
10h 21
11 250h
250h 30
10h 26
50 250h
50h 15
50h 8
50h 6
250h 3.1
50h 25 3.2 2000h
BG594519.wmf
BG 20H/2005 9 - 11
MAINTENANCE
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 fis-
sures).
- The outer layer of the hose is brittle (cracks in the tubing).
- The hose does no longer comply with its natural shape, both with and without pres-
sure and while it is bent (e.g. layers separating, bubbles forming).
- 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 is exceeded.
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, since they do no longer meet the requirements.
BG 20H/2005 9 - 12
MAINTENANCE
· 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.
· Every 50 operating hours or once a week, grease the cylinder lugs (holes for pins).
· Once or twice a week, rub down piston rods with a hydraulic oil, or retract and
extend the rods repeatedly.
· Before a longer standstill, preserve piston rods with an acid free grease.
BG 20H/2005 9 - 13
MAINTENANCE
The elements of the line filters must be replaced after the first 250 operating hours or
one month. Subsequent replacements of the line filter elements are due every 2000 op-
erating hours or whenever contamination is indicated (optional; by a warning lamp or by
a text message).
WARNING!
Serious injury hazard!
Before beginning to replace a filter element, remove the pressure from
the hydraulic system and allow it to cool down.
While the hydraulic oil is still cold, it can happen that the contamination
indication comes on for a little while.
NOTE
Line filters:
1
1 Free-fall filter
BS756512.wmf
BG 20H/2005 9 - 14
MAINTENANCE
9.7 WINCHES
9.7.1 Checking the Oil Level
The oil level must be checked every 50 operating hours or once a week, and whenever
the equipment is started up again after a longer standstill.
BG 20H/2005 9 - 15
MAINTENANCE
The oil must be changed after the first 250 operating hours or one month. Subsequent
oil changes are due every 1000 operating hours or once a year.
BG 20H/2005 9 - 16
MAINTENANCE
BG 20H/2005 9 - 17
MAINTENANCE
BG 20H/2005 9 - 18
MAINTENANCE
10 Operating hours/
daily
BM659821.jpg
BM659822.jpg
automatical
BM659823.jpg
BG 20H/2005 9 - 19
MAINTENANCE
BG 20H/2005 9 - 20
MAINTENANCE
1
2 1
3
4 2
KG228501.wmf
BG 20H/2005 9 - 21
MAINTENANCE
The oil level in the main gear must be checked every 10 hours of operation or daily.
KG228502.wmf
BG 20H/2005 9 - 22
MAINTENANCE
The oil must be changed after the first 250 operating hours and subsequently every
1000 operating hours or once a year.
To carry out an oil change, the oil had better be as warm as possible
from operating.
NOTE
K0000507.wmf
Danger of scalding!
Hot gear oil can cause severe injury!
CAUTION
BG 20H/2005 9 - 23
MAINTENANCE
· Inspect magnets on magnetic sticks for gear abrasives, and clean the screws (see
also sect. "Oil Sampling").
Check the mounting bolts of the hollow shaft (see sect. “Hollow Shaft
Mounting Bolts”).
NOTE
· If the outside temperature is low at the time of the oil change, warm up (to approx.
50°C / 122°F) a part of the new oil and rinse the gear housing with this oil before re-
filling.
Benzol (benzene) or flushing oils too may be used here for rinsing.
NOTE
Line filter:
1 Rotary drive
KX000502.wmf
BG 20H/2005 9 - 24
MAINTENANCE
BG 20H/2005 9 - 25
MAINTENANCE
Every 250 operating hours or monthly, take an oil sample from the main and planetary
gears and inspect it:
BG 20H/2005 9 - 26
MAINTENANCE
The mounting bolts of the hollow shaft must be checked every time the oil of the rotary
drive is changed.
BG 20H/2005 9 - 27
MAINTENANCE
KG228510.wmf
· Apply Loctite to threads of the mounting bolts, and screw the bolts down with the
specified torque in a diagonal manner.
BG 20H/2005 9 - 28
MAINTENANCE
· If the wear (x) is in excess of 8 mm, turn the strip around by 180° and reinstall it, or
replace it right away with a new one.
Replace also bushings (4) and bolts (3) if they are worn down.
When fitting a new driver strip, the play (y) should not exceed 0.5 mm.
NOTE
A - A:
A A
B B
1
B - B:
2
3
4
5
6
x y
B0000580.wmf
BG 20H/2005 9 - 29
MAINTENANCE
KG228506.wmf
Schnitt B-B
Section B-B
1
A B B
3
2
4 B0000752.wmf
To replace:
· Unscrew bolts (2) and remove the tension plate (3).
· Pull out the strip (1) and install a new strip.
· Reinstall the tension plate and screw tight.
BG 20H/2005 9 - 30
MAINTENANCE
· With the uppercarriage positioned crosswise, thoroughly clean crawlers free of mud
and dirt.
· Walk-around inspect for wear, damage and loss of oil, especially on following com-
ponents:
1 2 3 4
8 7 6 5
B0000676.wmf
BG 20H/2005 9 - 31
MAINTENANCE
B0000680.wmf
· Remove cover plate (5) and clean the grease nipple (2).
2
5
1 3 4
B0000725.wmf
BG 20H/2005 9 - 32
MAINTENANCE
2
5
1 3 4
B0000725.wmf
WARNING!
· Retighten the safety valve when the proper track tension is obtained.
· Check the track tension again after a short travel forward and backward.
· Clean the nipple and surrounding free of grease.
· Reinstall the cover plate.
WARNING!
BG 20H/2005 9 - 33
MAINTENANCE
5 8 2 1
4 3 6
BK587502.wmf
BK587440.jpg BM564683.jpg
BG 20H/2005 9 - 34
MAINTENANCE
The oil must be changed after the first 500 operating hours or 3 months. Subsequent oil
changes are due every 2000 operating hours or once a year at least.
BG 20H/2005 9 - 35
MAINTENANCE
The grease jar, which has a capacity of 2 kg of standard normal grease of NGLI-Cl. 2
grade, must be topped up by a grease gun (preferably a pneumatic one) every 50 op-
erating hours or weekly.
BG 20H/2005 9 - 36
MAINTENANCE
· After the first 250 operating hours, re-tension all the bolted connections described in
the following.
· Every 5000 hours of ordinary operation, replace all elements used in the bolted con-
nections.
WARNING!
Serious accident hazard !
Replace the elements of bolted connections which have been opened-
up 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
· Every 10000 hours of ordinary operation, replace all elements used in the bolted
connections.
WARNING!
Serious accident hazard !
Replace the elements of bolted connections every time components are
mounted or reassembled anew and whenever the connections have
been excessively stressed from rig tipping or improper handling.
BG 20H/2005 9 - 37
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.
The lubricants listed in the lubricant tables of this manual are suitable
for ambient temperatures from -20°C to 40°C (-4°F to 104°F).
Information on applications below -20°C and above 40°C can be or-
NOTE
dered from the BAUER Service Centre.
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LUBRICANTS / TABLES
The following table lists the lubricants with which the equipment is filled when leaving
the factory.
The quantities given in the table serve as a guide only. Decisive are the
specifications found on the nameplates of the respective parts and the
NOTE actual fill level found when checking.
Alternative lubricants are listed on following pages.
Gear oils,
CLP
petroleum
Auxiliary winch ISO VG 220 ARAL DEGOL BG 220 1.25
Main winch ISO VG 220 ARAL DEGOL BG 220 11.0
Crawler drive gears ISO VG 220 ARAL DEGOL BG 220 2 x 6.0
Gear oils,
API
petroleum
*) At 40°C:
Gear oils, 38mm2/s
ATF
petroleum At 100°C:
7.1 mm2/s
Rotary drive
ATF SHELL Donax TA 45.0
main gear (final drive)
Rotary drive
ATF SHELL Donax TA 2 x 7.5
planetary gears
Gear oils,
CLP PG
synthetic
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LUBRICANTS / TABLES
Specifica- Qty.
Application Viscosity grade Producer Name of product
tion [litres]
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LUBRICANTS / TABLES
Viscosity grade
2
ISO-VG / DIN 51519 at 40°C (104°F) in mm /s
Producer
VG 100 VG 150 VG 220
Product
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LUBRICANTS / TABLES
Specification
Application
DIN 51502
API GL-5 /
Petroleum gear oils
MIL-L-2105 B
Viscosity grade
SAE / DIN 51511
Producer
SAE 90 SAE 85W-90
Product
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LUBRICANTS / TABLES
Specification
Application
DIN 51502
Viscosity grade
Producer *) At 40°C:
2
38 mm /s
At 100°C:
2
Product 7.1 mm /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
KLÜBER
ELF
FUCHS
AGIP
DEA
PANOLIN
*) 40°C = 104°F
100°C = 212°F
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LUBRICANTS / TABLES
Viscosity grade
2
ISO-VG / DIN 51519 at 40°C (104°F) in mm /s
Producer
VG 100 VG 150 VG 220
Product
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LUBRICANTS / TABLES
Viscosity grade
2
ISO-VG / DIN 51519 at 40°C (104°F) in mm /s
Producer
VG 46 VG 68
Product
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LUBRICANTS / TABLES
Specification
Application
DIN 51502
API CF-4 /
Petroleum engine oils
MIL-L-2104 C/D
Viscosity grade
SAE / DIN 51511
Producer
SAE 5W-40 SAE 10W-40 SAE 15W-40
Product
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LUBRICANTS / TABLES
Specification
Application
DIN 51502
Name
Producer Multi-purpose
grease on lithium
Product soap base
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LUBRICANTS / TABLES
Specification
Application
DIN 51502
API CF /
Synthetic engine oils
MIL-L-2104 C/D
Viscosity grade
SAE / DIN 51511
Producer
SAE 5W-40 SAE 10W-40 SAE 15W-40
Product
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LUBRICANTS / TABLES
Bolt torque values given in the following tables are valid only for slightly
oiled bolted connections and where the Spare Parts List does not pre-
CAUTION scribe other torque values.
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LUBRICANTS / TABLES
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