en BG36 888

Instruction Manual
BG 36
BM514511.wmf
Keep this manual also for future use!
BAUER Maschinen GmbH

P.O. Box 12 60 · D-86522 Schrobenhausen · Germany
Phone: Germany + 82 52/97-0 · Fax: Germany + 82 52/97-13 59
INTRODUCTION
This manual has been made for operators and maintenance personnel.
Before putting the equipment in operation, please:
Carefully read through the whole Instruction Manual and

Safety Information book supplied with the equipment
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 book of Safety Information 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.
This manual was edited and published by

BAUER Maschinen GmbH · P.O. Box 12 60 · D-86522 Schrobenhausen · Germany
© 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 36/2005 I
TABLE OF CONTENTS
INTRODUCTION............................................................................................................................................I
TABLE OF CONTENTS..............................................................................................................................II
ABOUT THE MANUAL ............................................................................................................................ VII
NAMEPLATES............................................................................................................................................ IX
AFTER SALES SERVICE.......................................................................................................................... X
WARRANTY TERMS................................................................................................................................. XI
WARRANTY CLAIM .................................................................................................................................. XIII
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 - 3
2.4.4 Medical Box ............................................................................................................................2 - 3
2.4.5 Emergency Exit ......................................................................................................................2 - 3
2.4.6 Limit Switches.........................................................................................................................2 - 4
2.4.7 Fall Protection Equipment ......................................................................................................2 - 5
2.5 STABILITY..............................................................................................................................2 - 6
2.5.1 Guidelines for Stability............................................................................................................2 - 6
2.5.2 Load Capacity Chart with Kelly Equipment ............................................................................2 - 7
2.5.2.1 Kelly BK 36/470/4/44 ..............................................................................................................2 - 7
2.6 PERMISSIBLE WIND SPEED..............................................................................................2 - 8
3 TECHNICAL SPECIFICATIONS ..........................................................................................3 - 1

3.1 DIMENSIONS.........................................................................................................................3 - 1
3.1.1 Kelly Equipment BK 36/470/4/44............................................................................................3 - 1
3.2 EQUIPMENT SPECIFICATIONS ..........................................................................................3 - 2
BG 36/2005 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
3.5.3 Crowd Ropes..........................................................................................................................3 - 8
3.6 NOISE EMISSION.................................................................................................................3 - 9
3.7 TEMPERATURE CONDITIONS............................................................................................3 - 9
3.8 EXPOSURE TO VIBRATION ...............................................................................................3 - 9
4 CONTROLS AND INDICATORS .........................................................................................4 - 1

4.1 CAB ........................................................................................................................................4 - 1
4.2 BASE MACHINE CONTROL CONSOLE ...............................................................................4 - 2
4.3 CONTROL PANEL 1 ..............................................................................................................4 - 3
4.4 CONTROL PANEL 2 ..............................................................................................................4 - 4
4.5 MONITOR UNIT .....................................................................................................................4 - 5
4.6 REMOTE CONTROL FOR CASING OSCILLATOR ..............................................................4 - 6
5 OPERATION ..........................................................................................................................5 - 1
5.1 TRAVEL..................................................................................................................................5 - 1
5.1.1 To Select the Travel Mode .....................................................................................................5 - 1
5.1.2 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 - 4
5.4 MAST PROP CONTROL........................................................................................................5 - 5
5.5 TRAVELLING WITH THE RIG ............................................................................................5 - 5
5.5.1 Travelling over Level Ground .................................................................................................5 - 5
5.5.2 Travelling Up and Down Slopes .............................................................................................5 - 6
5.5.2.1 With Raised Mast without Drilling Equipment ........................................................................5 - 6
5.6 ROTARY DRIVE CONTROL................................................................................................5 - 7
5.6.1 Kelly Application .....................................................................................................................5 - 7
5.6.2 Additional Functions ...............................................................................................................5 - 8
5.6.2.1 To Operate with "Freewheel" .................................................................................................5 - 8
5.6.2.2 To Operate with Torque Amplifier ..........................................................................................5 - 8
5.7 WINCH CONTROL................................................................................................................5 - 9
5.7.1 Lifting / Lowering ....................................................................................................................5 - 9
5.7.2 To Operate with Freewheel ..................................................................................................5 - 10
5.7.3 To Operate with "Slack Rope Switch-Off" ............................................................................5 - 11
BG 36/2005 III
5.8 DEPTH MEASURING CONTROL........................................................................................5 - 12
5.8.1 To Reset the Depth Measuring ............................................................................................5 - 12
5.8.2 To Interrupt the Depth Measuring ........................................................................................5 - 12
5.9 CROWD CONTROL ............................................................................................................5 - 13
5.9.1 Crowd Control in Kelly Application .......................................................................................5 - 13
5.9.1.1 Manual Control of the Crowd Pressure ................................................................................5 - 13
5.9.1.2 Automatic Control of the Crowd Pressure............................................................................5 - 14
5.9.2 Crowd Control in CFA Application........................................................................................5 - 15
5.9.2.1 Manual Control of the Crowd................................................................................................5 - 15
5.9.2.2 To Operate with "Auto Pull"..................................................................................................5 - 16
5.9.3 To Use the Main Winch in Combination with Crowd ............................................................5 - 17
5.10 CENTRAL LUBRICATION CONTROL (OPTIONAL) ...........................................................5 - 18
5.11 EMERGENCY CONTROL....................................................................................................5 - 19
6 START-UP / SHUT-DOWN....................................................................................................6 - 1
6.1 START-UP..............................................................................................................................6 - 1
6.1.1 Initial Start-Up.........................................................................................................................6 - 1
6.1.2 Visual Inspection before Starting............................................................................................6 - 1
6.1.3 Daily Start-Up .........................................................................................................................6 - 1
6.1.3.1 Starting the Equipment...........................................................................................................6 - 1
6.1.3.2 Selecting the Work Application...............................................................................................6 - 2
6.1.4 Safety Tests before Starting to Work .....................................................................................6 - 3
6.1.4.1 Checking the Emergency STOP ............................................................................................6 - 3
6.1.4.2 Checking the Pilot Control Safety Stick..................................................................................6 - 3
6.1.4.3 Checking the End Limiters .....................................................................................................6 - 4
6.2 SHUT-DOWN .........................................................................................................................6 - 5
6.2.1 Daily Shut-Down.....................................................................................................................6 - 5
7 RIGGING / DE-RIGGING .......................................................................................................7 - 1

7.1 GUIDELINES FOR RIGGING AND DE-RIGGING .............................................................7 - 1
7.2 WAX REMOVAL....................................................................................................................7 - 2
7.3 EXTENDING THE CRAWLERS.............................................................................................7 - 3
7.4 MOUNTING THE COUNTERWEIGHT ..................................................................................7 - 4
7.5 ASSEMBLING THE MAST...................................................................................................7 - 5
7.5.1 Mounting the Trestle...............................................................................................................7 - 5
7.5.2 Assembling the Mast ..............................................................................................................7 - 6
7.5.3 Installing the Ropes ................................................................................................................7 - 8
7.5.3.1 Installing Main and Auxiliary Rope .........................................................................................7 - 8
7.5.3.2 Installing the Upper Crowd Rope ...........................................................................................7 - 9
7.5.4 Raising the Mast...................................................................................................................7 - 10
7.6 ASSEMBLY OF WORK ATTACHMENTS.........................................................................7 - 11
7.6.1 Assembly of Kelly Equipment...............................................................................................7 - 11
7.6.1.1 Mounting the Rope Swivel....................................................................................................7 - 11
7.6.1.2 Mounting the Rotary Drive....................................................................................................7 - 12
7.6.1.3 Mounting the Kelly................................................................................................................7 - 14
7.6.2 Mounting Casing Oscillator (Optional)..................................................................................7 - 16
BG 36/2005 IV
7.7 DISASSEMBLY OF WORK ATTACHMENTS...................................................................7 - 17
7.7.1 Disassembly of Kelly Equipment ..........................................................................................7 - 17
7.7.1.1 Removing the Kelly ..............................................................................................................7 - 17
7.7.1.2 Removing the Rotary Drive ..................................................................................................7 - 18
7.8 DISASSEMBLING THE MAST...........................................................................................7 - 19
7.8.1 Lowering the Mast ................................................................................................................7 - 19
7.8.2 Removing Ropes ..................................................................................................................7 - 20
7.8.2.1 Removing the Main and Auxiliary Rope ...............................................................................7 - 20
7.8.2.2 Removing the Upper Crowd Rope .......................................................................................7 - 21
7.8.3 Disassembling the Mast .......................................................................................................7 - 22
7.8.4 Lowering the Trestle .............................................................................................................7 - 22
7.9 REMOVING THE COUNTERWEIGHT ................................................................................7 - 23
7.10 RETRACTING THE CRAWLERS ......................................................................................7 - 24
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 TYING DOWN .......................................................................................................................8 - 5
8.6 TRANSPORT DATA..............................................................................................................8 - 6
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 LUBRICATION PLAN ..........................................................................................................9 - 10
9.5 MAINTENANCE DURING LONGER PERIODS OF STANDSTILL .....................................9 - 11
9.6 HYDRAULIC SYSTEM ........................................................................................................9 - 12
9.6.1 Hose Assemblies..................................................................................................................9 - 12
9.6.2 Hydraulic Cylinders...............................................................................................................9 - 13
9.7 WINCHES.............................................................................................................................9 - 14
9.7.1 Checking the Oil Level .........................................................................................................9 - 14
9.7.2 Changing Gear Oil................................................................................................................9 - 15
9.7.3 Lubricating Counter Bearings...............................................................................................9 - 15
9.8 WIRE ROPE ACCESSORIES............................................................................................9 - 16
9.8.1 Rope Swivel..........................................................................................................................9 - 16
9.8.2 Rope Hold-Down Rollers ......................................................................................................9 - 16
9.8.3 Rope Fasteners, Thimbles and Sockets ..............................................................................9 - 17
9.8.4 Rope sheaves.......................................................................................................................9 - 18
9.8.4.1 Greasing Rope Sheaves ......................................................................................................9 - 18
9.8.4.2 Checking Rope Sheaves......................................................................................................9 - 19
BG 36/2005 V
9.9 ROTARY DRIVE..................................................................................................................9 - 20
9.9.1 Routine Inspection................................................................................................................9 - 20
9.9.2 Checking the Oil Level .........................................................................................................9 - 21
9.9.2.1 Main Gear.............................................................................................................................9 - 21
9.9.3 Changing the Oil...................................................................................................................9 - 22
9.9.4 Oil Sampling .........................................................................................................................9 - 24
9.9.5 Hollow Shaft Mounting Bolts ................................................................................................9 - 25
9.9.6 Kelly Driver and Guide Flange .............................................................................................9 - 26
9.9.6.1 Checking the Mounting Bolts................................................................................................9 - 26
9.9.6.2 Checking Driver Strips for Wear...........................................................................................9 - 27
9.9.7 Cardan Joint .........................................................................................................................9 - 28
9.9.8 Sledge Sliding Strips ............................................................................................................9 - 29
9.10 CRAWLER TRACK ASSEMBLIES ....................................................................................9 - 30
9.10.1 Routine Inspection................................................................................................................9 - 30
9.10.2 Crawler Tracks .....................................................................................................................9 - 31
9.10.2.1 To Check the Track Tension ................................................................................................9 - 31
9.10.2.2 Adjusting Crawler Track Tension .........................................................................................9 - 31
9.10.3 Checking Mounting Bolts......................................................................................................9 - 33
9.10.4 Crawler Drive Gears .............................................................................................................9 - 34
9.10.4.1 Checking the Oil Level .........................................................................................................9 - 34
9.10.4.2 Changing the Oil...................................................................................................................9 - 34
9.10.5 Checking and Adjusting Crossbeam Play ............................................................................9 - 35
9.10.5.1 Play at Beam Centres ..........................................................................................................9 - 35
9.10.5.2 Play at Beam Ends ...............................................................................................................9 - 36
9.11 BOLTED CONNECTIONS ..................................................................................................9 - 37
10 LUBRICANTS / TABLES...................................................................................................10 - 1
10.1 LUBRICANTS.......................................................................................................................10 - 1
10.1.1 General .................................................................................................................................10 - 1
10.1.2 Lubricant Table.....................................................................................................................10 - 2
10.1.3 Lubricant Guide ....................................................................................................................10 - 4
10.1.3.1 List of Approved Gear Oils, Petroleum - CLP ......................................................................10 - 4
10.1.3.2 List of Approved Gear Oils, Petroleum – API.......................................................................10 - 5
10.1.3.3 List of Approved Gear Oils, Petroleum – ATF......................................................................10 - 6
10.1.3.4 List of Approved Gear Oils, Synthetic – CLP PG .................................................................10 - 7
10.1.3.5 List of Approved Hydraulic Oils, Petroleum – HVLPD..........................................................10 - 8
10.1.3.6 List of Approved Hydraulic Oils, Fixed – HEES ...................................................................10 - 9
10.1.3.7 List of Approved Engine Oils, Petroleum – API CF-4.........................................................10 - 10
10.1.3.8 List of Approved Greases, Petroleum – KP2N...................................................................10 - 11
10.1.3.9 List of Approved Engine Oils, Synthetic – API CF .............................................................10 - 12
10.2 BOLT TORQUE VALUES ................................................................................................10 - 13
10.3 CONVERSION TABLE ......................................................................................................10 - 14
BG 36/2005 VI
ABOUT THE MANUAL
This manual is made for

Equipment model: BG 36
Construction number: 888
Construction year: 2005
Date of 1st operation: .. / .. / ....
Certification: CE
This manual was published in
11.2005
The chapters of this manual
1 DESCRIPTION
2 SAFETY
3 TECHNICAL SPECIFICATIONS
4 CONTROLS AND INDICATORS
5 OPERATION
6 START-UP / SHUT-DOWN
7 RIGGING / DE-RIGGING
8 TRANSPORT
9 MAINTENANCE
10 LUBRICANTS / TABLES
11 EXTRA EQUIPMENT (OPTIONAL)
APPENDICES
G:\...\0000408897_en_BG36_888
BG 36/2005 VII
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 given 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" is used to identify a hazard that can result in

moderate injury and/or damage to the equipment if the instructions
CAUTION 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
NOTE the work.
BG 36/2005 VIII
NAMEPLATES
Nameplates on the equipment
Assembly Location Nameplate

Total equipment Beside cab door Bauer Maschinen GmbH
D - 86522 Schrobenhausen Made in Germany
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 36/2005 IX
AFTER SALES SERVICE
How to reach the Service Centre
Phone Germany + (8252) 97 - 25 86

Fax Germany + (8252) 97 - 25 87
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:
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 36/2005 X
WARRANTY TERMS
The warranty terms listed in the following apply to all equipment sold by the BAUER
company.
Þ Warranty Period: The warranty period is either

- 12 months starting with the date of commissioning, or
- in accordance with contractual agreements.
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.
Þ Warranty - Improper use or operation (misuse) of the equipment.

exclusions: - Failure to adequately maintain or service the equipment
causing 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.
Damages resulting from manufacturing faults shall, how-
ever, be dealt with on a warranty basis.
BG 36/2005 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.
- 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 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.
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 the responsibility of the Client.
- Local transport to a final destination (construction site) in connection with a war-
ranty 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 36/2005 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
From (Customer, Agent):
Phone: Fax:
Total number of pages of claim:
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.
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 working time (hrs): Estimated additional costs:
Date Name of claimant Signature Company

(please print)
4. For internal use only (to be filled in by BAUER)

Subject to warranty? Yes No
If yes, give order number: If no, give reasons:
Further reports:
Further actions:
Return of damaged parts by:
01/2003
Estimated working time (hrs):

910.396.2
(Signed by authorized BAUER employee)

DESCRIPTION
1 DESCRIPTION
1.1 EQUIPMENT APPLICATIONS

The equipment is designed and intended for the following applications only:
Area of application In short Allowed

Drilling with Kelly equipment Kelly Yes
Drilling with Continuous Flight Auger equipment CFA No
Drilling with Front-of-Wall equipment FOW No
Drilling with Twin Rotary Drives equipment TRD No
Drilling with Triple Auger ("Mixed-in-Place")
MIP No
equipment
Piling with Vibrator equipment No
Drilling with High Pressure Injection equipment HPI No
Drilling with Full Displacement System equip-
FDS No
ment
Drilling with Soil Stabilization equipment CSV No
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 36/2005 1-1
DESCRIPTION
1.2 COMPONENTS
1.2.1 Basic Rig / Kelly Equipment
1.2.1.1 Components Overview
Basic Rig
1 Boom 16
2 Boom cylinders
3 Swing mechanism 21
4 Crawler drives
5 Counterweight 10
6 Main winch
7 Main rope
8 Auxiliary winch
9 Auxiliary rope 22
10 Wedge
11 Masthead tilting cylinder * 13
12 Kinematic triangle *
13 Mast (upper section / lower section)
14 Mast prop * 46
15 Mast pivot
16 Masthead
17 Mast extension (intermediate) *
18 Mast extension (lower) 26
17
19 Backstay cylinders 43
20 Uppercarriage 41/45
21 Rope swivel
22 Crowd rope tensioning cylinder 44 9
23 Supporting boom * 42 7
24 Supporting trestle
19
25 Undercarriage 40
26 Crowd sledge 27
27 Crowd ropes (upper/lower) 29
28 Thrust rod *
29 Crowd winch 8
13
30 Crowd cylinder *
24
Kelly equipment 2 6 20
15
40 Drilling tool 18 5
41 Rotary drive 14 3
42 Casing drive adapter 1
25 4
43 Shock absorber
44 Cardan joint BM678503.wmf
45 Kelly drivers
46 Kelly bar
*) does not exist with this version
BG 36/2005 1-2
DESCRIPTION
1.2.1.2 Components Description
Table Basic rig components description

Component Description / Function
Boom Is a movable link from the machine to the mast pivot.
Are movable connections of the boom to the machine.
Boom cylinders They enable adjustment of the machine's distance to
the bore.
Swing mechanism Enables rotation of the uppercarriage to both sides.
Crawler drives Drive the two crawlers forward and reverse.
Counterweights Render stability to the equipment.
Main winch with main rope Is used as a hoist for the kelly.
Auxiliary winch with auxiliary rope Is used for rigging operations and load handling.
Wedge Allows changing the distance from mast to bore.
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) Allows the crowd sledge be positioned further down.
Are movable supports of the mast. They raise and
Backstay cylinders lower the mast and allow adjustment of the inclination
of the mast.
Uppercarriage 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) Is a mount for the backstay cylinders.
Carries the rig and moves it from one drilling spot to
Undercarriage
the next.
Runs up and down the mast while carrying the rotary
Crowd sledge
drive and drilling tool.
Crowd ropes (upper/lower) (S) Transfer force from crowd winch to crowd sledge.
Thrust rod (Z) Is a distance keeper for the crowd cylinder.
Crowd winch (S) Generates the crowd forces.
Crowd cylinder (Z) Generates the crowd forces.
Z) for rig fitted with cylinder crowd V) for mast lowering to the front
S) for rig fitted with rope crowd H) for mast lowering to the rear
BG 36/2005 1-3
DESCRIPTION
Table Kelly equipment components description

Component Description / Function
Drilling tool Erodes and conveys soil.
Generates rotary movement and torque for the drilling
tool and/or casing tube.
Rotary drive
Its final gear is driven by planetary gears which take
power from hydraulic motors.
Serves as a connector between the cardan joint and
Casing drive adapter
the casing tube and transfers the torque.
Shock absorber Absorbs shocks from the kelly bar.
Transfers torque from rotary drive to casing drive
Cardan joint
adapter and prevents torsional stress.
Kelly driver Transfers torque from rotary drive to kelly bar.
Consists of telescoping tubes the total length of
which determines the achievable depth of the bore.
Kelly bar (Kelly)
It transfers torque from the rotary drive to the drilling
tool.
BG 36/2005 1-4
SAFETY
2 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 re-
quirements.
Equipped safety devices guarantee highest possible safety standard.
2.3 MAJOR HAZARDS

− 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, repair
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 36/2005 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 1 Emergency Stop
NOT-AUS
stop.
To re-start, pull the depressed Emergency STOP

button.
B0000819.wmf
2.4.2 Pilot Control Safety Stick
With the safety stick (1), the operator must shut 1.1
off the pilot control before leaving the driver's
seat. With the stick in the "Off" position, all hy-
draulic functions are blocked.
1.2
Pilot control On: Stick moved to position (1.1)
Pilot control Off: Stick moved to position (1.2) Emergency Stop
NOT-AUS
B0000820.wmf
BG 36/2005 2-2
SAFETY
2.4.3 Fire Extinguisher
Machine with an engine power of <

200 kW is equipped with one fire extin-
guisher / Machine with an engine power of
> 200 kW has two fire extinguishers.
Their location in or on the machine is iden-
tified with a decal (see fig.).
Personnel must recapitulate the text on

fire extinguishers from time to time to be
familiar with their use.
B0000506.wmf
2.4.4 Medical Box
A First Aid medical box is found in the op-

erator’s 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
equipped emergency hammer (see fig.) to
smash a window.
The hammer is found in the upper corner

behind the operator’s seat.
GAALM055.wmf
BG 36/2005 2-3
SAFETY
2.4.6 Limit Switches
Table Limit switches
Name Function
ES 2 Limits mast inclination to left.

Initial situation:
HS 1
- ES 2 out of order
ES 2.1 HS 2
Switches off engine when max. permis-
sible mast inclination to left is obtained.
Enables the Rigging Mode when boom
ES 3
cylinders are fully extended.
ES 4 Limits mast inclination to right.
Initial situation:
- ES 4 out of order
ES 4.1
Switches off engine when max. permis-
sible mast inclination to right is obtained.
Initial situation:
- boom cylinders fully extended ES 2 / ES 2.1
ES 10* - inclinometer out of order ES 4 / ES 4.1
Limits mast inclination forward or back- ES 10

ward for drilling operations. ES 3
BM452509.wmf
Stops lifting by the main winch
HS 1
before load may hit the masthead.
Stops lifting by the auxiliary winch
HS 2
before load may hit the masthead.
*) optional
With switch ES 2.1 or ES 4.1 activated, the engine can be restarted by

holding the by-pass button depressed while turning the ignition on.
NOTE
BG 36/2005 2-4
SAFETY
2.4.7 Fall Protection Equipment
WARNING!
Danger of falling!
When climbing the mast ladder, the provided fall protection equipment
must be used.
Personnel climbing the ladder must wear a body harness secured by
lanyards to a fall protection slide and by a lifeline, at all times! The per-
son in question must be familiar with the fall protection equipment.
1 Shoulder straps, orange red 1

2 Ring for attaching a lifeline 2
3 Buckles for shoulder strap positioning 3
4 Waist strap with wide support for the 4
back
5
5 D-rings for attaching lanyards
6 Rings for attaching a seat support
7 Seat support, blue
8 Leg straps, blue 6
7
8
B0000793.wmf
How to don
Slip on the orange-red shoulder straps like a jacket, with the lifeline ring to the back. Pull
the free end of the waist strap through the twin-buckle at the other end and return
through the inner buckle. Step into the loose hanging leg straps, pull them through the
crotch and through the corresponding rings and secure using the twin-buckle, like with
the waist strap. The seat support must be in position under the buttocks.
How to use
The body harness (DIN 7478 sec. A) may be used only in conjunction with a fall-
preventing slide and lanyards (DIN 23326) or a lifeline (DIN 7471) together with a fall-
damping device. The harness including all accessories must be checked for good work-
ing order before put to use. Never use damaged equipment. Safe anchoring points must
be provided above the user’s position. Possible fall height must be kept at a minimum
using rope shorteners. Never work with slack lanyards or lifeline. Be careful that lifeline
and ring (2) are in proper position at all times. Lanyards must be snapped on directly to
D-rings (5) on harness.
BG 36/2005 2-5
SAFETY
2.5 STABILITY
2.5.1 Guidelines for Stability
Rig capacity charts are calculated in compliance with the European standard EN 791.
WARNING!
Rig tipping hazard !

The conditions listed in the following must be observed in order that the
stability of the rig is guaranteed.
Conditions for operation:

- Rig angles and loads on main rope, auxiliary rope and crowd given in the capacity
charts are maximum values which must not be exceeded for safety reasons.
The specified loads apply only when not combined and not used on an altered setup
of equipment.
- Machine on firm and level surface. National safety codes and guidelines observed
concerning the soil and working platform conditions.
- Uppercarriage held stationary with crowd and main rope load.
- Slow swing of uppercarriage with load on auxiliary rope.
- No diagonal pull.
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.
Conditions for onsite travelling:

- Uppercarriage in line with undercarriage.
- Work attachments and movable loads kept as close to the ground as possible.
- Mast vertical.
- No abrupt movements.
BG 36/2005 2-6
SAFETY
2.5.2 Load Capacity Chart with Kelly Equipment
2.5.2.1 Kelly BK 36/470/4/56

Valid only for Mast extension 0.0 m 0.00 to
Kelly BK 36/470/4/56 11.3 to
Casing drive adapter Æ 1500 mm 1.85 to
Drilling tool Æ 1350 mm 2.15 to
Conditions for operation Crowd sledge stroke limiter mounted (max. stroke: 9250 mm)
B0000689.wmf Max permissible load [tonnes]
B0000691.wmf
B0000690.wmf Min drill distance*: m Max drill distance*: 4.65 m
Auxiliary
10
rope
Main
25
rope
Crowd 37
"= ° " = 5°
Auxiliary $= ° $ = 5°
10
rope (= ° ( = 0°
*= ° * = 85°
"= ° " = 5°
Main $= ° $ = 2°
25
rope (= ° ( = 4°
*= ° * = 85°
"= ° " = 5°
$= ° $ = 2°
Crowd 40
(= ° ( = 4°
*= ° * = 85°
"= ° " = 5°
Auxiliary
$= ° $ = 5° 3.0
rope
(= ° ( = 0°
"= ° " = 5°
Main
$= ° $ = 2° 25
rope
(= ° ( = 4°
"= ° " = 5°
Crowd $= ° $ = 2° 21
(= ° ( = 4°
Max travel gradability ° 5°

* Drill distance = centre distance from machine to drilling tool
BG 36/2005 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 Barrier effect

m/s km/h miles/h Beaufort ktn
20 72 45 8 39 250 (N/m²)
WARNING!
Rig 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 uppercarriage in line with the undercarriage and interlock them.
· Set the mast into the minimum working range.
· Extend the mast prop (if equipped) to the ground.
Table of wind forces and speeds

Wind force Wind speed Wind effects
Beaufort English m/s km/h
0 calm 0 - 0.2 less than 1 Smoke rises straight in the air, sea is calm-glassy
1 light air 0.3 - 1.5 1-5 Smoke drifts but vanes remain still, sea is rippled
2 light breeze 1.6 - 3.3 6 - 11 Wind can be felt on your face, leaves rustle, sea
has wavelets
3 gentle breeze 3.4 - 5.4 12 - 19 Leaves and thin twigs move, pennants stretch,
wave crests begin to break
4 moderate breeze 5.5 - 7.9 20 - 28 Dust and paper lift, twigs and branchlets sway,
waves are growing in length, scattered white-caps
5 fresh breeze 8 - 10.7 29 - 38 Small trees begin to sway, waves are white-
capped all over the sea
6 strong breeze 10.8 - 13.8 39 - 49 Sturdy branches move, wires sing, umbrellas are
hard to handle, sea is rough, crests break
7 near gale 13.9 - 17.1 50 - 61 Whole trees swaying, walking towards the wind is
difficult, sea is very rough, foam on crests
8 gale 17.2 - 20.7 62 - 74 Branches break off, walking outdoor is extremely
difficult, waves are high, spray from crests
9 strong gale 20.8 - 24.4 75 - 88 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
BG 36/2005 2-8
TECHNICAL SPECIFICATIONS
3 TECHNICAL SPECIFICATIONS
3.1 DIMENSIONS
3.1.1 Kelly Equipment BK 36/470/4/56
Dimensions in [mm]
24195
22064
10000
13073
11390
9250
9500
9250
4800
1300
2600
800
3420
1210
0
4600
16
5660
4288 R 4500
BM888500.wmf
BG 36/2005 3-1
3.2 EQUIPMENT SPECIFICATIONS

Base Machine
Uppercarriage
Type BS 80/B
Serial number 80.6.623
Engine
Type CAT C-15
Serial number BEM 05 728
Output 365 kW
Speed 1850 rpm
Undercarriage
Type UW 110
Serial number 568
Width over crawlers 3300 - 4600 mm
Length of crawlers 5660 mm
Width of track pads 800 mm
Mast Inclination
During operation without work equipment
forward 5°
backward 15°
to left 5°
to right 5°
During operation with work equipment
See load capacity chart
Operating Range
See load capacity chart
Working Weight
With:
Equipment BK36/470/4/56 121 tonnes
BG 36/2005 3-2
Main Winch
Type 4.29 / 1000279

Serial number 156
Pulling force (1st layer) 250 kN
Rope diameter 32 mm
Rope length 90 m
Rope speed 82 m/min
("lifting" with 20 kN load)
Auxiliary Winch
Type 4.22 / 1000328

Serial number 207
Pulling force (1st layer) 100 kN
Rope diameter 20 mm
Rope length 60 m
Rope speed 75 m/min
("lifting" with 10 kN load)
Crowd Cylinder
Stroke of crowd sledge Not equipped

Max. pushing force Not equipped
Max. pulling force Not equipped
Reduced pulling force (optional) Not equipped
Crowd speed:
"Fast crowd" up Not equipped
"Fast crowd" down Not equipped
"Slow crowd" up Not equipped
"Slow crowd" down Not equipped
Crowd Winch
Type 77 WH 103/12
Serial number 45335
Max. stroke of crowd sledge 16680 mm
Max. pushing force 400 kN
Max. pulling force 400 kN
Rope diameter 28 mm
Length of upper / lower rope 75 m / 70 m
Crowd speed:
"Fast crowd" up 26 m/min
"Fast crowd" down 26 m/min
"Slow crowd" up 6.0 m/min
"Slow crowd" down 7.0 m/min
BG 36/2005 3-3
3.3 ROTARY DRIVE SPECIFICATIONS

3.3.1 Rotary Drive, Shiftable
Pth = 300 kW
Qth = 2 x 320 l/min
1st gear 1st gear with reduced torque
400
300
368
350
306 250
300
Drehmoment / Torque M [kNm]
208

250 200
200
150
150
110
100
110
100
50
50
0 88 0
23 11 12 23
0 5 10 15 20 25 0 5 10 15 20 25
Drehzahl n [1/min] / Speed n [rpm] Drehzahl n [1/min] / Speed n [rpm]
BM658500.wmf BM658502.wmf
2nd gear
200
177
160
147
120
80
53
40
0
16 17 48
0 10 20 30 40 50
Drehzahl n [1/min] / Speed n [rpm]
BM658501.wmf Efficiency not considered
BG 36/2005 3-4
3.4 DRILLING SPECIFICATIONS

3.4.1 Kelly Equipment
Dimensions [mm]
L1
L2 L1 22050
L2 13073
L3 3823
A max. 18227
Hd 9250
A Bore diameter [mm]

uncased 1830
cased 1500
Casing length
without CO Hw – 0.5 m
with CO Hw – 1.5 m
Hd
L3
Hw
Drilling depth / Kelly specifications

locked unlocked
kelly kelly
kelly type without with without with
CO CO CO CO Weight
A [m] B [m] B1 [m] Hw [m] T [m] T [m] T [m] T [m] [to]
B
BK 36/470/4/56 17.25 58.79 58.48 2.60 56.85 55.35 57.16 55.66 11.30
Notice: Drilling depth specifications are based on min. operating radius of mast.
With max. operating radius the drilling depth increases by 0.40 m.
A: Length of retracted kelly

A max.: Max lifted length of kelly
B / B1: Length of extended kelly unlocked / locked
T: Max. possible drilling depth
Hw: Maximum height to drilling tool
Hd: Maximum height to casing drive adapter
L1: Highest possible position of kelly lifting eye
W L2: Highest possible position of kelly driver upper edge
L3: Lowest possible position of kelly driver upper edge
B0000669.wmf
W: Length of drilling tool: 2.2 m
CO: BAUER Casing Oscillator
BG 36/2005 3-5
3.5 ROPE SPECIFICATIONS

3.5.1 Main Rope
Finish length 100 m
Nominal diameter 32.00 mm

Permissible deviation + 4.00 %
Weight per meter 5.29 kg/m
Nominal wire strength 1960.00 N/mm2
Fill factor 0.745
Spinning loss factor 0.77
Nominal aggregate breaking load 1158 kN
Minimum breaking load 916 kN
Diameter of outer wires 1.75 mm compacted outer strands
Total metal cross section 591.00 mm
Total number of wires 284
Number of load-bearing wires
(outer strands) 112
Rope structure (1+6) + 5 (1+6) + 5 (1+6) + 5 (1+6+6+6) + 16 (1+6)

Rope core Steel core (SC)
Wire surface Ungalvaniced, bright
Lay and direction Long-lay (right)
Characteristics Low-stress
Corrosion protection Steel core greased
Rope description All strands compacted,

Features non rotating,
very good coiling characteristics,
radially elastic,
with plastic coated steel core
BG 36/2005 3-6
3.5.2 Auxiliary Rope
Finish length 70 m

Fill factor 0.75
Diameter of outer wires 1.10 mm compacted outer strands
(outer strands) 112
Rope structure 16 (6+1) + 5 (6+1) + 5 (6+1) + 5 (6+1) + SC (6+1)

Rope core Steel core (SC)
Lay and direction Regular-lay right
Corrosion protection Steel core greased
Rope description All strands compacted,

Features non rotating,
very good coiling characteristics,
radially elastic,
with plastic coated steel core
BG 36/2005 3-7
3.5.3 Crowd Ropes
Finish length upper rope 75 m

lower rope 70 m

Fill factor 0.647
Diameter of outer wires 1.51 mm
(outer strands) 216
Rope structure 6 (14+7+7+7+1) + IWRC = 6 (6+1) +7

Rope core Independent wire core (IWRC)
Lay and direction Regular-lay right
Corrosion protection Greased
Rope description Compacted outer strands,

Features pre-stressed,
rotation-resistant
BG 36/2005 3-8
3.6 NOISE EMISSION
1. Inside Cab
Measurement made in accordance with ISO 6394
Sound-pressure level in cab LpA = 79 dB(A)
2. Outside
Measurements made in accordance with DIN 45635 T.33
Sound-power level LWA = 114 dB(A)
3.7 TEMPERATURE CONDITIONS
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.
3.8 EXPOSURE TO VIBRATION
The operator’s exposure to vibration acceleration during operation with this equipment
is less than 0.5 m/s².
BG 36/2005 3-9
CONTROLS AND INDICATORS
4 CONTROLS AND INDICATORS
4.1 CAB
1.5
1.3
1.1 2.1 3
5
22
21 4
20 4
5
6
7
2
8
1
9
10
0
19 1.2 2.2 6
18 1.4 2.3 7
1.6
15.7 17/17.1 8/8.1 10.7
13
15.5 9/9.1 10.5
15.1 10.1
15.3 15.4 10.3 10.4

16
5
15.10
6
15.9 10.10
4
10.9
3
7
2
8
1
9
0
10
Em er gency Stop
N OT -AUS
5
4 6
3
7
2
11
8
1
9
10
0
15.2 23 10.2
15.6 10.6
15.8 14 10.8
24
25 0 0 00 0 0 00
12
29
BN683501.wmf
1.1 Left crawler travel forward 11 Engine speed adjustment
1.2 Left crawler travel reverse 12 Engine ignition On/Off
1.3 In CO mode: Tube lower* 13 Heater control
1.4 In CO mode: Tube lift* 14 Crowd / Pulling speed control
1.5 In CO mode + Clamping cylinders selected: 15.1 Winch 1/2 down
Tube unclamp* 15.2 Winch 1/2 up
1.6 In CO mode + Clamping cylinders selected: 15.3 Uppercarriage swing to left
Tube clamp* 15.4 Uppercarriage swing to right
2.1 Right crawler travel forward 15.5 Rigging mode + Backstay cylinders selected:
2.2 Right crawler travel reverse Left backstay cylinder extend
2.3 In CO mode: Oscillate* 15.6 Rigging mode + Backstay cylinders selected:
3 Free-fall / Freewheel release Left backstay cylinder retract
4 Free-fall / Freewheel mode On/Off 15.7 not used
5 Indication: Free-fall / Freewheel released 15.8 not used
6 Crowd fast mode On 15.9 In FOW / TRD mode: Tube rotate right*
7 Horn On 15.10 In FOW / TRD mode: Tube rotate left*
8 In Kelly mode: To dump spoil 16 Emergency STOP
8.1 In CFA / FOW / TRD mode: Auto pull On 17 Auger cleaner retract/extend*
9 In Kelly / CFA mode: 17.1 In FOW / TRD mode: Tube high torque On/Off*
Rotary drive fast mode On/Off 18 Swing brake unlock
9.1 In FOW / TRD mode: 19 Swing brake lock
Auger high torque On/Off* 20 Free-fall / Freewheel release
10.1 Crowd down 21 Pilot control On/Off
10.2 Crowd up 22 Rope retract force control
10.3 In Kelly / CFA mode: 23 Freewheel speed control
Rotary drive rotate right 24 Central lubrication system On /
10.4 In Kelly / CFA mode: Rotary drive rotate left Flashing code
10.5 Rigging mode + Backstay cylinders selected: 25 Warning: Central lubrication system fault
Right backstay cylinder extend 29 Central lubrication On/Off
10.6 Rigging mode + Backstay cylinders selected:
Right backstay cylinder retract
10.7 Rigging mode + Boom cylinders selected: * = not used in this version
Boom cylinders retract FOW = Front Of Wall
10.8 Rigging mode + Boom cylinders selected: TRD = Twin Rotary Drive
Boom cylinders extend CFA = Continuous Flight Auger
10.9 In FOW / TRD mode: Auger rotate right* CO = Casing Oscillator
10.10 In FOW / TRD mode: Auger rotate left*
BG 36/2005 4-1
4.2 BASE MACHINE CONTROL CONSOLE

1 Indicator: Freewheel / Free-fall released
2 Rope retract force adjustment
3 Freewheel / Free-fall mode On/Off
4
4 Diagnostic system monitor
5 Check battery charging
6 Check fuel level 5 6 7 8
7 Check coolant temperature n
min
9 10 11 12
8 Check engine oil pressure
9 Check hydraulic oil temperature
10 Check engine speed 1 13 14 15 16 17
11 Check operating hours 18 19 20 21 22
12 Clock
13 Indicator: Swing brake locked 5 6
3
4
1 2
7
14 Warning: Air filter contaminated
8
1
9
0
10
15 Warning: Hydraulic oil return line filter
contaminated 46 45 44
16 Warning: Pilot oil filters contaminated
17 not used
24 25
18 Warning: Coolant temperature too high
19 Warning: Coolant level too low 29 30
20 Indicator: Valve on hydraulic tank closed
21 Warning: Hydraulic oil level too low
22 not used
23 Right control lever 23
24 Front light On/Off
25 Rear light On/Off
28 Wiper interval adjustment
29 Front window wipe On/Off
30 Roof window wipe On/Off 28 41
31 Air conditioning On/Off
35 Engine idling automatic On/Off 35
36 Load limit sensing control
Manual/Automatic 31
37 Warning: Engine diagnostic
Red indication = Switch engine off!
36
Yellow indication = Observe flash code
39 Electrical socket 37
40 Ventilator On/Off
41 Engine speed adjustment 40
42 Engine ignition On/Off
43 Hourmeter: Operating hours
44 Bypass of end limiters, 00000000
43 39
to restart the engine
45 not used 42
46 not used
B0000763.wmf
BG 36/2005 4-2
4.3 CONTROL PANEL 1
Rope tensioner Mast prop cylinder

On fast tension release retract extend
KDK KDK
high
torque
Winch Rigging Derigging Boom Backstay cylinder Extendable crawlers

rigging extend extend extend retract / extend
Mast Backstay Boom Backstay cylinder Winch

Auto Reset cylinders retract retract retract main aux
AT
1 2
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24
B0000873.wmf
1.1 In Kelly/CFA mode: 15 Extendable crawlers select

Rotary drive high torque On/Off 16 Not used
1.2 In TRD mode: 17 Set mast automatically vertical
Auger high torque On/Off 18 not used
2 Indicator: Rotary drive fast mode 19 In rigging mode:
3 Crowd rope tension Indicator: Backstay cylinders selected
4 Crowd rope relieve 20 In drilling mode: Boom retract
5 not used 21 In drilling mode:
6 not used Left backstay cylinder retract
7 Mast prop retract 22 In drilling mode:
8 Mast prop extend Right backstay cylinder retract
9 Rigging mode: 23 Winch 1 (main winch) select
Winch operation select 24 Winch 2 (auxiliary winch) select
10 Rigging mode select
11 Derigging mode select
12 In drilling mode: boom extend
13 In drilling mode:
Left backstay cylinder extend
14 In drilling mode:
Right backstay cylinder extend
BG 36/2005 4-3
4.4 CONTROL PANEL 2
Casing Drill-/Pull Depth

Travel interrupt
oscillator automatic
CO Auto
Casing oscillator
On CO
unlocking locking clamping cyl.
KDK
KDK
middle
freewheel
torque
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24
B000861.wmf
1 Not used 17 Not used

2 Not used 18 Not used
3 not used 19 Not used
4 not used 20 Rotary drive:
5 Automatic crowd pressure On/Off Middle torque On/Off
6 not used 21 not used
7 Depth measuring interrupt 22 not used
8 not used 23 Not used
9 not used 24 not used
10 not used
11 not used
12 not used
13 not used
14 not used
15 not used
16 not used
BG 36/2005 4-4
4.5 MONITOR UNIT
For Details of the Monitor Unit, please refer to the supplementary documentation sup-
plied with the equipment.
BG 36/2005 4-5
4.6 REMOTE CONTROL FOR CASING OSCILLATOR
1.1 2.1
1.3 2.3
1.2 2.2
4
3.1 3.2
BO000668.wmf
1.1 Tube unclamp

1.2 Tube clamp
1.3 Oscillate
2.1 Tube lift
2.2 Tube lower
2.3 Automatic press mode On
3.1 Casing oscillator unlock
3.2 Casing oscillator lock
4 In automatic press mode:
pressure adjust
BG 36/2005 4-6
OPERATION
5 OPERATION
5.1 TRAVEL
5.1.1 To Select the Travel Mode
The "Travel" mode comes on automatically when the machine is started.
With machines equipped with provisions for 3 4

a casing oscillator, however, a selection must
be made between "Travel" or "Casing Oscilla-
tor" mode to begin with:
To select "Travel":
· Press button (1). CO
Indicator light (3) glows.
To select "Casing Oscillator": 1 2

BK331518.wmf
· Press button (2).
5.1.2 To Travel and Steer
Initial position: Crawler drive wheels to the rear
B0000552.wmf
BG 36/2005 5-1
OPERATION
5.2 UPPERCARRIAGE SWING

5.2.1 Swing brake
The swing brake serves to arrest the uppercarriage against rotation during operation.
Risk of damaging components!

The swing brake may be applied only when the uppercarriage has
CAUTION come to a stop.
Swing brake lock:

· Press button (19);
indicator light (30) comes on. 30
19
Swing brake unlock: 18
· Push button (18);

15.3 15.4
indicator light (30) goes out.
B0000798.wmf
5.2.2 Swing control
Uppercarriage swing to left:

· Unlock swing brake.
· Move control lever (15) to left (15.3) from centre.
Uppercarriage swing to right:

· Unlock swing brake.
· 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 opposed
direction.
BG 36/2005 5-2
OPERATION
5.3 MAST REPOSITIONING
Risk of damaging components !

The mast must be parallel to the drilling axis at all times!
During drilling operation – and especially so in casing oscillator applica-
tions – it is important to watch the inclination of the mast on the opera-
CAUTION tor’s screen. Should the inclination change, due to the forces, the mast
must be repositioned to the original inclination.
Risk of damaging components and risk of rope breaking !

On machines where the winches are housed in the uppercarriage, the
ropes must be sufficiently slackened before the mast is repositioned.
CAUTION Otherwise, the ropes may be subjected to excessive stress.
Risk of damaging components and risk of rope breaking !

On equipment fitted with an overload protection for the main rope, vari-
ous functions will shut off when the rope is overloaded and a message
will appear on the operator's screen.
CAUTION 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.
5.3.1 Mast Auto Reset to Vertical

Neither the mast prop nor components of the drilling equipment may be
CAUTION in touch with the ground when the "Mast Auto Reset" is actuated.
AT Reset
· Press button or 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 36/2005 5-3
OPERATION
5.3.2 Mast Repositioning by Manual Control
5.3.2.1 To Adjust the Mast Inclination
- In Drilling Mode
The rigging modes , and are not se-

lected:
· Extend left backstay cylinder by
· Extend right backstay cylinder by
· Retract left backstay cylinder by
· Retract right backstay cylinder by
- In Rigging Mode
Rigging mode or and backstay cylinders
are selected:
B0000504.wmf
Lowering the mast:
· Move left/right control lever forward
Raising the mast:
· Move left/right control lever back
5.3.2.2 To Adjust the Drill Distance
Increasing machine’s distance to the bore:
· Extend boom cylinders by
Decreasing machine’s distance to the bore:
· Retract boom cylinders by
To adjust the mast parallel (see fig.), the mast

inclination must be readjusted.
NOTE
B0000505.wmf
BG 36/2005 5-4
OPERATION
5.4 MAST PROP CONTROL
The mast prop must be fully extended when strong forces result from the extraction of
the tool.
To extend the mast prop:

· Press button (2) and hold on.
To retract the mast prop:

· Press button (1) and hold on.
Releasing one of these buttons too soon interrupts

the action. 1 2
BK331528.wmf
5.5 TRAVELLING WITH THE RIG

5.5.1 Travelling over Level Ground
Risk of accident due to driver’s 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.
· Travel on firm and level surfaces only.
· Avoid making abrupt movements.
BG 36/2005 5-5
OPERATION
5.5.2 Travelling Up and Down Slopes
5.5.2.1 With Raised Mast without Drilling Equipment
Tipping hazard!
Observe all instructions found in sect. "Travelling over level ground"!
CAUTION
Tipping hazard!
Max. permissible gradient is 5°.
CAUTION Travel straight to the grade only. Never zigzag or traverse!
· Arrange the machine to carry the

mast on the uphill side.
· Tilt the mast slightly forward.
· Travel up or down a slope in the

manner shown here:
B0000757.wmf
BG 36/2005 5-6
OPERATION
5.6 ROTARY DRIVE CONTROL

5.6.1 Kelly Application
1 2
5 6
4
7
2
8
1
9
0
10
on fast
6
KDK KDK
high
torque
4
3 8
4
5
6
Emergency Stop
NOT-AUS
5.1 5.2
3
7
2
8
1
9
10
0
on
5 6
4
3
7
2
8
1
9
0
10
KDK
middle
torque
7 0000 0000
B0000777.wmf
Risk of damaging the planetary gears!

Torques may be shifted only when the rotary drive is out of motion and
CAUTION the drilling tool is not in touch with ground.
Function Control Indicator

To select "High Torque" mode Press button (3) Lamp (1) glows
To select "Low Torque" mode Press button (3) Lamp (1) does NOT glow
To select "Middle Torque" Press button (6) (only possible, Lamp (8) glows
mode (optional) if low torque is selected)
To rotate with the rotary drive in Press button (4) Lamp (2) glows
"Fast" mode
In this mode, the rotary drive
makes max. revolutions under no
load. The higher the load and the
required torque the lower the
speed - down to min. revolutions
at max. torque
To rotate with the rotary drive in Press button (4) Lamp (2) does NOT glow
"Slow" mode
In this mode, the "High Torque"
is available right away
To accelerate rotary speed Move lever (5) away from centre -
To decelerate rotary speed Move lever (5) back to centre -
To rotate counter-clockwise Move lever (5) to right -
To rotate clockwise Move lever (5) to left -
To dump spoil Move lever (5) to left -
(abruptly stopping clockwise and press button (6)
rotation)
BG 36/2005 5-7
OPERATION
5.6.2 Additional Functions
5.6.2.1 To Operate with "Freewheel"
This is a function that permits the rotary drive to coast freely, enabling additional opera-
tion with a casing oscillator without having to remove the casing tube from the casing
drive adapter.
Risk of damaging the rotary drive!

When using a casing oscillator, the freewheel function of the rotary drive
must be activated or the casing tube must be disengaged from the casing
CAUTION drive adapter.
2
"Freewheel" activation:
CO
"Freewheel" deactivation: KDK

Freewheel
Indicator light (2) does not glow.
1
B0000697.wmf
5.6.2.2 To Operate with Torque Amplifier
The equipped BAUER torque amplifier doubles the torque generated by the rotary
drive.
Danger of damaging the swing mechanism, the swing brake or the mast
pivot!
Release the swing brake when the torque input in the amplifier exceeds
CAUTION 50 % of the max. torque output of the rotary drive.
To use the torque amplifier:

· Align the mast at the drilling spot.
· Apply the swing brake.
· With reduced torque (max. 50 %), screw the borehole casing into the ground by
about 3 - 4 m. From this depth on it can be guaranteed that the casing will remain
plumb.
· Release the swing brake and sink the casing by reversible operation with the rotary
drive.
BG 36/2005 5-8
OPERATION
5.7 WINCH CONTROL

5.7.1 Lifting / Lowering
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.
CAUTION
Risk of damaging the rig !

Hoist limiters are out of function during rigging operations so that the
winches must be controlled with great care.
CAUTION
In Drilling mode In Rigging mode
· Set all Rigging controls to OFF. · Select "Winch rigging" mode:
Lamp in buttons , and Lamp in button glows.

do not glow.
Winch selection:
1
· Press button for Main winch or
2
· press button for Auxiliary winch.
Control of selected winch
B0000702.wmf
BG 36/2005 5-9
OPERATION
5.7.2 To Operate with Freewheel
The freewheel function enables the main winch to automatically follow the drilling pro-
gress and prevents the drilling tool getting stuck in soft soil formations.
Preconditions for release of freewheel function:

- Load on rope is maximum: 2.0 tonnes 4 7
1
Freewheeling Slack rope Lift / lower
winch 1 activ limiter Freewheel
5 6
4
7
2
8
9
1
Freewheel activation: 3
10
0
5
· Turn key-operated switch (1) to position of Free-
wheel mode "On".
· Press foot switch (4) all way down and hold on. 2
· Briefly press button (3).

Slack rope
lim iter
5 6
4
7
2
8
9
1
10
0
Slack rope
lim iter
5
4 6
7
2
8
9
1
10
0
Slack rope
lim iter
5
4 6
7
2
8
Þ Freewheel is released ! Indicator (5) glows.
9
1
6
10
0
Slack rope
lim iter
5 6
4
7
8
2
9
1
10
0
BM514501.wmf
The rope will first automatically tension (by up to approx. 500 kg), en-
suring tipped swivel raises to upright. This avoids damage resulting to
NOTE the rope.
Freewheel speed setting:

· By potentiometer (6), set the freewheel speed such that the operating pressure at
the rotary drive will not exceed 200 - 250 bar during the drilling progress. This pre-
vents the drilling tool getting stuck.
Potentiometer setting Freewheel speed

0 Max
10 0
If the potentiometer is set to max, the winch will stop and the indication (5) go out. In
this case, turning the potentiometer 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 position of Freewheel mode "Off".
BG 36/2005 5 - 10
OPERATION
5.7.3 To Operate with "Slack Rope Switch-Off"
The "switch-off" here is a function that enables power-controlled and slack-free unspool-
ing of rope from the main winch.
To activate the Slack rope switch-off:
· Turn potentiometer (7) to right past the 4

switch-point. 5
· Set potentiometer (7) to the desired rope re- 4
5
6
1
3
7
traction force (= the value at which the winch
8
7
9
10
0
is to stop unspooling rope).
2
Potentiometer setting Retraction force [to] 4
5
6
Eme rgency Stop
NOT-AUS
7
2
8
1
9
0
10
1 0 4
5
6
7
2
8
6
9
0
10
10 2.0
00 000000
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
From now on, activation of the "Freewheel" function of the main winch
(see separate sect.) can be used to continue the automatic slack-free
NOTE unspooling of rope.
To deactivate the Slack rope switch-off:
· Turn potentiometer (7) to left up to stop.
BG 36/2005 5 - 11
OPERATION
5.8 DEPTH MEASURING CONTROL

5.8.1 To Reset the Depth Measuring
· Place drilling tool in desired position.

T=0
· Press button , to reset the depth indicator to "0".
The depth measuring may be reset to zero at any time.

NOTE
5.8.2 To Interrupt the Depth Measuring
In CFA applications, the depth measuring must be interrupted every time the drill string
is extended with a new section:
· Press button to interrupt the depth measuring.
· Press the button anew to re-start the depth measuring.
BG 36/2005 5 - 12
OPERATION
5.9 CROWD CONTROL

Do not use the boom cylinders to boost the crowd system.
Or, the crowd system will be overloaded and the drilling axis distorted.
CAUTION
5.9.1 Crowd Control in Kelly Application
5.9.1.1 Manual Control of the Crowd Pressure
30
Drill-/ Pull
automatic
5 6
4
3
7
2
Auto
1
9
10
0
6
10.1 31
B000860.wmf
E m erge ncy S top

N O T-AU S
4 5 6
3
7
2
8
1
9
10
10.2
0
14
4 5 6
3
7
2
8
1
9
10
0
00000000
Start
B0000826.wmf

To select "Manual con- Press button (31). Lamp (30) does not glow.
trol of crowd pressure".
To adjust the crowd Set the potentiometer (14): Lamp (30) does not glow.
pressure. 0 = Max. crowd pressure
(Crowd pressure with 10 = Min. crowd pressure
control lever moved to
max. off centre)
To run the crowd Push control lever (10) Lamp (30) does not glow.
sledge down. forward (10.1).
To run the crowd Pull control lever (10) Lamp (30) does not glow.
sledge up. back (10.2).
To change the crowd Speed changes with the amount Lamp (30) does not glow.
speed. of lever (10) movement.
To operate in Press button (6) and hold on. Lamp (30) does not glow.
fast crowd mode. Move lever (10) off centre.
BG 36/2005 5 - 13
OPERATION
5.9.1.2 Automatic Control of the Crowd Pressure
30
Drill-/ Pull
automatic
Auto
5 6
4
7
2
8
1
9
0
10
6 31
10.1 B000860.wmf
Emer genc y S top

N OT- AU S
4 5 6
3
7
2
8
1
9
10
0
14
4 5 6
10.2
3
7
2
8
1
9
10
0
00000 000
Start
B0000826.wmf

To select Press button (31) Lamp (30) glows.
"Automatic control of
crowd pressure".
To adjust the crowd Crowd pressure adjusts auto- Lamp (30) glows.
pressure. matically to pressure at rotary
drive
= "Anti-jam automatic"
To run the crowd Push control lever (10) Lamp (30) glows.
sledge down forward (10.1) and hold on
= the automatic is on.
To run the crowd Pull control lever (10) back Lamp (30) does not glow.
sledge up (10.2) = the automatic is off.
To change the crowd Regulation of pressure runs Lamp (30) glows.
pressure automatically.
fast crowd mode. Move lever (10) off centre =
the automatic is off.
BG 36/2005 5 - 14
OPERATION
5.9.2 Crowd Control in CFA Application
5.9.2.1 Manual Control of the Crowd
5 6
4
7
2
8
1
9
0
10
6
10.1
E mer gen cy Sto p

NOT- AUS
5 6
4
3
7
2
8
1
10.2
10
0
14
5 6
4
3
7
2
8
1
9
10
0
000 000 00
Start
B0000826.wmf

To run the crowd Push control lever (10) -
sledge down forward (10.1).
To run the crowd Pull control lever (10) -
sledge up back (10.2).
To change the crowd Speed changes with the amount of -
speed lever (10) movement.
To operate in Press button (6) and hold on. Move -
fast crowd mode control lever (10) off centre.
BG 36/2005 5 - 15
OPERATION
5.9.2.2 To Operate with "Auto Pull"
30
Drill-/ Pull
automatic
Auto
5
6
4 6
7
2
8
1
9
10
0
8.1 31
B000860.wmf
10.1
E me rg en cy S to p
NOT- AU S
5 6
4
3
7
2
8
1
9
0
10
14 10.2
4 5 6
3
7
2
8
1
9
10
0
0 0 0 0 0 0 00
Start
B0000829.wmf

To run the crowd sledge Push control lever (10)
up at constant speed. back (10.2), hold on and addi-
tionally press button (8.1) once
= the Auto Pull is on. Lamp (30) glows.
To adjust the pulling Set the potentiometer (14): Lamp (30) glows.
speed. 0 = min speed
10 = max speed
To cancel the Auto Pull. Press button (8.1) anew, or re- Lamp (30) does not glow.
lease control lever (10).
To run the crowd sledge Push control lever (10) Lamp (30) does not glow.
down. forward (10.1).
fast crowd mode. Move lever (10) off centre.
The Auto Pull is off.
BG 36/2005 5 - 16
OPERATION
5.9.3 To Use the Main Winch in Combination with Crowd
Danger of damaging the slewing ring and undercarriage by overloading!

Pulling by the main winch combined with pulling by the crowd system is
CAUTION permissible only under observance of the following instructions.
Pulling by the main winch together with the crowd system is allowed only
– in the case of a 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)
Equipment fitted with a mast prop may have a monitoring automatic

which stops the main winch from pulling during crowd as soon as a cer-
tain value of the combined forces is exceeded.
NOTE Where there is no such monitoring automatic, the operator himself is
responsible for not endangering the capacities of the rig when forces
sum up.
BG 36/2005 5 - 17
OPERATION
5.10 CENTRAL LUBRICATION CONTROL (OPTIONAL)

The central lubrication greases automatically at preset intervals all the spots linked up to
the central lubrication system. Both the length of the lubrications and the length of the
pauses are pre-adjustable.
In addition, a green push-button enables release of lubrication at any time.
The lubrication interval will be interrupted and saved when ignition is turned off, and will
be resumed when ignition is turned on again.
Not all the places to be lubricated are covered by the central lubrication
system. Please, find in the Lubrication Plan the places requiring separate
NOTE lubrication.
During the automatic lubrication, it is recommended to run the crowd

sledge up and down the mast 2 - 3 times in order to distribute the grease
NOTE from the runners to the rails.
Additional lubrication with a grease gun is possible through a free nipple
found on the distributor block on the crowd sledge.
Flashing codes of the green push-button:
1.5 sec.
1
1 System on
2 Lubrication on 2 0.5 sec. / 0.5 sec.
3 Low lubricant level 1 sec. 1 sec.

2 sec. 2 sec.
4 High lubricant pressure 3
5 Lubricator control failure 4 2 sec. 4 sec. 2 sec. 4 sec.
5 Dauerlicht / Permanently
B0000705.wmf
Red warning light:
Indicates a failure in the automatic lubrication of the runners of the crowd sledge. The
failure must be repaired without delay, to avoid extensive damage.
To avoid failures in the central lubrication system, switch OFF central lubri-
cation system during rigging procedure of the rig (switch in the cab).
NOTE
A manufacturer's documentation on the Central Lubrication System is

supplied in the Appendices of this manual.
NOTE
BG 36/2005 5 - 18
OPERATION
5.11 EMERGENCY CONTROL

The emergency control enables the major functions of the equipment still be controlled
in case the normal control system is failing.
WARNING!
Rig damage and tipping hazard!

The emergency control does not allow fine operation of the individual
functions.
The emergency control must be used in an emergency only, to move
the equipment out of a hazardous situation when the normal control is
failing.
The emergency control may be controlled from the operator’s cab only.
How to use:
· Shut down the equipment and stop the

engine.
· In the control cabinet, unplug proces-
sors B1.2 and B1.3 (pull safety lever
down (1) and remove plug (2)).
· Turn the key-operated switch (3) into
2. 2.
"On" position. B 1.2 B 1.3
· Start up the equipment. Now the essen-
tial functions may be controlled by the
control levers. 1. 1.
· When the emergency operation is com-
pleted, shut down the equipment and
stop the engine.
3
· Repair the defect.
· Turn the key-operated switch into "Off"
position.
· Plug in the processors again.
· Start up the equipment.
B0000764.wmf
BG 36/2005 5 - 19
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.
6.1.2 Visual Inspection before Starting
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.
6.1.3 Daily Start-Up
6.1.3.1 Starting the Equipment
Risk of damaging the equipment!

Observe instructions in the manual of the base machine!
CAUTION
· 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.
Risk of damaging the engine!

Allow cold engine to warm up at idle speed for approx. 10 minutes!
CAUTION
BG 36/2005 6-1
Risk of damaging the control!

When starting with the aid of an external power source, first switch off
CAUTION main fuse F1 (BAUER part)!
· Move the safety stick of the pilot control to "On" position.
6.1.3.2 Selecting the Work Application
When the unit has started, a menu comes on display offering the operator to select the
kind of application in which to work.
With equipment designed for one work application only, the Operating
Screen of the respective application will appear right away when the
NOTE unit has started up.
The operator has 10 seconds now to select a new application:
· Touch the button for the desired application
Button 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
CFA with main winch
sustained by main winch pull
HPI Drilling with high-pressure-injection equipment
· Touch .
The Operating Screen of the new application comes on display.
If no new selection is made within 10 seconds, the Operating Screen of

the already selected application comes automatically.
NOTE
BG 36/2005 6-2
6.1.4 Safety Tests before Starting to Work
WARNING!
Serious accident hazard!
Faulty safety devices are dangerous.
All equipped safety devices must be tested prior to starting to 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 36/2005 6-3
6.1.4.3 Checking the End Limiters
Initial situation: Drilling mode selected
- Hoist limiters (HS 1 and HS 2)

· Select main winch.
· Spool in rope and lift the suspended load (approx. 100 kg) slowly up to the contactor
weight.
® The winch must come to an immediate stop.
· Repeat the procedure with the other winch.
- Boom cylinder end limiter (ES 3)

· Extend boom cylinders half way.
® Selection of rigging modes must not be enabled.
· Extend boom cylinders completely.
® Selection of rigging modes must be enabled.
- Mast sideward angle end limiters (ES 2 and ES 4)
WARNING!
Danger of being crushed!
Do not actuate end limiters with your bare hands!
Only actuate them by touching with an object (piece of wood e.g.)
held in your hand.
· 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.
- Mast forward/backward angle end limiter (ES 10, optional)

Pre-condition: Inclinometer out of function
· Retract or extend both backstay cylinders.
® Drilling operation is blocked when a certain mast angle forward or backward is
exceeded.
BG 36/2005 6-4
6.2 SHUT-DOWN
6.2.1 Daily Shut-Down
· Park the machine on firm level ground.

· Set the mast upright.
· Lower attached work equipment, tools and suspended load as close to the ground as
possible.
· Adjust the uppercarriage in line with the crawlers.
· Set all control elements to "0" position.
· Move the safety stick of the pilot control to "Off" position.
· Stop the engine.
Risk of damaging the engine!

If the engine has been operating with a high load, let it run idle for about
CAUTION 5 minutes before stopping, to allow the temperature of coolant and oil
drop and stabilize.
· Before leaving, remove the ignition key and lock the cab.
· Set the battery main switch to "Off" position.
BG 36/2005 6-5
RIGGING / DE-RIGGING
7 RIGGING / DE-RIGGING
7.1 GUIDELINES FOR RIGGING AND DE-RIGGING
· Have assembly job carried out by skilled personnel only.
Severe accident hazard!

The operator must be familiar with all the control elements and their
CAUTION 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.
Rig tipping hazard!

During rigging operations, the uppercarriage must be in line with the
CAUTION undercarriage and be interlocked with the same.
· Select Rigging mode:
To rig up: Press button
To de-rig: Press button
BG 36/2005 7-1
7.2 WAX REMOVAL
· 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.

Detergents used must not be harmful to seals etc.
CAUTION Check detergents for their areas of application prior to use.
BG 36/2005 7-2
7.3 EXTENDING THE CRAWLERS
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.
First extend the left crawler:
Photo shows left crawler with

the idler wheel (1) at the front
NOTE and the drive wheel (2) at the
rear.
BOHSL038.tif
● From the outside, lift up pawl (3) found midway on track carrier of left crawler (see
arrow).
3 3
BK675501.wmf
● Press on control panel to

release the hydraulic, and activate tele-
scoping by the respective control lev-
ers:
1 Right front telescoping cylinder
2 Right rear telescoping cylinder
3 Left rear telescoping cylinder
4 Left front telescoping cylinder
Lever pulled up Þ Cylinder retracts BK675415.jpg
Lever pushed down Þ Cylinder extends
● Remove pins from inclined tubes behind crossbeams, insert into bores (4) and secure.
● Repeat the procedure with the right crawler.
BG 36/2005 7-3
7.4 MOUNTING THE COUNTERWEIGHT
Rig tipping hazard!

Prior to further rigging operations, the machine must be fitted with the
proper counterweights.
CAUTION
WARNING!
Serious injury hazard!
There must be no people on or under the counterweights while they are
being mounted.

Counterweights consisting of several parts are to be transported in up-
right position.
CAUTION
To mount counterweights:
· By an assist crane, lift one by one the

single counterweights in place on the
frame.
· Apply "Loctite 270" thread locker ad-
hesive on counterweight mounting
bolts and screw down tight. Observe
adhesive instructions!
See right: Counterweights from be-

neath. BM779402.jpg
· Fixate counterweights to machine by

long bolt (see arrow) and "Loctite
270".
BK590428.jpg
BG 36/2005 7-4
7.5 ASSEMBLING THE MAST

7.5.1 Mounting the Trestle
· Select backstay cylinder operation by pressing button .
· Using the control levers, retract backstay cylinders and slightly raise the mast.
Risk of damaging the rig!

With the trestle folded to the front, the mast may be raised by max. 20°.
CAUTION
· 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
· Open up the mechanical swing lock.
· Release the swing brake.
· Extend backstay cylinders (1) by control levers, until 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 sup-
ports (4) to be removed from the lower mast section.
1 2 3
4
BM339512.wmf
BG 36/2005 7-5
7.5.2 Assembling the Mast
· 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.

· By 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 2 3
B0000567.wmf
· Install the mast assembly pins and secure.

· Retract backstay cylinders to raise the lower mast section until flange faces meet.

Take care the locating pins are properly in place!
CAUTION
· Bolt the mast section (7) to the lower mast section (6), in the manner shown here.
Bolt torque value in Ma [Nm]: 1850 7 6
1 Hex head bolt

2 Washer
3 Tension bush
4 Hex nut
5 Locknut
6 Lower mast section
7 Upper mast section
1 2 3 24 5
B0000568.wmf
BG 36/2005 7-6
· 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 trans-
port socket (2) and plug it to the next
mast section.
· Check on the ladder that transits in

the fall protection rail (3) are in line.
Readjust at the ladder mounting
points (4) as necessary.
BM400462.jpg
WARNING!
Risk of falling!
Thoroughly check all transits in the fall protection rail are tight, to pre-
vent lanyards slipping out.
BG 36/2005 7-7
7.5.3 Installing the Ropes
7.5.3.1 Installing Main and Auxiliary Rope
The main (4) and the auxiliary (3) rope will be installed while the mast is down.
· Select “Winch rigging” mode by pressing button .

· Remove rope guard pins (1) from masthead.
1
· Select the Main winch by pressing button or the Auxiliary winch by pressing
2
button .
· By left control lever, unspool sufficient length of rope from selected winch.
· Pass ropes over guide sheaves (5) and unspool until rope ends are at contactor
weights (6).
· Thread ropes through contactor weights (6) of hoist limiter switches (7).
· Reinstall the rope guard pins and secure (1).
· Unspool until rope ends are at the machine.

Check contactor weights are properly attached.
CAUTION
1 5 5 1 3 4
1 1 5 7
6
BM091514.wmf
BG 36/2005 7-8
7.5.3.2 Installing the Upper Crowd Rope
· Select "winch rigging" mode by button .
· Extend rope tensioning cylinder (1) by button .

· Remove crowd sledge stoppers from transport position (2) and install them
in bores (3) on upper mast section.
7 1
5 4
3 4 6
5 3 2
7 3 6 2
BK651521.wmf
· Remove crowd rope from transport deposit.
· Move crowd sledge down to lowermost point.
· Pass end of rope behind guide sheave (4), up and around upper left guide sheave
(5) down to guide sheave on sledge (6), counter-clockwise back up to sheave (7) on
upper end of mast to rope tension cylinder (1).
· Anchor rope end with wedge to rope tension cylinder (1).
WARNING!
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.
· Press to tension the crowd ropes.

· Run the crowd sledge up and down several times.
· Run the crowd sledge down to the lowermost point.
· Press to re-tension the crowd ropes.
BG 36/2005 7-9
7.5.4 Raising the Mast
Danger of being injured by falling objects!

All loose objects must have been removed from the mast.
CAUTION
· Select backstay cylinder operation and uniformly and synchronously pull both control
levers back to raise the mast.
Rig tipping hazard!

Do not allow the mast to drift aside. The backstay cylinders must be
CAUTION retracted in a uniform manner and without interruptions.
BG 36/2005 7 - 10
7.6 ASSEMBLY OF WORK ATTACHMENTS

7.6.1 Assembly of Kelly Equipment
7.6.1.1 Mounting the Rope Swivel

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

Mount the swivel in the right way.
CAUTION The lube nipple must be up.
· After mounting, grease the swivel and test it rotates freely.
6
5
1 Main rope
2
2 Pin
3 Lube nipple 4
4 Hex head bolt
5 Lock washer 3
6 Washer
B0000572.wmf
BG 36/2005 7 - 11
7.6.1.2 Mounting the Rotary Drive
· Set mast to upright.

· Move crowd sledge to lowermost point.
· Attach lifting slings to lifting eyes (5), and lift
and put down the rotary drive to front of the 1 1 2 2
mast.
· Suspend the slings to the rig's main rope (3)
(or to the hoist rope of an assist crane, if not
equipped) and lift until rotary drive may be 3
pinned to the sledge.
· Thread the rotary drive onto the sledge, mount
with pins (1 and 2), and secure the pins. 4
On rotary drive fitted with an auxiliary 5 5
lifting lug, the rig's auxiliary rope (4)

may be used additionally to help align
NOTE
the rotary drive.
· Remove lifting slings. B0000700.wmf
· Stop engine.
BG 36/2005 7 - 12
· Connect hydraulic lines.

Connect the leak oil line first.
CAUTION
Connection
Description
No.
1/T Leakoil from KDK
3/A1 KDK 1st axis to right
4/B1 KDK 1st axis to left
5/A2 KDK 2nd axis to right "A"
6/B2 KDK 2nd axis to left
114 151 116
9/SPL Feed oil line to KDK
12/P Control oil supply to KDK 115 152 62 117
Auto casing drive adapter "open" "A" 59
41/Auto (40 bar cyl. retract/oil supply 12/P)
Auto casing drive adapter "close"
42/Auto (100 bar cyl. extend/oil supply 58)
58/Relat. Auger-to-casing "extend" (100 bar)
Auger-to-casing "retract" (150 bar high torque of one
59/Relat. TRD drive - 200 bar low torque of the other)
60/Verrieg. FOW locking "extend" (100 bar)
62/Verrieg. FOW locking "retract" (150 - 200 bar) 1 4 5 12
114/Betons. TRD concrete valve "extend" (100 bar) 9 6 3 58 41
115/Betons. TRD concrete valve "retract" (100 - 200 bar) 60
116/Ausw. TRD ejection slot "open" (100 bar) 42
117/Ausw. TRD ejection slot "close" (100 bar)
151/Lufts. Air intake "open" (100 bar) / Auger cleaner control BK590516.wmf
152/Lufts. Air intake "close" (100 bar) / Auger cleaner control
Hydraulic lines and connections wear

matching identifications.
NOTE
· Connect electric lines.
BG 36/2005 7 - 13
7.6.1.3 Mounting the Kelly
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.
Suspension eye on kelly must face the machine.
NOTE
· Mount rope swivel to eye on kelly, in accor- 1

dance with fig. below.
1 Main rope
2 Rope swivel 2
3 Pin 8
4 Kelly 7 3
5 Lock washer
6 Hex head bolt 6
7 Washer 5
8 Lube nipple
4
B0000621.wmf
· Move rotary drive to lowermost position.
· Tilt mast forward by approx. 2 – 3°.
· By the main winch, lift the kelly as shown to

right and at the same time travel with the
machine towards the kelly.
B0000622.wmf

Keep the main rope vertical at all times.
CAUTION
BG 36/2005 7 - 14
Lift kelly until its square stub is approx. 20 cm above the rotary drive.

Avoid collision with the rotary drive!
CAUTION
· Set mast to upright again.
· 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
· Insert the kelly through the rotary drive.
· Mount drilling tool to kelly with two pins.

At all times, use TWO pins to mount the drilling tool, and do not forget
CAUTION to secure the pins.
BG 36/2005 7 - 15
7.6.2 Mounting Casing Oscillator (Optional)
How to mount a casing oscillator to the machine is described in the

separate manual belonging to the casing oscillator in question.
NOTE
· Pass hoses from casing oscillator

over left and right crawler crossbeam
up to bulkheads "A". A
BM779507.wmf
· Stop the engine of the base machine.
· Remove dust caps from hydraulic connections.
· Mount the hydraulic couplings in compliance with the provided numbers.
· Make electric connection of casing oscillator and base machine.
View "A":
Undercarriage seen from the rear. The identified couplings are found on the front side of
the two bulkheads.
BM779414.jpg
20 Oscillation [P] 28 Locking

21 Oscillation [R] 29 Unlocking
22 Unclamping 30 Leakoil [T] (optional)
23 Clamping PST Pilotoil (optional)
24 Lowering E1 Electric connection (optional)
25 Lifting
BG 36/2005 7 - 16
7.7 DISASSEMBLY OF WORK ATTACHMENTS

7.7.1 Disassembly of Kelly Equipment
7.7.1.1 Removing the Kelly
· Set mast to upright position.

· Lower drilling tool to ground.
· Remove drilling tool.
· Unlock kelly sections and move rotary drive to lowermost position.
· Lift kelly until square stub is approx. 20 cm above rotary drive.
· Tilt mast forward by 2 – 3°.
· Lower kelly until kelly rests with square stub on ground.
· Go on lowering the kelly and at the same time travel in reverse with the machine.
· Remove kelly from main rope.
BG 36/2005 7 - 17
7.7.1.2 Removing the Rotary Drive
· Set mast to upright.

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

Disconnect the leak oil line (1) last.
CAUTION
1 4 5 12
9 6 3 58 41
60
42
BK590516.wmf
· Attach lifting slings to lifting eyes (5).

· Suspend the 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. 1 1 2 2
· Remove pin retainers and pull the pins out
(1 and 2).
On rotary drive fitted with an auxiliary 3

lifting lug, the rig's auxiliary rope (4)
may be used additionally to help align
NOTE the rotary drive.
4
· Lift off and put the rotary drive down on ground. 5 5
B0000700.wmf
BG 36/2005 7 - 18
7.8 DISASSEMBLING THE MAST

7.8.1 Lowering the Mast
· Adjust the uppercarriage in line with the undercarriage, with the mast located on the
same side as the crawler drive wheels.
Risk of colliding the mast with the crawlers!

The uppercarriage must be in the correct position.
CAUTION
· Unspool main and auxiliary rope, and put the ropes on the ground beside the ma-
chine.
· Completely extend the boom cylinders.
· Select the "De-rigging" mode.
· Select Backstay cylinder operation and uniformly and synchronously push both con-
trol levers forward to extend the backstay cylinders. The mast lowers.
Rig tipping hazard!

Take care not to let the mast drift aside during the lowering. The back-
CAUTION stay cylinders must be extended uniformly and without interruptions.
BG 36/2005 7 - 19
7.8.2 Removing Ropes
7.8.2.1 Removing the Main and Auxiliary Rope
The main rope (4) and the auxiliary rope (3) will be retrieved with the mast lying down.
· Select the "Winch rigging" mode by button .

· Remove rope guard pins (1) from the masthead.
1 2
· Select the winch: Press button for the Main winch or button for the
Auxiliary winch.
· Carefully spool in rope by the left control lever.
· Unthread the ropes from the contactor weights of the hoist limiters.
· Spool in both rope ends to the intermediate guide block (2).
· Reinstall the rope guard pins (1) on the masthead.
1 2
1
BM526513.wmf
BG 36/2005 7 - 20
7.8.2.2 Removing the Upper Crowd Rope
To remove the rope, the mast must be lying.

NOTE
14 15 13
X
7 6 2 1
8/9 10 4 3 12
Y
8 7 "X" 6 2 1 3
9 11
9 "Y" 6 2 10 4 16
8 16 3 12
BK587507.wmf
· Move the crowd sledge down to 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 (13) out, 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 36/2005 7 - 21
7.8.3 Disassembling the Mast
· Mount transport supports to upper mast section.

· Undo hydraulic and electric connections between mast sections.
· Unscrew bolts from mast connecting flanges, and stow the bolts for later use.
· Lower the mast until masthead and rear mast supports rest on ground.
· Remove pin retainers from rear side of mast, and pull the pins out.
· Travel in reverse with machine and disengage upper mast section from lower mast
section.
Risk of corrosion!
Corrosion protect flange faces with grease if the storage or transport of
the rig is expected to take long.
CAUTION
7.8.4 Lowering the Trestle
· Mount transport support (4).
· Lower the lower mast section until the transport support rests on the ground.
· Pull pins (2) out of trestle.

Prevent the pins dropping down.
CAUTION
· Retract backstay cylinders until trestle (1) rests on bearing point (3).
4 3
BM639515.wmf
BG 36/2005 7 - 22
7.9 REMOVING THE COUNTERWEIGHT
WARNING!
There must be no people on or under the counterweights while they are
being removed.

Counterweights consisting of several parts are to be transported in up-
right position.
CAUTION
To remove counterweights:
· Unscrew long bolt (see arrow).
BK590428.jpg
· Suspend the outer counterweight to an

assist crane.
· Unbolt the suspended counterweight
from the frame and lift off.
· Repeat the procedure with the next
counterweight.
See right: Counterweights from be-

neath.
BM779402.jpg
BG 36/2005 7 - 23
7.10 RETRACTING THE CRAWLERS
Begin with the right crawler.
Photo shows left crawler with

idler wheel (1) at the front and
NOTE drive wheel (2) at the rear.
BOHSL038.tif
● Remove pins (4) and stow them away in inclined tubes behind crossbeams.
● Press on control panel to

release the hydraulic, and activate
telescoping by the respective control
levers:
1 Right front telescoping cylinder
2 Right rear telescoping cylinder
3 Left rear telescoping cylinder
4 Left front telescoping cylinder
Lever pulled up Þ Cylinder retracts BK675415.jpg
Lever pushed down Þ Cylinder extends
● Retract crawler until pawl (3) snaps to fixate the track carrier (arrow).
● Repeat the procedure with the left crawler.
3 3
4
BK675501.wmf
BG 36/2005 7 - 24
TRANSPORT
8 TRANSPORT
8.1 SAFETY GUIDELINES FOR TRANSPORT

· Only use hoisting equipment and lifting slings that have sufficient capacity.
WARNING!
Danger of serious accidents!
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.
Lifting points on individual components are painted RED.
The hoist rope must be vertical at all times, to prevent swinging.

If the load begins to swing, land it immediately and readjust until the
rope is vertical again.
CAUTION
· 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
a road or on a construction site and that they 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 haulier in charge is responsible for the transport of the equipment, the machine
and accessories.
· The haulier should be informed of the transport dimensions and weights and the
route.
· A road permit must be asked for.
BG 36/2005 8-1
TRANSPORT
8.2 MEASURES TO TAKE FOR TRANSPORT

MACHINE
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 have been removed from the mast,

- the mast is lowered,
- the upper mast section is removed,
- the lower mast section is removed (as necessary),
- 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 counterweights have been removed (as necessary).
After loading
· Underpin the lower mast section with transport supports and secure.
· Put the safety stick of the pilot control to "Off" position.
· Stop the engine and remove the ignition key.
· Lock the cab and remove the key.
· Put the battery main switch to "Off" position.
· Tie the machine safely down to the deck of the transporting vehicle.
EQUIPMENT
· The rotary drive must be in upright position during the transport.
BG 36/2005 8-2
TRANSPORT
8.3 DRIVING ON/OFF A LOWLOADER
Aufrüsten Abrüsten
6.
7.
9. 9.
5. 10. 10.
5
4 6
7
2
8
1
9
0
10
11. 11.
8. 8.
2. 4.
00 000 000
3.
1.
max.40°
9 10
11
? ? 10 A
?
B0000818.wmf
1 Set battery switch to "ON" 7 Select backstay cylinders rigging mode

2 Release "Emergency STOP" button 8 Slightly raise lower mast section by right and left
3 Start engine control lever
4 Adjust engine speed 9 Travel forward by pushing both levers forward
5 Move pilot safety stick to "ON" 10 Travel reverse by pulling both levers back
6 Select rigging mode 11 Lower mast section by right and left control lever
Risk of damaging the equipment!

With the trestle still folded to the front, the lower mast section must not
be raised by more than 40°.
CAUTION
BG 36/2005 8-3
TRANSPORT
8.4 LIFTING POINTS
BM638505.wmf
Risk of damaging the machine!

Do not lift the machine, when the trestle is folded to the front.
CAUTION
BG 36/2005 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 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.
Example of tying points
CI439400.jpg
BG 36/2005 8-5
TRANSPORT
8.6 TRANSPORT DATA

Dimensions in [mm]
3250
1550
3400
1400
1050
12300
12200
715
ø350
2200
1550
3600 10300 1700 6030
2350
3450
3420
3100
2696
1200
1895 4600
715
300
10600 5660
3350 4150
1600
1600
1600
2350
3450
200 200 575
12300 4150
600
200
16450
2000
2240 R 4500
800
BM795500.wmf
BG 36/2005 8-6
TRANSPORT
Weights
Unit Weight in [tonnes]
Machine with lower mast section and mast extension without
73.0
counterweights
Counterweights 10.5 + 5.3 + 5.3
Upper mast section with masthead 7.0
Mast extension 1.5 (Optional)

Masthead 1.8
Lower mast section 22.2
with backstay cylinders and with mast pivot
Rotary drive 7.8
Transport width
Unit in [mm]
Upper mast section with mast head 1960
Upper mast section without mast head 1700
Masthead 1560
Lower mast section 2450
Undercarriage 3300
Width of the track pads 800
Counterweights 3000
Rotary drive 2600
BG 36/2005 8-7
MAINTENANCE
9 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.
· Replace with genuine spare parts from the BAUER company only.
· Observe the "Safety Information" book 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 three months
- Every 1000 hours of operation or yearly
- Every 2000 hours of operation or yearly
- Every 3000 hours of operation or two years.
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.
Loss of the equipment warranty!

Maintenance carried out on the equipment shall be entered into the sup-
plied "Maintenance and Repair Log". This is to be done by the person who
CAUTION carried out the job and be signed by himself and a foreman.
In case of a warranty claim, BAUER shall have the right to consult the log.
BG 36/2005 9-1
MAINTENANCE
9.3 MAINTENANCE PLAN

9.3.1 Entire Equipment
Table Entire equipment maintenance

Item Prescribed intervals
10 hrs 50 hrs 250 hrs 500 hrs 1000 hrs 2000 hrs 3000 hrs Note
daily weekly monthly monthly yearly yearly 2 years
Service
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
* only during the first run-in
BG 36/2005 9-2
MAINTENANCE
9.3.2 Components
Table Components maintenance

10 hrs/ 50 hrs/ 250 hrs/ 500 hrs/ 1000 hrs/ 2000 hrs/ 3000 hrs/ Note
Service daily weekly monthly 3 months yearly yearly 2 years
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 36/2005 9-3
MAINTENANCE
Table Components maintenance continued

Winches
- Check oil level in
main winch X
auxiliary winch X
crowd winch X
- Change oil in
main winch X* X
auxiliary winch X* X
crowd winch X* X
- Grease counter bearings of
main winch X
auxiliary winch X
crowd winch X
- Check mounting bolts of winch X*
trestles are firm; re-tension them
- Replace mounting bolts of winch 10000 hrs
trestles
Cylinders
- Clean piston rods X
- Check cylinders are tight X
- Grease joints X
Bearings and bearing pins
- Grease all bearings and bearing X
pins fitted with lube nipples
Wire rope and accessories
Rope, sockets and end fittings
- Check for wear and damage X
Rope swivel
- Grease X
- Check mounting pins are firm X
- Check swivel is free to rotate X
Rope hold-down rollers
- Check roller is parallel to winch X
drum
Rope guide sheaves
- Check for wear and damage and X
excessive play
- Check sheaves are free to rotate X
- Check sheave centre pins are X
firm
- Put grease in lube nipples where X
fitted
BG 36/2005 9-4
MAINTENANCE
Table Components maintenance continued

Rope roller brackets

- Check mounting bolts of roller X*
brackets are firm; re-tension them
- Replace mounting bolts of roller 10000 hrs
brackets
BG 36/2005 9-5
MAINTENANCE
9.3.3 Work Equipment
Table Work equipment maintenance

Rotary drive
Rotary drive
- Clean 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
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 36/2005 9-6
MAINTENANCE
9.3.4 Uppercarriage
Table Uppercarriage maintenance

Engine Observe separate manual for the engine!!
Cooling system Observe separate manual for the engine!!
Pump distributor gearbox

- Check oil level X
- Change oil X* X
Hydraulic system
Hydraulic tank
- Check oil level X
- Change oil X* X
- Take oil sample and check it X
Hose assemblies
- Have them checked for damage X
by a skilled person
Filter replacement
- Pilot-oil filter element X* X
- Return-flow filter element X* X
- Leak-oil filter element X* X Or on con-
- Secondary filter element X* X tamination
- Free-fall filter element X* X indication
- Rotary drive filter element X* X
- Filler filter element X
Pressure accumulators
- Check pre-tension pressure X* X
Oil cooler
- Clean X
- Check for damage X
Swing mechanism
- Grease external gear teeth on X
swing ring
- Grease ball bearing race and X* X
rotor bearing
- Retension mounting bolts X* X
BG 36/2005 9-7
MAINTENANCE
Table Uppercarriage maintenance continued

Service daily weekly 3 months monthly yearly yearly 2 years
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
Table Undercarriage maintenance

Service daily weekly. monthly monthly yearly yearly 2 years
Crawler track assemblies

Visual inspection
- Check for missing or damaged X
parts
- Visually check mounting bolts of X
crawler drive wheels, tread rollers
and gear cases are firm; tighten
up as necessary
Crawler drives
- Check oil level X
- Change oil X* X
Crawler tracks
- Check track tension X
- Check mounting bolts of track X
pads are firm
Telescoping surfaces
- Clean and grease X
BG 36/2005 9-8
MAINTENANCE
9.3.6 Optional Equipment
Table Optional equipment, maintenance

Air conditioning
- Put air conditioner into operation X 2 - 3 weeks
- Clean air filter (optional) X
- Clean condenser X
Compressor Observe separate manual for the compressor!!
- Clean cooling ribs X
- Clean suction air filter X
- Replace suction air filter X
- Clean lube oil filter X
- Replace lube oil filter X
- Change oil X* X
- Check maintenance unit X
- Drain condensate X
after every
on compressor, maintenance unit,
use
pressure accumulator 70 l
CRT System (Oxidation-type catalytic converter)

- Measure the counter pressure of X
the exhausts treated by the CRT
system
BG 36/2005 9-9
MAINTENANCE
9.4 LUBRICATION PLAN

11000h
10h 18
1000h 21
250h 17 22 250h
23 1000h
250h 15 2 50h
50h 31
3 50h
10h 14 4 50h
50h 20 24 1000h
50h 13 30 50h
50h 12 5 50h
25 250h
50h 11 1000h 19
50h 10
250h 9 10h 29 28 50h
50h 8
50h 6 50h 26 26 50h
250h 7 27 250h
BV737506.wmf
Every 10 hours of operation: Every 250 hours of operation:

14 Rope sheaves * 7 Supporting trestle pin
18 Rope swivel * 9 Mast support joint
29 External gear ring * 15 Crowd cylinder joint **
17 Crowd cylinder joint **
22 Crowd rope tensioning cylinder joints *
25 Rope sheaves (optional) *
27 Crawler cylinder joints (optional) *
Every 50 hours of operation: Every 1000 [yearly] hours of operation:

2 Guide rails 1 Masthead rope sheaves *
3 Rope sheaves * 19 Crowd rope sheave *
4 Backstay cylinders joints 21 Crowd rope sheaves*
5 Boom cylinders joints 23 Crowd rope sheave *
6 Boom pin 24 Ballast cylinder attachment (optional)
8 Mast pivot assembly pin*
10 Mast pivot assembly joints
11 Boom cylinders joints
12 Mast supporting cylinder joint
13 Auxiliary winch bearing
20 Crowd winch bearing
26 Crawler guides * *) Grease lubrication points manual
28 Swing gear bearing * **) not used in this version
31 Rotary shaft seal *
BG 36/2005 9 - 10
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 r.p.m. range
for about 1 hour.
Risk of engine damage!

If engine starting will not be possible during the standstill, preservation
measures must be taken. To do so, please refer to the manufacturer’s
CAUTION manual of the diesel engine.
Air conditioning
· Every 2 to 3 weeks, turn the air conditioning on (if equipped) for a short while.
Slewing ring
· Preserve gear teeth.

· From time to time during the standstill, remove dust and inspect the surface of teeth
and drive pinion for beginning corrosion; clean and grease as required.
Telescoping guides on undercarriage (only with extendible crawlers)
· Preserve the telescoping surfaces with grease.
BG 36/2005 9 - 11
MAINTENANCE
9.6 HYDRAULIC SYSTEM

9.6.1 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 re-
placed 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.
Storage and service life

· Hoses and hose assemblies are to be stored in a cool and dry place free of dust.
Direct exposure to sunshine or UV-rays should be avoided.
Storage and service life

Hose Hose assembly
Storage time 2 years 2 years
Service life
6 years
(including storage time)
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 36/2005 9 - 12
MAINTENANCE
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 damaging the piston rod!

Do not clean cylinder piston rods with a water jet, sharp tool, caustic lye
CAUTION or an abrasive.

Immediately repair or replace cylinders that are not tight.
CAUTION
· Every 50 operating hours or once a week, grease the cylinder lugs (holes for pins).
On cylinders that are kept extended during rest:
· 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 36/2005 9 - 13
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.
Danger of oil spray!

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

upright.
· Unscrew and remove the oil dipstick (1). 1
· Dry the dipstick with a clean and lint-free cloth.
· Reinstall the stick, completely. max.
· Pull the stick out again and read it: min.
· If the oil has sunk to the MIN mark, top up with 2

new oil and check again. 3
The MAX mark must not be exceeded.
· Clean sealing surfaces, check seal for wear B0000574.wmf
and damage, replace it as required.

· Reinstall the dipstick and screw it down tight.
Winches with sight glass
Checking of the oil level can be performed with

the winch in any position. 2
· 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), max.
20 mm
then recheck the oil level. Be sure to avoid the min.
oil level exceeding the upper limit ("max." =
winch centre line).
· Clean sealing surfaces, check seal for wear
and damage, replace it as required. 1
B0000846.wmf
· Reinstall the screw plug and screw it down
tight.
BG 36/2005 9 - 14
MAINTENANCE
9.7.2 Changing Gear Oil
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.
Danger of oil spray!

Change oil only when the winch is off.
CAUTION
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 gear-
1
box.
· At low outdoor temperatures, flush the empty max.
gearbox with a warmed-up part of the new oil. min.
· Clean sealing surfaces, check seal for wear and 2
damage, replace it as required.
3
· Reinstall the drain screw.
· Refill with new oil. B0000574.wmf
· Check the oil level.
· Reinstall the oil dipstick (1) and screw it down
tight.
Winches with sight glass
Changing of the gear oil can be performed with the
2
winch in almost any position.
· Unscrew and remove any of the screw plugs (2).
· Unscrew and remove any of the screw plugs (1)
and allow the gear oil to drain. max.
20 mm
· At low outdoor temperatures, flush the empty min.
gearbox with a warmed-up part of the new oil.

· Clean sealing surfaces, check seal for wear and
damage, replace it as required. 1
· Reinstall the screw plug (1). B0000846.wmf
· Refill with new oil.

· Reinstall the screw plug (2) and screw it down
tight.
9.7.3 Lubricating Counter Bearings
Every 50 operating hours or weekly, grease counter bearings.
BG 36/2005 9 - 15
MAINTENANCE
9.8 WIRE ROPE ACCESSORIES

9.8.1 Rope Swivel
Every 10 operating hours or daily:

1
· Apply grease to nipple (2) until grease exits from the
housing.
2
· Test the swivel rotates freely.
Conduct the test by hand, without load suspended to
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. Re-
tension them as required, to the proper torque. Re- 3
place tie bolts with new ones when they are torn or
B0000576.wmf
have excessive play.

Immediately inspect the swivel for damage after an accidental drop of
CAUTION the kelly bar.
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 B0000509.wmf
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.
· 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 respec-
tively 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 springs will have to be pre-tensioned correspondingly.
BG 36/2005 9 - 16
MAINTENANCE
9.8.3 Rope Fasteners, Thimbles and Sockets
· Check 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.
Danger of rope breaking!

If a defect is found on a rope fitting, cut off the rope end and re-fit it.
CAUTION
BG 36/2005 9 - 17
MAINTENANCE
9.8.4 Rope sheaves
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.
CAUTION Repair or replace as necessary sluggish or seized rope sheaves if greas-
ing will not do.
9.8.4.1 Greasing Rope Sheaves
Rope Sheave Type Prescribed interval Maintenance instructions

Rope sheaves with fric-
tion bearings
10 Operating hours/
daily
BM659821.jpg
Rope sheaves with rol-

ler bearings
Risk of damaging the
bearing sealing !
1000 Operating hours/ Grease during rotat-
yearly ing rope sheave.
CAUTION Fill in grease slowly
to prevent squeeze
out bearing sealing.
BM659822.jpg
Rope sheaves greased

by the central lubrica-
tion system
automatical
BM659823.jpg
BG 36/2005 9 - 18
MAINTENANCE
9.8.4.2 Checking Rope Sheaves
Service Prescribed interval Maintenance instructions
Check the rope sheaves 250 Operating hours/

are free to rotate. monthly
Check sheave centre

pins have the proper 250 Operating hours/
bearing play and are monthly
properly in place.
Check for burrs and

edges on the sheaves
Re-machine the groove, or replace
and that grooves in 1000 Operating hours/
the sheave with a new one, if the
sheaves still comply yearly
groove does no longer comply.
with the diameter of the
rope used.
BG 36/2005 9 - 19
MAINTENANCE
9.9 ROTARY DRIVE

9.9.1 Routine Inspection
· Clean the rotary drive with a water jet.

· Inspect all components for wear and
damage.
On rotary drives with shock absorbers 1
check especially: 2
3
- Buffer ring (1) 4
- Spring-loaded ring (2)
- Compression springs (3)
- Shock absorbers (4)
· Check the rotary drive for leaks. B0000577.wmf

At once, replace damaged components with new ones.
CAUTION
BG 36/2005 9 - 20
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 hours of operation or daily.
· Set the rotary drive to upright position.

· While the drive is out of motion, check the oil level.
The oil must reach half way up the glass (see fig.).

At all times, watch for proper oil level.
CAUTION
B0000624.wmf

If the oil is cloudy, water has intruded and the oil must be changed im-
mediately. Drain and thoroughly flush the drive repeatedly with the new
CAUTION oil before refilling.

A too high oil level in the main gear is an indication of a defect in the
planetary gears. Shut down the rotary drive and repair.
CAUTION
BG 36/2005 9 - 21
MAINTENANCE
9.9.3 Changing the Oil
Main Gear
The oil in the main gear must be changed after the first 250 operating hours and subse-
quently 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
To change the oil:
· Shut down the rotary drive.

Ansicht "A"
· Place the rotary drive such that drain screws View "A"
2 2
(1) are in their lowermost position.
· Unscrew filler screws (2).
· Have an oil collecting container ready. Ansicht "B"
Ansicht "A"
View "A"
View "B"
· Fit a plastic tube or hose of suitable size and
length from the drain to the container!
1
· Unscrew drain screw(s) (1) and let the oil out.
Ansicht "B"
View "B"
B0000578.wmf
Danger of scalding !
Hot gear oil can cause severe injury!
CAUTION
· Inspect magnets on all drain screws and 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
BG 36/2005 9 - 22
MAINTENANCE
· 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
Danger of damaging the gear!

Do NOT use petrol (gasoline), petroleum or diesel oil for rinsing here.
Allow the rinsing fluid to drain off completely.
CAUTION
· Replace seals (if equipped), reinstall drain screws and tighten them.
· Refill with new oil, and let the oil settle.
If there is no oil to be seen in the sight glass after the gear has been
refilled with the proper quantity of oil, close the filler neck, start the en-
gine and let the drive rotate for a short while, to bleed the lines free of
NOTE
air that may be have been trapped.
· Reinstall the filler screws and tighten them.
BG 36/2005 9 - 23
MAINTENANCE
9.9.4 Oil Sampling
Every 250 operating hours or monthly, take an oil sample from the main and planetary
gears and inspect it:
· 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 100°C (212°F). This makes gear oil wear out prematurely and lose
the lubricating effect so that the oil change intervals must be shortened correspond-
ingly.
· Inspect the oil for water and dirt.

If the oil is found to be contaminated or water has intruded, 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 gear-
box must not exceed 0.15 %. Particles found in the oil must not exceed 5 mm in size
(as measured in compliance with DIN 51592); if they do - no matter the amount - the
rotary drive will have to be removed and taken apart.
BG 36/2005 9 - 24
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 the mounting bolts (2) are properly

in place and firm. 1 1 1
Risk of damaging the drive!

Do not re-tension these bolts unless
necessary, or the Loctite seal of the
bolts will break making the bolts loosen
CAUTION
during operation. Check visually only.
Do not put fingers into the bores.
1
Turning around the rotary drive enables 2
checking all the bolts.
NOTE
Ansicht von unten:
View from below:
1
· Unscrew mounting bolts found to be loose, clean
them and apply Loctite to threads, reinstall and ten-
sion the bolts with the specified torque.
1 1
1
BHVSF177.wmf
Bolt torque value

Ma[Nm]
Hollow shaft mounting (2)
Hex head bolts see Spare Parts List
BG 36/2005 9 - 25
MAINTENANCE
9.9.6 Kelly Driver and Guide Flange
9.9.6.1 Checking the Mounting Bolts
· Visually, check mounting bolts of kelly driver and

guide flange (1 and 2) are properly in place and
firm.
Risk of damaging the drive!

Do not re-tension these bolts unless
necessary, or the Loctite seal of the bolts
CAUTION will break making the bolts loosen during
operation. Check visually only.
1
2
· Unscrew mounting bolts found to be loose, clean
them and apply Loctite to threads, reinstall and ten- B0000579.wmf
sion the bolts with the specified torque (see below).
Bolt torque value

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

Hex head bolts see Spare Parts List
Set screws with nut see Spare Parts List
Replacing 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 36/2005 9 - 26
MAINTENANCE
9.9.6.2 Checking Driver Strips for Wear
· Check kelly driver strips (5) for wear.
· 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
Bolt torque value

Ma [Nm]
Kelly driver strips mounting
Hex socket head bolts see Spare Parts List
Hex socket head bolts with nuts see Spare Parts List
1
2
3
4
5
x y
6
B0000727.wmf
BG 36/2005 9 - 27
MAINTENANCE
9.9.7 Cardan Joint

· Check suspension pins (see arrow) are properly in place and firm, with the holes for
the pins completely assembled.
· Check rubber buffers for damage.
K0000501.wmf
BG 36/2005 9 - 28
MAINTENANCE
9.9.8 Sledge Sliding Strips
· Check the wear on the strips (1) in the runners (4) of the crowd sledge.
· Where the remaining thickness (X) is found to be less than 21 mm, replace with
a new strip (see below).
"A"
B-B
1
"A" B B
4
B0000582.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 36/2005 9 - 29
MAINTENANCE
9.10 CRAWLER TRACK ASSEMBLIES

9.10.1 Routine Inspection
· 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:
- Track pads (1)

- Track links (2)
- Carrier rollers (3)
- Front idlers (4)
- Track guides (5)
- Tread rollers (6)
- Crawler drive wheels (7)
- Gear cases (8)
1 2 3 4
8 7 6 5
B0000676.wmf
On machine with crawlers extended, the crawler telescoping surfaces

should be kept corrosion protected with grease.
NOTE
BG 36/2005 9 - 30
MAINTENANCE
9.10.2 Crawler Tracks
9.10.2.1 To Check the Track Tension
Check track tension every 10 operating hours or daily.

1 - 1,5 m
2-3 cm
· Thoroughly clean each crawler, track
and rollers.
· Travel forward a bit with the machine 1 - 1,5 m

and then park it. 2-3 cm
· Using a straight rod, measure the sag

of 1 - 1.5 m length of track in midway
(see fig.): The distance from the rod to 1 - 1,5 m
the track should be approx. 2 – 3 cm. 2-3 cm
Otherwise, the track tension must be
readjusted.
B0000680.wmf
9.10.2.2 Adjusting Crawler 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 track tension again after a short travel forward and backward, and top up
with more grease as necessary.
· Reinstall the cover plate.
BG 36/2005 9 - 31
MAINTENANCE
To loosen the track
2
5
1 3 4
B000000725.wmf
· Remove cover plate.

· Unscrew the safety valve (1) by approx. 3 revolutions (SW 41) until excessive grease
escapes at the spot identified with (4).
WARNING!
Injury hazard by pressurized grease!

Unscrew the safety valve with great care only.
· 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!
Injury hazard by loaded spring!

If a track tensioner is defective, replace it completely with a new one.
Do not attempt to repair it, for safety reasons.
BG 36/2005 9 - 32
MAINTENANCE
9.10.3 Checking Mounting Bolts
· Check visually mounting bolts are tight.

· Retension bolts that are loose.
5 8 2 1
4 3 6
BK587502.wmf
BK587440.jpg BM564683.jpg
Bolt torque value Prescribed intervals in

Bolted connection
Ma [Nm] operating hours
Track pad (1) 1410+70 50

Carrier roller (2) 560 250
Track guide (3) 560 250
Tread roller (4) 720 250
Crossbeam (5) ─ 250
Drive wheel (6) 1600 250
Gear case (7) 1100 250
Telescopic cylinder mounting 280 250
Swing ring (8) 960 After the first 250
and then every 2000
BG 36/2005 9 - 33
MAINTENANCE
9.10.4 Crawler Drive Gears
9.10.4.1 Checking the Oil Level
Check the oil level every 250 operating hours or monthly.
· Move machine until oil drain plug (2) on

crawler drive wheel is in lowermost posi-
tion.
· Unscrew inspection/filler screw (1) to-
gether with seal (if equipped).
The oil must reach the lower edge of the
filler opening; top up with oil as neces- 1
sary.
· Clean inspection/filler screw and sealing
surfaces on housing, and replace with
new seals as necessary. 3
· Reinstall the inspection/filler screw with 2
new seal and tighten.
B0000514.wmf
9.10.4.2 Changing the Oil
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.
· Move machine until oil drain plug (2) on

crawler drive wheel is in lowermost posi-
tion.
· Unscrew inspection/filler screw (1) to-
gether with seal (if equipped).
· Place an oil collecting container under-
neath the drain. 1
· Unscrew the drain plug (2) and let the oil
out.
· Clean screw and plug and sealing sur-
faces on housing.
3
· Reinstall drain plug with new seal and
screw tight. 2
B0000514.wmf
· Refill with new oil to proper level.
· Reinstall inspection/filler screw with new
seal and screw tight.
BG 36/2005 9 - 34
MAINTENANCE
9.10.5 Checking and Adjusting Crossbeam Play (Optional)
The play at the two crawler crossbeams must be checked after the first 250 operating
hours and subsequently every 1000 operating hours.
Starting position:
− Both crawler crossbeams extended
− The pins installed
9.10.5.1 Play at Beam Centres
Detail X: 1 2 2
s2
1 Bolts 3 3
2 Cover with pressure pin
x
s1
3 Distance plates
4
4 Small pressure pin 4
Y Z
Bm779511.wmf
To check the play:
· Unscrew bolts (1) and remove the cover and pressure pin (2).
· Measure the length of the pin (s2).
· Measure the depth of the bore (s1).
s1 − s2 = ∆x = play
Permissible play ∆x: 0 mm − 0.5 mm.
To adjust the play:

· Remove the respective distance plate (3).
· Reinstall the pressure pin and cover, and screw down the bolts (1) with 540 Nm.
BG 36/2005 9 - 35
MAINTENANCE
9.10.5.2 Play at Beam Ends (Optional)
Detail Y: Y Z
1 Wedge
2 Bolts
3 Distance plates
Y
1 1
2
2
3
3
Bm779512.wmf
To measure the space:
· Measure with an inside caliper the space ∆Y between the wedge and the cross-
beam.
Permissible space ∆Y: 0.5 mm − 0.1 mm
To adjust the space:

· Slacken bolts (2) to loosen the wedge
(1).
· If the wedge will not loosen,
tension the extraction bolt (4).
· Remove the respective plate (3) in com-
pliance with the table below:
BM564690.jpg
Thickness of distance plate in mm Altered space at wedge in mm

0.5 à 0.09
1.0 à 0.18
2.0 à 0.35
3.0 à 0.53
· Screw down bolts (2) with 960 Nm to tighten the wedge.
· Adjust space DY with the same procedure.
BG 36/2005 9 - 36
MAINTENANCE
9.11 BOLTED CONNECTIONS

· After the first 250 operating hours, re-tension all the bolted connections described in
the following.
Generally, apply the prescribed torque on these bolts to tension them

("torque pretension method").
NOTE
Bolted connections of Mast sections
· 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 36/2005 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.
Risk of damage to the equipment and loss of the equipment warranty!

A damage resulting from non-observance of lubricant instructions in this
CAUTION 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 -20°C to 40°C (-4°F to 104°F).
NOTE Information on applications below -20°C and above 40°C can be or-
dered from the BAUER Service Centre.
BG 36/2005 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.
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.
Table Initial lubricant fill

Qty.
Application Specification Viscosity grade Producer Name of product
[litres]
Gear oils,
CLP
petroleum
Rotary drive
ISO VG 220 ARAL DEGOL BG 220 100.0
main gear (final drive)
Pump distributor ISO VG 220 ARAL DEGOL BG 220 8.5
Crowd winch ISO VG 220 ARAL DEGOL BG 220 15.0
Gear oils,
API
petroleum
*) At 40° C:
2
Gear oils, 38 mm /s
ATF
petroleum At 100° C:
2
7.1 mm /s
Gear oils,
CLP PG
synthetic
Main winch ISO VG 220 AVIA AVIALUB VSG 220 15
Auxiliary winch ISO VG 220 AVIA AVIALUB VSG 220 3
*) 40° C = 104° F; 100° C = 212° F
BG 36/2005 10 - 2
LUBRICANTS / TABLES
Specifica- Qty.
Application Viscosity grade Producer Name of product
tion [litres]
Hydraulic oil, HVLPD

petroleum
Hydraulic systems ISO VG 46 ARAL Vitam VF 46 660
Hydraulic oil, HEES

fixed (biodegradeable)
Engine oil, API CF-4

petroleum
Engine SAE 15W-40 ARAL Aral Multi Tuboral 32
SAE 15W-40
Crawler drive gears SAE 15W-40 ARAL Aral Multi Tuboral 2 x 20
SAE 15W-40
Grease, KP2N-20 Multi-purpose

petroleum NLGI- grease on lithium
Grade2 soap base
Roller bearings/ ARAL Aralub HLP 2
friction bearings
Central lubrication ARAL Aralub HLP 2
system
BG 36/2005 10 - 3
LUBRICANTS / TABLES
10.1.3 Lubricant Guide
10.1.3.1 List of Approved Gear Oils, Petroleum - CLP
Table Gear oils, petroleum - CLP

Specification
Application DIN 51517 /
DIN 51502
Petroleum gear oils CLP
Viscosity grade
2
ISO-VG / DIN 51519 at 40° C (104° F) in mm /s
Producer
VG 100 VG 150 VG 220
Product
ARAL ARAL ARAL

ARAL
Degol BMB 100 Degol BG 150 Degol BMB 220
SHELL SHELL Omala 100 SHELL Omala 150 SHELL Omala 220
BP Energol BP Energol BP Energol
BP
GR-XP 100 GR-XP 150 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
NL Gear NL Gear NL Gear
CHEVRON
Compound 100 Compound 150 Compound 220
ESSO Spartan EP 100 Spartan EP 150 Spartan EP 220
FINA Giran 150 Giran 220
EP Lubricant EP Lubricant
GULF
HD 150 HD 220
TEXACO Meropa 150 Meropa 220
TOTAL Carter EP 150 Carter EP 220
KLÜBER Unimoly Oil 100 Unimoly Oil 150 Unimoly Oil 220
ELF Reductelf SP 100 Reductelf SP 150 Reductelf SP 220
Renep
FUCHS
Compound 106
AGIP Blasia 100 Blasia 150 Blasia 220
DEA Falcon 100 Falcon 150 Falcon 220
PANOLIN Mecano ISO 220
BG 36/2005 10 - 4
LUBRICANTS / TABLES
10.1.3.2 List of Approved Gear Oils, Petroleum – API
Table Gear oils, petroleum – API
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
Gear oil HYP

ARAL Gear oil HYP 90
SAE 85W-90
SHELL SPIRAX
SHELL
MB 90
Energear
BP Energear Hypo 90
Hypo 85W-90
Mobilube
MOBIL Mobilube HD-A 90
HD 85W-90
AVIA
AVIA
HYPOID 90 EP
CASTROL Castrol EPX 90
RPM Universal
CHEVRON Gear Lubricants
SAE 80W-90
ESSO GEAR OIL ESSO GEAR OIL
ESSO
GX-D 90 GX-D 85W-90
FINA PONTONIC
FINA
MP 85W-90
Gulf Multi-Purpose
GULF Gear Lubricant
SAE 90
TEXACO
TOTAL
KLÜBER
TRANSELF
ELF
TYP B SAE 90
Fuchs Titan Gear Fuchs Titan Gear
FUCHS
Hypoid 90 8090 MC
AGIP Agip Rotra MP
Daegear EP-B
DEA
SAE 85W90
Panolin Super Duty Panolin Super Duty
PANOLIN
SAE 90 SAE 80W-90
BG 36/2005 10 - 5
LUBRICANTS / TABLES
10.1.3.3 List of Approved Gear Oils, Petroleum – ATF
Table Gear oils, petroleum – ATF
Specification
Application
DIN 51502
Petroleum gear oils Dexron II D
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
Aviafluid ATF
AVIA
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
BG 36/2005 10 - 6
LUBRICANTS / TABLES
10.1.3.4 List of Approved Gear Oils, Synthetic – CLP PG
Table Gear oils, synthetic – CLP PG

Specification
Application DIN 51517/
DIN 51502
Synthetic gear oils CLP PG
Viscosity grade
2
ISO-VG / DIN 51519 at 40°C (104°F) in mm /s
Producer
VG 100 VG 150 VG 220
Product
ARAL Degol ARAL Degol

ARAL
GS 150 GS 220
SHELL SHELL TIVELA WA SHELL Tivela WB
BP Enersym BP Enersym
BP
SG-XP 150 SG-XP 220
MOBIL Mobil Glygoyle 22 Mobil Glygoyle 30
AVIA Avilub VSG 150 Avilub VSG 220
CASTROL
CHEVRON
Circulation oil
ESSO
S 220
FINA
GULF
TEXACO
TOTAL
Klübersynth Klübersynth
KLÜBER
GH 4-150 GH 4-220
ELF Syntherma P 270
FUCHS Renodiol PGP 220
AGIP
DEA
PANOLIN
BG 36/2005 10 - 7
LUBRICANTS / TABLES
10.1.3.5 List of Approved Hydraulic Oils, Petroleum – HVLPD
Table Hydraulic oils, petroleum – HVLPD

Specification
Application DIN 51524/
DIN 51502
Petroleum
HVLPD
hydraulic oils
Viscosity grade
2
Producer
VG 46 VG 68
Product
ARAL ARAL Vitam VF 46

SHELL
SHELL
HYDROL HV 46
BP BP Bartram HV 46
MOBIL Mobil DTE 15 M
AVIA Avia Fluid HVD 46
CASTROL
CHEVRON
ESSO
Fina Hydraulic oil
FINA
D 3017
GULF
TEXACO
TOTAL
KLÜBER
ELF Elf Hydrelf DS 46
FUCHS
AGIP Agip Arnica 46
Dea Actis
DEA
HVLPD 46
PANOLIN
BG 36/2005 10 - 8
LUBRICANTS / TABLES
10.1.3.6 List of Approved Hydraulic Oils, Fixed – HEES
Table Hydraulic oils, fixed – HEES
Application Specification
Fixed hydraulic oils

HEES
(biodegradeable)
Viscosity grade
2
Producer
VG 46 VG 68
Product
ARAL Aral Vitam EHF 46

SHELL
SHELL NATURELLE
HF-E 46
BP BP Biohyd SE-S 46
Mobil
MOBIL
EAL Syndraulik 46
AVIA
AVIA
SYNTOFLUID N 46
CASTROL
CHEVRON
HYDRAULIKÖL
ESSO
HE 46
FINA BIOHYDRAN
FINA
TMP 46
GULF
TEXACO
TOTAL
KLÜBER
ELF HYDRELF BIO 46
FUCHS Plantohyd 46 S
AGIP Agip ARNICA S46
DEA Econa E 46
PANOLIN
PANOLIN
HLP SYNTH 46

Oils from different producers must not be mixed with one another.
CAUTION
BG 36/2005 10 - 9
LUBRICANTS / TABLES
10.1.3.7 List of Approved Engine Oils, Petroleum – API CF-4
Table Engine oils, petroleum – API CF-4
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
Aral Multi Turboral

ARAL
SAE 15W-40
Rimual TX
SHELL
SAE 15W-40
BP Vanellus Multigrad
Mobil Super M
MOBIL
15W-40
AVIA MULTI HDC
AVIA
15W-40
Castrol RX Super
CASTROL
Plus 15W-40
Chevron RPM
Heavy Duty
CHEVRON
Motor oil
SAE 15W-40
ESSO Essolube XT 401
Fina Kappa Supra
FINA
SAE 15W-40
GULF
TEXACO
TOTAL
KLÜBER
ELF
ELF PERFORMANCE
XR 15W-40
Titan Universal
FUCHS
HD 1540
AGIP Agip Sigma Turbo
Super DX
DEA
SAE 15W-40
PANOLIN
PANOLIN UNIVERSAL
SAE 15W-40
BG 36/2005 10 - 10
LUBRICANTS / TABLES
10.1.3.8 List of Approved Greases, Petroleum – KP2N
Table Greases, petroleum – KP2N
Specification
Application
DIN 51502
Petroleum greases KP2N-20
Name
Producer Multi-purpose
grease on lithium
Product soap base
ARAL Aralub HLP 2

SHELL Retinax EP 2
Energrease
BP
LS-EP 2
MOBIL Mobilux EP 2
AVIA
CASTROL
CHEVRON
ESSO Beacon EP 2
FINA Marson EPL 2A
GULF
TEXACO
TOTAL
KLÜBER
ELF Epexa 2
FUCHS Renolit MP
AGIP Agip GR MUEP 2
DEA Glissando EP 2
PANOLIN EP Grease 2
BG 36/2005 10 - 11
LUBRICANTS / TABLES
10.1.3.9 List of Approved Engine Oils, Synthetic – API CF
Table Engine oils, synthetic – API CF
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
Aral Extra Turboral

ARAL
SAE 10W-40
MYRINA
SHELL
TX SAE 10W-40
BP Vanellus HAT
MOBIL Mobil Delvac 1310
AVIA TURBO
AVIA SYNTH HAT-E
10W-40
Castrol RX Super
CASTROL
15W-40
Chevron RPM
Heavy Duty
CHEVRON
Motor oil
SAE 10W-40
ESSO Essolube XTS 301
FINA Fina Kappa FE
GULF
TEXACO
TOTAL
KLÜBER
ELF ECOMAX
ELF
FE PLUS 10W-40
Titan Unic 1040
FUCHS
MC
Agip Sigma
AGIP
Super TFE
Premium XL
DEA
SAE 10W-40
PANOLIN
UNIVERSAL SFE
PANOLIN
LC
SAE 10W-40
BG 36/2005 10 - 12
LUBRICANTS / TABLES
10.2 BOLT TORQUE VALUES
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.
Bolts with coarse-pitch metric thread
Strength class as per DIN/ISO 898

8.8 10.9 12.9
Coarse-pitch metric thread Bolt torque values MA [Nm]
M4 2.8 4.1 4.8
M5 5.5 8.1 9.5
M6 9.5 14 16.5
M8 23 34 40
M 10 46 68 79
M 12 79 117 135
M 14 125 185 215
M 16 195 280 330
M 18 280 390 460
M 20 390 560 650
M 22 530 750 880
M 24 670 960 1120
M 27 1000 1400 1650
M 30 1350 1900 2250
M 33 1850 2600 3000
M 36 2350 3300 3900
Bolts with fine-pitch metric thread
Strength class as per DIN/ISO 898

8.8 10.9 12.9
Fine-pitch metric thread Bolt torque values MA [Nm]
M 8x1 24.5 36 43
M 10x1 52 76 89
M 10x1,25 49 72 84
M 12x1,25 87 125 150
M 12x1,5 83 122 145
M 14x1,5 135 200 235
M 16x1,5 205 300 360
M 18x1,5 310 440 520
M 20x1,5 430 620 720
M 22x1,5 580 820 960
M 24x2 730 1040 1220
M 27x2 1070 1500 1800
M 30x2 1490 2120 2480
M 33x2 2000 2800 3300
M 36x3 2500 3500 4100
BG 36/2005 10 - 13
LUBRICANTS / TABLES
10.3 CONVERSION TABLE
Measures for Power

N dyn kp Mp p
1 105 0.102 1.02×10-4 102
10-5 1 1.02×10-4 1.02×10-9 1.02×10-2
9.81 9.81×105 1 10-3 103
9.81×103 9.81×108 103 1 106
9.81×10-3 981 10-3 10-6 1
Measures for Energy and Operating Efficiency

J erg kpm kWh kcal ev
1 107 0.102 2.78×10-7 2.39×10-4 6.24×1018
10-7 1 1.02×10-8 2.78×10-14 2.39×10-11 6.24×1011
9.81 9.81×10-7 1 2.72×10-6 2.34×10-3 6.12×1019
3.60×106 3.60×1013 3.67×105 1 860 2.25×1025
4187 4.19×1010 427 1.16×10-3 1 2.61×1022
1.6×10-19 1.6×10-12 1.63×10-20 4.45×10-26 3.83×10-23 1
Measures for Output

W kW kpm/s PS kcal/s kcal/h
1 10-3 0.102 1.36×10-3 2.39×10-4 0.86
103 1 102 1.36 0.239 860
981 9.81×10-3 1 1.33×10-2 2.34×10-3 8.43
735.5 0.7355 75 1 0.1757 632
4187 4.19 427 5.69 1 3600
1.16 1.6×10-3 0.119 1.58×10-3 2.78×10-4 1
Measures for Pressure

at atm bar N/m² Torr Psi
1 0.968 0.981 98100 736 14.22
1.033 1 1.0133 101330 760 14.69
1.02 0.987 1 105 750 14.5
1.02×10-5 9.87×10-6 10-5 1 75×10-4 14.5×10-5
1.36×10-3 1.32×10-3 1.33×10-3 133 1 19.28×10-3
0.070 0.0680 0.0689 0.145 51.72 1
Measures for Length

in ft yd mm m km
1 0.08333 0.02778 25.4 0.0254 -
12 1 0.3333 304.8 0.3048 -
36 3 1 914.4 0.9144 -
0.03937 3281×10-6 1094×10-6 1 0.001 10-6
39.37 3.81 1.094 1000 1 0.001
39370 3281 1094 106 1000 1
BG 36/2005 10 - 14

en BG36 888

Uploaded by

Copyright:

Available Formats

You might also like

en BG36 888

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

en BG36 888

Uploaded by

Copyright:

Available Formats

Instruction Manual

Keep this manual also for future use!

BAUER Maschinen GmbH

Before putting the equipment in operation, please:

Carefully read through the whole Instruction Manual and

This manual was edited and published by

ABOUT THE MANUAL ............................................................................................................................ VII

AFTER SALES SERVICE.......................................................................................................................... X

3 TECHNICAL SPECIFICATIONS ..........................................................................................3 - 1

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

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

This manual is made for

This manual was published in

The chapters of this manual

"Danger!" is used to identify an immediate hazard that can result in

"Warning!" is used to identify a potential hazard that can result in

"Caution" is used to identify a hazard that can result in

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

Nameplates on the equipment

Assembly Location Nameplate

How to reach the Service Centre

Phone Germany + (8252) 97 - 25 86

For possible check-backs

- Name of person to contact, phone / fax:

Þ Warranty Period: The warranty period is either

Þ Warranty - Improper use or operation (misuse) of the equipment.

- Redeliveries via air freight: 4 weeks

B) Liabilities and Responsibilities of the Client

- Any customs duties payable in the country of destination for a consignment of

From (Customer, Agent):

Total number of pages of claim:

Note (symptoms/malfunctions, causes, position of damaged parts):

3. Delivery of new parts and repair

Date Name of claimant Signature Company

4. For internal use only (to be filled in by BAUER)

Estimated working time (hrs):

(Signed by authorized BAUER employee)

1.1 EQUIPMENT APPLICATIONS

Area of application In short Allowed

1.2.1.1 Components Overview

1.2.1.2 Components Description

Table Basic rig components description

Table Kelly equipment components description

2.1 GENERAL SAFETY REQUIREMENTS

2.2 EQUIPMENT SAFETY

Equipped safety devices guarantee highest possible safety standard.

2.3 MAJOR HAZARDS

2.4 SAFETY DEVICES

To re-start, pull the depressed Emergency STOP

2.4.2 Pilot Control Safety Stick

2.4.3 Fire Extinguisher

Machine with an engine power of <

Personnel must recapitulate the text on

2.4.4 Medical Box

A First Aid medical box is found in the op-

2.4.5 Emergency Exit

Whenever the normal exit from the cab is

The hammer is found in the upper corner